Training for Pioneer Cement Operation

Kiln Operation

Pioneer Cement22-28 July 2006

Prepared by Hatsachai prahanphapSiam cement (Ta-Luang) Co.,ltd

Training for Pioneer Cement Operation

Content• Quality of Clinker • Kiln Operation Parameter• Cooler Operation• Burner Operation

Training for Pioneer Cement Operation

Clinker quality• Clinker

Component– SiO2 22.8%– Al2O3 5.98%– Fe2O3 3.42%– CaO 63.95%

• Compound in Clinker– 3.CaO.SiO2 , C3S– 2.CaO.SiO2 , C2S– 3.CaO.Al2O3 , C3A– 4.CaO.Al2O3.Fe2O

3 ,C4AF

Training for Pioneer Cement Operation

Clinker Quality• C3S (Give initial strength of concrete)

- 407 76= . CaO . SiO2 - 672 2O3 - 143. Fe2O3

= 42.0% • O2O (Give late strength of concrete

= 8 .6 SiO2 + 5 .0 7 2O3 108+ . Fe2O 3 - 307. COO= 33.8%

• O3O (Give some initial strength and give the plasticity of mortar)

265= . Al2O3 - 169. Fe2O3= 10.06%

• O4OO 304= . Fe2O3 =10.4%

Training for Pioneer Cement Operation

Quality concern Kiln operation

• LSF CaO / (2.8SiO2+1.18Al2O3+0.65Fe2O3)( LSF <90 easy burn , >98 hard burn)Higher LSF ,

- Harder burn clinker - Use higher fuel consumption- Higher C3S

Normal fluctuation = Setpoint +/- 1.5Pioneer cement LSF-Cli = 88% (expect 90%)

Training for Pioneer Cement Operation

Quality concern Kiln operation

• Ms SiO2 / (Al2O3 + Fe2O3)(Ms <2.0 easy burn , >3.0 hard burn)Higher Ms = Higher Silica - Harder burn clinker - Higher Fuel consNormal fluctuation = setpoint +/- 0.1

Training for Pioneer Cement Operation

Quality concern Kiln operation

• Ma Al2O3 / Fe2O3(Ma <1.3 easy burn , >2.5 hard burn)

Fe2O3 is better fluxing agent than Al2O3 Higher Ma = Harder burn clinker

Normal Fluctuation = setpoint +/- 0.1

Training for Pioneer Cement Operation

Quality concern Kiln operation

• FCaO– Remain CaO from incomplete reactivity

of clinkering process – High FCaO = Dusty Clinker– FCaO > 1.5%

Lead to expansion of mortar and concrete

Training for Pioneer Cement Operation

Kiln Operation Parameter

Input

Operation

Output

-Rawmeal Quality ( R90u, R200u, LSF ,Ms ,Ma)-Coal Quality ( R90u , LHV)

-Kiln feed , Filling Degree-Fuel Feed rate , Fuel Ratio-Burning Zone Temp -Kiln Torque (Amp of Motor)-Calciner Temperature-O2 , CO at K-line , C-line-Degree of Calcinations-Clinker Cooler Operation-FCaO -LSF -Ms -Ma -Liter weight

Training for Pioneer Cement Operation

Kiln Input• Kiln feed

– Fineness of Kiln feed : Residue on 200u sieve should less than 1.0%

– Quality of kiln feed (LSF , Ms ,Ma) are according to clinker quality

Training for Pioneer Cement Operation

Kiln Input• Fuel

– Fineness of fuel 0.5 -0.8* VM(dry ash free)

– Coal Analysis in As fired basisVM 39.46% , Ash 13.9% ,Moist 1.0%VM(dry ash free)

