Kiln Audit service – we can do it for your plant for 900 USD Only online , or 3,000 USD at your site.

Below , I describe our exact steps for Kiln Audit & Benchmark service. If you need our service online or offline at your site please email me at ceo.benchmark@cementequipment.org

IF YOU WORK IN A CEMENT PLANT AND YOU NEED COURSES AND MANUALS LIKE THIS MANUAL AND BOOKS AND EXCEL SHEETS AND NOTES I SPENT 23 YEARS COLLECTING THEM YOU SHOULD CLICK HERE TO DOWNLOAD THEM NOW 

Kiln Audit : What it means?

Review
• Present operation philosophy
• Operating parameters
• Operation / Quality targets
• Present Constraints
• Status of PID control loop operation

Establish equipment / system performance
• Production
• Heat Consumption
• Power Consumption
• Efficiency

 Benchmark
• Past performance
• Supplier guarantees
• Type of equipment / system
• Anticipated performance

Recommend for performance improvement
• Changes in operation philosophy, operating parameters, operation / quality Targets
• Modifications to individual equipment / system

Kiln Audit : Steps involved

Pre-audit information checklist.
• Plant base information (Flow sheet, equipment details).
• Past performance data (Run / production / reliability factor, energy consumption, quality).
• Type of fuels used and products manufactured.
• Present problems faced by plant.

Measurement / sampling tools
• Instruments (availability, suitability, functioning, calibration)

Measurement / sampling plan
• Measurements / sampling / analysis requirments with priority level.
• Frequency of measurement / sampling.

Calculation tools
Data from other plant audits
Result Interpretations.
Report writing
Reference documents

Kiln Audit : Pre-audit information

The Plant
• Location (place, nearest city, MSL, Ambient temperatures, % RH)
• Local line No. (if any)
• Supplier
• Year supplied
• Supplier guarantees (Production, heat consumption, power consumption etc).

Preheater & Pre-Calciner
• No. of stages
• No. of strings
• Whether In line calciner / separate calciner / AS / AT
• Type of calciner: Low NOx / hot point etc.
• Cyclone sizes
• Calciner dimensions with sketch (showing firing / feed /Tertiary air entry point locations)
• Feeding arrangement (air lift / bucket elevator)

Kiln
• Size (Diameter x Length)
• No. of supports (2 / 3)
• Slope (3.5 / 4%)
• Maximum speed, rpm
• Lining thickness, mm
• Installed motor power

Cooler
• Supplier
• Supplier product code (e.g. FLS COOLAX 1284)
• Type (Conventional chamber aerated / Beam aeration etc.)
• Type of inlet (e.g. Fixed)
• No. of Grates
• Dimensions (width x Length)
• Effective Grate area
• No. of compartments
• No. of fans (Specify v-belt / direct drive, variable / fixed speed)
• Enclose sketch showing grate plate layout with aeration arrangement
• Vent air de-dusting arrangement (ESP, Heat exchanger + Bag filter)
• Emergency cooling arrangements (fresh air / water spray)
• Cooling air & Vent air fan specifications
• Tertiary air take-off point (through kiln hood / separate)
• Dust Settling Chamber in tertiary air line?
• Any hot air tapping (for raw / coal / cement mill)
• Under-grate dust collection arrangement (drag chain / hoppers with pneumatic gates)

Burner
• Supplier
• Supplier product code (e.g. FLS Duoflex)
• Type (Uni-flow / Multi-channel?)

Miscellaneous
• Fuels used (with proportions, way of preparation)
• Sketch showing gas & material flows
• Present performance (Production, heat / power consumption)
• Present constraints
• Sketch indicating measurement / sampling point locations
• Modifications done w.r.t. original supply (e.g. changed to Lafarge Burner, installation of Hurrivanes in preheater cyclone)

Kiln Audit : Samples & analysis

Inputs

Kiln Feed
• Fineness (Residues on 90 and 212µ)
• Temperature
• Moisture
• Uniformity (KFUI),
• Homogenization (Standard deviation of CaO/CaCO3/RC3S at silo exit)
• Burnability (K1450)
• Coarse quartz and calcite content
• LOI
• Chemical analysis (incl. minor oxides and chlorine)
• Organic carbon
• Water of crystallization / hydration
• Sulfur as pyrites
• TC

Fuel, as fired
• Moisture
• Fineness (Residues on 90 and 212µ)
• Temperature
• Heat value
• Proximate analysis
• Ultimate analysis

Outputs

Clinker
• Temperature
• Sieve analysis
• Free lime
• Liter weight
• LOI
• Chemical analysis (incl. Minor oxides)
• Microscopy

