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This report investigates the kiln line of Sharrcem, Titan Group Company, in Kosovo, focusing on its performance and efficiency during an audit period from September 19 to 26, 2013. The kiln has a low efficiency rate of 54.3% and significant air inleakage issues, resulting in high heat consumption and dust losses. Recommendations for improvement include eliminating false air sources, optimizing cooler and kiln operations, and adjusting duct arrangements to enhance overall efficiency and increase output to 1650 tpd.

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100% found this document useful (1 vote)

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150 21 281 2013 Anlagenoptimierung Ofenanlage en

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ThyssenKrupp Industrial Solutions

Page: 1
Date: 2014-01-20

INVESTIGATION OF KILN LINE

SHARRCEM SH.P.K, TITAN GROUP COMPANY
HANI I ELEZIT / KOSOVO

Investigation period: 19.09.2013 – 26.09.2013

Persons responsible: Rüdiger Beyer TKRT, dept. 150

Thomas Landmann TKRT, dept. 150

Report number: 150/21-281/2013

Distribution list: EB-SD, 020, 021, 150, 300, 600/630, customer

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Correspondence address: ThyssenKrupp Industrial Solutions GmbH, Business Unit Resource Technologies, Graf-Galen-Straße 17, 59269 Beckum, Germany
Phone: +49 2525 99-0 Telefax: +49 2525 99-2100 E-mail: [email protected] Internet: www.thyssenkrupp-industrial-solutions.com

Business address: ThyssenKrupp Industrial Solutions GmbH, ThyssenKrupp Allee 1, 45143 Essen
Management Board: Dr. Hans Christoph Atzpodien (Chairman), Martin Hilbig, Dr. Joachim F. Panek, Jörg Schönewolf
Registered office: Beckum Registration court: Local Court of Münster HRB No. 7717 VAT ID No.: DE811152653
ThyssenKrupp Industrial Solutions

Page: 2
Date: 2014-01-20

Contents

1. Summary

2. General

3. Plant description

3.1 Technical specification

3.2 Photo documentation

4. Audit of the plant situation – service package I

4.1 Investigation team

4.2 Investigation period
4.3 Diagram of measuring points
4.4 Individual measurements
4.5 Sampling and analyses
4.6 Measuring devices

5. Discussion of the measurement results

5.1 Energy balance of the kiln plant

5.2 Kiln output and fuel
5.3 Dust quantity
5.4 Specific loadings
5.5 Air and gas quantities
5.6 Kiln ID fan
5.7 Temperature and pressure profile of the preheater
5.8 Velocity profile of the preheater tower
5.9 False air
5.10 Cooler balance / operation

6. Process data of SHARRCEM

6.1 Heat balance of the complete kiln at 20 °C

6.2 Specific loadings
6.3 Clinker
6.3.1 RRSB diagram of clinker
6.4 Kiln feed
6.4.1 RRSB diagram of kiln feed
6.5 Petcoke sintering zone burner

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Date: 2014-01-20

6.6 Chemical analysis

6.7 Gas and air conditions
6.8 Exhaust gas quantity summary
6.9 Gas-analyses, air excess, H2O-contents and dew points
6.10 Dust
6.11 Radiation and convection
6.12 Kiln shell temperatures
6.13 Temperatures, pressures and gas analyses at preheater
6.14 Gas velocities in preheater
6.15 Air and gas flow
6.16 Heat balance of cooler at 20 °C
6.17 Cooler balance / graphic
6.18 Cooling air flows
6.19 Cooler diagrams
6.20 Cooling air fans

7. Gas interconnection system

8. Catalogue of measures – service package II

8.1 Elimination of false air sources

8.2 Optimisation of the combustion conditions
8.3 Kiln / preheater efficiency
8.4 Kiln feed meal finenesses
8.5 Kiln rotation speed
8.6 Cooler optimisation
8.7 Kiln exhaust gas fan
8.8 Instrumentation
8.9 Duct arrangement
8.10 Gas interconnection system

APPENDIX

Chemical analysis

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Date: 2014-01-20

1. Summary
The kiln line of Sharrcem, Titan Group Company, in Hani i Elezit / Kosovo was put into service in
1979. The plant now essentially consists of:

- a 3-support rotary kiln, 4.6 x 67.6 m

- a 2-string, 5-stage SKET preheater (lower section 3 shaft stages, upper
section 2 cyclone stages)
- and a reciprocating grate cooler from KHD with type designation PSC 1_034.08 HT.

The kiln plant was modernised in recent years. In 2001/2002 the old SKET cooler was replaced
by a new reciprocating grate cooler from KHD. During this conversion, the kiln was shortened in
length from 69 m to 67.6 m. The cooler exhaust air dedusting system was replaced some years
ago by a new bag filter with upstream air-air heat exchanger. A new bag filter with filter fan was
also installed at the kiln/mill dedusting side.

