1

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Suitable materiel for temp range 1100-120 degree Centigrade and

properties of weldable and fabricated also.

Seelam Naveen

Seelam Naveen •• AISI 321 available in plates, it can used upto degreeAISI 321 available in plates, it can used upto degree 1000 C. This stell is weldable

1000 C. This stell is weldable Ahmad Nilforoushan

Ahmad Nilforoushan •• Steel 1.4848 & 1.4823Steel 1.4848 & 1.4823 Amit Agarwal

Amit Agarwal •• HRS grade 7 and grade 9,commonly known asASTM AHRS grade 7 and grade 9,commonly known asASTM A 297 grade HH and HK material....

297 grade HH and HK material.... muralimohan paladugu

muralimohan paladugu •• hrcs gr 9 and ss 316hrcs gr 9 and ss 316 Mukesh Doshi

Mukesh Doshi •• HRCS grade 9 is suitable, pl check for area of HRCS grade 9 is suitable, pl check for area of application also

application also James Kelly

James Kelly •• With respect, I believe that for an alloy to withstandWith respect, I believe that for an alloy to withstand 1100C, let alone 1200C, it must have over

1100C, let alone 1200C, it must have over 30% nickel and about 25%30% nickel and about 25% chromium. I believe 321 (1.4541 or 1.4878) is useful only to 870C, chromium. I believe 321 (1.4541 or 1.4878) is useful only to 870C,

maybe to 900C for modest life. HRCS Gr 9 and cast HH not much better. maybe to 900C for modest life. HRCS Gr 9 and cast HH not much better. HK is the lowest alloy I would suggest.

HK is the lowest alloy I would suggest.

My own experience, since 1974, has been with wrought

My own experience, since 1974, has been with wrought alloys whichalloys which may be fabricated. There are a limited number of wrought alloys with may be fabricated. There are a limited number of wrought alloys with the strength and oxidation resistance to survive a cement mill

the strength and oxidation resistance to survive a cement mill

operation 1100 -1200C. One such was 353 MA (1.4854) 25Cr 35Ni 1.5Si, operation 1100 -1200C. One such was 353 MA (1.4854) 25Cr 35Ni 1.5Si, but Outokumpu has chosen to discontinue its production.

but Outokumpu has chosen to discontinue its production.

There are a range of cast alloys available. Two of the best foundries in There are a range of cast alloys available. Two of the best foundries in North America are Kubota Metal Corp, Fahramet Div, in Ontario,

North America are Kubota Metal Corp, Fahramet Div, in Ontario, Canada www.kubotametal.com, and Duraloy Technologies,

Canada www.kubotametal.com, and Duraloy Technologies,

Pennsylvania, USA www.duraloy.com. Both have excellent technical Pennsylvania, USA www.duraloy.com. Both have excellent technical

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personell, for Duraloy I would suggest Roman Pankiw personell, for Duraloy I would suggest Roman Pankiw

[email protected]. The French alloy foundry, Manior Industries, is [email protected]. The French alloy foundry, Manior Industries, is represented on Linked in by Benjamin Fournier.

represented on Linked in by Benjamin Fournier.

One cast alloy used in the steel heat treating industry is the 28Cr 48Ni One cast alloy used in the steel heat treating industry is the 28Cr 48Ni 3Co 5W grade, called Super 22H by Duraloy, and KHR48NCo by Kubota. 3Co 5W grade, called Super 22H by Duraloy, and KHR48NCo by Kubota. For the highest temperature service one might consider MO-RE 2, 33Cr For the highest temperature service one might consider MO-RE 2, 33Cr 50Ni 16W from Duraloy, or KHRSA,

50Ni 16W from Duraloy, or KHRSA, 29Cr 49Ni 13W from Kubota29Cr 49Ni 13W from Kubota Sagar Raysoni

Sagar Raysoni •• SS 310S plates are easily available in the local marketsSS 310S plates are easily available in the local markets in India and are able to with stand higher temperature upto 1050 deg in India and are able to with stand higher temperature upto 1050 deg cen than 321 grade . Also 310S is widely used in cement plants in India cen than 321 grade . Also 310S is widely used in cement plants in India because of easy availability and economy as compared to costlier grade because of easy availability and economy as compared to costlier grade such as 353 MA . I have never come across

such as 353 MA . I have never come across any customer asking any customer asking for 353for 353 MA here locally . We do have few plants using 30815 instead of 310S MA here locally . We do have few plants using 30815 instead of 310S here

here

James Kelly

James Kelly •• I suspect that no customers ask for 353 MA as it wasI suspect that no customers ask for 353 MA as it was never promoted in India and is no longer made. Until Outokumpu never promoted in India and is no longer made. Until Outokumpu

ceased production Rolled Alloys was developing the US market for this ceased production Rolled Alloys was developing the US market for this grade (I am retired Director of Technolog

grade (I am retired Director of Technology for RA).y for RA).

In cement kilns RA's competition was one or the other high alloy casting In cement kilns RA's competition was one or the other high alloy casting as I noted previously.

as I noted previously.

310S is a decent choice, I have noticed that in Asia 310S is used many 310S is a decent choice, I have noticed that in Asia 310S is used many places where in Europe and North America we w

places where in Europe and North America we would use one of theould use one of the higher nickel, higher strength alloys available to us.

higher nickel, higher strength alloys available to us.

I am inclined to believe that alloy selection across the globe is based on I am inclined to believe that alloy selection across the globe is based on local availability, and rightly so. Better alloy properties do no good if local availability, and rightly so. Better alloy properties do no good if one cannot buy the material.

one cannot buy the material.

Should some foundry or alloy stockist decide to promote the higher Should some foundry or alloy stockist decide to promote the higher

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alloys, the cement industry in India will eventually find that these alloys, the cement industry in India will eventually find that these expensive grades perform so much better that

expensive grades perform so much better that they pay for themselves.they pay for themselves. arun rao

arun rao •• James, I agree with your comments. On a few ocassions I hadJames, I agree with your comments. On a few ocassions I had recommended using HT or HU grades with a life guarantee. The plants recommended using HT or HU grades with a life guarantee. The plants were reluctant to consider. I then proposed ,t

were reluctant to consider. I then proposed ,that they could pay me HKhat they could pay me HK grade price and based on performance,they could pay the rest. The grade price and based on performance,they could pay the rest. The parts outlived their expected life by 2 years.

parts outlived their expected life by 2 years.

Investment cost: cement plant

excluding land and development, what could be the thumb rule figure

for a 1000 and 1500

for a 1000 and 1500 tpd plant?tpd plant?

Maréchal Philippe

Maréchal Philippe •• Dear Mr Pabitra,Dear Mr Pabitra,

The cost is around 100.000.000 € for

The cost is around 100.000.000 € for 1.000 tpd clinker converted into1.000 tpd clinker converted into

cement. For 1.500 tpd consider 30% more. cement. For 1.500 tpd consider 30% more.

