081_TSP HUA400 20080305 Kiln Audit Dec07

ATC REPORT Activity: AUDIT/PROCESS China / Huaibei Plant KILN AUDIT by: ATC P&E Team 04~08Dec2007

Distribution: Region BU Plant ATC Other Codification

Rosy Wang /Wang ZhiHonh( for plant distribution) Renaud de Belmont // G.Benveniste TSP/HUA400/NQI/20080205/HUA kiln audit

Table of Content A.

Executive Summary............................................................................................................... 2

B. Main Report............................................................................................................................ 4 B.1. Introduction......................................................................................................................... 4 B.2. Work Done:........................................................................................................................ 4 B.3. Analysis / Argument / Conclusions.....................................................................................5 B.3.1 Safety alert.................................................................................................................5 B.3.2 Plant information.........................................................................................................5 B.3.3 Heat and mass balance..............................................................................................8 B.3.4 Cooler performance..................................................................................................10 B.3.5 Preheater and precalciner inspection........................................................................12 B.3.6 Gas analyzer and false air........................................................................................15 B.3.7 NOx and SO2........................................................................................................... 18 B.3.8 Burner audit.............................................................................................................. 19 B.3.9 Volatile balance.........................................................................................................22 B.3.10 Fan efficiency............................................................................................................ 24 B.3.11 Operation.................................................................................................................. 25 B.3.12 Quality and Sample analysis.....................................................................................26 B.4. Recommendations............................................................................................................ 27 B.5. Acknowledgements.......................................................................................................... 29 B.6. References....................................................................................................................... 29 B.7. Appendices....................................................................................................................... 29

A.

Executive Summary

Objectives • Training of Lafarge ATC P&E engineers • Make an “extensive” kiln heat and mass balance • Run tests of general interest for technical assistance in LSO • NOx abatement  Environmental protection standards A 7 day report was sent after the audit based on the [presentation given to the plant (see attachment) Results and Findings Global heat consumption was 777kcal/kg-ck @ clinker production 1145.5tpd. Main KPIs are as following: Kiln parameters: actual target clinker production 1145.5 tpd Clinker C3S & clinker CaOl 777kcal/kg-k specific heat consumption 730 efficiency of top cyclones 94.9% >92% ID fan power consumption 12.45kWh/t-k ID fan efficiency 53% >70% kiln/calciner ratio 38.6 : 62.4 >40% at kiln Decarbonation 90~95% primary air ratio 16% 12% total false air (based C1 18.31%