KilnLine Operation

December 21, 2016 | Author: breakthrough1988 | Category: N/A
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Page 1

Operation of the kiln line Training Klaus Grittner Polysius Services Polysius Headquarters / Germany 19. May – 13. June 2008

Training THALOFA

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SilzR

13 Jun 2008

S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Operation of the Kiln Line Heating Up Starting Sequence Start Up Increasing Performance Normal Operation Optimisation Main Control Loops Normal Shut Down Emergency Power Consumers

Training THALOFA

Page 3

Clinker Production Line 80 °C

Pre heater Calciner

340 °C; to raw mill and / or EP

fuel

900 °C Tertiary Air Duct

55 – 60 %

860 °C

fuel

1700 °C Rotary kiln

280 °C; to EP

40 – 45 %

350 °C 1400 °C Clinker cooler 80 - 100 °C Ambient air temp.

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S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Heating up the kiln line • The fuel burns with the smallest possible amount of combustion air. • There is no CO, or only slightly formation of CO at the kiln inlet • Most of the heat remains in the clinkering zone • The flame is short and compact. • for the new kiln heating up takes approx. -- 48 hrs. (with new brick lining) -- 30 – 36 hrs. (after normal maintenance shut down)

Training THALOFA

Page 5

Example for 1st heating up the kiln line

or heavy fuel oil

Continuous turning

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S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Tilting and turning the kiln During the heating up the kiln should be continuously inched and turned, the guide values for a new kiln are : 0 – 12 h:

1/3 revolution with auxiliary drive

every 30 minutes

12- 24 h:

1/3 revolution with auxiliary drive

every 20 minutes

24 – 36 h:

1/3 revolution with auxiliary drive

every 15 minutes

36 – 46 h:

1/3 revolution with auxiliary drive

every 10 minutes

46 - 46 h:

continuous rotation with auxiliary drive

 0,1 rpm

from 48 h:

turn kiln with main drive

app. 0,6 rpm and start feed

Training THALOFA

Page 7

Starting-up Sequence of the Kiln Line Remarks: Auxiliaries of the kiln line

De-dusting plant

Control air compressors, cooling water system. rapping system

Filter dust transport De-dusting filter fan

Kiln waste gas fan (ID-fan)

with closed damper

with closed damper

Training THALOFA

Page 8

Starting-up Sequence of the Kiln Line Remarks: Primary air fan for MB

Fuel supply (fuel oil or coal)

With damper closed

CO < min. - analyser behind cyclone 2 - analyser before bag house

Clinker transport

Cooler waste air filter dust transport

„Bull Nose“ cooling fan

cooler roof protection

Training THALOFA

Page 9

Starting-up Sequence of the Kiln Line Remarks: Cooling for roller crusher

Roller crusher Cooling air fans for recuperation zone

Cooler exhaust air fan

Cooler de-dusting filter

With damper closed

With damper closed

Training THALOFA

Page 10

Starting-up Sequence of the Kiln Line Remarks:

Main burner

many preconditions (CO, T….)

Cooler grates

Kiln main drive

Cooling fans for kiln shell

Cooling fans for kiln outlet

slow speed  0.6 rpm

only if main drive is running

Training THALOFA

Page 11

Starting-up Sequence of the Kiln Line Remarks: Kiln feed

Cooling tower

Pre-heater cleaning systems

Open tertiary air dampers

Calciner burners

app. 20 %

Fuel MIN

Training THALOFA

Page 12

Start of the Kiln Line / Kiln Feed

!

For kiln feed start sufficient personnel has to be in the pre-heater to watch the function of the pendulum flaps and material flow!!!

1. Cooler Grates:

~ 3 - 5 stroke/min, (minimum speed)

2. Kiln main drive :

0,6 – 0,8 rpm

3. Cooler Fans :

~ 30% of the nominal quantity kiln hood pressure: -1 to -2 mm WG (Automatic control)

4. Main burner fuel:

Heavy oil: Coal / Pet coke:

5. Start Kiln Feed :

~30 to 35% of nominal feed rate (new kiln, no coating) att.: there is a time delay between kiln feed group start and real kiln feed.

6. Adjust draft after : cyclone pre-heater

- 12 to -15 mbar by ID-fan/ dampers exhaust gas duct.

~1.000 Nm³/h ~ 6.000 kg/h

Training THALOFA

Page 13

Start of the Kiln Line / Kiln Feed 7. Main burner :

Increasing of the fuel quantity to specific heat consumption  1300 ...1500 kcal/kg clinker Att. ! : It’s only a guide value!!!

