Manufacturing Workforce Training Production: Operation Area(s) : Category: Module/Sub-Module: Presentation Name: Date

Manufacturing Workforce Training
PRODUCTION
Operation Area(s): Clinker Production

Category: Process Operation & Control
Module/Sub-Module: Kiln Control
Presentation Name: Introduction to Process Operation and Control Kiln
Version: 1.1
Date: May-08
MWFT-PROCEM IMPLEMENTATION
General Considerations
Objectives of kiln operation:
 Protection of equipment and personnel
 Production of consistent clinker quality
 Smooth and stable process operation
 Maximum thermal efficiency
 Maximum production rate
2
Holcim Indonesia Kiln Control.ppt
MWFT/Basic Kiln Operation
Content
1. Basic Kiln Process

2. Basic Clinker Reaction
3. Basic Pembakaran
4. Basic Cooler
5. Basic Kiln Control
3
1 Precalciner Kiln Comparison
4
1
Temperature & Pressure Profile
5
1
Principle Heat Exchanger Types
(schematic)
Counter current (shaft stage) Co-current (cyclone stage)
Kiln ?? 6
1
Location of Tertiary Air Takeoff
Tertiary air extraction Tertiary air extraction

from kiln hood from cooler roof
Tertiary air temperature = Hot secondary air

Secondary air temperature Cold tertiary air
7
1
Calcination
8
1
Flame of a multi channel burner
Maximum fuel
concentration
Secondary air
Internal
Fuel recirculation
zone
Primary air
Mixing of fuel, secondary

air and combustion
gases
Macro mixing
completed
9
1 Flame temperature and length: influence of process
The flame temperature and length depend basically on:

Amount of excess air
Primary air pressure and rate

Ratio between axial and radial air
Burner position
Secondary air temperature
Dust load from the cooler
10
1
Objectives of Cooler Operation
 The primary objectives of cooler operation are to cool the
clinker and maximize heat recuperation.
 Functions of a grate cooler are:

 Clinker cooling
 Recuperation of heat for use within the kiln system
 Clinker transport away from the kiln system
 Efficient cooler operation is characterized by:

 Maximum heat recuperation
 Optimum cooling airflow
 Unrestricted availability
11
1
Undergrate Pressure (Bed Resistance)
Illustration of Air Flow as a Function of Clinker Size
Low Resistance High Resistance
clinker
12
2
Basic Sequence of Reactions
reactants + products
alite + belite
Raw mixture + cooled
+
(20°C) intermediate products clinker
melt (1450°C)
(450 - 1300°C)
13
2 Sequence of Reactions Occurring in a Rotary Kiln
Heating (°C)
20 - 100 Evaporation of H2O
100 - 300 Loss of physically adsorbed water
400 - 900 Removal of structural H2O (H2O and OH groups)
from clay minerals
>500 Structural changes in silicate minerals
600 - 900 Dissociation of carbonates
>800 Formation of belite, intermediate products, aluminate
and ferrite
>1250 Formation of liquid phase (aluminate and ferrite melt)
~1450 Completion of reaction and growth of alite
and belite
Cooling (°C)
1300 - 1240 Crystallization of liquid phase into mainly aluminate
and ferrite
14
3 Pembakaran
2C + O2  2CO + heat
2CO + O2  2CO2 + Heat
N2 + O2  2NO
Control Parameter Pembakaran:
O2 (Oxygen)
CO (Carbon Dioxide)
NOx
15
4
Grate Cooler Control Parameters and Variables
Control Parameters
Control Variables
Exhaust Fan Speed
Kiln Hood Pressure
Secondary &Tertiary Air Temperature
Grate Plate Temperatures
Undergrate Pressure
Air Flowrate
Grate Speed
Clinker Discharge Temperature
Cooling Air Flowrate 16
4 Control Cooler
Control variable Control Parameter
Grate speed Under grate pressure
Flow fan cooler Temperature Clinker
Speed exhaust fan Mantle hood pressure
Secondary air temperature
Clinker Temperature
Dsb
17
5
Kiln Control
Control parameters of a kiln system:
 Back End Temperature (BET)
 Burning Zone Temperature (BZT)
 Oxygen concentration of the combustion gases at kiln inlet
Control parameters of a precalciner system:
 Precalciner outlet temperature
 Oxygen concentration of the combustion gases at precalciner

exit
18
5
Control Variables
Control variables of a kiln system:
 Fuel rate to kiln
 Material feed rate to kiln
 Kiln draft (ID fan speed or damper position)

 Kiln speed
Control variables of a precalciner system:

