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Kiln Control and Operation

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397 views36 pages

Kiln Control and Operation

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alfandari
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© © All Rights Reserved
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INFINITY FOR CEMENT EQUIPMENT “35% ox) [0%] Oxygen at Ki for coal) BET 25-35% ow dada Kindat Fuelrate —Kinspocd pric Fae Kiln Control and Operation “4 commen / Cement plant Operation {CR operat, KILN OPERATION, Process, Operation andmporant Forms y adn Previous Post Next Post )) OWNING AND READING MOST IMPORTANT BOOKS IN CEMENT INDUSTRY + MANUALS AND NOTES AND SHEETS FROM THE MOST SUCCESSFUL PLAYERS IN CEMENT INDUSTRY WILL CHANGE YOUR CAREER AND WILL MAKE YOU REACH MANAGERIAL POSITIONS FASTER , KINDLY CLICK HERE TO GET EVERYTHING Kiln Control and Operation TO DOWNLOAD THE MOST IMPORTANT BOOKS , MANUALS , OPERATION NOTES , FORMUFLAS , EXCEL SHEETS CLICK HERE NOW !! ‘The most important contol paramsters in any ype oil syst at: + Burning Zone Tempartue fan incisor forthe produced clinker gully Sack End Temperature a an indicator fr the rw mes presration wes mail ying heat up ad ealnatin) + «igen concentration ofthe in a 938 as an ineestr forthe eine af combustion) 1+ incase of gate coolers Bel height of the clinker Byer onthe gre + Fuckatete the + Mateal fees ato the kn + raftinthe in + Kinspeee ‘objectives of kn operas + Protection of equipment and personnel altines + consistent good cer quality + Smooth andsable operation 1 Masi thera eficiency + Marina production ate 1, INTRODUCTION ‘The dlferent ih systems canbe distinguishes by the moisture content of there materi wich sed tothe kin yen, The dierent process ype 1 Wet orocess 80-40% Mote ‘Athough each ype of process has fs own partculi operation paramaters, the aw mel has o undergo smi chemical and physi reactions unt the clinker lly + Drying ofthe aw meal + Heat up ofthe mateal + cation + Frmtion of he clinker mines The man atference between the ifeent types of proces les nthe raged tne and energy each escon needs to be completed Therefore the operating range of the diferent contol pararaterssvaying from one kh system to the other. The some apples tothe response tne a wellas tothe ‘requency an magnitude of ry control vrisleajustmant 1. CONTROL PARAMETERS Some of thon to iformation purpose oly ei ap is opened or loses, othr to detect dangerous situations (eg cjelne bloceges, tony ow af ther ae contnously see foro operaton ROTARY KILN, DRYER & COOLER PARTS rue ign olin open ais Onaones ‘The most inporant contol parameters hat r looked 3 1 forthe produced linker ual + incase ofa gate cooker Bo hight ofthe sinker es 1 Location of the control parameters and variables get ales ae given below. The contro veils, which ar aust to beep the ‘The lsstion where he diferent contol parameters are measured sn some 1.1 Wet kiln Fuel ate Kilnspesd Feed rate Kilndratt ‘Onygen (for coal, ber 15-25% ezr 1080 °¢ Fut ato Kiln Foodiais Kiln (Horm oe Figure 2 Conrl parameters nd vrables of epol xin 1.1.1 Preheater kiln bbob = Fuelrate ——Kilnspeed Kinda Feed rate Figure 3 Conol parameters and vile of PK 1.1.1 Precaleiner kiln MT ‘Oxygen after PCT=15% Oxygen at Ki (loro ezr BET 25-35% 1450 °C ~1450 "0, Kindo for PCat Feet rato Fuetrata —_Kilnspeed 1 Burning Zone Temperature (BZT) {Ye LT determines, how wllthe nker is bumed and how compete the transformation from C2 to CS is When th keris leaving he burning zone should no ROTARY KILN, DRYER & COOLER PARTS rue ign olin open ais Onaones Ove te changes ofthe aw meal compeston an alteration ofthe 8ZT target canbe requed now and the, sine burnabilty of raw material changes wth Mucus ofthe LS, SR magnesia net ala content among other fictrs.