This report describes the current condition of the kiln plant. It represents the measuring period
during the audit of the plant situation from 19.09.2013 to 23.09.2013. During this period of time
there were minor disturbances which did not have a negative influence on the kiln operation.
However, for the determination of the performance data only those periods with stable kiln opera-
tion were taken into consideration and evaluated.

During the investigation the kiln plant ran with a weighed average kiln output of 1504 t/24h. The
heat consumption was 892.1 kcal/kg clinker and was covered by the Petcoke fuel with 808.1
kcal/kg of clinker and by carbon in the kiln feed meal with 84.0 kcal/kg of clinker.

It is noticeable that the cooler had a very low efficiency rate of only 54.3%. The calculated cooler
losses were 154 kcal/kg of clinker. In the area of the cooler system and the kiln outlet there is a
serious inleakage of false air, which reduces the efficiency rate. The dust discharge of 22.9%
downstream of the preheater also has a negative effect. As a result of these high losses, the heat
consumption of the entire plant is increased.

There is another serious air inleakage into the system between the measuring points after the
preheater and after the kiln exhaust gas fan. This also has a negative effect on the gas intercon-
nection system.

The following table 1 shows a summary of the main process-technological data recorded during
the plant situation audit:

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Kiln audit Sept.2013 Dimension

Clinker production
Design 1500 t/day
Obtained 1504 t/day
Spec. heat consumption
Total 892.1 kcal/kg clinker
From fuel 808.1 kcal/kg clinker
From carbon 84.0 kcal/kg clinker
RM/Cl factor
Indicated value 1.596 kg kiln feed/kg clinker
Calculated 1.763 kg kiln feed/kg clinker
Kiln volume loading 1.65 tpd/m³
Exhaust gas quantity
Measured 1.526 Nm³/kg clinker
Calculated 1.412 Nm³/kg clinker
Exhaust gas temperature 395 °C
Dust losses referred to production 22.93 %
Cooler efficiency 54.3
Cooler grate loading 44.24 tpd/m²
Secondary air quantity 0.722 Nm³/kg clinker
Exhaust air quantity
Measured 1.133 Nm³/kg clinker
Calculated 0.909 Nm³/kg clinker
Exit air temperature 319 °C
Ultimate clinker temperature 250 °C
Fineness portion, clinker < 3 mm 6.0 mm
Clinker particle size slope 1.62 %
Clinker equivalent diameter 16.75 mm

Table 1: Summary of the investigation results

The customer wishes to increase the output of the kiln plant to 1650 tpd. On the basis of the
measurement campaign, the evaluation of the available measurement results and the prepared
heat balance, this report proposes measures that will lead to an increase in output. Clarification
of whether these measures can be implemented from a design point of view has to be estab-
lished in the scope of a separate investigation. This point is not covered by this report. The
measures can be summarised as follows:

 Elimination of false air sources

In the area of the cooler and kiln system, as well as in the exhaust gas interconnection
system, there are high air inleak rates that have to be eliminated.

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 Lowering the exhaust gas dust quantity

Checking of the cyclone stages and, if necessary, replacement of the dip pipes. Change
the kiln feed meal fineness (coarser)

 Optimisation of the cooler and kiln operation

Alteration of the compartment-aeration rates, checking of the aeration air supply piping
and grate plates, possible replacement of cooling air fans 1 and 2.
Increase of the kiln rotation speed.

 Optimisation of the duct arrangement upstream and downstream of the kiln exhaust gas
fan
This will increase the fan efficiency and positively influence the pressure conditions
downstream of the fan.

Under the precondition that higher filter inlet temperatures of up to 240 °C are permissible in mill
bypass operation, the existing gas interconnection system (kiln/mill exhaust gas filter and filter
fan) is adequate. If temperatures of up to 240 °C are not permissible for the kiln/mill exhaust gas
filter, the cooling tower will have to be reactivated and the water injection will have to be put back
into operation. If the amount of inleaked air is properly eliminated, the mill exhaust air rates oc-
curring in interconnected operation (see Report No. 150/11 – 008/2014 Investigation of raw mill
at Sharrcem) will be lower than the exhaust air rates measured during the plant situation audit.
This means that the kiln/mill exhaust gas filter and the filter fan are adequately dimensioned for
this mode of plant operation.

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Date: 2014-01-20

2. General
In July 2013, ThyssenKrupp Resource Technologies GmbH (TKRT) was contracted to carry out a
plant situation audit (Service Package I) and to make optimisation proposals (Service Package II)
with the aim of increasing the output of the kiln system at the Sharr Cement plant of the Titan
Group in Hani i Elizit / Kosovo.

This report comprises the situation audit of the kiln plant and of the gas interconnection system.
In addition, information and dimensioning data of individual plant components, such as:

 homogenisation system
 Raw material grinding
 clinker burning system

were recorded insofar as they were available.