Dust from Preheater
• PSD
• LOI
• Chemical analysis (incl. Minor oxides)

With in Process

Bottom stage exit material
• LOI
• Temperature
• Chemical analysis (incl. minor oxides)
• Un-burnt Carbon

Kiln Audit : Sampling frequency

Kiln Audit : Field Measurements

 Preheater

Preheater Exit Gas (Downcomer duct)
• Temperature
• Static Pressure
• Flow
• Gas analysis (O2, CO, CO2, SO2, NOx)
• Dust concentration

Calciner exit
• Temperature
• Static Pressure
• Gas analysis (O2, CO, CO2, SO2, NOx)

Each cyclone inlet and outlet
• Temperature
• Static pressure
• Gas analysis (O2, CO, CO2)

Kiln

Kiln inlet
• Temperature
• Static Pressure
• Gas analysis (O2, CO, CO2, SO2, NOx)

Primary Air (Kiln / Calciner Burner)
• Flow
• Pressure
• Temperature

Transport air for fuel
• Flow
• Temperature

Cooler

Cooling air
• Flow
• Temperature
• Pressure (at fan outlet, for each individual duct after flap damper)

Cooler vent air
• Temperature
• Static pressure
• Flow

Secondary air
• Temperature

Kiln hood
• Pressure

Tertiary air (at cooler end)
• Temperature
• Static pressure
• Flow (if possible)

Kiln Audit : Other Measurements

Mass flows
• Kiln Feed
• Clinker (by drop test)
• Preheater exit dust (by drop test)
• Fuel to Kiln
• Fuel to calciner

Power
• Kiln main drive
• Preheater fan
• Cooler vent fan
• Individual cooling air fan
• Total shop

Surface temperatures
• Kiln shell
• All components of preheater (cyclones incl. risers, material pipes, smoke chamber, kiln riser pipe, calciner vessel)
• Tertiary air duct
• Kiln hood
• Cooler walls

Kiln Audit : Measurements

Remember!
• To cross-check CCR indications w.r.t. field measurements
• To have Minimum 2 sets of measurements
• To perform measurements during stable kiln operation
• To Specify measurement point locations
• To check suitability of flow measurement point (8D – 3D criteria)
To record:
• Pitot tube constants
• Duct diameters at flow measurement point
• Emissivity used for surface temperature measurement
• Surface areas required for radiation loss calculation
• Transport air details (fuel / feed)

Kiln Audit : Measurement tools

• Gas analyzer (2 Nos.) : With CO, CO2, O2, NOx, SO2 sensor

• Digital manometer (1 each)
Low range: 0–100 mmWG for Pd measurement
High range: 0–4000 mmWG

• Thermocouple with indicator (2 Nos.)
• Radiation pyrometer (1 No.)
• Stroboscope / Taco meter (1 No.)
• Measuring tape (2 Nos.)
• Insulated container for clinker temperature measurement (1 No.)

• Pitot tubes
S type, 2m long (2 Nos.)
L type for primary air flow measurement (1 No.)

Kiln Audit : Operating parameters

• Kiln Speed
• Preheater fan speed & damper opening
• Tertiary air duct damper position
• Cooler grate speeds
• Cooler under-grate pressure (way of calculation)
• Ratios used for grate-2, 3 speed w.r.t. grate-1 speed
• Individual cooler fan speed, damper opening
• Cooler vent fan speed, damper opening
• If SLC kiln, feed dividing gate (at PH Top) position
• Material dividing gate position for material diverted to kiln riser
• Primary air fan speed, damper opening
• Any other relevant parameter

Kiln Audit : Miscellaneous

• Check performance of PID control loops
• Check adequacy Sampling / measurement frequency from quality /operation / process aspects
• Look for sources of air leakages / false air entry in to the system
• Understand present constraints in terms of operation / quality
• Analyze Stoppages / Slow downs
• Monitor safety
• Record fuel and power cost

Kiln Audit : Calculation tools

Pitot Measurement
• For gas / air flow calculation

Air Distribution
• Compare cooler flows w.r.t. recommended

Cooler Heat Balance
• K – factor
• Recovery ratio
• Cooling efficiency
• Cooler loss

Kiln Shell & Preheater losses
• For calculation of surface / radiation heat loss

Heat & Mass Balance for Kiln
• Overall heat balance of pyro-processing section

Kiln Audit : Benchmarking

Above , I describe our exact steps for Kiln Audit & Benchmark service. If you need our service online or offline at your site please email me at ceo.benchmark@cementequipment.org