8. Start PC-burner :

Sufficient Oxygen

Fuel distribution: Kiln inlet : After stage I: Hot meal 1:

- after cyclone stage 2: > 2,5 % - after DOPOL: > 4,0 % MB ~70-75%, PC ~25-30%. ~ 1050 °C, ~ 860 °C, ~ 840 °C

9. Adjustment of cooling air:

according to kiln feed ( ~ 2,0 Nm³/kg clinker)!!!

10. Observing clinker formation:

visual check, kiln camera, pyrometer, observe the power consumption of the kiln drive.

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S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Gas analyser / Alarm set points

Gas analyser behind Calciner -- CO (max-max. 0,8 %; calciner burner) -- O2 normal value app. 2,5 %

CO > 0.6 % alarm CO > 0.8 % shut off the calciner burners CO > 1,1 % stop the main burner

Gas analyser before bag house -- CO (max-max 1,1 %; main burner) -- O2 normal value app. 4,0 %

Gas analyser behind kiln -- CO (max 0,8 %, Alarm) -- O2 (min 1,0 %, Alarm)

Training THALOFA

Page 15

Increasing the kiln performance Precondition: granulated clinker in the sintering zone and in the clinker cooler 1.

Increasing the gas flow through the cyclone pre-heater

via damper or speed of ID-fan- / filter-fan Oxygen content behind cyclone stage 5 > 4,0 % before increasing fuel. After ID-fan: keep -50 mm WG (by EP-fan)

2.

Stepwise opening of the tertiary flaps

(Oxygen at kiln inlet adjust to ~2 – 3 %)

3.

Increasing of clinker cooler air quantity

keep kiln hood pressure -1 to -2 mm WG. (control loop)

Training THALOFA

Page 16

Increasing performance 4.

increase of kiln feed and fuel

target of fuel distribution: -- MB ~ 45%, -- PC ~ 55%

5.

increase of kiln speed

according to the kiln feed

6.

close fresh air flap (if open)

depends on temp. after the pre-heater

7.

operate clinker cooler with

-- until a clinker bed dept ~ 500 mm

slow speed

-- pressure in aeration chamber 1 ~ 40 mbar)

Same above mentioned steps for further increasing of the kiln feed!

Training THALOFA

Page 17

Increasing performance Cooler grate velocity

(watch the pressure!!!) and cooling air quantities have to be adapted (1,8 …2 Nm³/kg Clinker)!

Att.: Secondary air and tertiary air temperatures will rise! The specific heat consumption will reduce!!! Prevent overheating the sintering zone!!! Take attention to:

the kiln inlet temperature (max. 1150°C), the hot meal temperature (max 870°C), the temperature after pre-heater (normal 340°C, max. 450°C):

Training THALOFA

Page 18

Normal Operation Preconditions of trouble-free operation: - most homogeneous raw meal (LSF, SR, AR) - constant kiln feed (variation < 1 % / minute) - constant fuel rates (variation < 1 % / minute) - constant gas flows, cooling air flows

Training THALOFA

Page 19

Optimisation of the plant

-- Process parameters -- Typical operating parameters -- Burner-/ Flame adjustments

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S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Process Parameters 1.

kiln feed rate

tons / h

2.

Specific heat consumption,

kcal / kg

3.

Total fuel rate ,

tons / h

4.

Proportion of fuel to pre calciner / riser,

%

5.

Secondary air temperature ,

degree C

6.

ID fan draft ,

mbar

7.

Pre-heater exhaust gas temperature,

degree C

8.

Kiln inlet gas analyser

O2 %, CO %, NOx mg

9.

Cyclone stage II gas analyser

O2 %, CO %, NOx mg

10. After ID.-fan gas analyser

(calculated)

O2 %, CO %, NOx mg

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S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Process Parameters 11.

Water into the cooling tower

l/h

12. Kiln feed material (meal chute 1)

SO3 %, LoI. %, (Lab. results)

13. Kiln drive power ,

kW, Amps

14. Primary air pressure

mbar

15. Clinker cooler ventilators, air volume

Nm3 / h

16. (Primary air,

Nm3 / h)

17. Pre-heater profile (Temp. Pressure)

°C; mbar;

18. Specific Calculations

kcal/kg clinker

-- Specific kiln volume loading,

tons / m³day

-- Gas velocity in burning zone,

m / sec

-- Specific heat loading of burning zone,

Mcal / h per m2

Training THALOFA

Page 22

Typical Operation Parameters Temp.:

Press.:

Clinker cooler:

-- gas duct 1:

860….... 880 °C

-- meal chute 1:

840….... 860 °C

-- tertiary air:

850….... 950 °C

-- after pre heater:

320….... 340 °C

-- Kiln Hood:

- 0,1……- 0,3 mbar

-- Kiln Inlet:

- 4…. ….- 6 mbar

-- Gas Duct 1:

-14…….- 16 mbar

-- after Pre heater:

- 50…….- 60 mbar

-- Chamber 1 pressure

50…..…. 60 mbar

-- Secondary air temp.

