Process pictures

Kiln

Fig. 36 Process picture "Kiln" (typical)

This plant diagram provides a general overview of the kiln and its components, such as the hydraulic system, cooling air and combustion air blowers as well as suspended cylinders (optional), including their most important operating parameters.

The graphical user interface consists of dynamic (active) areas.

When the mouse pointer is moved over these areas, a button or check box is opened with a left mouse click.

On this page, the process parameters of the kiln can be adjusted and individual components can be started and controlled.

All individual systems can be started and controlled from the left-hand side of the graphical interface.

Hydraulic unit

Each pump can be started individually. A second one might be preselected to support the operation of the hydraulic flap system.

The oil temperature is controlled automatically by means of special parameters.

Combustion and cooling air blowers

When set to manual mode, each blower can be stopped individually. The lance cooling air blowers only run in manual mode and cannot be switched to automatic mode.

Suspended cylinders (option)

The kiln monitoring device must adjust the cooling air volumes for the suspended cylinders in such a way that the temperature of the escaping cooling air remains within the stipulated range.

Kiln charging

Kiln charging via conveyor-reversal belts can be run in automatic mode. The amount and direction of kiln charging is determined by the kiln parameters.

WARNING

Injury from contusions!

Running the drives on the kiln valves using the pop-up menus is only allowed during manual operation and when the kiln has been shut down or is being pre-heated.

Moving the kiln valves may cause squeezing or personal injury. Before adjusting the kiln valves, it has to be ensured that nobody is nearby.

Hot gases from the kiln can cause burns.

Toxic gases from the kiln can cause poisoning.

Firing system: Natural gas

Fig. 37 Process picture "Gas firing system" (typical)

This diagram explains the natural gas firing system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: natural gas

Firing system: Lean gas

Fig. 38 Process picture "Firing system: Lean gas" (typical)

This diagram explains the lean gas firing system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: Lean gas

Firing system: Lean gas (Gas booster)

Fig. 39 Process picture "Gas booster" (typical)

This diagram explains the gas booster system for the lean gas system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: Lean gas

Firing system: Lean gas (Wobbe meter)

Fig. 40 Process picture "Wobbe meter" (typical)

This diagram explains the wobbe meter system for the lean gas system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: Lean gas

Firing system: Solid fuel (classic)

Fig. 41 Process picture "Firing system: Solid fuel (classic)" (typical)

This diagram explains the solid fuel (classic) firing system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: Solid fuel (classic).

Firing system: Solid fuel (static)

Fig. 42 Process picture "Firing system: Solid fuel (static)" (typical)

This diagram explains the solid fuel (static) firing system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: solid fuel (static)

Fig. 43 Process picture " Firing system: solid fuel (static) " (typical)

This diagram explains the classic coal / wood dust firing dosing system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

Firing system: Liquid fuel

Fig. 44 Process picture " Firing system: Liquid fuel " (typical)

This diagram explains the liquid fuel firing supply system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: Liquid fuel

Fig. 45 Process picture " Firing system: Liquid fuel " (typical)

This diagram explains the liquid fuel firing dosing system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

INFORMATION

For further information, refer to the chapter Firing system: Liquid fuel

Waste gas filter

Fig. 46 Process picture “Waste gas filter” (typical)

This diagram explains the waste gas filter.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

The kiln works with two modes of operation:

- Charging during the reversal time - Charging during the burning time

If the kiln is also charged during the reversal time, the filter is operated at a constant negative pressure. If the kiln is charged during the burning time, the negative pressure level is automatically increased in order to ensure that no toxic gases enter the kiln house during charging.

Once charging has been completed, the negative pressure level is again reduced to the original value.

The filter can be operated both in automatic mode and in manual mode.

Kiln temperatures (optional)

Fig. 47 Process picture “Kiln temperatures” (typical)

This diagram explains the kiln temperatures (supended cylinder temperatures, discharge table temperatures, centre cone temperatures).

Limestone transport system (optional)

Fig. 48 Process picture “Limestone transport system” (typical)

This diagram explains the limestone transport system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

Lime transport system (optional)

Fig. 49 Process picture “Lime transport system” (typical)

This diagram explains the lime transport system.

The graphical user interface is composed of dynamic areas. When moving the mouse pointer over these areas, clicking the left mouse button will open a switch or check box.

Lime transport progresses in automatic mode (time controlled) or in manual mode, if required.

6.3.7 Alarms

Alarms are classified into 3 groups:

- Kiln alarms (red background) - Lime discharge (green background) - Limestone alarms (orange background)

Depending on the type of alarm, automatic sequencing is either stopped, or merely an alarm will be triggered. In any event, the kiln attendant must localize and solve the problem before acknowledging the alarm and continuing kiln operation either automatically or manually.

INFORMATION

The Software Documentation contains a list of all possible alarms.

Kiln alarms

Fig. 50 Parameter table “Kiln alarms” (typical)

Fuel alarms

Fig. 51 Parameter table “Fuel alarms” (typical)

Use this screen to set the limits for fuel alarms.

Gas booster alarms

Fig. 52 Parameter table “Gas booster alarms” (typical)

Use this screen to set the limits for gas booster alarms.

Alarm screen

Fig. 53 Alarm screen (typical)

This page shows all active alarms to be checked and processed. The alarm archive lists and stores all alarms that have already been acknowledged.

NOTICE

Danger caused by unjustified acknowledgment.

Take alarm messages seriously at all times. They may highlight dangerous situations. Never acknowledge an alarm message without having removed its cause.

The manufacturer cannot assume any liability for damage or processing errors caused by failure to acknowledge alarm messages.