For the homogenisation system and the raw material grinding system, the information and di-
mensioning data are stated in separate reports.

A list with the data made available by the customer is included in the appendix of this report.

Furthermore, this report contains optimisation proposals for an expected increase in kiln output to
1650 tpd. However, these proposals are not based on a complete collection of plant data, as the
design and performance data of some equipment still has to be checked by the customer and
must be appropriately taken into account later. The present raw material components are taken
as the basis for this modernisation.

The following sections present the results and describe the procedure applied for the audit of the
plant situation and the optimisation.

We extend our thanks at this point for the friendly assistance during the plant situation audit at
the SHARRCEM factory.

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3. Plant description

The SHARRCEM plant has one kiln line. The kiln plant operates by the dry process. The kiln
plant consists of a 5-stage, 2-string Sket preheater, a rotary kiln and a grate cooler. The plant
was put into service in 1979. The three lowest Sket preheater stages are so-called shaft stages,
and the two upper stages are normal cyclone stages.

In 2001/2002, the kiln plant was modified by KHD. The length of the kiln was reduced from the
original 69 m to 67.6 m and the old clinker cooler was replaced by a grate cooler of type PSC 1-
034.08. Further conversion measures were carried out in subsequent years. The Multiclone cool-
er exhaust air dust collector was replaced by a new bag filter with upstream air-air heat exchang-
er supplied by Scheuch. In addition, the electrostatic precipitator was replaced by a Redecam
bag filter for dedusting the kiln/mill systems. The filter fan was also replaced. In mill bypass oper-
ation, the kiln exhaust gases are now cooled by means of fresh air. The former cooling tower is
no longer supplied with water, but now serves as a mixing chamber. At the upper cooling tower
inlet, three fresh air fans are installed around the periphery. These deliver fresh air to cool down
the kiln exhaust gas to an appropriate temperature of < 240 °C. In interconnected operation the
kiln exhaust gas is supplied to the grinding plant. Due to the grinding and drying process, and to
the inleaked air in the gas interconnection system, the kiln exhaust gas is cooled down to the low
temperature of approx. 100 °C.

The raw grinding plant produces the raw material for the kiln. The grinding plant comprises a
double rotator with upstream Impact dryer (double-shaft impact crusher). The stated grinding
capacity of the mill is 100 - 110 tph. Further considerations and analyses of the grinding plant are
contained in a separate report.

3.1 Technical specification

Kiln System
Make: SKET
Size: 4.6 x 67.6 m
Kiln inclination: 3.0 %
Year/Modification: 1979/2001
Rotation speed: 1.7 rpm
Kiln drive: 355 kW
Number of tyres: 3
Fuel: heavy oil / pet coke

Kiln Drive
Make: ASEC
Type: MCV 400I
Drive power: 320 kW
Speed: 750 rpm
Voltage : 400 V
Current: 800 A

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Kiln Gear
Make: VEB
Type: 40 A7-2780x71 LP
Power: 240 kW
Speed n1: 730 rpm
Speed n2: 10.1 rpm

Preheater
Make: SKET
String: 2
Year/Modification: 1979/2001
Type: 3 shaft stages and 2 cyclone stages

Main burner
Make: PILLARD
Type: Rotaflam
Mean Fuel: heavy oil / pet coke
Main fuel max. heat output: 65 MW
Main fuel max. mass rate: 6100 kg/h heavy oil / 7310 kg/h pet coke

Primary air fan for main burner

Make: PILLARD
Type: Centrifugal
Volume 10000 m³/h
Density: 1.16 kg/m³
Total pressure difference: 257 mbar
Fan speed: 2975 rpm
Shaft power: 98.0 kW

Primary air fan motor

Make: ABB
Type: M2BA 315 SMA 2
Drive power: 110 kW
Speed: 3000 rpm
Voltage: Υ 660 V
Δ 380 V
Current: 80.4 A
Cos  0.88

Coal feed dosing device for main burner

Make: PFISTER
Type: DRW 3.10/1.6
Nominal feed rate: 10 t/h
Min. feed rate: 1 t/h

Compressor pump for main burner

Make: AERZEN
Type: GM 50 L DN150
Conveying air capacity: 42.9 m³/min
Inlet pressure: 1 bar
Delta P: 0,44 bar
Power: 43.4 kW
Speed of compressor: 2955 rpm
Speed of motor: 3000 rpm

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Kiln feed dosing device

Make: PFISTER
Type: FRW 3.14/5
Number: 2
Nominal feed rate: 80 t/h
Min. feed rate: 8 t/h

Compressor pump for kiln feed

Make: AERZEN
Type: VM 140
Conveying air capacity: 159.18 m³/min
Inlet pressure: 1 bar
Final pressure: 3.5 bar
Power: 702 kW
Speed of compressor: 5791 rpm

