EXTREMELY IMPORTANT NOTES ABOUT KILN OPERATION PLEASE SHARE AS MUCH AS YOU CAN

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some very important tips during kiln operation.  It is requested to use these tips during operation:

• Every 1 % reduction in free lime increases 10 – 25 kcal/kg clinker heat consumption.
• Every 10% increase in preheater exit temp., increases 7-10 kcal/kg clinker heat consumption.
• Every 10% increase in clinker temperature, increases 2 kcal/kg of clinker heat consumption.
• Every 1% increase in kiln PH exit O2% increases 7 kcal/kg of clinker heat consumption.
• Every 1% increase in residue (kiln feed) in 90 micron, increases 5-10 kcal/kg clinker heat consumption.
• Every 0.1 increase in silica modulus, increases 10kcal/kg clinker heat consumption.
• Every 1% increase in kiln feed LSF increases 15 kcal/kg clinker heat consumption.
• Every 100 blain increase in cement increases 1.5 kwh/MT of power consumption.
• Every 1% reduction in primary air reduces 0.7 kcal/kg clinker heat consumption.
• Every 10 degree centigrade increase in flame temperature increases 1% kiln production.
• Every 100 blain increase in cement increases 1.5 Mpa of strength.
• Every 1% increase in fine coal moisture reduces 10 to 14 degree centigrade flame temperature.
• Every 1% reduction in clinker-free lime, increases 4.0 % C3S in clinker.
• Every 1% increase in C3S reduces 0.3 to 0.5 kwh/MT clinker grinding energy consumption.

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