ONODA ENGINEERING CO., LTD.
C
ENGINEERING JAN. 0 6. i9.97
KILN HEATING UP TIME
o oitte-17 '2- 1/-Q-
PROJECT
At the time of kiln heating up, it is necessary to pay attention to the following items. (1)
To avoid mechanical troubles of kiln shell, tyre, roller metal bearings, etc.
(2)
To avoid refractory troubles (The refractories protect directly or indirectly the above components against heat).
1
DETERMINATION OF HEATING UP TIME The heating up time is determined taking into account the environment in vicinity of refractory. (1)
For new kiln, it is necessary to consider the drying time for castable, burning down time for cardboard spacer (installed for expansion allowance), thermal expansion of refractory, balance of kiln revolution by 180°, etc.
(2)
Kiln inside temperature at the beginning of start-up (e.g. ambient temperature, high and medium temperature at shut down).
(3)
Others such as flame pattern, whether or not there is refractory lining in top cyclone, etc. Notwithstanding the above, it is most important to comply with the following.
(1)
Burning Section (Preheater - Kiln) The heating up should be carried out to achieve the target temperature at outlet of top cyclone, kiln inlet hood and burning zone
-1-
ONODA ENGINEERING CO., LTD.
as well as balance among these temperatures. The raw meal feeding is started once the temperature of gas at kiln inlet hood reaches the target temperature. Nonetheless, the temperature at burning zone during heating up should not exceed the target temperature to avoid damage to refractory. (2)
The heating up time should be decided so as to prevent melting down of refractory as well as to avoid damage of refractory due to thermal stress inside refractory. The non-compliance with the above two items during heating up will lead to refractory troubles and some other troubles (such as unstable condition inside the kiln, raw meal flushing, overheating, clogging of cyclones, etc.) which may occur after raw meal feeding. Even if there is no apparent refractory trouble during heating up, there is always a danger of causing serious damage to refractory. If heating up time is too long (24-36 hours) or too short (8 hours), in either case, it is practically difficult to achieve a continuous balance among the three temperatures mentioned above both during heating up and after raw meal feeding. If heating up time is too long, the above troubles will be experienced repeatedly but too short heating time is worse. Accordingly, the most optimum heating up time is 12-15 hours which has been decided considering the mechanism of causing damage to refractory (described hereafter) and to achieve a stable kiln operation after raw meal feeding.
2
ONODA ENGINEERING CO., LTD.
2.
MECHANISM OF CAUSING DAMAGE TO REFRACTORY DURING HEATING UP
(1)
High temperature of burning zone, highest temperature point, causing melting down of refractory. - Too short flame causing overheating locally. - Also, it is not possible to achieve a balance among three temperatures i.e. temperature at outlet of top cyclone, kiln inlet hood and burning zone. For example, the burning zone temperature may be high while other two temperature are low.
•
•
(2)
When the heating up time is too short, sudden increase in temperature will cause excessive thermal stress inside refractory, thus damaging it.
(3)
When there is rapid rise in temperature during short time, the newly lined refractory (without coating), particularly the refractory in burning zone will be damaged due to thermal shock, thus leading to unstable operation condition of burning section.
(4)
Others
ONODA ENGINEERING CO., LTD.
3.
HEAT DISTRIBUTION DURING HEATING UP
Even if the total heating up time is optimum, the improper speed of raising the temperature will give rise to troubles mentioned at 2(2) and 2(3) above. The bending strength of refractory decreases with increase in temperature. If the difference in temperature rise between loaded face and inside of refractory is large (i.e. rapid rate of raising the temperature), the thermal stress in refractory will increase. If this thermal stress at a particular temperature, exceeds the bending strength of refractory at that temperature, then refractory will be damaged. (According to laboratory tests conducted by Asahi Glass Co., Ltd., Japan for basic refractory bricks, if half of the thermal stress developed at particular temperature exceeds the bending strength at that temperature, the inside of refractory is damaged.) Considering the above, the rate of raising the temperature at least up to about 800°C should be kept as slow as possible (actually it is decided by stable burning condition achieved at minimum fuel feed rate corresponding to burner design). In our opinion, the rate of raising the temperature up to about 800°C during heating up can be kept as 80--i 00°C per hour. Above 800°C, the rate of raising the temperature is determined by dividing 1,500-800 = 700°C temperature by remaining heating up time. For example, Normal temperature to 800°C : 9Q°C/hour, heating up time 8.5 hours 800 to 1,500°C : 700/(15-8.5)=110°C/hour, heating up time 6.5 hours