Waste gas fan

Make: SKET
Type: LRMSDE 1450-2/L90
Speed: 950 rpm
Volume 384000 m³/h
Temperature: 360 °C
Static pressure: 540 mmWS
Power at shaft: 920 kW
Power of motor: 1350 kW

Waste gas fan motor

Make:
Type: AT 630 S38
Drive power: 1000 kW
Speed: 990 rpm
Voltage: 6000 V
Current: 114 A
Frequency: 50 Hz

Quenching chamber (conditioning tower)

Make:
Effective height: 27.3 m
Inner diameter: 6.6 m

Fresh air damper fans

Make: REDECAM
Number: 2
Location : on top of the quenching chamber
Volume: 60000 m³/h
Temperature: -20 + 40 °C
Static pressure: 65 mm WS
Power required: 16.2 kW
Power of motor: 22 kW
Fan speed in design condition: 1450 rpm

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Kiln / mill dust collector

Make: REDECAM
Type: Baghouse filter DPD
Model: 10 DPD 11x9/8
Year: 2011
Number of compartments: 10
Number of bags per compartment: 22
Total number of bags: 1980
Cloth area: 7580 m²
Type of bags: FG + PTFE
Composition: Fibre glass
Treatment: PTFE membrane
Max. operating temperature: 240/260 °C

Mill bypass operation Interconnected operation

Volume at filter inlet Nm³/h 232000 286000
Temperature c 130 95
Static pressure at inlet mmWS 55 55
Volume at filter inlet m³/h 358913 401775
Air/cloth ratio m³/m²h 0.79 0.89
Raw gas dust content g/Nm³ 50 50
Clean gas dust content mg/Nm³ 5 5
Efficiency % 99.99 99.99
Recovered dust kg/h 11600 14300

Filter fan
Make: ACOVENT
Type: Centrifugal
Model: NFLA-D 1900
Year: 2011
Speed range: 99 – 990/1051 rpm
Design temperature: 300 °C

Mill bypass operation Interconnected operation Design

Volume m³/h 363077 409991 459515
Density  kg/m³ 0.914 0.998 0.659
t c 130 95 230
Static pressure at inlet [mbar] -22.07 -25.02 -26.98
Speed rpm 820 868 1051
Power kW 258.0 335 390
Efficiency % 86.6 85.3 88.6

Filter fan motor

Drive power: 500 kW
Speed: 990 rpm
Voltage: 680 V
Current: 570 A
Frequency: 50 Hz

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Cooler
Make: KHD
Type: PSC 1-034.08 HT
Year: 2001
Number of grates: 1
Slope: 0°
Cooling area: 34 m²
Clinker capacity (design): 1500 t/d
Specific grate load (aerated): 44.1 t/d/m²
Length: 13.86 m
Width: 2.44 m
Chambers: 6

Cooler grate drive

Make:
Type: 244/1155/1188
Drive power: 30 kW
Motor speed range: 187.5 - 1456 rpm
Stroke length: 100 mm

Cooler fan drives

Cooler fans: Fan 1 Fan 2 Fan 3 Fan 4 Fan 5
Make: REITZ REITZ REITZ REITZ REITZ
Inlet volume m³/min 400 250 280 500 1320
Density inlet kg/m³ 1.073 1.073 1.117 1.134 1.154
Inlet temperature °C 20 20 20 20 20
Static pressure, discharge [mbar] 114.4 114.4 71.7 56.4 46
Impeller speed rpm 2975 2970 2965 2970 1485
Required power at shaft kW 108.15 69.4 49.49 68.42 123.18

Motor data:
Make: SIEMENS SIEMENS SIEMENS SIEMENS SIEMENS
1LA6310- 1LA6280- 1LA6253- 1LA6280- 1LA6313-
Type:
4AA60-Z 4AA60-Z 4AA60-Z 4AA60-Z 44AA60-Z
Power (installed): kW 110 75 55 75 132
Speed: rpm 1500 1500 1500 1500 1500
Voltage: V 400/690 400/690 400/690 400/690 400/690

Crusher
Make:
Type: Hammer crusher

Cooler exhaust air heat exchanger

Make: SCHEUCH
Type: Air / Air heat exchanger
Capacity: 235000 m³/h
Temperature at inlet: 300 – 400 °C
Temperature at outlet: 140 – 145 °C

Cooler dust collector

Make: SCHEUCH
Type: baghouse filter
Volume: 165000 m³/h
Operating temperature: 140 °C
Max. temperature: 150 °C
Number of bags: 825
Dust content of crude gas: 10 g/Nm³
Dust content of clean gas: 5 mg/Nm³
Load per unit area: 1.02 m³/m²h