900….... 1000 °C

-- Cooler exhaust air temp.

250….... 300 °C

-- Clinker temperature

80……... 100 °C

Training THALOFA

Page 23

Burner- / Flame Adjustment

-- to burn a good clinker quality, but prevent damages in the refractory. -- to build and to keep good coating formation. as protection of kiln bricks and reduced kiln shell temperature, but also to avoid coatings rings etc. -- good heat transfer to the material by radiation and convection.

Training THALOFA

Page 24

Burner- / Flame Adjustment Main Burner Fuel:

-

Total Fuel:

- Specific heat consumption (kcal/kg clinker) - Temperatures of meal and gas in the pre-heater

Fuel Calcinator:

- Hot meal temperature - Degree of calcination (92...95%)

Attention:

Temperature of sintering zone Kiln inlet temperature Kiln main drive power (A or kW) Free lime (CaO) in the clinker

Orientation only! Parameters/Results may overlap!!!

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S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Training THALOFA

Page 26

Optimal Operation: Gas conditions:

CO ---> to be prevented!!! min. of Oxygen is required!

Oxygen after pre-heater:

~4%

by damper or fan speed

Oxygen after stage II

~2–3%

by damper or fan speed

Kiln inlet:

~ 1,5 - 2 %

by Tertiary Air Flaps

-- more open: Oxygen stage II up / kiln inlet down!!! -- more closed: Oxygen stage II down / kiln inlet up!!!

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SilzR

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S:\Team\Training\THALOFA\CD-for-Customer\05-04-KilnLine-Operation.ppt

Main control loops of a kiln plant Kiln hood pressure

Target: Actuator:

 -0.1 mbar Cooler exhaust fan speed or damper

Under grate press. (chamber 1 or 2)

Target: Actuator

constant at set point hydraulic drive for grates

Cooler air flow

Target: Actuator:

constant at set point Cooler fan speed or damper position

Press. after kiln ID fan

Target: Actuator:

 - 5 mbar EP-fan speed or damper position

Temp. after Cooling tower

Target: Actuator:

 160-190 °C Water valve at the return line

Training THALOFA

Page 28

Normal shut-down of the kiln plant Generally -- reducing of the kiln feed in steps of app. 5% -- minimal kiln feed is about 40…50% -- an empty kiln can be easier heated-up and re-started! •

Stop of PC-Burners and kiln feed



Reduce fuel at the main burner



Reduce pre-heater draft



Close the Tertiary air sliders / flaps



Stop of main burner primary fans to be kept in operation (for cooling!!!)



Close the DOPOL-flaps to 10-15%

Training THALOFA

Page 29

Normal shut-down of the kiln plant •

DOPOL-fan:

dampers to be closed



Clinker cooler fans: dampers to be closed



Cooler exhaust air fan: controlled by kiln hood pressure measurement, or set to minimum value



Kiln to be tilted! - during cooling down - if raining continuously with auxiliary drive - 1st and 2nd hour each 10 min 120° - 3rd hour each 15 min 120° - 4th hour each 20 min 120° - 5th till 8th hour each 25 min 120° - then... each 30 min 120° ...till a kiln shell temperature (sintering zone) of about 100°C is reached



cooler track units:

to be operated in intervals

Training THALOFA

Page 30

Emergency power consumers -- Emergency lighting -- Communication systems -- UPS unit for computer and process automation equipment -- Control voltage for the total kiln plant -- Cooling water supply system -- Dampers in DOPOL exhaust gas duct -- Kiln auxiliary drive including lubrication) -- Oil pumps for circulation lubrication system for roller bearings -- Primary air fans for all burners including actuators -- Protective air fan for sintering zone pyrometer -- Actuators for damper in tertiary air duct -- Fan for kiln outlet cooling -- Cooling air fans for roller crusher -- Cooling air fans for recuperation section

Page 31

Training THALOFA

Rotary Kiln Main Plant Interlock

Temperature Preheater > Max Max

STOP

FILTER FAN STOP

CO Preheater > Max Max

KILN ID-FAN

PRIMARY AIR FAN

STOP

STOP

Stop Timer 0,5 hour

KILN FEED STOP

STOP

Temperature Preheater > Max Max

STOP

MAIN BURNER

STOP

CALCINER BURNER

Filter dust transport

STOP

Stop Timer

CO Stage 2 > Max Max CLINKER Transport STOP

MAIN DRIVE

5 min

Grate 2

Grate 1

Stop Timer 5 min

STOP

CLINKER COOLER failure of 2 or more air fans

CLINKER COOLER

CLINKER COOLER Exhaust air fan

failure of one fan

Stop Timer 15 min

Page 32

Training THALOFA

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