& change inthe fame characte; whic an raul om the use of ipl flor varying combustion conltions hae a init an therefore may alo requis an alteston of the AZT target \Varitios ofthe ZT get are made ony over 2 longteom perio, nthe same way asthe fee C30 (or Kar weigh ismansred normally only ona one or two hourly ROTARY KILN, DRYER & COOLER PARTS = le Ria, Opn Goan. ars "he acl 821 must be measured to dtering fa davaton between the temporary frgetand the Acs RZT eis ‘Since ln operations damic proces devon ve que fequant and of short-term characte Seversindicators are ued to determine the ZT and they ae ted below reseed compares to an eater setined ost do no xpi expres an sbsohitetenperatre bu thy give aun information to estab he BZTinereszel ord target This mean they ge the short-term rand ofthe conta arate BZT Ti hlpe to estimate the probable re C30 forthe erwin nel mut ridge theme nti he atl linker ana i able 1.1.1 Pyrometer reading ‘The tation of dnka nd costing inthe burning zane hs rein os temperate. Thetlore the SZT can be detuned by messuing te ntensty othe calor of ROTARY KILN, DRYER & COOLER PARTS ur igo open ais oars ‘Sirk re to hen 00 650-750" orange to yllow 00-1100 Yellow 0 toh alow 100-1350" Light yellow to white 1350-1550 5 messing the color of he burning zone ane nt only the ation ites, the ening les intuence by esturbances the the dst load ofthe secondary sir aed ‘Therefore moder yrometers snl kh carere mainly masse the coor and not he inten of iaton 1.1.2 NOx of the exhaust gases produce during combustion and vce versa, 1 gas ofthe burning zone. The hole the fms the more NOx nen 477 dees fom the NOx content ofthe exhaust se, the ongen and CO concentration nthe exaust gases hve tobe considered ai, sine CO reduces ard ‘nygen promotes the formation of NO ‘Marner factor inteencing ox formation ithe ype of fl burned the fuel mx changes, the quanti of NOx produced may change too (especial when buming sheratv fuk. 1.11 Kiln torque The burning zone sits upwards and ges ng he ZT. |Ahgher ZI proses mor li phen he cnt ‘The ameter ofthe clinker bls increases and the granulation of he aw malin the kh Stas eae. Therefore more and bigger clinker shave tobe moved inside the ene the 821 seeing, ‘tthe same tine the matariatbed inthe ini ites up more which moves the entero gravity aay rom then ais The ferent granulation ofthe clinker andthe changing ange of repos increase the require torque tum the kn ZT os. etka co in gute S Torque of hot and cols ‘This torque is proportional tthe cuanto » DC drive and proportonslto the quotient ih power /nsped incase a an AC drive ora hye dive | changing coating stustion nthe uring zone strongly intuences th ln torque (at move a lower the 0 ati ofthe kh). Aa result the il torque can ehange Slgncantly on long-term tat without any change ofthe 87, Theraore he ki torque signal mos ces ony seve aba short-term ination af the BT, Shot termis defined 36. up to 12 hours Trqueis 3 ery weal nestor a kl conlton lative tos rene. 1.1.1 Secondary Air Temperature (SAT) or Tertiary Air Temperature (TAT) ‘ces grat cooler which te equipped with a rlable SA or AT mestorment device often use SA or A 3 indetor for he ZT. {Pe hohe the B77, the ote the released clinker and the higher SAT of TAT and vice versa 1.12 Position of the dark feed (valid only for pure natural gas flames) the vty inside the kn does permis ite cuty, hme shape, ec), the caine hot mel can besten a3 ak tha when entering the benng one. An ares cin be etemined where this meal floating like water starts to form quid phases and whee wansorms to solid linker bal ‘The poston of the rea where hs transformation ‘kes pace i anaes ndetor ofthe ZT, rhisares ets downwards the BZTeling snc vers, clinker coating dark feed area of transformation rig oon fhe a ed 1.1 Back End Temperature (BET) x ‘The tem BCT refers tothe temperature af the exaust gs he nit in cae of kis wh a preheater ant the intemesiate gas tempersture (before the cin Secon) the kn is equipped wth chains. The BET depends on the typeof system and the L/D = ratio hel. Kranges fom ~800 Cin wet hs before the an secon up 0 1200" in AS precalcners. Haale temperature measuterent a the lilt fal with prehanas or before the chain scion als with chains} set aval, aque the peeheste et temperate els ith rehantes ofthe inet temperature als wih eh) suse ‘The BT's an inetor of haw wellthe hot med i prepaced hen entering he kn for hen passing the intermediate measing pont in ate an systems with sin efre the meals rally dnkered in the burning zone, thas to undergo dyout