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Cooler filter fan

Make: SCHEUCH
Type: vkd 90-1250-fb14
Volume : 165000 m³/h
Temperature: 145 – 150 °C
Total pressure increase: 28.2 mbar
Pressure increase: 23.01 mbar
Low pressure at suction nozzle: 25.0 mbar
Density at suction nozzle: 0.794 kg/m³
Speed of fan: 1475 rpm
Power requirement at shaft: 169.7 kW

Cooler filter fan motor

Make: SIEMENS
Power: 200 kW
Speed: 1476 rpm
Voltage: 400 V
Frequency: 50 Hz

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3.2 Photo documentation

Fig.: 1 Preheater tower Fig.: 2 Preheater tower from kiln outlet

Fig.: 3 Preheater tower and kiln from raw meal silo Fig.: 4 Preheater tower and raw mill building

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st
Fig. 5: Cyclone stage 1 Fig. 6: Meal chute of 1 stage

st nd
Fig. 7: Meal chute of 1 stage Fig. 8: Cyclone of 2 stage

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nd nd
Fig. 9: Cyclone of 2 stage Fig. 10: Meal chute of 2 stage

nd
Fig. 11: Meal chute of 2 stage Fig. 12: Meal chute of 3rd stage

th rd
Fig. 13: Expansion joint of 5 stage to downcomer Fig. 14: Pendulum flap in meal chute to 3 stage
duct

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Fig. 15: Damper in down comer duct Fig. 16: Fresh air damper in downcomer duct

rd
Fig. 17: Cyclone cleaning system Fig. 18: Meal chutes after 3 stage

nd rd
Fig. 19: Expansion joint in downcomer duct Fig. 20: Connection between 2 and 3 stages

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Fig. 2: Kiln inlet Fig. 22: Sampling port for gas analyses

Fig. 23: Cooling tower Fig. 24: ID fan assembly

Fig. 25: Kiln from inlet to outlet Fig. 26: Raw meal conveyance pipes

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st
Fig. 27: Kiln inlet sealing Fig. 28: 1 roller station

Fig. 29: Thrust roller Fig. 30: Gear box for main kiln drive

Fig. 31: Kiln outlet sealing Fig. 32: Gap between kiln and kiln hood

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Fig.: 33 Pillard main burner Fig.: 34 Measurement ports for cooler exhaust air

Fig. 35: Primary air and emergency cooling fan Fig. 36: Cooler outlet with clinker conveyor

Fig. 37: Cooling air fans at clinker cooler Fig. 38: Hot clinker on clinker conveyor

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Fig. 39: Cooling air supply to static grate Fig. 40: Hot clinker on clinker conveyor

Fig. 41: Cleaning system at static grate Fig. 42: Deformed clinker cooler roof

Fig. 43: Cooler drive Fig. 44: Cracks in clinker cooler roof

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Fig. 45: Cracks cooler roof Fig. 46: Cracks in cooler roof

Fig. 47: Air/Air heat exchanger and cooler filter Fig. 48: Cooler chimney

Fig. 49: Pfister coal dosing device for main burner Fig. 50: Coal conveyance pipe for main burner

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4. Audit of the plant situation – service package I

In accordance with the operational sequence, the plant situation audit consists of recording the
relevant process data required for optimisation and increase in output.

The recording of such process data as:

 Temperatures
 Pressures
 Volume flows
 Mass flows
 Gas analyses, etc.

enables the production of an energy balance. This energy balance is a particularly good means
of identifying negative points - i.e. excessive heat losses, and indicates approaches for optimisa-
tion work. In addition, the quantities of false air inleaking into the plant are quantified and as-
signed to the individual plant sections. The mass flows stated in the energy balance are always
related to the produced mass flow of 1 kg of clinker in the case of the kiln plant or 1 kg of ground
product in the case of the raw grinding plant. The calculated heat quantities are always related to
an ambient temperature of 20 °C.

4.1 Investigation team

From SHARRCEM:

Giorgos Lazarou
Mevlud Vila
Zenulla Fida

From TKRT:

Rüdiger Beyer Dept. 150

Thomas Landmann Dept. 150
Andreas Enders Dept. 150

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4.2 Investigation period

Recording of the relevant data for the kiln plant took place during the period 19.09.13 to
23.09.13. During this period there was a lengthy kiln stoppage on 19.09.13 from 19:35 hrs until
20:40 hrs and from 22:50 hrs until 20.09.13, 01:00 hrs. The cause was a faulty damper for the
cooling air fan of the main burner. On 20.09.13 at 08:45 hrs the kiln was again shut down and the
damper was replaced. At about 09:30 hrs the kiln plant was started up again. The operating data
of the gas interconnection system were also recorded during the measurements of the grinding
plant during the period 24.09.13 to 26.09.13.