Keep in mind the standard economical size is today around 5.000 tpd. Keep in mind the standard economical size is today around 5.000 tpd. We can help you in the conceptual design of your cement plant (raw We can help you in the conceptual design of your cement plant (raw mix, mass balance, process, layout, flow sheet, cost estimate, operating mix, mass balance, process, layout, flow sheet, cost estimate, operating cost and profitability).

cost and profitability). Regards

Regards Philippe Philippe

Pabitra Mukherjee (Mukhopadhyay)

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Jagat Singh Rathee

Jagat Singh Rathee •• The investment in terms of capitThe investment in terms of capital employed peral employed per ton of installed capacity for a brown field integrated cement project of ton of installed capacity for a brown field integrated cement project of about 10,000 TPD clinker production capacity

about 10,000 TPD clinker production capacity is in the range of 180 -is in the range of 180 -200 USD per ton , with some variation to the tune of 5 - 10%, on 200 USD per ton , with some variation to the tune of 5 - 10%, on account of inflation and currency rate fluctuations.

account of inflation and currency rate fluctuations. Ben Cardwell

Ben Cardwell •• I agree with Marechal to a point, we have preformedI agree with Marechal to a point, we have preformed numerous studies and designed plants around the world for different numerous studies and designed plants around the world for different clients and there are multiple factors to be considered. unfortunately clients and there are multiple factors to be considered. unfortunately TPY of clinker is not linier and one must consider region and other TPY of clinker is not linier and one must consider region and other factors besides economy of scale

factors besides economy of scale Zaza Sadunishvili

Zaza Sadunishvili •• Price for green field from chinese supplier will be 30Price for green field from chinese supplier will be 30 % less that from european company.

% less that from european company. Jagat Singh Rathee

Jagat Singh Rathee •• Price from Chinese designers / suppliers likePrice from Chinese designers / suppliers like Sinoma ,CNBME and others may be even 30 - 40 % cheaper than the Sinoma ,CNBME and others may be even 30 - 40 % cheaper than the European ,Japanese or even the Indian suppliers / designers, but their European ,Japanese or even the Indian suppliers / designers, but their equipment ,plant and machinery ,including systems & subsystems are equipment ,plant and machinery ,including systems & subsystems are yet to be fully established from the very reliability and operational yet to be fully established from the very reliability and operational sustainability angle.They also in most of the cases do not follow sustainability angle.They also in most of the cases do not follow International Systems / Standards, for parts and spares and even International Systems / Standards, for parts and spares and even consumables supplies.Other supplier's always cross the rated / consumables supplies.Other supplier's always cross the rated / guaranteed outputs , by a factor of minimum of 15-20% ,and the guaranteed outputs , by a factor of minimum of 15-20% ,and the cement plant stabilization period is also significantly lower vis-a-vis cement plant stabilization period is also significantly lower vis-a-vis Chinese plants.

Chinese plants.

The best example is the quality and extreme reliability of FLS ,KHD The best example is the quality and extreme reliability of FLS ,KHD ,Polysius and Japanese cement plants all over the world,e.g. Holcim ,Polysius and Japanese cement plants all over the world,e.g. Holcim integrated cement plant of 12,000 TPD capacity in USA at St.Genevivie integrated cement plant of 12,000 TPD capacity in USA at St.Genevivie ,3X10,000 tpd KHD integrated cement plants of UTCL ,India ,& 2x

,3X10,000 tpd KHD integrated cement plants of UTCL ,India ,& 2x 10,000 TPD plants of JP Cement ,India ,al

10,000 TPD plants of JP Cement ,India ,also from KHD, and the 1x10,000so from KHD, and the 1x10,000 TPD integrated cement plant from Thyssen Krupp Polysius , of Reliance TPD integrated cement plant from Thyssen Krupp Polysius , of Reliance Cementation ,India.and many more ,in India ,Thailand ,Indonesia ,South Cementation ,India.and many more ,in India ,Thailand ,Indonesia ,South

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Korea and Japan. Korea and Japan.

Have the true feedback from two 10,000 TPD production lines from Have the true feedback from two 10,000 TPD production lines from Sinoma ,China, for equipment ,machinery and systems reliability and Sinoma ,China, for equipment ,machinery and systems reliability and operational sustainability. These plants ha ve yet to be fully stabilized , operational sustainability. These plants ha ve yet to be fully stabilized , even after a couple of years of

even after a couple of years of commissioning. You save in the projectcommissioning. You save in the project capital costs initially ,but pay in the long run. These have been the capital costs initially ,but pay in the long run. These have been the observations of the technocrats involved in such projects from across observations of the technocrats involved in such projects from across the globe.

the globe.

Maréchal Philippe

Maréchal Philippe •• I agree with Jagat. Today there is still a lack of I agree with Jagat. Today there is still a lack of reliability of Chinese EPC(turnkey) Cement plant. The first 2 years, the reliability of Chinese EPC(turnkey) Cement plant. The first 2 years, the net operating time of the plant is 30% lower and all weak components net operating time of the plant is 30% lower and all weak components of the plant are progressively replaced by European parts. This could be of the plant are progressively replaced by European parts. This could be acceptable only if the plant doesn't need to run at full capacity the first acceptable only if the plant doesn't need to run at full capacity the first years according to the business model. Otherwise the profitability of years according to the business model. Otherwise the profitability of the project will be reduced and the savings on the investment will the project will be reduced and the savings on the investment will disappear.

disappear.

For your specific project, several cost simulations according to your For your specific project, several cost simulations according to your business plan can be studied. If needed contact me at

business plan can be studied. If needed contact me at [email protected]

[email protected]

Jagat Singh Rathee

Jagat Singh Rathee •• Even for their own large size ,big capacity cementEven for their own large size ,big capacity cement plants at Anhui Conch and a few others cement manufacturers in ,China plants at Anhui Conch and a few others cement manufacturers in ,China , have preferred to go to FLS , Polysius, Loesche ,Christian Pfeiffer ,

, have preferred to go to FLS , Polysius, Loesche ,Christian Pfeiffer , Haever & Boecker,even refractory manufacturers, conveyor belting Haever & Boecker,even refractory manufacturers, conveyor belting manufacturers and other European suppliers / designers ( the

manufacturers and other European suppliers / designers ( the manufacturing and fabrication shops of these International plant, manufacturing and fabrication shops of these International plant,

machinery & equipment suppliers / designers are located within China machinery & equipment suppliers / designers are located within China itself ,owing to the much lower manpower costs in that country, but itself ,owing to the much lower manpower costs in that country, but

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the Quality Assurance is strictly

the Quality Assurance is strictly under the European Engineers ) ), onlyunder the European Engineers ) ), only from the reliability and uninterrupted sustainability of integrated

from the reliability and uninterrupted sustainability of integrated

cement operations. The above example, in my above note example , is cement operations. The above example, in my above note example , is of the 2X10,000 tpd Sinoma ,China clinker pr

of the 2X10,000 tpd Sinoma ,China clinker production lines in KSA (oduction lines in KSA ( Kingdom of Saudi Arabia ,at Najaran

Kingdom of Saudi Arabia ,at Najaran

Zaza Sadunishvili

Zaza Sadunishvili •• We have very good experience with ChineseWe have very good experience with Chinese equipment in Georgia.

equipment in Georgia.