Instructions for Optimization of Kiln and Cooler Operation Doc. No : UT - KLCL - 01 Date : 7 Jan. 1998 1. Purpose of this document UBE invited Mr. Kimura and Mr. Ujikawa ( Chichibu Onoda Cement Co., ) to CHC site from 15 — 25 Dec.1997 in order to check and optimize the kiln and cooler operation. During their stay, Mr. Kimura explained much important and useful] matter for kiln and cooler operation, and also prepared reports. The purpose of this document is to record Mr. Kimura's various explanation during meetings ( which were written and explained on white board ) to keep as technical document in CHG. t)C\wu&O.,A 2. Contents Explanation by Mr. Kimura ( Chichibu ()noda) about kiln cooler operation No. 1 : on 16 Dec.'97 at 9 . 30 — 12:00 No. 2 : on 18 Dec.'97 at 10 00 — 11:45 No. 3 : on 19 Dec.'97 at 14:00 — 15:00 No. 4 : on 22 Dec.'97 at 14: 45 — 16: 30 No. 5 : on 25 Dec.'97 at 14'00 ,,, 16:30 (Explained with above mentioned report "Report concerning damaged grate plates, 25 Dec.'97") 3. Reference documents Refer to the following documents which were submitted to CHC together with this document. 0.) Report concerning damaged grate plates ( 25 Dec.'97 by Mr. Kimura, Mr.Ujikawa ) (Z Modification proposal during kiln shut-down from 21 Dec.'97 to beginning of Jan. '98 ( UBE letter ; A/N - 234 on 24 Dec. '97 ) - New grate narrowing - Installation of kiln burning zone thermometer at the side of kiln hood - 2 sets of new inspection hole for cooler inside - Change of location for grate thermometers - Installation of guide vane for cooler 1st chamber cooling air (a) Reference training text (Prepared by Mr. Kimura for a training text book of cement plant in Taiwan )
(1 4 47
tit
Explanation of Kiln, Cooler Operation by Mr. Kimura on16 Dec.'97 No. 1 : Present operating condition on 16 Dec. '97 at 9:30 — 12: 00 I. Status of the meeting - To explain the present operating condition - To explain some important matter for kiln Operation 2. Kiln torque and kiln speed Kiln torque Kiln power (kW) Kiln speed (rpm)
Kiln power (kW)
Kiln speed (rpm) Kiln torque shoidd be observed to monitor the kiln burning condition. 3. Problem of the present kiln operation condition The most problem of the present kiln operation is that the kiln burner flame is " too short ". In this case, the following problem occur. (1) Kiln brick trouble around 7m-12m from kiln discharge end © Clinker telrnperature at the kiln discharge becomes high, then it causes the grate damage. OO The quality of clinker becomes worse - Free Ca0 increase
(1/41 c
- Voltnetric weight (V.W) of clinker increase
AAL
freSerit" (VI Temp.
C ond 111'011 0
CHC
3
)
-t- ern
Max.
tem retoch ,o- e
■
mi- v€ 1420°C 1250°C
Kiln length (m)
Om 7m (Kiln out let) •
Burning time is short Maximum temprature high
Free CaO increase Volmetric weight (V.W) of clinker is high.
The present operating condition of CFIC kiln is "the short flame condition of kiln burner" and "the high max;mum temperature". (Show in
line in above graph)
In this case, free CaO is high and the volmetric weight ( V.W. ) of clinker is high The brick problem ( about 7m) is caused by the short fl.nie condition.
4. Operat ng condition of yesterday (15 Dec.'97 ) Due to the leakage at the pulverized coal transport piping, kiln fuel was changed to 100% heavy oil conbustion. The kiln torque was high after changing to 100% heavy oil, then red river was not observed in cooler.
15 Dec
Kiln power
Kiln speed
Kiln burning zone 12nip.
Kiln torque
Red river
14 : 00
221 kW
2.44 rpm
1459 "C
221/2.44 = 90
NO
15 :00
231 kW
2.51 rpm
1491°C
231/2.51 = 92
NO
Kiln tol que Vs temperature of kiln burning zone
Tool-et
IS In _til 15 cir€q•
Buthing zone
f5; 00 on /590
Temp. 7 7/"'\
1500°C r N4
1450
/ 1-z 00
\_ %I/ r ftd----
on i C. -t) ec.
1400 Kiln torque ( kiln power/ kiln rpm )
90
80
100
6. Calculation of liquid phase of clinker at 1340°C
6.1 Fe 203 + MgO R20 = 6.1X 3.16 + 0.87 + 0.47 = 20.6%
at 1400°C
2.95 Ae 203 2.2Fe2 O 3 + MgO 1- R 20 = 2.95 x 5.34 +2.2 x 3.16 +0.87 -4-0.47 = 24.1 %
at 1450°C
3.0 A(. 203 + 2.25 Fe203 + MgO + R20 = 3.0 x 5.34 + 2.25 x 3.16 + 0.87 +0.47 7 24.47 %
Normally, 24_5% of liquid phase id desirable figure.
,Sh ort an
,,, e
°
4thie
CooQer
jh Co.se of S‘/tort
fame, di'iiker
is 191A 1 akic( &Ae
ic'ttiki'o( r r( _.,_
T4E/i,
cooffria
wors-e. occukv-s,
teinrerafore
rAase ineveAcec,
efi-Ec I. o i- Cx irl ker
pier lore
becomes
, v-a-te olan-,75
eas,1/
5
'7. Heat Flux Heat flux means quantity of heat trasfer,
171-
L "Pi A 4-f
;ek incide
CoGr6in
V = calorific value of Fuel ( kcal/kg ) m = amount of fuel ( kg/sec ) Heat flux Ilfr , V x m
(kcal / sec.m 2 )
ixTcxD 0 In case that the length of coatingt is around 15m — 16m, Free - Ca0 is high, or Free - Ca0 fluctuate ( high, low, high, low ). In this occasion, kiln operation becomes quite difficult. The present kiln operation is in such conditions caused by short flame.
Free — CAO -OtAc -Evcs -tes,
© About 22 —,25m of coating length (
)
is desirahble for this size of kiln.
© The coating length can be observed by kiln shell temperature scanner. 8. Important factors of kiln operation Et) Following factors are very important for kiln operation, - Volmetric weight ( V.W ) of clinker
6 - Free-CaO - kiln power ( kW) and torque
the prfseht rocitiur,
- TBZ ( temperature of kiln burning zone ) - Length of kiln coating (2) Especially, the monitoring of kiln burning zone temp. ( TBZ) is quite important.