 Fuel rate to precalciner
 Precalciner draft (ID fan speed or damper position /
tertiary air damper or kiln orifice)
19
5
Control Parameters and Variables
Precalciner kiln
Oxygen after PC
1,4 – 1,8 %
Oxygen at KI
2,5 – 3 %
BZT BET
~1000 °C
1450 °C
Fuel rate Kiln speed Kiln draft Feed rate

and PC draft
Fuel rate PC
20
5
Control Parameters (BZT)
BZT
NOx
Amps
21
5
Kiln Amps (BZT)
x x
Hot kiln Cold kiln
Hot kiln = High torque  High kiln Amps
Cold kiln = Low torque  Low kiln Amps
22
5
Control Parameter Condition
Control parameters can be assigned to a certain
state, depending on the actual value.
Example for kiln with preheater (limits may vary):
BZT BET Oxygen
LOW <1430 °C <980 °C < 2.0 %
O.K. ~1450 °C ~1000 °C ~2.5 %
HIGH >1470 °C >1020 °C > 3.0 %
23
5 The Three Basic Parameter and Control
 Back End Temperature (BET)

Which is the principal control on operational stability
 Burning Zone Temperature (BZT)
Which is the dominant influence on the quality of the
production
 Oxygen (Ox) concentration at kiln inlet
Which is governs combustions & fuel efficiency
24
5
Control Parameter Condition
The Three Basic Variables and Control
27 states
25
5 KILN OPERATING PROCEDURES
Case Condition Action to be taken Reason
1. BZT low When BZT is drastically low
Ox low a. Reduce kiln speed To increase BZT & BET
BET low b. Reduce fuel To move the Ox percentage into range
When BZT is slightly low

c. Increase ID fan speed To raise the BET & the Ox percentage for action (d)
d. Increase fuel rate To raise the BZT & To return Ox percentage into range
2. BZT low a. Reduce kiln speed To raise BZT

Ox low b. Reduce fuel rate To raise Ox percentage for action (c)
BET ok c. Reduce ID fan speed To maintain BET
3. BZT low a. Reduce kiln speed To raise BZT

Ox low b. Reduce fuel rate To increase Ox percentage for action (c)
BET high c. Reduce ID fan speed To reduce BET (but be sure the BET is in a definite down ward trend)
4. BZT low When BZT is drastically low
Ox Ok a. Reduce kiln speed To raise both the BET & BZT
BET low When BZT is slightly low
b. Increase ID fan speed To raise the BET & the Ox percentage for action (c)
c. Increase fuel rate To raise the BZT
26
Expert Optimizer
27
END SLIDE
QUESTION ??
35

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Operation Area(s): Clinker Production

 Protection of equipment and personnel

 Production of consistent clinker quality

 Smooth and stable process operation

 Maximum thermal efficiency

 Maximum production rate

1. Basic Kiln Process

5. Basic Kiln Control

Counter current (shaft stage) Co-current (cyclone stage)

Tertiary air extraction Tertiary air extraction

Tertiary air temperature = Hot secondary air

Mixing of fuel, secondary

The flame temperature and length depend basically on:

Primary air pressure and rate

 Functions of a grate cooler are:

 Efficient cooler operation is characterized by:

Low Resistance High Resistance

Control Parameter Pembakaran:

Exhaust Fan Speed

Kiln Hood Pressure

Secondary &Tertiary Air Temperature

Grate Plate Temperatures

Control variable Control Parameter

Grate speed Under grate pressure

Flow fan cooler Temperature Clinker

Speed exhaust fan Mantle hood pressure

Secondary air temperature

 Burning Zone Temperature (BZT)

 Oxygen concentration of the combustion gases at kiln inlet

Control parameters of a precalciner system:

 Precalciner outlet temperature

 Oxygen concentration of the combustion gases at precalciner

 Kiln draft (ID fan speed or damper position)

Control variables of a precalciner system:

Fuel rate Kiln speed Kiln draft Feed rate

Hot kiln Cold kiln

Hot kiln = High torque  High kiln Amps

Cold kiln = Low torque  Low kiln Amps

BZT BET Oxygen

LOW <1430 °C <980 °C < 2.0 %

O.K. ~1450 °C ~1000 °C ~2.5 %

HIGH >1470 °C >1020 °C > 3.0 %

 Back End Temperature (BET)

BET low b. Reduce fuel To move the Ox percentage into range

When BZT is slightly low

2. BZT low a. Reduce kiln speed To raise BZT

3. BZT low a. Reduce kiln speed To raise BZT

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