2007 we installed two Coal mills with coal handling systems and 2007 we installed two Coal mills with coal handling systems and equipment still is working without any problem

equipment still is working without any problem Guadalupe Rodriguez

Guadalupe Rodriguez •• Standard equipment by FLS or others similarsStandard equipment by FLS or others similars are around 300 MM dlls for a normal 1500 TPD plant

are around 300 MM dlls for a normal 1500 TPD plant

The best return of the investment could be a medium size plant as 3000 The best return of the investment could be a medium size plant as 3000 TPD

TPD

Chineese equipment is cheaper as first investment, however the cost of Chineese equipment is cheaper as first investment, however the cost of maintenance and relibility are very high in the first 2 years

maintenance and relibility are very high in the first 2 years

Special attention to wear parts as liners and grinding media, usually Special attention to wear parts as liners and grinding media, usually chineese is not the best quality for this materials

chineese is not the best quality for this materials Hopefully find this information valuable for you Hopefully find this information valuable for you Jagat Singh Rathee

Jagat Singh Rathee •• Every investor wants to get immediate & quickEvery investor wants to get immediate & quick returns on the capital employed in the cement p

returns on the capital employed in the cement project .This is possibleroject .This is possible only ,when the project gets quickly commissioned and gets stabilized only ,when the project gets quickly commissioned and gets stabilized it's operations without any interruptions & through the asset sweating. it's operations without any interruptions & through the asset sweating. And this is only possible when the quality of equipment ,plant

And this is only possible when the quality of equipment ,plant ,machinery ,components and the systems / subsystems are highly ,machinery ,components and the systems / subsystems are highly reliable / dependable , so as to ensure long campaign life of the plant reliable / dependable , so as to ensure long campaign life of the plant ,particularly the kiln system. In such a scenario ,the European ,Japanese ,particularly the kiln system. In such a scenario ,the European ,Japanese

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and even the Indian equipment suppliers / designers have a

and even the Indian equipment suppliers / designers have a definitedefinite edge over the Chinese.This is the practical experience of a number of edge over the Chinese.This is the practical experience of a number of users of technology across the global cement industry.

users of technology across the global cement industry. Jean-Marc Ritzenthaler

Jean-Marc Ritzenthaler •• This interesting discussion did so far notThis interesting discussion did so far not

address the State garantee that, at least some of, the Chinese builders address the State garantee that, at least some of, the Chinese builders may have. Any comments or

may have. Any comments or experience?experience? Wilhelm Maier-Krebs

Wilhelm Maier-Krebs •• dear Sir, we are able to provide a unuseddear Sir, we are able to provide a unused Cement production plant, cap. 2200 tp p.day. German

Cement production plant, cap. 2200 tp p.day. German brand. can bebrand. can be fired with oil, gas or coal. cement grinding mill and coal mill available.If fired with oil, gas or coal. cement grinding mill and coal mill available.If of serious interest, please contact:

of serious interest, please contact: [email protected]@wmk-cnc.com

Ibrahim Munir

Ibrahim Munir •• we are chinese company , we can we are chinese company , we can help you out in thishelp you out in this project according to your requirement , if you are intrested please mail project according to your requirement , if you are intrested please mail me more details at [email protected].

me more details at [email protected].

our techical department will give you quick feed back. our techical department will give you quick feed back. Concrete Block Making Machine

Concrete Block Making Machine •• XIAMEN SUNLIGHT XIN MECHANICXIAMEN SUNLIGHT XIN MECHANIC EQUIPMENT CO.,LTD,is a leading supplier of building materials

EQUIPMENT CO.,LTD,is a leading supplier of building materials machinery and block production plant,which is experienced in machinery and block production plant,which is experienced in

manufacturing fully automatic concrete brick making machines, paving manufacturing fully automatic concrete brick making machines, paving brick and Curbstone making machine,hydraulic forming machines.

brick and Curbstone making machine,hydraulic forming machines.

Regards, Regards, Jack Tang Jack Tang

Xiamen Sunlight Xin Mechanic Equipment Co.,Ltd Xiamen Sunlight Xin Mechanic Equipment Co.,Ltd Facebook: [email protected] Facebook: [email protected] Gmail: [email protected] Gmail: [email protected] Skype: xrc.sonny Skype: xrc.sonny Mob: +86-1885030 6144 Mob: +86-1885030 6144

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Tel:0086 592 5103028 Tel:0086 592 5103028 Fax:0086 592 5103029 Fax:0086 592 5103029 Web:

Web: http://www.xmyg.cnhttp://www.xmyg.cn

Add: No. H12, North Zorth of Xiamen Gaoqi International Airport, Fujian Add: No. H12, North Zorth of Xiamen Gaoqi International Airport, Fujian 361006, China

361006, China

Dear all experts,is it possibl

Dear all experts,is it possible when sieve residue is high the blaine wille when sieve residue is high the blaine will

be high,what are the reasons of this case?

Nohman Mahmud

Nohman Mahmud •• Yes it is possible that although blaine is high & atYes it is possible that although blaine is high & at the same time residue on 90 or 45 micron

the same time residue on 90 or 45 micron is also on higher side , thiis also on higher side , this iss is experienced / encountered normally when weathered clinker is used . experienced / encountered normally when weathered clinker is used . The phenomenon occurs due to partial hydration of clinker.

The phenomenon occurs due to partial hydration of clinker. Also note that

Also note that

The blaine method determines the fineness of hydraulic cement, using The blaine method determines the fineness of hydraulic cement, using the Blaine air-permeability apparatus, in terms of the specific surface the Blaine air-permeability apparatus, in terms of the specific surface expressed as total surface area in square centimetres per gram, or expressed as total surface area in square centimetres per gram, or square metres per kilogram, of cement.

square metres per kilogram, of cement.

While residue analysis determines the size on a particular sieve While residue analysis determines the size on a particular sieve Munusamy Murugan

Munusamy Murugan •• At normal operation it should be in Reverse ieAt normal operation it should be in Reverse ie When Blaine increases ,Residue should drop

When Blaine increases ,Residue should drop

When material distribution is not even at separator inlet, then both When material distribution is not even at separator inlet, then both Residue and Blaine will increase,

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prabodh singh

prabodh singh •• If seasoned or aged clinker is usIf seasoned or aged clinker is used for cement grindinged for cement grinding ,troumph curve of PSD becomes wider , caused due to superfines

,troumph curve of PSD becomes wider , caused due to superfines

generated during grinding, that fills the voids , and makes the cell bed generated during grinding, that fills the voids , and makes the cell bed more compacted, , thus there is an increase in time for air flow through more compacted, , thus there is an increase in time for air flow through the given bed of cement in the Blai

the given bed of cement in the Blaine cell,its residue is also found inne cell,its residue is also found in higher side.

higher side.

It is not a typical case , it often happens , whenever we use aged clinker It is not a typical case , it often happens , whenever we use aged clinker or particle PSD is not narrow.

or particle PSD is not narrow.

Cement quality managers do not depend on blaine value only, use of Cement quality managers do not depend on blaine value only, use of any masking material can give u higher blaine value , cross checking the any masking material can give u higher blaine value , cross checking the residue in such case becomes inevitable.

residue in such case becomes inevitable.

some cement industries uses correction factor for bla

some cement industries uses correction factor for blaine value ,basedine value ,based on LOI of cement .

on LOI of cement .

how we can reduce the kcal/kg of clinker in my plant the kcal/kg of

clinker is approx. 850kcal/kg of clinker.coal ash is around 20% and

moisture is 1.5 %. we are using indian coal

how can we decide what is the

how can we decide what is the optimum kcal/kg of clinker.optimum kcal/kg of clinker.

Maréchal Philippe

Maréchal Philippe •• It is necessary to do an audit It is necessary to do an audit of the burning line byof the burning line by testing the real major parameters (as O2

testing the real major parameters (as O2 measures because false air ismeasures because false air is very important) and then to design what's necessary to be done to

very important) and then to design what's necessary to be done to reducereduce the heat consumption.

the heat consumption. Examples:

Examples:

- Improvement of the kiln operation by adjusting the settings - Improvement of the kiln operation by adjusting the settings - Reducing the false air

- Reducing the false air

- To optimize the burner settings - To optimize the burner settings - To adjust the raw mix

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If you need support contact

If you need support contact philippe.marecha [email protected]@tcmi.be

Wolfgang Linke

Wolfgang Linke •• It is all relative. If you have a 4-stage preheater kilnIt is all relative. If you have a 4-stage preheater kiln with no calciner and an old grate cooler you are world class with 850 with no calciner and an old grate cooler you are world class with 850 kcal/kg. Travel around the world

kcal/kg. Travel around the world and teach the others!and teach the others!