7
In the most of ONODA cement factories, the temperature of discharged clinker from the kiln end is monitored. Then, such modification is recommended. (;3) Average temperature of discharged clinker at kiln end in ONODA factories is 1350°C. 9. Brown color clinker The reason of" Brown color clinker /1
is low MgO content in clinker.
( MgO content is 0.74% in CHC clinker. ) Mr. Kimura experienced " Brown color clinker" in a cement factory in China. Finally, this factory decided to feed dolomite ( as adding MgO) in raw material.
C3S
Ae203
Fe20,
MgO
SO3
Ordinary clinker
0.83
0.53
1.04
0.08
1.57
Brown clinker
0.97
0.72
1.08
0.15
1.35
: Ordinary clinker
1.71
0.92
0.47
0.89
1.85
Brown clinker
2.14
1.2S
1.75
1.24
1.71
24.81
15.45
4.94
0.07
31.82
5.07
0.54
0.00
:
C2S
GAF : Ordinary clinker Brown clinker
The color of cement is effected by C4AF. Cement color is indicated " b value " in Japan High (Brown r) b value low (blue
)
1.0
20
3.0
MgO.
Ap
n
/p,a
-2.,3,
.
‘...2%-, 3
In case of low MgO content in clinker, Fe-2.03 goes to C 3 S and C2 S, and Fe2O3 in C4AF becomes low. If MgO content increase by 0.1%, b value degrease 0.5%. ( Cement color becomes blue. ) 10. Actual method for change of kiln operation Or Following procedures shall be done, - Change of the length of kiln burner flame ( from short flame to long flame ) - Change of fuel combustion ratio of SC / kiln ( Increase of kiln burner fuel ) Howere, a high temperature position of kiln shell ( 440°C) is observed at 7.6m from discharge end. Therefore, change of operation should be done very carefully. © The fuel combustion ratio of SC/ kiln is decided by a de-carbonation ratio of raw meal ( at the inlet of kiln ) and free - CaO content in clinker. The target value is ; De-carbonation ratio of raw meal = more than 90% Free-CaO in clinker= less than 0.8 vo The present. de-carbonation ratio is reported about 85%, but sometimes it decrease to 70-75%. © In case of the consideration of fuel ratio of SC / kiln and De-carbonation ratio of raw meal , not only the . SC fuel, but also the tertiary air temp. shall be taken into account. Total heat value of SC = SC (fuel) + ( tertiary air temp. x tertiary air volume x Cp ( specific heat air ) ) In case of low temperature of tertiary air, fuel amount increases.
OD Relation between the vonietric weight ( V.W ) of clinker and tertiary air temperature V.W of clinker increase -4 Tertiary air temp. decrease V.W of clinker decrease
Tertiary air temp. increase
8
11. Cooler width control and operation
Reference of cooler width control CHC
China 1
China 2
Japan 1
4,000
4,300
4,100
4,000
4.55 4
4.64)
4.64)
4.24
0.2
0.2
0.2
0.2
2,7
2.4
2.4
2.1
2.7/4.15-0.65
2.4/4.2 = 0.57
2.4/4.2 = 0.57
0.55
Clinker Production ( t/d ) Kiln D Brick thickiless(T) Non width ! control e I (m) e ti D
(0 The cooler width control in ONODA plant is done by blind grate, not by castable like CIIC. (.4 In case of width control by castable, cooling air leakage occurs between the clinker bed and the castable (r41,1- t 0 nett- r--,9.e•)
[A.r1
Ctoier
Co4er- w 04 Cory( r-
04: Non ,6/
4
vtid-til Coerti-oY = Q . s-
O. 6
(3) Control of cooler The following matters are important factors for cooler operation. - Setting of suitable thickness of clinker bed, and keep this thickness - Control of red hot area of clinker In orderix) know the thickness of clinker bed, the following method is recommendable. In order to look inside of cooler of 1st — 4th chamber, installation of additional inspection hole is recommended .
Cooler Narrowin
/
/
r
In ONODA's plant, narrowing is made by blind grate.
it hn4
A ir
ct;r
/j7
-
T.
/ /
In case of narrowing by castable ( as present CHC cooler ), air goes through between the castable and clinket bed.
Cas-ta e
Confirmation of the clinker bed thickness
0,8m 71 h.0.6p, —,--,—... --, '',,I
/
,
i
In order to check the clinker bed thickness, it is recommended to install the marking brick. /
,
/0 (J) Cooler efficiency vs Thickness of clinker bed Cooler Efficiency
0.6
0.8 clinker bed thickness (m)
- In case that the thickness of clinker bed is too thick, the secondary sintering occurs on the surface of clinker bed. - The target of clinker bed thickness is about 600mm. (.5) Heat consumption vs tertiary air temp. Heat Consumption Kcal / kg.c1
To
goo Ro O
Tertiary air temp. ( °C ) (0) Monitoring of grate plate temperature
dinkr ir o9rstribt"tior, of Coo
--
(11) Cooler efficiency Cnventional cooler : Normal 55% — 60% In case of good width control 60% — 65% Mulden type cooler = 70% — 75%
-
re r tr, °meter riird e
YERR:14MALVIA W
.11.21a c.1;m1
9200 4100 4000 3900 3800 3700 3600 31121
35 I. 30
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101110
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fwe i rctaddi
50 48 46 44
31170
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nuoutri: 7>ip of
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311711
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800 780 ' vs
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9111511 1
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CHINFON HAIPHUNG CEMENT CORP. TRANGKENI I - MINHDUC - 1111, )/NIGUYEN -11A1PlIONG - VIETNAM FAX (84.31) 875 478 ) TEL: (84.31) 875 —441,
❑ Poi Hand Cement
TEST CFI VITICATE
Dale Supplied lo Sampling Dale Vessel
Conlract,l40.
