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Start Up Procedures PDF

The document discusses best practices for kiln start-up procedures, including: 1. The objectives of standardized start-up procedures are to safely and efficiently heat up the kiln in a minimum amount of time while protecting equipment integrity and meeting environmental regulations. 2. Each plant must customize procedures to their specific equipment, but procedures generally include preheat curves, production ramp schedules, record keeping requirements, and instructions for short shutdowns. 3. Detailed steps are outlined for pre-start checks, burner pipe and refractory preparation, monitoring tyre creep and turning schedules during the heat up process, and recommendations for raw material feeding and post-start audits.

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100% found this document useful (2 votes)
1K views18 pages

Start Up Procedures PDF

The document discusses best practices for kiln start-up procedures, including: 1. The objectives of standardized start-up procedures are to safely and efficiently heat up the kiln in a minimum amount of time while protecting equipment integrity and meeting environmental regulations. 2. Each plant must customize procedures to their specific equipment, but procedures generally include preheat curves, production ramp schedules, record keeping requirements, and instructions for short shutdowns. 3. Detailed steps are outlined for pre-start checks, burner pipe and refractory preparation, monitoring tyre creep and turning schedules during the heat up process, and recommendations for raw material feeding and post-start audits.

Uploaded by

bulentbulut
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Operator Development

Kiln Control Best Practices

Kiln Start-up Procedures


Presentation & Instructor Notes

BP Objectives Kiln Start-up Procedures

Master procedure for heating up the pyro-line


standard, safe & efficient manner minimum transition periods no failed start-ups assure the integrity of equipment & refractory stay in environmental compliance rapid compliance with clinker quality objectives

Each plant must customize to the specific characteristics of their equipment & develop more detailed checklists & SOPs
Pyro-processing: Kiln Control 2

BP Deliverables

Preheat curve & kiln turning schedule


adjustment for different refractory work

Procedure to reach full production Recommended record keeping Start-up after short shutdowns (<48 hrs) Information required for customization of SOP Indicators required

Pyro-processing: Kiln Control

Kiln Start-up Procedures Learning Objectives

At the end of this session you should be:


familiar with the start-up BP able to list the major steps involved name the required process indicators able to explain the customization differences with your plants SOPs

Pyro-processing: Kiln Control

Kiln Start-up Procedures


End-users: Content:

Production Operators/technicians

Checks prior to start-up Kiln preheat preparation: Burner pipe, Refractory Kiln Preheat schedule: Parameters to monitor Tire Creep Turning schedule Start-up Process data sheet Kiln lining preheat schedule Feeding raw mix What to do in case of deviations Start-up Post-audit

Pre Start-up Checks

Dry run & complete check sheets


Feed System Cooler & Clinker Handling ID fan Coal Conveying System Kiln Baghouse ESP Pre-heat system Pre-heater tour Burner Pipe alignment Common & auxiliary equipment

Check sheets should include room for comments & assigned responsibility
Pyro-processing: Kiln Control 6

Sample: Pre Start-up Checks

Feed System
recirculation mode & calibrate if no recirculation ... run briefly check operation, leaks run dust evacuation (elevators, screws & pumps)

Cooler & clinker handling


run cooler drives & inspect for loose grates check cooler alignment while running run for 12 hours (mechanical integrity) Breaker, fans, conveying equipment alignment, motor direction, automation & full motion operation & seal of all Plattco valves calibration of all pressure transmitters
Pyro-processing: Kiln Control 7

Kiln Preheat Prep

Burner pipe alignment


exactly where is the pipe in relation to the kiln laser alignment measured in 3 places

Refractory preparation
manage the installation of refractory, proper installation is key to longevity follow procedure for preheating to maximize brick life

Burner pipe lining


poured castable must cure 24 hrs before removing forms or attempting bake-out

Pyro-processing: Kiln Control

Burner Pipe Lining Preheat Schedule Four inch refractory lining

700 600
550 600 600 600 600 600

bake-out - adjust per inch of refractory

500
450

500

400
350

400 Temperature C

300
250

300

200
150

200

200

200

200

200

100
50 0 1 2

100

10

11

12

13

14

15

16

17

18

19

20

Pyro-processing: Kiln Control

Kiln Preheat Schedule Determined Prior to Start-up


10-14 process parameters should be recorded


list differs for precalciner & long kilns

Example list (incomplete)


oxygen back-end, BZ temperatures tyre creep, tyre & bearing temperature hood pressure fuel consumption turning schedule Kiln shell temperature ( BZ) ESP/Baghouse

