7 Most Common Problem in PyroProcessing for Kiln and Cooler

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To download the below  and all other Useful Books and calculations Excel sheets please click here 

 

7 Most Common Problem in PyroProcessing for Kiln and Cooler

 

 

Ø Cyclone Blockage

Ø Kiln inlet Blockage

Ø Big clinker ball formation

Ø kiln Coating

Ø Feed rushes and dusty kiln

Ø Cooler Snow Man

Ø Red river in clinker cooler

 

Main Reasons for Cycolne Blockage 

  • 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)

Main Reasons for Kiln Inlet Blockage 

  • High Iron % in Raw mix.
  • High Sulfur % in fuel(i.e- coal)

Main Reasons for big size clinker ball formation 

  • 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).

 

Main Reason for heavy coating  formation in kiln

  • High Iron % in Raw m
  • High Sulfur (S)% in fuel(i.e- coal).
  • Kiln running with slow rpm & % filling is m
  • % liquid is m
  • Higher % of Magnesia (MgO).

 

Main Reason for Feed rushes and dust kiln

  • High lime in Raw mix or high LSF.
  • Very less % of liqui
  • High A
  • Less iron% in raw m
  • Blockage of hot meal due to clinker ball occasion

SNOWMAN FORMATION IN COOLER

  • 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.

RED RIVER IN COOLER

  • Uneven distribution of cooling ai
  • Misalignment of kiln & cooler

 

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