:
Type . Qu Inlay Lot Ito. i
E Clinker
Clinker
v- ^ tr-9ec - A ve vole
CHEMICAL COMPOSITION & MINF,LAL CONS'ITIVENT Results*
Requirements Los on ignition In s~lilhl¢~IZ~si~luc SiO z I Al z03 13&:*.y. 81; X.
(W' ) (%) y';', (`;"(),
MgO SO3 K2 0 Nai9 Total alkalies (as Na 2 0) Fro Ca()I
(rg,)
mar. .
(VC')
111 a X.
C3 5
0.47
max. max.
22.06 5.32 3.36 64.97 0.74 0.38 0.63 0.19 0.61 0.76 55.21 21.60 8.41 . 10.22
((70
C;f0)' ' M a X.
I
e2S
(:)c(:))
C3 A
(To) (%)
C4 A li
PITYSICAI., PROPERTIES Con tires 1tC strenglli 3(tiys 7days I 28days Setting tiMe: (Vicat lest) set Final set Soul' lness: (Le Chatelicr) Fineness: Sieve 0.08 nun • Plaine .
*Tet
(N/n), , )
min.
(min) (min) (`ro)
max. max.
(%) (cin'j); I
min.
TCVN
Oft lion Clung - SI Hung Chief()wilily Mgt Sec.
Explanation of Kiln, Cooler Operation by Mr. Kimur No 2 : Change of kiln speed and burner position, Kiln passage time on 18 Dec.'97 at 10:00 11:45 1. Status c f the meeting After checking of the present operating conditions, the following matters are proposed. - Change of kiln speed - Change of burnner position ( for long flame ) - Consideration of passage time of raw material in the kiln 2. Present operating condition •
CO The present kiln speed 2.60 rpm at 260 t/h Kiln feed rate is too fast. According to the attached graph, the target of material filling rate in the kiln shall be 6%, then the target of kiln speed is 2.34 rpm at 260 t/h kiln feed. Kiln speed
Kiln
kiln burning zone
Passage time
torque
Temp. ( TI;Z )
in kiln
17 Dec.
75
1550°C
22 min
2.60 rpm
5 Dec.
85
1450°C
27 min
2.60 rpm
In case that the material filling ratio in the kiln Is changed, the condition of falling down clinker on the cooler is also changed. 3. Importantfactors for kiln operation Factors
The present condition of CHC
(-0
Kiln torque
Low
W
Temperature of burning zone ( TBZ )
High
.r)
End of kiln coating
15m ( short )
(4)
Material passage time in the kiln
22 min. ( short )
V
Volmen ic weight of kiln
High
©
Free - Ca0
High
-7)
Temp. Of kiln inlet end
Low
V
Temp. of tertiary air
OK
(
2 ,,
1, ,....,
...-s. - I.:,
%.." ■■••
,
in.5icke r-Q,lorcutvvi
kt 0 rn
betw e.e ,n Fateal feed
tune om
ty,
1%.t,t froAi 0 tA.
49
a. 6
2
(
Yir)6° ;. 1 6
147
2 16
— 2.6
2_, cg
207 2. c)
— 22
185 30
1. 2 0
/. 77 7a
/.62
(. 6 1.541 .4 -
0A -feed
zoo
icrrdtwfioil, raw wts.r.ot,/ / t-
270
2-2 9
3 00
cAin,4e-
230
.240
> 60 0
2 SO
•
_aeo
270
280
E_-`71,3
f.-)00 T +A1.3
17 4. Operation data on 17 Dec.'97 Kiln speed
Kiln
TBZ
Kiln
Sift
( rpm )
torque
( Kiln burning zone)
passage time
1st
: 2.60
75
1435 — 1576
25 min.
2nd
2.60
73
1400 — 1597
25 min.
3rd
2.55
80
1407 — 1598
28 min.
5. Raw material passage time in kiln
Kiln passage time
Kiln condition
Less than 25 min.
Kiln condition becomes unstable.
30 min, More than 40 min.
Kiln condition is stable, and clinker quality is good. Kiln condition becomes dusty. Red river occurs.
(t) The red river of CHC occurs in the condition of the passage time of less than'25 min, and high temperature of clinker discharged from kiln. The red river of CHC is not the case of long passage time of more than 40 min. The target of the passage time is 28 min — 3 0 min. 6. Target of kiln speed, kiln torque and the burning zone temperature ( TBZ )
Target of kiln torque
80 — 90
Target of TBZ
1400 — 1500 °C
Target of kiln speed is 2.50 rpm as a first step. Present kiln speed 2.60 x 60 = 156 rph First target
2.50 x 60 = 150 rph
/8. Theorei ic ally, final target is 2.34 rpm x 60 = 140 rph 7. Kiln burner position and adjustment of burner flame
A
/ Present-
(0,Feco
PrRseht et,pet
cbnd4isot
cAcie
Tc nip.
b(aveh)
/ /
Under the area of 1420°C
142.0°C is a cooling zone.
