Presentasi Build Up

Build -up control Build-up (in Preheater Kilns)

Technica Technic l g e n d a

Mastering -ups Mastering Riser Riser and and Tower Tower Build Build-ups ATC_November 2005 - 1

General information

Build-up Control (in preheater kilns)

ƒObjective • Consolidate know-how on build up control in PH Towers • Identify practical ways & means to master build-up

ƒDeliverables • Produce a complete reference book and a shorter practical quick reference guide for plant users

ƒDivision wide team • C. Venkateswarlu (ATC, leader) J. Desseix (RR)C. Landais (CTEO) • H. Schoffmann (CTEC) P. Muithya (CTI)S. Fujimoto (CTS)

ƒPresent Status • Document completed in September’05

ATC_November- 2005 - 2

Build-up Control (in preheater kilns)

ƒTarget Group Plants ƒOptimization Managers ,Process & Production Engineers ƒCCR operators ƒ Key

Messages

ƒPreheater buildups can be mastered under any circumstances as long as the appropriate levers(Specific to each plant) are applied. ƒImplementation of this TA will lead to significant improvement in kiln performance and reliability even with high usage of alternative fuels.

ATC_November- 2005 - 3

Content of study

Build-up Control (in preheater kilns)

ƒ Reference Main document, Quick Reference Guide & Other references in annex

ƒ TA Agenda covers: • Chemistry • Operations • Refractory • Geometry (design) • Build-up Removal equipment sections

• Quick Reference Guide • Key recommendations • Check-lists ATC_November- 2005 - 4

Content of study

Build-up Control (in preheater kilns)

ƒ Preventive measures • Control Chemistry of kiln inputs • Kiln operation by Managing • Burning zone • Combustion • Kiln control loops • Refractory • Geometry of preheated

ƒ Curative measures • Build up detection & cleaning

ATC_November- 2005 - 5

1 - Chemistry

Build-up Control (in preheater kilns)

ƒ Determine balance (SO3, Cl & Alkalis) • Reduce inputs – to regain balance where possible

ƒ Track bottom stage meal Cl vs. SO3 • Track tendency to determine thresholds • Control levers • Maintaining Chart • Unique to each plant

ATC_November- 2005 - 6

Build-up Control (in preheater kilns)

CTEC Region Plants- Hot meal monitoring

ATC_November- 2005 - 7

2 - Operations

Build-up Control (in preheater kilns)

ƒ Check-List of Kiln Mastery items • Calciner • Kiln • Burner • Cooler

ƒ Special techniques for older & smaller calciner designs

ƒ Meal curtains are more effect techniques • Creating dirty backend • Alternatives are ESW chains to lifters • Appendix includes a more complete meal curtain report (design&optimization)

ATC_November- 2005 - 8

Build-up Control (in preheater kilns)

Meal Curtain Figure A1: Meal

• Recommended: • Best variable control • Plants with no bypass

• Likely a standard feature on new kilns

• Cost depends on layout

ATC_November- 2005 - 9

3 - Refractory

Build-up Control (in preheater kilns)

ƒ CKHC Reference ƒ Use of SiC refractory • Better refractory life • Coating Repellent

ƒ SiC percentage in refractory • Buildup Severity • Check with Suppliers / Technical Centers

ATC_November- 2005 - 10

4 – Geometry (Design)

Build-up Control (in preheater kilns)

ƒ Designs to avoid build-up by eliminating dead zones ƒ Topics include • Cyclones • ducts • Meal pipes • Flaps • Splash boxes

ƒ Key notes • Simple changes • Correct Design mistakes • Corrective Case Studies

ATC_November- 2005 - 11

5 – Removal Equipment

Build-up Control (in preheater kilns)

ƒPreventive equipments. • Safety • Optimize Blasters • Placement maintenance

• CO2 cartridges • High pressure water gun

ƒWhen build-ups are minimized cleaning is effective in managing the problem

ATC_November- 2005 - 12

Conclusions

Build-up Control (in preheater kilns)

• Build-up can be mastered • ARM / AF is not a good excuse for poor performance

ƒSolution can be complex – often a mixture of techniques • Bigger challenge on older designs • TA document is a tool to help plants to self audit & use to determine plant unique final solutions.

ATC_November- 2005 - 13