4.3 Diagram of measuring points

Fig. 51: Diagram of measuring points

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4.4 Individual measurements

During the entire investigation period, the following individual measurements were carried out:

Material temperatures: Raw meal feed system

Clinker at cooler outlet
Clinker at kiln outlet

Gas temperatures: Exhaust gas downstream of preheater

Gas temperatures in the individual cyclone stages
Kiln inlet temperature
Primary air temperature at the main burner
Cooling air
Cooler exhaust air before air-air heat exchanger
Cooler exhaust air after baghouse filter
Preheater exhaust gas in the direct duct to the mixing cham-
ber
Gas after raw mill system fan
Gas after dryer fan
Exhaust gas after baghouse filter

Surface temperatures: Rotary kiln

Preheater
Cooler

Gas flow volumes: Exhaust gas after preheater

Primary air
Cooling air
Cooler exhaust air after baghouse filter
Preheater exhaust gas in the direct duct to the mixing cham-
ber
Gas after raw mill system fan
Gas after dryer fan
Exhaust gas after baghouse filter

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Pressures: Exhaust gas after preheater

Gas temperatures in the individual cyclone stages
Kiln inlet
Primary air for main burner
Cooling air
Cooler exhaust air before air-air heat exchanger
Cooler exhaust air after baghouse filter
Preheater exhaust gas in the direct duct to the mixing cham-
ber
Gas after raw mill system fan
Gas after dryer fan
Exhaust gas after baghouse filter

Gas analyses: Exhaust gas after preheater

Kiln inlet
Gas temperatures in the individual cyclone stages
Preheater exhaust gas in the direct duct to the mixing cham-
ber
Gas after raw mill system fan
Gas after dryer fan
Exhaust gas after baghouse filter

Exhaust gas dust: Filter dust weighing in mill bypass operation

4.5 Sampling and analyses

The following samples of material were taken by the customer and analysed by the Sharrcem
plant laboratory:

Kiln feed: Complete chemical analysis

Moisture content
Fineness (residue on 90µ and 200µ)

Clinker: Complete chemical analysis

CaO-free

Filter dust: Complete chemical analysis

Hot meal at kiln inlet: Complete chemical analysis

Fuels: Ultimate analysis

Proximate analysis
Calorific value

A summary of these customer's analyses is provided in the appendix.

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The following samples of material were also analysed by the TKRT laboratory:

Kiln feed: Fineness determination by Alpine air-jet screening

Fineness determination by CILAS
Determination of C

Filter dust: Fineness determination by CILAS

Determination of C

A summary of the TKRT laboratory analyses is provided in the appendix.

4.6 Measuring devices

The following devices were used for taking the measurements:

Gas and material temperatures: Ni-Cr-Ni thermocouple

Digital thermometer

Clinker temperatures: FLUKE infrared radiation pyrometer

Clinker discharged from the kiln: Impact radiation pyrometer

Surface temperatures: FLUKE infrared radiation pyrometer

Pressures: MANOAIR digital pressure gauge

Barometer

Gas volumes: Prandl pitot tube

S-Type pitot tube
Anemometer

Gas analyses: MRU gas analyser

Humidity: Hygrometer

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5. Discussion

5.1 Energy balance of the kiln plant

In order to acquire the current operating data and to assess the process-technological condition
of the plant, all operating parameters of the kiln line were measured during the investigation peri-
od 19.09.13 to 23.09.13.

Table 6.1 shows a compilation of the heat balance of the kiln plant. The calculated heat input
from fuel was 808.1 kcal/kg of clinker. This heat input from fuel resulted from the quantity of coal
dust supplied to the clinkering zone burner, as weighed in bulk transporter vehicles.

The customer stated that the calorific value of the coal is 8362 kcal/kg. Table 6.5 shows the
complete analysis of the coal (ultimate analysis, ash, water content and calorific value), as well
as the quantity of fuel supplied to the kiln plant.

A further 0.66% of carbon is supplied to the kiln plant with the kiln feed meal, while 0.51% of car-
bon is again discharged from the plant in the exhaust gas dust. The calculated quantity of heat
remaining in the system is 84.0 kcal/kg of clinker, which correspondingly increases the heat input
of the kiln plant. The calculated total input from these combustion products is 892.1 kcal/kg of
clinker. However due to the incomplete combustion of the carbon input in the kiln feed meal,
there is a CO loss of 0.15 % (equals 6.6 kcal/kg of clinker) in the preheater exhaust gas.

The installed preheater system is one of the causes of the high heat consumption of the overall
plant (892,1 kcal/kg of clinker). A 5-stage cyclone preheater usually has a heat consumption of
approx. 720 – 760 kcal/kg of clinker, while a 4-stage cyclone preheater normally has a heat con-
sumption of 740 – 780 kcal/kg of clinker. Even the GEPOL preheaters built in earlier times
achieved a heat consumption of 820 – 860 kcal/kg of clinker.

The calculated total losses due to radiation and convection amount to 94.8 kcal/kg of clinker.
Table 6.11 provides a detailed list of the individual losses. The corresponding kiln shell tempera-
tures are shown in figure 6.12.