1250°C
15m
Kiln length
20m
The current operating condition is show in " burning zone temperature and short burning time ( short flame ). © The operating condition shown in condition should be changed to "
"
" line, and it means high
line is desirable, and the current " line . "
After change of operation
Condition B
Free - CaO is high. Volmetric weight of clinker is low . Then, kiln fuel shall be increased from 42% to 43%.
B=A
Free CaO is low Volmetric weight of clinker is low Then,this condition is OK
A,B is each area above 1420°C ( A is current condition, B is the condition after change of kiln flame. ) (i) Length of kiln cooling zone Desirable length of kiln cooling zone = (
1.5 ) x D = 4.15 — 6.2m
D = kiln inside brick dia. ( m ) The present cooling zone length seems to bey about 2m only.
V When the bUrner position is changed, operating condition should be monitored for minimum 4 hours until situation changes. ( Due to large heat capacity of kiln ) 8. Raw material passage time in the kiln
T=
KxL
T = Passage time min. )
DxNx0
K : constant value L : Kiln length ( 76 m ) D = Kiln inside bri&k dia. 4.15 in ) N = Kiln speed ( rpm )
e kr 110 "Xo )t
0 = Kiln inclination ( 4/ 100 ) The theoretical value of K is 0.142. In CHC kiln, T is measured as 22 min by trend chart graph. K is caliculated by using T = 22, then K is 0.13. Method of determination T by trend chart
geduce
-Peel to -6A -Soy. 5 ^- 10 m in.
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Z2 Explanation_of Kiln,Cooler OperationbyMr,Kimura No. 3 : Condilion_after 100mm insert_of kiln burn= _on Mice. '97 al 14:00 15:00 —
1. Status of meeting (1) Kiln burner was inserted into kiln by 100rum on 18 Dec. at 14 : 30. The burner position before insert was just the kiln end at hot condition. After insert of burner, the burner front end is 100mm inside of kiln in hot condition.
2. Condition after inserting kiln burner ( 100m n The condition after inserting burner is the case B < A. ( Refer to the explanation of 18 Dec.'97) That is, Free - Ca0 is high and Volumetric weight of clinker is low. 3. Analysints by the concept of Heat Flux ( refer to explanation on 16 Dec.'97 ) Hf = 7200 kcal/kg / 3600 x 7400 kg/h = 73.7 kcal/m2 x D x-e D = 4.15 m (;kiln inside brick dia. )
e
= 15 in ( Coating length )
Le ri e A
,e
Coating length was changed from 15m to 16m. Hf ( at kcal/m 2 If Hf is kept constant, fuel shall be increased as follow. 7400 x 75.7 = 7890 kg/h 71.0 7890 - 7400 = 490 = 0.5 ton coal/h
= 16m ) = 75.7 x 15 = 71.0
23 Therefore, fuel of kiln and SC ( calciner) shall be changed as follow. Kiln fuel 7.4 -1- 0.5 = 7.9 t/h SC ( calciner ) 10.5 - 0.5 = 10.0 t/h 4. Kiln Coating monitored by kiln shell temp. Scanner
When the butter position is changed or burner flame shape is changed, the most import check points are above mentioned coating end position ( coating length ) and the position or coating ring . 5. Fluctuation of ELM in the kiln feed raw mul If H.NI fluctuates as 2.15 ± 0.04, kiln operator can not control the operation. In case ,of fluctuation as 2.15 ± 0.02 which has continued from yesterday, it is very difficult to keep good operation. In the worst case, it may cause the melting of kiln brick.
(Ii) Kiln heat load of cross section heat load is calculated of follow. Heat load = 7,200 kcal/kg x 7,400 kg/h 3.9 x 10 6 kcal/m2 h 7C /
4xD2
t 1 3,0)
D = kiln inside brick dia = 4.15m The average figure of kiln heat load in Japanese cement fectories is 5.0 — 5.2 x 10 6 kcal/m 2h. The, figure. of CHC is lower than the average of kiln in Japan, thus even if ELM flactotes, there is not concern about melting of kiln brick. But, low heat load cause high Free-CaO in general. Thus, the heat load is recommended to be increased more. If the kiln fuel is increased from 7,400 kcal/h to 7,900 kcal/h, the kiln heat load is increased from 3.9 x 10 6 to 4.2 x 106 kcal/m2 h.
21The kiln heat load about 4.2 x 106 kcal/111 2h is recommended to keep Free-CaO in a target range. (E)) In Tsukumi plant, the target value of ITN; deviation ( clinker basis ) is ± 0.02. 0 The kiln heat load is depended on burnability of raw material. In case of low burnability material, kiln heat load should be higher.
(4) Whtn R. 1W mill is stopped, kiln dust collected by EP ( high HM dust ) should be stored in kiln dust bin. After Raw mill start, the kiln dust is gradually discharged, and is mixed to raw meal. (After finish of this day's meeting, it is confirmed that kiln dust is stored in the kiln dust bin from 2 months ago. Operator forgot this action only on 18 Dec. ) 6. The next action for operation If the lbllowing conditions are fulfilled, > 2.17 Kiln torque > 70 Kiln burning zone temp. < 1550 ° C ( TBZ ) Change fuel by the step of 0.1t/h at avery 30 minutes. 7. Mater* filling ratio in kiln For rough visual checking method is described in Cement Data Book. ( It is attached to this report. ) 8. When S.M is decreased, the burnability of raw meal becomes good. ( It becomes easy burning. ) 9. Kiln heat load vs Free-CaO the normal relation is as follows. Free CaO
711100•IMII■
4.2 Kiln heat load
5.0 x 106 kcal/m2 h
2 510. Action of operation on 19 Dec.'97. After finish of above explanation, kiln condition is as follows. Kiln torque = 140kW/ 2.51rpm = 56 ( very low ) TBZ = 1600° C ( very high ) Therefore, the damper of kiln primary air +An ( 24FN5 ) is reduced in order to make burner flame longer.