clchation elas of C02 and toa minor extend also reaction he structural ‘madieatons ad the feimtion of intrmadiate produce Me C1247 or CX. ‘The higher the energy demand ferntemediate rescionn the kh, (which depend msinly ftom the typeof pocess the mrelmporant is prope ont of he BET ence the BET in wet kin it more etic {0-10% einai missing) than a separate pecan in (-10% clnation ming. ‘The BET rents as slower to any control varabl adjustment as longer the kl ight L/D rat and as more entgy is consumed inthe hi for hentermedate reactions efre clarion ally the materi shoul says hve the same degree of preparation, but due othe hl operation if and normal actuation af the aw mateal properties, ue, ‘artion in the at teri are fest observe trough the BT, thereby fting et theatre imac on he BZT al eer parameters remain constant andthe 3 drops this evidence that all eacton zone hf downward and vice vers ithe zones within the nei thar down or up the BT wll decrsee or erste consequently afterwards lk, fo counter masse are taken eal. 1.2 Oxygen control for good cmbuston fh fel» erin amount of xs ied ‘pies oxygen anges tthe kn forthe most cor:mon kin sytens te gue nthe fllowing abl The rie exygenIvel depends onthe ype a kn system but als sronglyon the ype of ful being ued fg gas need ls xc srthan coal or old AFR. _Mfurnerimportan intent the angen vis she amount of slur, chlorine a lawn the kh sytem Therefore the higher oiygen evel within the given ‘anges are chosen slr oat is prblem, sot are Werkn 05-10% 10-20% 15-20% 20-25% ep n 10-15% 15-20% 15-25% 20-10% Presta 10-15% 15-20% 15-25% 20-20% Infos kn 25-20% 25-30% 25-35% 25-40% Separate Roe ra 15% 15-20% 15-25% 20-30% ‘ble I Typical oxygen level a the in inlet ry 938), Ino in systems the equiv amount of exes siti sights sbows the point where the nr tamperture woul be highest duet slr chlorine or ala stuation ‘Therefore sigh retion ofthe amount of exces iinceses the the temperture se {atvemel lw exces si for oxygen) edces the lime temperature, which engthens he flame (pstcombuston and lowers the uc fficency Aetionaly sur nd sll viet is ehanced hich my Led to bil up are ncusationpblems win the kn te, Too much exces sir oxygen) coc the fame too an ads slo to 3 poor thermal fue fcency due othe deteriorating hest anf Since the total gas fom it Increnced, heh interlace dust cycles a ners Hence ower oxygen evel ae chose, isu velstlzation snot problematic ‘Asa generale spl, that at the minimum permissible ygen lve no notable CO is formed fe. < 005 % atin ine CONTROL VARIABLES Inthe proceeing paragraph the mala contol parameters se fr contol were resented ‘Those parameters mute kept in nattow range dosed target in ade ore hein in smeath ad fen manner General spening te ser the de ofthe parameter rom the tage the better hen contr ‘To ksep the conta parameters closet target itis generally necessary o make asjustments toe contol ‘The main contol variables ate (exuding precatiner systems: + Mater! eesrateto the kn + Kina + Kinspees Inthe following the fc of any austen mad o one of he fur contol vatblesis sown To keep te nor restive complex eons simple is sumed, ‘hat the acjustment is done onl to one varble ata ine the hes remain untouched) and that he adjustment isso sal that none ofthe contel parmetes devates {atom tage di Fuel rate to the kiln 1+ azrinersses 1+ BFTineeaees + «gen concentration dereases (Adecese ofthe ful ate has the invere tect ‘More energy introduce nt the systom therefore the BZT and the BET Hse. Onygen evel crops, since part of the exes af consumed forthe combustion ofthe nt fa Cf course the above apes ont ifthe combustion dos not take place under raducing condone 1.2 Feed rate to the kiln \Wnem increasing the mater ee at int the ke ‘A decease ofthe fed rate hasan invite len more feed introduced into the ih sate the temperature tarts oop fst tthe backend Aer the higher mint af feed ha teaches he buming 206, the AZT ants to dacest so ‘The ena feed reas aditonl H2C and CO2. The sedtons riount of gs rom the mea duces the quonty of combustion sir ane thus of aces sit sne the amount of exaust 96 rensine almost) constant. This sd o decrease of oxygen inthe ext ga. 13 Kiln draft When ncnaing the