On the output side of the heat balance the following heat losses are conspicuous and are also
responsible for the high heat consumption figure.

- Cooler losses totalling 154 kcal/kg of clinker.

- Exhaust gas losses totalling 209.7 kcal/kg of clinker.
- Exhaust gas dust losses totalling 21.5 kcal/kg of clinker.
- CO losses totalling 6.6 kcal/kg of clinker.
- Radiation and convection losses totalling 94.8 kcal/kg of clinker.

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The heat balance shows a good correspondence between heat inputs and heat expenditures. On
the heat expenditure side there is a calculated remainder of 23.6 kcal/kg of clinker (equals
2.58%) over the total inputs. Positive remainders of up to 3% of the total heat inputs are accepta-
ble when producing a heat balance. These remainders are non-recordable losses (e.g. additional
radiation loss through stiffeners).

5.2 Kiln output and fuel

The produced quantity of clinker was determined over a period of 24 hours from 20.09.13; 14:00
hrs to 21.09.13; 14:00 hrs by weighing trucks on a weighbridge.
No amount was added to take account of possible dust losses and losses during transportation to
the weighbridge. The average kiln output was 1504 tpd.
A previous clinker weighing period of 9 hrs. 35 min on 19.09.13, which ended due to the kiln plant
stoppage, also showed a kiln output of 1530 tpd.
The 24-hour weighing period result of 1504 tpd was used as the basis for production of the heat
balance and for further considerations.

The used quantity of coal was also weighed over the same time period. The coal dust was deliv-
ered in bulk transporter vehicles, weighed, and pneumatically conveyed to the coal dust silo
standing on load cells. The filling level weights of this silo were recorded. Over the period of 24
hours a total coal dust quantity of 145.35 tpd, equal to a feed rate of6.056 tph, was supplied to
the rotary kiln. The Pfister counter indications of the kiln feed meal dosing system and the coal
dust dosing system were also recorded. The determined average indicated coal dust feed rate
was 5.075 tph. The difference between the actually consumed coal dust quantity and the indicat-
ed feed rate is 0.981 tph. From this difference, a negative weigher error of 16.2% was calculated.

The determined average indicated kiln feed meal input rate was 100 tph. On the basis of the
weighed quantity of produced clinker (1504 tpd), the calculated raw meal/clinker factor is 1.596
kg/kg of clinker. On the basis of the loss on ignition of the kiln feed meal, clinker, exhaust gas
dust and ash of the supplied quantity of coal, a raw meal/clinker factor of 1.763 kg/kg of clinker
was calculated (see table 6.4). The difference between these figures means that there is a nega-
tive error of 9.5% in the Pfister weigher indications. The calculated actual kiln feed meal input
rate is therefore 110.5 tph.

5.3 Dust quantity

The quantity of exhaust gas dust downstream of the preheater was determined by weighing the
filter dust in mill bypass operation twice over a period of 1 hour each time. The dust weighing was
carried out at the later dates of 23.09.13 and 26.09.13. The weighed amount of filter dust results
in an average of 14.37 tph at an indicated kiln feed meal input rate of 100 tph. this corresponds to
an exhaust gas dust quantity of 22.93% related to clinker. This quantity of exhaust gas dust is
very high. In the case of a normal 5-stage cyclone preheater, exhaust gas dust losses are usually

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approx. 6-8%. However, the SKET preheater design has 3 shaft stages plus 2 cyclone stages.
The possible reasons for such a high quantity of exhaust gas dust could be large dust circula-
tions in the preheater due to its process-design with shaft stages, or non-uniform meal feeding to
the two strings, or excessive exhaust gas temperatures and non-optimum kiln feed finenesses of
9 to 14 % residue on 90 µm, or defective dip pipes in the topmost cyclone stage.

5.4 Specific loadings

At the kiln output of 1504 tpd, the calculated kiln volume loading is 1.65 t/m³24h. The calculated
cross-sectional kiln loading is 110.7 t/m²24h and the specific clinkering zone loading is 15.6
GJ/m²h (see table 6.2). The calculated specific cooler grate loading is 44.2 t/m²24h and the cool-
er width loading is 616.4 t/m24h.

5.5 Air and gas quantities

Table 6.7 shows the measured and calculated gas and air conditions in the overall system. The
exhaust gas flow volume of 1.526 Nm³/kg of clinker measured downstream of the preheater
shows a positive difference of 8.1 % compared to the calculated gas flow volume of
1.4123 Nm³/kg of clinker (calculated from ultimate analysis of the coal, fuel quantity, material and
gas analyses). Positive deviations up to 10% can be considered to be within the normal error
margin of pitot tube measurements and indicate a close correspondence between the measured
and the calculated exhaust air quantities.

