Start Up Procedures PDF
Start Up Procedures PDF
Each plant must customize to the specific characteristics of their equipment & develop more detailed checklists & SOPs
Pyro-processing: Kiln Control 2
BP Deliverables
Procedure to reach full production Recommended record keeping Start-up after short shutdowns (<48 hrs) Information required for customization of SOP Indicators required
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
Check sheets should include room for comments & assigned responsibility
Pyro-processing: Kiln Control 6
Feed System
recirculation mode & calibrate if no recirculation ... run briefly check operation, leaks run dust evacuation (elevators, screws & pumps)
Refractory preparation
manage the installation of refractory, proper installation is key to longevity follow procedure for preheating to maximize brick life
700 600
550 600 600 600 600 600
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
10
Preheat Schedule: -
Fuel Rate
11
Tyre #2 is critical
too rapid heating will constrict kiln shell result in permanent shell deformation excessive tyre slip after normal temp. regained
12
Turning Schedule
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
750 C UP TO FEEDING
15
900
1200*
800
{ {
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
16
900
800
20.0
700
TEMPERATURE
600
15.0
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
17
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
18
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
Use our collective knowledge & experience to become the worlds best cement producer!
Pyro-processing: Kiln Control 20