If you have a 6-stage preheater with calciner and an IKN cooler and you If you have a 6-stage preheater with calciner and an IKN cooler and you experience 850 kcal/kg, there is a lot of room for i

experience 850 kcal/kg, there is a lot of room for improvement. Themprovement. The important factors are very low

important factors are very low kiln feed variation, steady operation andkiln feed variation, steady operation and those factors Marechal Philippe has mentioned.

those factors Marechal Philippe has mentioned. tayyab ihtaysham

tayyab ihtaysham •• - Reducing the false air - Reducing the false air MAX heat recovery in cooler cooling

MAX heat recovery in cooler cooling air air Nick Sutherland

Nick Sutherland •• As Wolfgang mentioned, it's all relative and to knowAs Wolfgang mentioned, it's all relative and to know where you stand in terms of world class you need to

where you stand in terms of world class you need to benchmark againstbenchmark against other similar kiln plants.

other similar kiln plants.

I can recommend Michael Clark at

I can recommend Michael Clark at WhitehopelemaWhitehopeleman - n - see their websitesee their website for contact details

for contact details http://www.whitehopleman.com/key_performancehttp://www.whitehopleman.com/key_performance

VA.Kerishnan Velayuthan

VA.Kerishnan Velayuthan •• Most main false air , cyclone conditions ,Most main false air , cyclone conditions , raw mix ratio , bunner setting , flame adjustment , raw mix coal

raw mix ratio , bunner setting , flame adjustment , raw mix coal adjustment.

adjustment.

Jagat Singh Rathee

Jagat Singh Rathee •• Have the complete heat / energy balance done Have the complete heat / energy balance done , for , for a steady period of 24 hours

a steady period of 24 hours ,for all the 3 sections of the pyro,for all the 3 sections of the pyro-processing-processing plant ,covering the

plant ,covering the preheater ,precapreheater ,precalciner strings ,the lciner strings ,the cement rotary kilncement rotary kiln and the clinker cooler system ,so as to exactlypin point the areas where and the clinker cooler system ,so as to exactlypin point the areas where you are losing / wasting the heat / energy during

you are losing / wasting the heat / energy during sustained andsustained and uninterrupted kiln plant operations.This is extremely important to uninterrupted kiln plant operations.This is extremely important to findfind out a lasting solution to your problem.

out a lasting solution to your problem. Mr.Aditya Srivastava , of JP Ce

Mr.Aditya Srivastava , of JP Cement Satna / Rewa ( M.P.),India ,youment Satna / Rewa ( M.P.),India ,you have not informed about the number of stages

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pre-heater / precalciner streams for your kiln plants, that is very important to heater / precalciner streams for your kiln plants, that is very important to know about the standard range of specific heat consumption ( in terms of know about the standard range of specific heat consumption ( in terms of kcals /kg clinker ).Other things are supplementry to the issue.

kcals /kg clinker ).Other things are supplementry to the issue. Sampathkumar Ponnusamy

Sampathkumar Ponnusamy •• Aditya,Aditya,

For improvement in the existing running conditions: For improvement in the existing running conditions:

1. Stable cooler operation. Maintain constant bed in the cooler. Try to 1. Stable cooler operation. Maintain constant bed in the cooler. Try to increase the secondary and tertiary air temperature to

increase the secondary and tertiary air temperature to the optimum levelthe optimum level to your plant.

to your plant. 2. Arrest all the f

2. Arrest all the false air in the system. Especially in alse air in the system. Especially in preheater.preheater.

3. Reduce the standard deviation of raw meal and optimize the flux 3. Reduce the standard deviation of raw meal and optimize the flux -Al2O3 and Fe2O3.

Al2O3 and Fe2O3. Jagat Singh Rathee

Jagat Singh Rathee •• A few most important things to be watched for A few most important things to be watched for with care and attention are as

with care and attention are as under ,inorder to under ,inorder to optimize the specific heatoptimize the specific heat consumption in the pyro-processing system :

consumption in the pyro-processing system : Improve the degree of

Improve the degree of calcination in the calciner ,smoke chamber to acalcination in the calciner ,smoke chamber to a level of 94-96% , higher the better.I had operated a FLS

level of 94-96% , higher the better.I had operated a FLS /L&T kiln plant/L&T kiln plant at about 96-98% degree of

at about 96-98% degree of calcination ,by maintaining the calciner outletcalcination ,by maintaining the calciner outlet temp.in the range of 900-915 degrees C , with excellent results w.r.t

temp.in the range of 900-915 degrees C , with excellent results w.r.t stability and sustainability of kiln operations ,for a period of about 3 stability and sustainability of kiln operations ,for a period of about 3 years ,in India.

years ,in India.

Change the fuel firing ratio from the conventional 60:40 to may be 65:35 Change the fuel firing ratio from the conventional 60:40 to may be 65:35 in calciner to kiln or even higher ,provided your coal firing

in calciner to kiln or even higher ,provided your coal firing system issystem is capable of doing this ,i.e. if there are margins in the fuel firing

capable of doing this ,i.e. if there are margins in the fuel firing system'ssystem's capacity. It is not only better for stabilized kiln operations ,but is quite capacity. It is not only better for stabilized kiln operations ,but is quite helpful in improving the kiln BZ lining life ,because of reduced thermal helpful in improving the kiln BZ lining life ,because of reduced thermal load in the cement rotary kiln .

load in the cement rotary kiln .

The standard deviation of both the raw meal / kiln feed as well as the The standard deviation of both the raw meal / kiln feed as well as the pulverized fuel should be

pulverized fuel should be as minimum as possias minimum as possible ,so as to hable ,so as to have highlyve highly consistent quality of coal meal and kiln feed for the pyro system.This is consistent quality of coal meal and kiln feed for the pyro system.This is very much possible provided ,you always have enough stocks of kiln very much possible provided ,you always have enough stocks of kiln

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feed in your CF silo (

feed in your CF silo ( normal filling level to be +60-65% of normal filling level to be +60-65% of designdesign capacity ,for ensuring complete homogenization.Same applies to the capacity ,for ensuring complete homogenization.Same applies to the solid fuel ( coal ,petcoke or lignite or a combination of all these ) solid fuel ( coal ,petcoke or lignite or a combination of all these ) ,, Operate the kiln at higher speed ( about 5-7% more than the

Operate the kiln at higher speed ( about 5-7% more than the normalnormal speed / rpm ) to have a v

speed / rpm ) to have a very high degree of heat exchange by materialery high degree of heat exchange by material turning very rapidly , because of faster exposure of the feed inside the turning very rapidly , because of faster exposure of the feed inside the rotary kiln,so that the material residence time is reduced in the rotary rotary kiln,so that the material residence time is reduced in the rotary kiln ,as the meal before entering the kiln inlet has sufficient degree of kiln ,as the meal before entering the kiln inlet has sufficient degree of calcination ,and kiln's job is

calcination ,and kiln's job is to transform the calcined meal into to transform the calcined meal into clinker clinker compounds / mineral phases. This shall call for further increase in the compounds / mineral phases. This shall call for further increase in the kiln feed rate to

kiln feed rate to the PH tower, that is the PH tower, that is an improvement w.r.t. specifican improvement w.r.t. specific throughput from the kiln plant.

throughput from the kiln plant. Maintain kiln inlet O2

Maintain kiln inlet O2 maximum around 1.75% ,lower the better ,andmaximum around 1.75% ,lower the better ,and PH outlet at about 2.5-2.75 % maximum , lower the better ,this shall call PH outlet at about 2.5-2.75 % maximum , lower the better ,this shall call for complete inspection and arresting of any false air in-gressing into for complete inspection and arresting of any false air in-gressing into thethe PH / Precalciner strings, including at the kiln inlet seal, and the kiln

PH / Precalciner strings, including at the kiln inlet seal, and the kiln outlet seal at the clinker cooler

outlet seal at the clinker cooler beginning.beginning. Keep a very close watch on

Keep a very close watch on the secondary and tertiary air tethe secondary and tertiary air temperaturesmperatures ,the have to higher by 10-15 degrees C than

,the have to higher by 10-15 degrees C than your normal range , so as toyour normal range , so as to reduce your specific heat consumption in

reduce your specific heat consumption in the pyrosytsem.the pyrosytsem.