= 39.46*100/(100-13.9-1)= 46.3

– Fineness of Coal 0.5 x 46.3 = 23%

Training for Pioneer Cement Operation

Kiln Operation• Filling Degree

F = 3.2 x P D3 x H x NF = 3.2 x 4000 4.23x3.5x2.8F = 17.6%

Training for Pioneer Cement Operation

Kiln Operation• Kiln in hot condition

– Kiln amp increase– Burning Zone temp increase– Clinker has a good quality

•FCaO Low•Liter weight high

– At this condition O/P can increase feed 5-10 t/h in each 15-30min

Training for Pioneer Cement Operation

Kiln Operation• Kiln in cold condition

– Kiln amp decrease– Burning Zone temp decrease– Clinker has a poor quality

•FCaO higher•Liter weight lower

– At this condition O/P have to carefully observe the kiln

– Decrease Kiln speed – Decrease feed if necessary

Training for Pioneer Cement Operation

Kiln Operation• Calciner Control

– Control the temperature of Calciner constant (as possible) in range 860-880 C

– Check Degree of CalcinationsDOC = ( LOI[KF] – LOI[C4] )x100

(100 – LOI[C4])x(LOI[KF] /100)-LOI[KF] : Loss on ignition of Kiln feed-LOI[C4] : Loss on ignition of C4 Material

- DOC should control in range 90-95%

Training for Pioneer Cement Operation

Kiln Operation• Degree Of Calcination

Training for Pioneer Cement Operation

Kiln Operation• Free Lime, FCaO

– Control Range 0.5-1.5%– FCaO < 0.5

•Hard burn clinker•Lead to snowman at Cooler•Use higher heat consumption•Harmful to brick life

Training for Pioneer Cement Operation

Kiln Operation• Free Lime, FCaO

– FCaO > 1.5 •Low quality of clinker•Dusty clinker

Training for Pioneer Cement Operation

Kiln Operation• O2 at Kiln and Calciner

– Control >2.0% •Keep complete combustion in kiln and

Calciner•C + O2 -> 2CO : E = 2500 kcal/kg-C•C + O2 -> CO2 : E = 8060 kcal/kg-C•Heat loss 69% with CO condition

Training for Pioneer Cement Operation

Clinker Bed• Higher clinker bed can increase heat

recuperation from clinker cooler• Clinker Bed

1.15xT/Dx1000 (1.2x24x60)x (WxLxst) W = Grate width 3.6m L = Stroke length 150mm St = Stroke/min or rpm

Training for Pioneer Cement Operation

Clinker Cooler Operation• Combustion Air

– 0.85 Nm3/kg.cli– Use from Fan K11 – K30

• Heat Recuperation– Secondary Air temp > higher than 960

C– Tertiary Air temp > higher than 960 C

Training for Pioneer Cement Operation

Existing Clinker Cooler Operation

Too much air at K11-K23Control this value in range 0.85 Nm3/kg.cli

Control this value in range 2.1 Nm3/kg.cli

Training for Pioneer Cement Operation

Clinker Cooler Operation

Training for Pioneer Cement Operation

Clinker Bed• At 2,800 t/d ,G1 = 10.5 ,G2 = 11.5 stk/min

– Clinker bed G11.15 x 2800 x 1000 = 330 mm(1.2 x 24 x 60) x (3.6 x 0.15 x 10.5 )

– Clinker bed G21.15 x 2800 x 1000 = 300 mm(1.2 x 24 x 60) x (3.6 x 0.15 x 11.5 )

• Recommend Clinker bed > 500mm

Training for Pioneer Cement Operation

Burner Operation• Flame Momentum

– Primary Air (% of A) x Velocity (%.m/s)

• Stoichiometric air require– Ao = 1.01x(LHV+550)/1000 Nm3/kg.fuel– m = excess air 10-20%– A = (1+m)xAo

Training for Pioneer Cement Operation

Burner Operation• Velocity

– V = 4.4 x sqrt(10.2 x P) P = Fan Pressure – 20

• Flame Momentum– 1500 – 1700 %xm/s

Training for Pioneer Cement Operation

Burner Operation