cement process problems troubleshooting

3/27/2017

RNB CEMENTS (P) LIMITED DEPARTMENT- PROCESS Presented ByAkshay Kumar Si DGM (Process)

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WHAT ARE THE MAIN PROCESS PROBLEMS IN CEMENT PLANT? In Pyroprocessing➢ Cyclone Jamming ➢ Kiln inlet jamming ➢ Big clinker ball formation ➢ Coating formation in kiln ➢ Feed rushes and dusty kiln ➢ Snow man formation in cooler ➢ Red river in clinker cooler

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PROCESS PROBLEMS IN GRINDING ➢ Mill jamming ➢ Residue problems ➢ Blaine problems

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Cyclone Jamming Why cyclone jamming happens in Preheater? Main Reasons✓ Insufficient suction due to low rpm in PH fan. ✓ Flap valve failure & blockage in material pipe. ✓ Refractory failure. ✓ High Iron % in Raw mix. ✓ High Sulfur % in fuel(i.e- coal)

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KILN INLET JAMMING Why kiln inlet jamming happens? Main Reasons✓ High Iron % in Raw mix. ✓ High Sulfur % in fuel(i.e- coal)

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BIG CLINKER BALL FORMATION Why big size clinker ball formation happens? Main Reasons✓ High Iron % in Raw mix. ✓ High Sulfur (S)% in fuel(i.e- coal). ✓ Kiln running with slow rpm & % filling is more. ✓ High BZ temperature. ✓ % liquid is more. ✓ Higher % of Magnesia (MgO).

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HEAVY COATING FORMATION IN KILN Why heavy coating formation in kiln? Main Reasons✓ High Iron % in Raw mix. ✓ High Sulfur (S)% in fuel(i.e- coal). ✓ Kiln running with slow rpm & % filling is more. ✓ % liquid is more. ✓ Higher % of Magnesia (MgO).

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FEED RUSHES & DUST KILN Why Feed rushes and dust kiln happens? Main Reasons✓ High lime in Raw mix or high LSF. ✓ Very less % of liquid. ✓ High AR. ✓ Less iron% in raw mix. ✓ Blockage of hot meal due to clinker ball occasionally.

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SNOWMAN FORMATION IN COOLER Why snowman is formed in cooler? Main reasons✓ Higher % of liquid, may be iron % is more in raw mix so hot meal will be sticky and viscous. ✓ Shorter cooling zone; so may be shortage of adequate quenching . ✓ Higher BZ temperature, may be due to short flame. ✓ Failure of air blaster in cooler 1st grate if any.

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RED RIVER IN COOLER Why red river is shown in cooler? Main reasons✓ Uneven distribution of cooling air. ✓ Mis alignment of kiln & cooler.

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RED RIVER

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THANK YOU

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