What are reasons of coating in cement silo?

Ramakrishnan Iyer

Ramakrishnan Iyer •• Moisture in gypsum and probably moisture onMoisture in gypsum and probably moisture on

account of water spraying inside mill. And also unsealed man-hole doors account of water spraying inside mill. And also unsealed man-hole doors on silo top.

on silo top.

Sergey Perediriy

Sergey Perediriy •• If the coating is at the roof If the coating is at the roof - poor ventilation. If it is- poor ventilation. If it is on the walls it is a matter whether it is hard or

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combination of many factors^ humidity of

combination of many factors^ humidity of air, cement temperature, wallair, cement temperature, wall penetration

penetration

Mohammed Abdo

Mohammed Abdo •• when cement mill outlet temp above 125 when cement mill outlet temp above 125 ..then most..then most water content in gypsum will dehydrate to form high percentage of in water content in gypsum will dehydrate to form high percentage of in hydrate gypsum thus, this cement will be very edacious to react with hydrate gypsum thus, this cement will be very edacious to react with water -as humidity in the air - then the

water -as humidity in the air - then the cement coat ability will increasecement coat ability will increase inside silo .... then there are other factors will increase the coating as Mrs inside silo .... then there are other factors will increase the coating as Mrs sergey perediriy said above.

sergey perediriy said above. Sayed Hassan

Sayed Hassan •• Reasons of coating at cement silo is atriputed toReasons of coating at cement silo is atriputed to prehydration of cem

prehydration of cement caused by dehydratient caused by dehydration of gypsum which on of gypsum which causedcaused by high temp., to

by high temp., to overcome this problem overcome this problem you need to decreyou need to decrease thease the temperature of cement when entering the silo

temperature of cement when entering the silo (cooler), another way(cooler), another way decrease the quantity of gypsum or add precent of gypsum anhydrite decrease the quantity of gypsum or add precent of gypsum anhydrite Pradeep kumar

Pradeep kumar •• If cement temperature is high ie., > 80 deg C , If cement temperature is high ie., > 80 deg C , going togoing to the silo and the stock is very high

the silo and the stock is very high the gypsum gets dehydrated and thethe gypsum gets dehydrated and the moisture moves towards to colder walls and the inner cone. The vapors moisture moves towards to colder walls and the inner cone. The vapors wet the cement and gets hydrated .

wet the cement and gets hydrated . If you have If you have alkalies it accelerates thealkalies it accelerates the hydration forming syngenite , CasO4.K2SO4.H20 .Hence higher the hydration forming syngenite , CasO4.K2SO4.H20 .Hence higher the cement temperature higher is the evaporation.To avoid this make the cement temperature higher is the evaporation.To avoid this make the cement stock alive and reduce the cement temperature. As sergey said cement stock alive and reduce the cement temperature. As sergey said that silo must be ventilated with bag filter and if you are in

that silo must be ventilated with bag filter and if you are in tropical,tropical,

country moisture passing through the silo aeration blowers can be dried. country moisture passing through the silo aeration blowers can be dried. Imagine if you 10000 tons cement in a

Imagine if you 10000 tons cement in a silo which has 500tons gypsumsilo which has 500tons gypsum ie., 150 tons of water in combined form. May be 50 tons

ie., 150 tons of water in combined form. May be 50 tons can evaporatecan evaporate assumed and then think what will happen. If it is not possible to cool the assumed and then think what will happen. If it is not possible to cool the cement in your mills then FLS supply powder cooler which has heat cement in your mills then FLS supply powder cooler which has heat exchanger inside. I have an analysis on this and i can share with you exchanger inside. I have an analysis on this and i can share with you which you can help in uploading in the linked-in

which you can help in uploading in the linked-in to share with our allto share with our all friends. friends. Regards, Regards, Pradeep Kumar Pradeep Kumar

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Muhammad Usman

Muhammad Usman •• you are absolutely right Mr. Pradeep because onyou are absolutely right Mr. Pradeep because on our plant FLS engineers has installed cooler on cement mills that having our plant FLS engineers has installed cooler on cement mills that having heat exchanger.

heat exchanger. Ashok Sekar

Ashok Sekar •• Dear Mr. Khurram,Dear Mr. Khurram, I am from FLSmidth and if

I am from FLSmidth and if you need any assistance pls contact meyou need any assistance pls contact me (ashok.sekar@flsmi

([email protected]) and i can dth.com) and i can forward the same to coforward the same to concernedncerned Sales manager

Sales manager Asif Ali Sheikh

Asif Ali Sheikh •• Dear Khuram, kindly check the cement temperatureDear Khuram, kindly check the cement temperature ,and the compressed air used for areation could be the reason of

,and the compressed air used for areation could be the reason of moisuremoisure and resulting the coating for

and resulting the coating formation.mation. Chelladurai Palaniandy

Chelladurai Palaniandy •• In CEM II production in In CEM II production in tropical area i havetropical area i have experienced with high feed moisture in

experienced with high feed moisture in Gypsum , Open yard wet clinker Gypsum , Open yard wet clinker and Wet limestone and overall mill feed moisture is more than 8 % . But and Wet limestone and overall mill feed moisture is more than 8 % . But we didn't face much problem due to maintain temperate remove as much we didn't face much problem due to maintain temperate remove as much as moisture in vapor form before going in

as moisture in vapor form before going in side silo and maintain siloside silo and maintain silo ventilation , level and method of aeration etc. I think no need of cooler ventilation , level and method of aeration etc. I think no need of cooler also.

also.

plz i want any one tell m

e how can i calculate

heat balance, clinker factor

Arvind Gopalan

Arvind Gopalan •• Dear Maas,Dear Maas, I will try my best to

I will try my best to explain to you partly about the Clinker Factor, inexplain to you partly about the Clinker Factor, in other word the Mass Balance(mass in = mass out). There are two ways other word the Mass Balance(mass in = mass out). There are two ways of ascertaining the clinker factor ie., directly by

of ascertaining the clinker factor ie., directly by weighing the clinker weighing the clinker using a drop test for a period

using a drop test for a period of about 24 hours which is far of about 24 hours which is far more amore a practical and

practical and the most recommendethe most recommended way. The othed way. The other way is to go in for ar way is to go in for a Mass Balance based on specific kiln

Mass Balance based on specific kiln boundaries.boundaries. In the latter case we have to figure out the type of

In the latter case we have to figure out the type of Dust RecirculationDust Recirculation prevalent in the

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or the Internal Dust

or the Internal Dust Circulation.Circulation.