Pyro-processing: Kiln Control

10

Kiln Start-up Process Data Sheet


Date: _________________ _____ Hours ___________________
Hour of the Preheat Tyre Creep #1 Tyre

Time of Flame On:_________________

Preheat Schedule: -

Tyre Creep #2 tyre

Hour of the Day

Chain Gas Temp

Fuel Rate

Feed End Oxygen

Swirl Air Setting

Axial Air Setting

Feed End Temp

I.D. Fan Speed

Pyro-processing: Kiln Control

11

Tyre Creep Control

Minimum heating-up period


determined by the time required to stabilize the temperature difference, hence the clearance shell heats up faster than tyre

Tyre #2 is critical
too rapid heating will constrict kiln shell result in permanent shell deformation excessive tyre slip after normal temp. regained

Creep should be monitored at regular intervals


if low, heating should be slowed

Pyro-processing: Kiln Control

12

Turning Schedule

Ensures slow, uniform heating of the kiln and refractory


increase in temperature over time allows for the expansion of refractory and shell brick remains in place and shell expands uniformly along its longitudinal axis

Too Slow
overheating of refractory and shell shell & refractory damage (e.g. duck-nesting )

Too Fast
longer preheat times due to poor heat transfer potential brick spiraling
Pyro-processing: Kiln Control 14

Turning Schedule Example


Reference temperature (Lower stage) UP TO 120 C 120 C TO 210C 210 C TO 450C 450 C TO 600C 600 C TO 750C KILN TURNING PROCEDURE WITH AUXILIARY DRIVE KEEP THE KILN STOPPED TURN 90 TO 120 EVERY 45 MINUTES TURN 90 TO 120 EVERY 30 MINUTES TURN 90 TO 120 EVERY 15 MINUTES TURN 90 TO 120 EVERY 10 MINUTES CONTINUOUS TURNING

750 C UP TO FEEDING

Pyro-processing: Kiln Control

15

Kiln Preheat Schedule Major & short shutdown


HEATING-UP GRAPH FOR ROTARY CEMENT KILNS
1300* C 1000

Kiln exit gas temperature at inlet area

900

1200*

800

{ {

START OF MATERIAL FEED ACCORDING TO

KILN TYPE AND OPERATING PROCESS

700

600

900*

500

400

curve 1: Limited repairs 30-35 C/h curve 2: Complete relining 20-25 C/h

600*

300

200

300*

100

0 0 3 6 9 12 15 18 21 24 27 30 33 36 39 42

Heating-up Time, hours

Pyro-processing: Kiln Control

16

Kiln Preheat Schedule - Detailed


stepped to include two holding patterns (300, 550 C) allows refractor to catch-up with gas temperature
24 HOUR PREHEAT SCHEDULE
1000 25.0

900

800

20.0

700

TEMPERATURE

600

15.0

OXYGEN

STG 4 TEMP STG 1 TEMP STG1 OXYGEN

500

400

10.0

300

200

5.0

100

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 HOURS

0.0

Pyro-processing: Kiln Control

17

Feeding of Raw Material

Raw material feed ON


when burning zone is ready

Start of feed and arrival in sintering (burning) zone is critical to tyre creep
fuel supply must be increased compensate for heat absorbed by raw material

Close attention to tyre slip


if slip ceases, counter measures must be taken

Limited feed may be introduced prior to optimal temperature to assist coating

Pyro-processing: Kiln Control

18

Start-up Post Audit

Analyze deviations from the planned schedule to continuously improve operational performance
production coordinator, kiln coach & operators identify reasons for deviations make joint recommendations correct SOPs and circulate among all operators

Develop a table of variances and explanations

Use our collective knowledge & experience to become the worlds best cement producer!
Pyro-processing: Kiln Control 20

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