Professional Documents
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Production Department
27.06.16
Kiln Drive Amps
It is the most important sensor used to evaluate the burning zone state.
The running set point will change according to the raw material composition.
Amperage value changes with ring formation.
Amperage value changes with the size of the clinker.
The absolute value is important only when amperage is high (fuse protection
limitations).
The trend is a very good indication of burning zone length and temperature;
therefore the amps should be recorded in such a way to give a good indication in its
variations.
A drastic increase of the amps trend, followed by a fast decrease is an indication of
loss of coating or a broken ring inside the kiln.
A target amps range should be established (depending on raw mix and other
factors) through which this variable can fluctuate safely.
A drastic increase in amps could indicate a possible mechanical condition problem.
Secondary Air Temperature
It should be kept as stable as possible by the automatic cooler control system (+/85oF or 39oC).
Absolute value is not important because most indications are incorrect due to
instrument inaccuracy.
Trend is very important as it shows variations of material from the kiln and the gas
temperature variations to the kiln.
The secondary air temperature should be as high as possible in respect of the
various refractory temperatures in front of the kiln.
Hood Draft
Absolute value is important and is automatically controlled at a constant value
(usually looped to cooler exhaust fan damper / fan).
It should be low as possible (to reduce in-leakage).
It is the separation between cooler and kiln and it should be always constant to
avoid influences of changes in the cooler gas flow to the kiln operation.
A poor regulation of this signal will induce variations in the kiln gas flow and could
bring the kiln into cycling.
Under Grate Pressure
The absolute value should be maintained constant with automatic control.
The value varies with the cooler bed depth and with clinker size. It must be held
constant in order to achieve a constant secondary air temperature. Also, only a
constant air flow can allow the relationship between under grate pressure, bed
depth and secondary air temperature to be valid.
Kiln Speed
It should be related to feed rate.
Stop increasing kiln speed approximately 1 to 2 hours after initial slow speed in
order to overcome any upset in the material load of the kiln created by the speed
variation.
Restart increase the kiln speed after reception of material from slowdown is over.
Kiln speed increase should be reduced around 80 revs as we are getting near full
production (i.e. 2 revs at every 20 minutes).
When full production has been reached (i.e. 85 revs) the fuel flow must be kept one
step higher than normal for at least 2 more hours, and then it must be cut down
slowly following the normal operating procedures to get the load at the end of the
flame again.
A slowdown made in time and at proper speed will requires about 20 minutes before
to restart to increase the kiln speed again (as O 2 start to go back up).
Usually, the kiln should be back in full production about 4 hours after the slowdown
was made.
Slowdown t/h
Fuel flow
ID fan
O2
Operation
Example:
speed
revs
86
93
102 m3/h
530 rpm
1.5%
Normal
66
72
85 m3/h
acc. O2
0.7
Slowdown
level
36
40
50 m3/h
acc. O2
0.7
slowdown
level
Root cause analysis of Cooler 1st Grate tripping and melt formation inside cooler
Reasons for Melt formation inside cooler
1.
2.
3.
4.
The best available parameter with kiln operator is Kiln Main drive Amp that can tell you
the exact situation inside kiln.
In case of melt formation it is observed that kiln main drive (amp) suddenly increases and
then decrease. This is sign for melt formation.
Never wait for quality to give you the results rather push them to take spot sample of LSF
when you observe such an abnormality.
Have eyes in field to check the physical condition of kiln.
The cross LSF value will confirm that a decrease in quality have upset the condition
inside the kiln.
Carefully monitor and analyzer kiln main drive (amp) trends. The variation shows the
story, of the variation increases then coating has fall in that turn. During coating fall kiln
main drive amp trend is quite different.
Steps to be taken
A sudden increase in Kiln main drive amp is direct sign of melt formation inside kiln.
Immediately open kiln main drive trend on your other LCS and analyze the trend
variation.
Reduce rpm, fuel and feed.
Increase ID fan
Cool your kiln as much as you call to avoid this melt material to enter inside cooler.
Open 2nd grate fans, reduce TAD dampers up to 65 % to maximum secondary air.
Decrease secondary air temperature up to 900 C
Have an eye in the field to check the physical condition of kiln. Person in the sight will
confirm you melt formation inside kiln.
If you observe under grate pressure increasing above 8 KPa , further reduce kiln rpm and
increase ID fan.
Reduce fuel at main, reduce feed and make kiln dead slow.
If you do not take drastic steps then the melt can be controlled and it will trip your first
grate.
II.
III.
IV.
V.
VI.
VII.
Maintenance at flap of C5 was done at 1800 Hrs. Cooler grate tripping occurred at 1900
Hrs.
A probable reason is that grate over loading is maintenance at C5 flaps.
Maintenance of flap should be done while kiln is shutdown.
Low rpm of kiln some time add to melt formation because material residence time inside
kiln increases. Kiln rpm are may be less as compared to feed.
Since the kiln is being operated at less feed due to CF silo level, the fuel may be higher as
compared to feed.
Fuel at kiln main burner also have an error 5 %, may be this error have forced this high
melt formation.
Root cause