Considering the Case of External Dust

Considering the Case of External Dust Recirculation the recirculationRecirculation the recirculation dust needs to be taken into account(as the Dust goes back to the kiln dust needs to be taken into account(as the Dust goes back to the kiln

feed bin) in which case the mass balance will be with the likely inputs of feed bin) in which case the mass balance will be with the likely inputs of Kiln feed & Coal Ash component( if coal is used as f

Kiln feed & Coal Ash component( if coal is used as fuel) and the outputuel) and the output components which needs to be deducted will be

components which needs to be deducted will be the Recirculation dustthe Recirculation dust and the Bypass dust ( if bypass system is

and the Bypass dust ( if bypass system is available) to arrive the clinker available) to arrive the clinker as they cross the boundary.

as they cross the boundary. Likewise in the case of

Likewise in the case of Internal Dust Recirculation the recirculation dustInternal Dust Recirculation the recirculation dust need not be taken into account as they are within the boundary of

need not be taken into account as they are within the boundary of massmass balance(ie the

balance(ie the dust comes back tdust comes back to the system after the o the system after the kiln feed bin). Inkiln feed bin). In this case the inputs will be the same as the earlier case but the output this case the inputs will be the same as the earlier case but the output will only the Bypass dust( if bypass system is available).

will only the Bypass dust( if bypass system is available). As I could not explain to you clearly either by giving

As I could not explain to you clearly either by giving an example withan example with the calculations and the pictorial representation of

the calculations and the pictorial representation of the boundaries , Ithe boundaries , I have made efforts to explain the mass balance in a simple way. If you have made efforts to explain the mass balance in a simple way. If you are further interested to know the mass balance you can mail me to the are further interested to know the mass balance you can mail me to the following id. following id. [email protected] [email protected] Regards Regards Arvind. Arvind. Mohammad Khalessi-P.ENG., PMP

Mohammad Khalessi-P.ENG., PMP •• Factor for clinker factor from rawFactor for clinker factor from raw material (Raw Mill inlet) is:

material (Raw Mill inlet) is:

Clinker=Raw Meal x ((1-LOI)/100) x ((1-H2O)/100)) Clinker=Raw Meal x ((1-LOI)/100) x ((1-H2O)/100)) Factor for clinker factor from Kiln feed is:

Factor for clinker factor from Kiln feed is:

Clinker= Kiln Feed x((1-LOI)/100) x ((1-H2O)/100) x ((1

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Loss)/100) Loss)/100)

LOI= Loss of Ignition LOI= Loss of Ignition

H2O= Material Humidity(Normally it is 0.5% for

H2O= Material Humidity(Normally it is 0.5% for Kiln Feed)Kiln Feed)

Dust Loss= Return from ESP and GCT(Between 7-10% depend on the Dust Loss= Return from ESP and GCT(Between 7-10% depend on the top cyclone efficiency)

top cyclone efficiency)

Heat Balance is just a equation between inputs and outputs I consider the Heat Balance is just a equation between inputs and outputs I consider the outputs as positive and inputs as negative

outputs as positive and inputs as negative Outputs

Outputs

1-Heat loss from main stack from preheater tower and dust loss. 1-Heat loss from main stack from preheater tower and dust loss. 2-Heat loss fro By pass if

2-Heat loss fro By pass if a system has it.a system has it. 3-Heat loss from Preheater (Cyclones shell) 3-Heat loss from Preheater (Cyclones shell) 4-Heat loss fro Kiln shell

4-Heat loss fro Kiln shell 5-Heat required for burning. 5-Heat required for burning. 6-Evaporation

6-Evaporation

7-Heat loss in Clinker Cooler 7-Heat loss in Clinker Cooler 8-Heat loss from output clinker 8-Heat loss from output clinker Inputs

Inputs

1-Heat with Raw Material, Air and Fuel 1-Heat with Raw Material, Air and Fuel 2-Heat from Ignition

2-Heat from Ignition Hope that it helps Hope that it helps Mustafa Hussein

Mustafa Hussein •• Kindly, could you inform me about all the factorsKindly, could you inform me about all the factors affecting the gates speed of

affecting the gates speed of grate cooler grate cooler Juan Pedro Esperón

Juan Pedro Esperón •• Main factor or parameter to control is the pressureMain factor or parameter to control is the pressure below first gate.

below first gate. It is a good indicator It is a good indicator of clinker bed you haof clinker bed you have inside of ve inside of grate cooler. Second factor or parámeter to control is the secondary air grate cooler. Second factor or parámeter to control is the secondary air temperature. It is going to tell you about exchange termic energy

temperature. It is going to tell you about exchange termic energy between air a

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Mohammad Khalessi-P.ENG., PMP

Mohammad Khalessi-P.ENG., PMP •• Well that is a Well that is a complicatedcomplicated question and depends on

question and depends on the process parameters,kiln condition, burningthe process parameters,kiln condition, burning technology and cooler technology but the major points can be:

technology and cooler technology but the major points can be: 1-Controlling the teritary air temoerature.

1-Controlling the teritary air temoerature.

2-Controlling clinker bed thickness and pressure

2-Controlling clinker bed thickness and pressure under the clinker bed.under the clinker bed. 3-Snowman or red river effects

3-Snowman or red river effects

What are the procedure by wich we can

decrease the DP level in bag house??

Ramakrishnan Iyer

Ramakrishnan Iyer •• clean bags regularly. What is the clean bags regularly. What is the temperature of temperature of gases passing thru bag

gases passing thru bag house?.If low, water condensation will chokehouse?.If low, water condensation will choke bags. Poor quality ba

bags. Poor quality bags also will cgs also will choke the pores of bags. hoke the pores of bags. Calibrate allCalibrate all temperatures and pressures in bag house.

temperatures and pressures in bag house. Atef Ibeid

Atef Ibeid •• 1st check air press at B,H area is it enough 51st check air press at B,H area is it enough 5-6 bar?-6 bar? 2nd check Poppet valves movement one by one

2nd check Poppet valves movement one by one 3rd if every thing is ok

3rd if every thing is ok ,Cycle burging time ,,,etc ,then investigate ur ,Cycle burging time ,,,etc ,then investigate ur filter bags by take 3 -5

filter bags by take 3 -5 bags from different compartments & check bagsbags from different compartments & check bags poroosity,may be ur ba

poroosity,may be ur bags is exposed due to gs is exposed due to high temp,if this is high temp,if this is thethe case,then u ve to check ur bag house inlet temp Protection

case,then u ve to check ur bag house inlet temp Protection & to sure if it is

& to sure if it is activated or notactivated or not if ur bags loose porosity due to

if ur bags loose porosity due to high temp.,then u will ve high Presshigh temp.,then u will ve high Press Dropp DUE TO HIGH RESISTANCE

Dropp DUE TO HIGH RESISTANCE so u need to change ur bags with new one so u need to change ur bags with new one Munusamy Murugan

Munusamy Murugan •• Excess false air leakage at Bag House Excess false air leakage at Bag House inlet andinlet and through inspection doors will lead to higher DP because of low suction through inspection doors will lead to higher DP because of low suction or positive pressure at

or positive pressure at inlet.So arresting false air will reduce Dp inlet.So arresting false air will reduce Dp acrossacross Bag House

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Ashish Ghai

Ashish Ghai •• You must check the puYou must check the purging sequence, smooth operationrging sequence, smooth operation of all the solenoid valves, air leakages, Reverse air fan. Then go for bags of all the solenoid valves, air leakages, Reverse air fan. Then go for bags replacement.

replacement. Ashish Ghai

Ashish Ghai •• You must check the puYou must check the purging sequence, smooth operationrging sequence, smooth operation of all the solenoid valves, air leakages, Reverse air fan. Then go for bags of all the solenoid valves, air leakages, Reverse air fan. Then go for bags replacement.

replacement. Ashish Ghai

Ashish Ghai •• You must check the purging sequence, smooth operationYou must check the purging sequence, smooth operation of all the solenoid valves, air leakages, Reverse air fan. Then go for bags of all the solenoid valves, air leakages, Reverse air fan. Then go for bags replacement.

replacement.