Kiln prim. Air
Before action
16 : 15 19 Dec.
16 : 49 19 Dec.
26.8 °A
18.1 %
14.6 %
Keep continuously
fan damper 1150mm H2 O
Pressure of circulation
1050mm H2 O
950mm H2 O
flow of kiln burner Afer above action, kiln power was going high. 11. Operating condition on 20 Dec.'97 After the action on 19 Dec. ( making kiln burner flame longer ), kiln condition became stable and the following points were observed. (I) Free CaO keeps less than 0.8 %. Kiln torque became high
13e1bre 19 Dec 10 :00
Free-CEO (%) Kilit Torque
12 :00
14 :00
1.69 ' 61
60
After
Action for
Action
62
long flame 19 Dec 16:00
Action
19 Dec. 22 :00 0.86
20 Dec. 2:00
6:00
10 :00
0.38
0.49
0.86
14 :00 0.47
79
77
75
77
74
( Refer to attached " TY'end after action. )
(,3.) Grate plates of 2nd row in 1st chamber was heated to red color before action. ( was observed from inspection window under grate. ) Hoverer, after above action was taken, rcd color heat was disapeared. It meanS that the clinker temperature at kiln discharge end was rather decreased.
(4) The color of red river ( which is observed from the tertiary duct on 4th chamber of cooler ) became dark. According to the identification sample (color vs temperature), the color of red river was changed from " light orange red : about 950 ° C " to "orange red = about 850°C).
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19. The rotary kiln
19. Der Otehofun
schen C'fensch issen. Die Ausmauerung on 1Thergangsz Lien ist kompliziert, arbeitsaufwendi und verlam t Spe7dalforinsteine. Eine besonders F)rmgebung, die mehrfach angetroffen wind, ist lie Ve -engung der Auslaufzone des Drelic.fens ; dies (Wart z •t teil .veisen Ktahlung des Klinkers in, Olen und zu; schnellen Abnutzung des Ofenfutters ,n diesem At schnitt_
highly labor consuming, job, requiring specially shaped refractory bricks. A kiln shell shaping which is particularly disadvantageous, Is the narrowing of the kiln's discharge end; this results in partial cooling of the clinker in the kiln and in a rapid wear of the refractory in this section. I
Sowohl praktische Erfahrungen als auch theorctische Cfherlegungen ftihren zur Erkenntnis, dad der Drehofen ohne Einschniirungen bz-w. Erweiterungen die derzeit g , instigste Ofenform darstellt. Die Dreiirohre der mr dernen WarrnetauscherOfen weisea hereits durchwe.gs einheitliche Querschnitte auf. Schtechte Erfahrungen mit Drehofen verschiedener Querschnitte veranla3ten die Zementindustrie der Sowjetunion, rur noch Olen mit einheitlichem Durchmesser zu bauen,.
Practical experience as well as theoretical deliberations lead to the observation that rotary kilns without constrictions or enlargements represent currently the most useful kiln construction. The ;hells of modern preheater kilns already sh'c)w uniformity throughout the cross-sections. Unfavorable experience with rotary kilns of different cross-sections, prompted the cement industry of the SOviet Unio). to build rotary kilns with an invariable diameter exclusively.
19.1.1. Of.mfdlIungcgraci
19.1.1. Degree of kiln
Die Ma:erialftilleng ina Drehofen bildet einen Kreisabschni t des Ofnquerschnittes. Das Flachenv rhaltnis diesel Kreisabschnittes zum gesainten Ofenquerschnitt 'a Prozent ausgedriickt wird als OfehfUllungsgrad f bezeichnet (siehe Fig. 193.).
The feed forms a segment of the rotary 1- iln's cross: ection. The area ratio of this segment to the area of the kiln's cross-section expressed in percent is called the kiln's degree or percent of filling f, (see Fig. 19.3.).
Fig 19.3. Scheinatische Darstellung des OfenInflungsgrades
Fig 19.3.
Ofenfrillungsgrade schwanken in den Grenze i von
etwa 5— UnebbAngig vora Ofenclurchnies er ist der Fulliulgsgrail hit- die verschiedenen Wertz des Zentriwinkels rc wie Zentrk\a inkel Centric angle cc 11C ' 105 ' 100 '
95' 90' BO' 75' 70'
Der Einflu3 des Dfenhillungsgrades auf den Derchsatz des Drehofen; ist in Fig. 19.4. dargestellt. Drei Kurven reprasentieren FCillungsgrzele von 7, 1‘' und 13 Vo, wit den dazugeharigen Durchsatzen in t, h (dr Drehofen rift Durchmessern von 2 his 3.5 m.
g
Schematic of the de ree of kiln filling
Kiln filling degrees fluctuate within the limits of about 5-17 go. Independent from Ulf- kiln's diameter, the percent of filling for the different values of the centric angle a is as follows; r -tfenfrillungsgrad 0/0 010 of kiln filling 15.65 o/o 13.75 (lib 12.10 0/0 10.70 0/0 9.09 0/0 7.75 0/o 6.52 oio 5.40 0/0 4.50 nio Tile influence of the degree (.1 filling to the rotary kiln's capacity is shown in Fig. 19.1. Three curves represent filling degrees of 7, 10, and 13 0/o, with the corresponding capacities in t/h for rotary kilns with di imeter from 2 to 3.5 m.