atin the ki = + azr decrees + Oxgen concentration nceses (slight cecens ofthe craft hasan inure tect combustion ‘aes pce under reducing condone too Ie exces si she BZT drops agin sn BET ries ene chapter 24, ‘When the kin raf ites, more (and sigh scandary iri pled inte the kin and though the burning zone. This decenses the fame temperature and 82 result the 877 drops. though he amount of est spp othe kin sytem is smu higher (more secondary i, Isshest i alenced in he burning zone dower fhe emperature ‘esuin reduces het tans hue he BET res ‘The higher ls dat incteses both, the oxygen concentration ad the volume af the exaust gases. 14 Kiln speed hen inceaing the sped he th + tzrecesss temper {at deceass tempo + onsen acess tengo ‘hdecrse of the ti spn haste ves fet nen hen sped is increased the meal advancement faster: Al aaction zones shit temporsily downwards, which uss the BET andthe 827 Yo rap Since more mel enters temporal the dying andthe aening zone (ame effec gan neeasd feed rath higher amount of 20 ane CO? released which ad. 9 ropin the oxygen concentration ‘Those tec ae only temporary nce a higher speed at fie fed ate rece the filing degree inthe in, Once the ki filng degree hasbeen lowered in the centie kn (ll mate hat was inthe when she speed change was mad, as eft he kl, BZ, BET and oxygen recover. Mane In certain psa conston (especialy he dred hot mesl us he kiln speed hs tobe reduced hat much hat pals reduction of th in feed woul produce an ‘overeating ofthe back ed, n hese sustons, 3 comoromiae between increased fling degree ana BFT mort be made ander thi station, the so-al cjing ean cca. 2. CONTROL STRATEGY 21 General remarks ‘As seen before a adjstrent to ony one ofthe contel vale hasan impact ol vee contl parameters Tokeep ll contol parameters within cata range close to target its normaly necesny to make austnents to more than ane contol vail ‘84tn doing s0,the comaton of one particular conto parameter an increase the deviation ofan other |Asaesut a compromise mus be found that reduce the weighted average of all parameter deviations tea minimum ‘The welght degree of importance ofeach partic contol parameter dapends onthe type of system ad the particu i na precaine in for example the BET i les cel than na wet, Therefore the nflunce of the BE islets weighted na pecans ln than in wet Ki, The slot uta art gentcnenen ne tng one oF more contol parameter shat ar out of ange back» nots depend on the overall ve of alent} Inthe folowing an example of kn operation svatgy presented which describes the mee typicl Acton, which maybe taken forall types of in systems Certain ‘modieaton ofthis statgy may be maces in parca cases, since each ln behaves diferent and has cls precond tons. | very inpostant factor heten plays the aly to make posite changes to the con vatisles. may ths a botleneck eit that doesnt llow any postive change ‘uns arene wth masinum speed or withthe damper comaetely opened). TS te one othe contol varies once nominal spay has bee each fog a9 fan hs consequent may reqiean aeration of the presented statey. ‘The purpose o this sratey isto uncestand the princes of ln operation and may not be deel apolabe onan systems 2.2 Possible kiln parameter conditions Issued tht the three is parameters ZT, BET and Oxygen at linet can be tribute to ona of the follwing states akhough vanstins ae ih which sr + side the dese ange, which means 1 Above the deed range, which means high 1+ alow the dested ngs which meas ow ‘The desired ange forthe tre conto praaters ply 3 fllone wr er ‘owygen Workin Target 0/20 Tipe of 10 Tega 0/208 Lepr Tage 0/20 Tage f-15 °C Thuget of 05% Probestr tin Target of-20 Trget of 18 Tage +f-05% Intne Fn Tage +/-20°C Tiga +f-20°C eget 0/07 Separate PC Target +/-20°C Trager o/-20°C Trager o/-08% “ble 2: Desa range ofthe diferent convo parameters Combining the she contro parameters and shai respectve stat in any combination leads to 383227 posse condition. These 27 basic condons are shown ‘raphy below in th -cle decision toe 23 Decision tree Sasedon the 3 poss conditions ofthe 3 conve parameters the flowing decion we Is bulk, which coves all 27 posi states

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