Kiln Operations

Dear Experts, I would like to know that what we

are to mainly saw in

Kiln and cooler camera in

control room ?

carlos barbosa

carlos barbosa •• In the kiln you can see:In the kiln you can see: 1- the behavior of the clinker in the kiln. if

1- the behavior of the clinker in the kiln. if the material is not going the material is not going upup with the kiln moviment and falling down on the main burner. If

with the kiln moviment and falling down on the main burner. If so it is aso it is a problem. You should se

problem. You should see in this area e in this area only clinker's balls only clinker's balls falling down onfalling down on the cooler.

the cooler.

2- the temperatura of the flame is not monitored by instru

2- the temperatura of the flame is not monitored by instrument you canment you can infer it by the flame color.

infer it by the flame color. 3- how is the amount of

3- how is the amount of dust in the clinker.dust in the clinker. In the cooler you can see:

In the cooler you can see:

1- the ar distribution in the clinker bed. If

1- the ar distribution in the clinker bed. If there is no a place where therethere is no a place where there are red river or the air is

are red river or the air is in excess.in excess. 2- snowman

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Hassan

Hassan •• kiln camera:kiln camera:

you can judge the quality of clinker by it is

you can judge the quality of clinker by it is behavior, also you canbehavior, also you can determine the status of the kiln and burning zone,

determine the status of the kiln and burning zone, cooler camera:

cooler camera:

you can determine the status of the kiln, you can see the for

you can determine the status of the kiln, you can see the formation of mation of snowman and red river, in addition to the clinker bed

snowman and red river, in addition to the clinker bed

Er.aditya Srivastava

Er.aditya Srivastava •• Mr.Carlos Barbos in my plant we can moniter theMr.Carlos Barbos in my plant we can moniter the flame temprature

flame temprature Ashish Ghai

Ashish Ghai •• Thank you Mr.Hassan and Mr. Barbosa .Thank you Mr.Hassan and Mr. Barbosa . Sir, I would like to know about Snow man and Red River. Sir, I would like to know about Snow man and Red River. Ashish Ghai

Ashish Ghai •• Thank you Mr.Hassan and Mr. Barbosa .Thank you Mr.Hassan and Mr. Barbosa . Sir, I would like to know about Snow man and Red River. Sir, I would like to know about Snow man and Red River. Jagat Singh Rathee

Jagat Singh Rathee •• Dear Ashish Ghai,The red river in Dear Ashish Ghai,The red river in the cooler meansthe cooler means ,the clinker is not cooled properly while travelling over the cooler area / ,the clinker is not cooled properly while travelling over the cooler area / plates.This is be

plates.This is because of the imcause of the improper cooling air and cproper cooling air and clinker linker distribution over the cooler inlet

distribution over the cooler inlet area and in the area and in the subsequent zones.Air subsequent zones.Air distribution control , through the cooler bed control mechanism and the distribution control , through the cooler bed control mechanism and the cooler fans air control through the control mechanism like fan speed cooler fans air control through the control mechanism like fan speed ,damper and the cooler bottom air distribution control valves in the ,damper and the cooler bottom air distribution control valves in the modern coolers, is a must ,so as to arrest the red

modern coolers, is a must ,so as to arrest the red river formation ,to saveriver formation ,to save / recuperate the heat energy from the clinker, and also to avoid chances / recuperate the heat energy from the clinker, and also to avoid chances of mechanical damage to the cooler structure .

of mechanical damage to the cooler structure . Snowman is the formation ( in the form of

Snowman is the formation ( in the form of a small to medium or evena small to medium or even occasionally touching the kiln discharge end, just at

occasionally touching the kiln discharge end, just at the cooler beginningthe cooler beginning ,below the kiln burner pipe

,below the kiln burner pipe ,mostly towards the clinker discharge side ,mostly towards the clinker discharge side ,as,as the clinker cooler is about 600 - 6

the clinker cooler is about 600 - 650 mm off centre from the kiln center 50 mm off centre from the kiln center line ), is because of excessive liquid phase in the kiln burning zone ( line ), is because of excessive liquid phase in the kiln burning zone (

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mostly because of soft burning raw mix ) or so

mostly because of soft burning raw mix ) or sometimes excessive finemetimes excessive fine clinker dust in the clinker being discharged on to the cooler, or due clinker dust in the clinker being discharged on to the cooler, or due toto excessive burning zone temperature, maintained by the operator. These excessive burning zone temperature, maintained by the operator. These conditions have to arrested by reducing liquid in the range of 27.5

conditions have to arrested by reducing liquid in the range of 27.5 - 29.0- 29.0 % , in the clinker, and through appropriate flame control mechanism by % , in the clinker, and through appropriate flame control mechanism by the operator or use of fu

the operator or use of fuzzy logic ,kiln expert control or the Linkmanzzy logic ,kiln expert control or the Linkman software for kiln operations , if you do

software for kiln operations , if you do not want to depend too much onnot want to depend too much on the kiln plant operators.Even ,you can play with the kiln speed and

the kiln plant operators.Even ,you can play with the kiln speed and cooler to an extent for stabilized and uninterrupted smooth kiln cooler to an extent for stabilized and uninterrupted smooth kiln operations.

operations.

In this exercise ,both your kiln as well as cooler cameras come very In this exercise ,both your kiln as well as cooler cameras come very handy and are highly useful, for the operators, for flame view ,burning handy and are highly useful, for the operators, for flame view ,burning zone view , discharge /cooling zone

zone view , discharge /cooling zone view and the cooler overall view and the cooler overall viewview w.r.t. air distribution ,clinker distribution and

w.r.t. air distribution ,clinker distribution and the smowman formationthe smowman formation ,very clearly

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Burners and Flames - FLS , Pillard ,

KHD , Calculation of

Burner

Momentum

«

« on:on: February 24, 2013, 11:34:08 AM »February 24, 2013, 11:34:08 AM »

Pillard burners and flames Pillard burners and flames

======================================= ======================================= this lecture is about

this lecture is about

Know the criteria for burner design Know the criteria for burner design

Familiarise yourselves with the suppliers and burner

Familiarise yourselves with the suppliers and burner types that existtypes that exist

Know the consequences of poor burning, the combustion indicators that confirm this, an Know the consequences of poor burning, the combustion indicators that confirm this, an d thed the possibilities that exist to correct the

possibilities that exist to correct the situationsituation

Encourage your personnel to concentrate efforts on burner optimization Encourage your personnel to concentrate efforts on burner optimization

``If it is mixed, it is burnt´´ ``If it is mixed, it is burnt´´

============================================================ ============================================================ ========================

========================

Firing Systems + Burners and Flames Firing Systems + Burners and Flames

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Primary Air Rate : 10

Primary Air Rate : 10 –– 12 %12 %

Based on stoichiometric combustion air, exc transport Based on stoichiometric combustion air, exc transport

Specific Axial Momentum : Gax = 7

Specific Axial Momentum : Gax = 7 –– 10 N/MW10 N/MW Including fuel and transport air

Including fuel and transport air Primary air fan

Primary air fan –– Minimum 250 mbarMinimum 250 mbar

Injection Velocity Injection Velocity Coal Coal –– 30 m/s30 m/s Petcoke Petcoke –– 25 m/s25 m/s

Consider future use of AFR! Consider future use of AFR!