19.1.2_ 0'?;ineigun;
/P./.2. Kiln slope
Es gibt k eitie allgemein giiitige Regal fur (lie richtige Neigung von Dreil5fen. Neigungen von Drehofen lie-
No generally valid rule exists for the proper slope of rotary kilns. Rotary kilns shpv slopes from 2 to 6 0/o.
384
.1 19.1. Ausfri nrungsformen uas Drehofens
19.1. Types of rotary kAns
Fig 19.4. OfeuRillung.tgrail end Drehofendurchsatz
11'6 -
Fig. 19 4. Degree of filling versus rotary kiln capacity
1 0"
Ins ide kiln dia me ter
.7.
10'0'
10 Drenolendurchsotx
20
30
35 lin
60 Rotary kiln capacil y
120
1150
210 Win
gen zwi ir- hea 2 und 6 Vo. Meistens triff:, man jr loch Ofen mit Neigungen von etwa 2-4 Wo znr Hod? )ritaln an. Eirsprunglich hatten Drehofen qn56ere 1‘feig , ingen lei niedrigen Umdrehungszahlon von -,tv a 05-0.75 LUrnin. Geringere OfennuiguLrg erk dert e i ne ho'wre Drehzahl ; dies hat den Vo;teil, dad das Ofenmaterial besser gemischt und eLrem intensiveren Warmeaustausch ausgesetzt wird. Nlan erreicht auch mit geringerer Neigung hohere )(enhillungs grade. Aus praktischer Erfahrung resuliert, daft den folgenden Ofenneigungen im prakti; :hen Ofenbetri!b optimal erreichhare Ofenhillungs; rade entsprechen; siehe Tabelle 19.1.
Tabelle
Most kiln slopes are between 2 and 4 olo to the horizontal. Originally, rotary kilns had higher slopes with lower revolutions ranging (rola 0.5 to 0.75 rpm. Lower kiln slopes require higher numbers of revolutions; this has the benefit of better mixing of the kiln feed, together with a more intensive heat exchange. Lower slopes also permit higher degrees of kiln filling or of kiln load. Practical experie'r, :e resulting from kiln operation shows that the following kiln slopes yield the corresponding average kiln loads; see table 19.1.
19.1.
Table 19.1.
Drehoienneigung and Ofenifinungsvad
Rotary kiln slope ver as .11n load Ofenneigung No Kiln slope No
Entsprechender Ofentullungsgrail Corresponding kiln load 0/
4.5 ',la 4.0 0/o 3.5 No 3.0 wo 2.5 No
an
9 a/o 10 0/s II Vo 12 No
13 0/
:kndererseits wird behauptet, dab der Clenfrillv ngsgrad vorn Verhaltnis der Lange (L) zum 1,?nrc:hrn sser (D) des ()fens abhangt. NaBdrehofen mit 'einem './DVerhaltr is von 40 und darriber weisen Fullungst•rade his zu 11 0/o auf [1761 dedenfalls bestim nt die leigong des Drehofens in erster Linie den ngsg[ad, wobei ein steigendes L/D-Verhaltnis den Frillungsg -ad noch erhohen kann.
that the kiln load depends on the length (L) to diameter (D) ratio of the kiln. Wet process rotary kilns with an LID-ratio of 40 and more, show kiln loads of tip to 17 % 0761. In any case it is the rotary kiln's slo'pe which determines the kiln's load in the first place; in addition to this Is an increasing L/D - ratio a factor, v-hich can contribute to the kiln's higher load!
fm praktischen Ofenbetrieb soil ein Frillungsgrar' von 1:1 °A) nicht uberschritten werden, da 1rohere ['CIL tungsgrade den Warmelibergang versddr chtern.
In practical kiln operation the kiln load should not exceed 13 ,/o, since higher kiln loads impair the heat
On the other hand, it is said
transfer. 385
3l EN')lac ation of Kiln, Cooler Operation by Mr. Kimura No.4 : Modification plaA during Kiln stoppage on 22 Dec. '97 at 14:45 — 16 :30
1. Status of this meeting cooler was stopped on 21 Dec. at 20:00 by falling down of 2 pieces of nose ring of kiln discharge end. 0 In this meeting, proposal of next cooler narrowing and necessary modification plans were explained to CHC.
2. New narrowing idea of cooler Tis narrowin4 plan comes from much experiences of ONODA. 3. Installation of kiln burning zone pyro meter ( 24T72 ) at the side of kiln firing hood 4. New installation of 2 inspection holes at cooler 5. Relocation of grate plate thermometers to check the clinker bed conditions properly. 6. Guide vanes for cooler 1st chamber cooling air duct These modification items are officially proposed by UBE's letter. ( Ref. No. A/N-234 dated 2.4 Dec.'97 )
32 Explanation of Kiln, Cooler Operation by Mr. KitniAVok 16 Dec. And No.5:SumaryfInstciom Instruction for Next Kiln, Cooler Operation on 25 Dee. '97 at 14: 00 — 16 - 30
1. Status cf this meeting CO Mr. Kimura and Mr. Ujikawa prepared a report " Report Concerning damaged grate plates, dated on 25 Dec.'97 " and submitted it to CHC.
•
In this meeting, Mr.Kimura explained this report, and summarized the optimization of kiln and cooler operation. And also, important items for next kiln operation was explained to CHC. 2. Page 4/12 of the report " Trend after action ' (.0 When Mr. Kimura came to CHC site, and checked operating condition, the kiln passage time was short ( 22 min. ) and Frce-Ca0 was high. ( It fluctuated rapidly. ) The damper of kiln primary air fan was cb)sed from 26.8 % to 14.6 %, and tried to make the kiln burner flame longer on 19 Dec. at 16:50. (0) After this Ac tion was taken, kiln torque kept high, and Free —Ca0 was decreased.
•
This change of condition are obsered in the graph of " Trend after action " in page 4/12 of the report.
Kiln torque
70
19 Dec. 16 : 50
I )ate and time
33 Free CaO
Date and time
19 Dec. 16 : 50 3. Kiln material filling ratio S = 1.667 x T x M. x R = 7.2 % AxLN9 T = Kiln passage time ( 28 min. ) M = Clinker production 3900/24 = 162.5 t/h R = Average material in R
On
+ 1.0 - 1. 055
R 1 = Material at kiln inlet R j = 1 55 t/t x (1- 14)c ) 1- 1.0 t/t cl' x c 1.11 (q) c = Decarbonation ratio = 80% ) 100 100 A = Kiln cross section area = 7" x ( 4.55 - 0.4) 2 = 13.52 m2 4 L = Kiln. length = 76m G = Average bulk density = 0.9 + 1.27 = 1.085 Um' 2 In case of the calculation at the most recomn endable kiln passage time : T = 28 min the filling ratio S = 7.2 %. In case of the passage time T
( before the kiln burner shape adjustment )
S= 7,2 x 21 = 5.4 %. ( lt is too low. ) 28
The target value of kiln passage time should be 28 min. — 30 min. After fie action for the kiln burner long flame on 19 Dec.'97, the passage time is about 32 min ( 13y• the time difference of trend chart of kiln inlet temperature and burning zone to trip.
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35 4. Kiln heat load, Coating length and kiln inlet hood temperature Kiln heat load ( kcal/ in2 h)
Coating length m
Temperature of kiln inlet hood ( °C )
4.2x 106
17 — 18
.950
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22
1050
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In casc of the present low heat load ( about 3,9 x 10 6 kcal/m2 h ), clinker quality ( FreeCa0 ) is not stable C5 C/c2on(,
1 S ki,Qr 4.4 Imo/ -
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Around 4.2 4.7 x 10 6 kcal/m2 h is a recommendable range of kiln heat load for CHC kiln. 5. Kiln bi.irning 'zone temperature and kiln power ( Page 4/6 of the report " Report concerning daliaged grate plates" )
73X (
kArtitil 20rie teiT )
1c16*t
livv"vw%
In case that 113Z increase and kiln power decrease ( as above mentioned trend ), it means that the liquid phase of clinker is increasing. This case is a very dangerous situation for ttrate plates, because it is easy to be damaged by incerased liquid phase, In such case, operator must open the damper of cooler 1st chamber fan more for preventing grate damage.
3t If the damper can not be opened more, kiln buring zone temperature should be decreased. Operator must consider such cases as emergency case, i.e. grate plates might be easily damaged. For decreasing kiln buring zone temperature following action shall be taken - Decrease of kiln fuel - Open of kiln primary air fan damper to make flame longer 6. Difference of clinker bed thickness between 1st and 2nd stage grate ( Page 5/6 of the report " Report concerning damaged grate plates " ) The present difference of the pressure between 4th chamber and 5th chamber ( 1st stage and 2nd stage of grate ) is 150 — 200mm H 2 O ( = 15 — 20mbar ) It seems that the thickness of 2nd stage grate is much thinner than 1st stage grate. In this case, red river can easily flush from 1st stage to 2nd stage of grate, then grate damage occurs. The thiekticsS of clinker bed of 2nd stage grate should be same as 1st stage, or thicker than 2nd stage. This is a very important matter for cooler operation. The suitable pressure difference of 4th chamber and 5th chamber can be considered as about 70mm 14,0 ( = 7mbar ). However, the situation of clinker bed should be well obsertkd.
7. Kiln torque vs kiln burning zone temperature. ( The graph in page 2/12 of " Report concerning damaged grate plates" ) The operation target is kiln torque 75 and burning zone temperature 1500 — 1550 °C.
8. Red river in case of too long burning time
Red river occur at the following 2 cases - Too high temperature of kiln burning zone ( it is the case of CHC ) - Too long burning time
37 Temp. 1450°C 1250°C
KjIii length (m)
The largeo(eause smaller A lite size ( large size clinker) : The smallo(cause larger A lite size ( Dusty clinker ) then, red river easily occurs. ( But, this case of red river is not CI-IC case. ) ;
4. 2
9. Countermeasure for the damage of castable at SC ( Swirl calciner) of RSP In case of the tertiary air volume F I is less than F2, castable damage easily occurs. Therefore, it is important to make tertiary air flow Fl and F2 equal flow rate. ( It can be achie'ed by installing pressure gauge and making both pressure equal. ) Ak'fi2v4A, (A 0 0.3D
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