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Momentum = Velocity * Massflow Momentum = Velocity * Massflow

Quick calculation of specific axial momentum Gax: Quick calculation of specific axial momentum Gax:

Gax = %PA * vPA*

Gax = %PA * vPA* 1/300 [N/MW]1/300 [N/MW]

%PA = percentage of primary air [%] %PA = percentage of primary air [%] Primary air velocity (Bernoulli) : vPA =

Primary air velocity (Bernoulli) : vPA =  (2 * pTip /(2 * pTip / Tip ) [m/s]Tip ) [m/s] pTip

pTip pressure at burner inlet -5% [Pa]pressure at burner inlet -5% [Pa]

Tip = air density at burner tipTip = air density at burner tip T = 50°C, p = ambient pressureT = 50°C, p = ambient pressure

Example: Example:

Amount of primary air: PA

Amount of primary air: PA = 12%; pBurner Inlet = 200 mbar= 12%; pBurner Inlet = 200 mbar



 vPA = 187 m/svPA = 187 m/s  Gax = 7.5 N/MW + Gax = 7.5 N/MW + 1 N/MWfor Coal = 8.5 N/MW1 N/MWfor Coal = 8.5 N/MW

============================================================ ============================================================ ================================

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Pillard Rotaflam - Eclépens Pillard Rotaflam - Eclépens

250 mbar fan standard 250 mbar fan standard

Separate adjustment of PA

Separate adjustment of PA –– radial and axialradial and axial

Very flexible Very flexible

Extensive experience in Holcim Extensive experience in Holcim

============================================================ ============================================================ ===============================

===============================

Unitherm M.A.S Burner - Sigghental Unitherm M.A.S Burner - Sigghental

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New concept

New concept –– (one single primary air channel)(one single primary air channel) Interesting alternative to conventional burners Interesting alternative to conventional burners

============================================================ ============================================================ ===========================

===========================

FLS Duoflex

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250 mbar fan standard 250 mbar fan standard

Adjustment on burner tip (only sum of axial and radial air) Adjustment on burner tip (only sum of axial and radial air) Little experience in holcim but FLS

Little experience in holcim but FLS is reputable supplieris reputable supplier

============================================================ ============================================================ ============================ ============================ KHD - Pyrojet KHD - Pyrojet

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Jet air with 1000 mbar axial

Jet air with 1000 mbar axial pressure (blower needed)pressure (blower needed) No cross tip adjustment

No cross tip adjustment possiblepossible

Concept does not foresee amount of primary air (volume) Concept does not foresee amount of primary air (volume)

============================================================ ============================================================ ========================= ========================= Burner Adjustment Burner Adjustment

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Typical burner set-up (Rotaflam): Typical burner set-up (Rotaflam):

 60% axial air,60% axial air,  30% radial air, central air30% radial air, central air 50mbar (50mbar (10%)10%)

============================================================ ============================================================ ===========================

===========================

Fuel Oil Atomisation Fuel Oil Atomisation

Why do we atomise? Why do we atomise?

``To increase the surface area of fuel that

``To increase the surface area of fuel that is to be mixed to allow rapid is to be mixed to allow rapid burnout.´´burnout.´´

Reaction time of a particle increases approximately with the square of

Reaction time of a particle increases approximately with the square of its diameterits diameter

============================================================ ============================================================ ============================== ============================== Types of Atomisers Types of Atomisers

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Fixed Orifice - Pillard Fixed Orifice - Pillard Variable Orifice - FLS Variable Orifice - FLS Assisted Atomisation Assisted Atomisation ============================================================ ============================================================ ============================= =============================

What’s the Ideal Flame ? What’s the Ideal Flame ?

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Short, Hot and Stable! Short, Hot and Stable!

============================================================ ============================================================ ================================

================================

Consequences of Poor Burning Consequences of Poor Burning

============================================= =============================================

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============================================================ ============================================================ ================================ ================================ Combustion Indicators Combustion Indicators ========================================= ========================================= Clinker Quality Clinker Quality Free Lime Free Lime Liter Weight Liter Weight SO3 in clinker SO3 in clinker Microscopy Microscopy Magotteaux test

Magotteaux test –– Detects reducing conditions (CO)Detects reducing conditions (CO)

Coating Formation Coating Formation

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Temperature profile Temperature profile Length of fixed coating Length of fixed coating Stability of coating Stability of coating Ring formation Ring formation

Gas at kiln inlet Gas at kiln inlet

CO : < 0.05% - good burn CO : < 0.05% - good burn outout

Temperature at kiln inlet Temperature at kiln inlet

As low as possible : >

As low as possible : > 1100oC1100oC –– Long FlameLong Flame Short kilns L/D < 12

Short kilns L/D < 12 –– higher inlet temp acceptablehigher inlet temp acceptable

SO3 Volatilisation SO3 Volatilisation ============================================================ ============================================================ =============================== ===============================

Steps to improve combustion - Burner Steps to improve combustion - Burner

Carry out Burner Check and Combustion Check Carry out Burner Check and Combustion Check

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Impulsion Increase

Impulsion Increase –– shorter flameshorter flame PA ratio Increase

PA ratio Increase –– shorter flameshorter flame Fuel pressure fluctuations Decrease

Fuel pressure fluctuations Decrease –– stable flamestable flame Fuel velocities Ensure one flame

Fuel velocities Ensure one flame Burner alignment Parallel to kiln axis Burner alignment Parallel to kiln axis SAT Increase

SAT Increase –– shorter flameshorter flame Fuel quality Regulate

Fuel quality Regulate –– stable flamestable flame Burner Position Kiln outlet -

Burner Position Kiln outlet - shorter flameshorter flame

============================================================ ============================================================ =============================

============================= Know the criteria for burner design

Know the criteria for burner design

Familiarise yourselves with the suppliers and burner

Familiarise yourselves with the suppliers and burner types that existtypes that exist

Know the consequences of poor burning, the combustion indicators that confirm

Know the consequences of poor burning, the combustion indicators that confirm this, and thethis, and the possibilities that exist to correct the

possibilities that exist to correct the situationsituation

Encourage your personnel to concentrate efforts on burner optimisation Encourage your personnel to concentrate efforts on burner optimisation

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According to you, what are the best 3

innovations of the past 50 yrs in

each of the

following areas of Portland cement?

1.

1. Manufacturing, handling equipment and

Manufacturing, handling equipment and

storage

2. Raw materials & raw meals

3. Fuels & Energy

4. Process Control

5. Analytical techniques

6. Product Innovation (clinker and finished

cement)

7. Grinding Aids

8. Set retardation

Subhash Bhanot

Subhash Bhanot •• I agree with S. Kumar. The Industry has done a lotI agree with S. Kumar. The Industry has done a lot and still continuing in those 3 innovative areas i.e., Fuels and energy, and still continuing in those 3 innovative areas i.e., Fuels and energy, Process control and Product innovation. The

Process control and Product innovation. The alternate ways of alternate ways of manufacturing cement is taking more attention as the

manufacturing cement is taking more attention as the requirement isrequirement is having lesser carbon foot prints towards mitigating the carbon threat to having lesser carbon foot prints towards mitigating the carbon threat to the universe.

the universe. Sergey Perediriy

Sergey Perediriy •• Alternative fuels and raw materialsAlternative fuels and raw materials S Kumar