The gas compositions of the calculated exhaust gas volume in the kiln inlet and in the exhaust
gas downstream of the preheater is shown in table 6.8 and figure 6.13. The theoretically calcu-
lated carbon dioxide and nitrogen concentrations at the kiln inlet measuring point show a large
deviation from the measured values. This difference in the case of gas analysis at the kiln inlet is
due to the formation of strands in the kiln gas. The gas composition of the exhaust gas down-
stream of the preheater only shows a minor deviation from the values measured with the MRU
gas analyser at the measuring point. These gas analyses and the gas sampling at this measuring
point can thus be considered representative.

Table 6.9 shows the air excess factors calculated from the gas analyses as well as the dew
points and water contents at the individual measuring points. For the kiln inlet, an air excess fac-
tor of 1.131 was calculated at an oxygen content of 1.77 %. Combustion is almost fully completed
inside the kiln, with a low CO concentration of 0.02%. The mean oxygen content at the measur-
ing point after the third shaft stage was found to be 1.82%, and the CO concentration was 0.06%.
The calculated air excess factor was 1.122. The increase in CO concentration between the kiln
inlet measuring point and the measuring point after the shaft stages is caused by incomplete
combustion of the carbon fed in with the kiln feed meal. Up to the measuring point after the pre-
heater, the CO concentration increased to 0.15%. This means that a large portion of the carbon
is created in the top two cyclone stages. The average oxygen content is 2.64 %. This includes

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the conveying air brought into the system with the kiln feed meal. The calculated air excess factor
was 1.179.

The calculated theoretical combustion air flow volume for burning the coal in the main burner is
0.846 Nm³/kg of clinker. The calculated actual combustion air flow volume for the main fuel is
0.956 Nm³/kg of clinker. This combustion air comprises the secondary air, the primary air enter-
ing via the main burner, the input conveying air for the coal dust and a certain amount of false air
inleaking at the kiln hood. The measured primary air flow rate at the main burner is 0.103 Nm³/kg
of clinker. The measured coal dust conveying air flow rate is 0.039 Nm³/kg of clinker. The total
volume of primary and conveying air entering via the main burner is thus 0.142 Nm³/kg of clinker.
Related to the theoretical combustion air flow volume, the amount of primary air and conveying
air is 16.8%. This air volume is slightly higher than usual. Normally, the percentage volume of
primary and conveying air through the main burner is 10 – 12%. Naturally, these air volumes in-
crease the heat consumption of the kiln plant, as the recuperated secondary air flow volume is
correspondingly reduced.

5.6 Kiln ID fan

The following figure shows the design data of the exhaust gas fan:

Waste gas fan

Make: SKET
Type: LRMSDE 1450-2/L90
Speed: 950 rpm = 100 %
Volume 384000 m³/h
Temperature: 360 °C
Total pressure: 540 mmWS = 53 mbar
Power at shaft: 920 kW
Power of motor: 1350 kW

On the basis of the above design data, the calculated efficiency of the exhaust gas fan is:

.
p  V 53  mbar  384000  m 3 / h
   0,615
P 920  kW  36000

This calculated fan efficiency of 0.615 is very low for a double-flow radial fan. Normally, such ex-
haust gas fans have efficiencies of 0.8 – 0.84.

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The measurements in the exhaust gas duct after the preheater resulted in the following operating
data:

Volume 249867 m³/h

Pressure at measuring point: - 28.4 mbar
Temperature: 395 °C

Up to the measuring point after the exhaust gas fan, a calculated false air volume of 9600 Nm³/h
enters through leaks (fresh air sockets, dampers, expansion joints, shaft seal at the fan) in the ex-
haust gas system. From this figure, the following operating data were calculated for the exhaust gas
fan:

Volume 262515 m³/h

Pressure before fan approx.: - 32.4 mbar
Pressure after fan: - 0.3 mbar
Total pressure: 32.1 mbar
Temperature: 365 °C
Power consumption CCR: 549 kW
Damper position: 100 %
Fan speed: 77% = 732 rpm

.
p V 32,1 mbar  262515  m 3 / h
P   381kW
 0,615  36000

With these recorded operating data and the fan efficiency of 0.615, its theoretical power consump-
tion is 381 kW at the shaft. At a motor efficiency of 0.92, the calculated power input of the motor is
414 kW. Under the assumption that the control panel indication of 549 kW for power input of the
motor is approximately correct, the fan has an efficiency of only 0.43.

As no characteristic curve is available for the fan, the measured operating point cannot be entered
in the characteristics field, and therefore no detailed conclusions can be derived regarding the per-
formance capability of the fan.

However, under the present operating conditions, pressure and volume reserves must still be avail-
able. During the measurement, the fan speed was 732 rpm (77% of its rated speed).

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5.7 Temperature and pressure profile of the preheater

The measured temperatures and pressures inside the preheater are shown in figure 6.13. The
total pressure drop from the kiln inlet to downstream of the preheater is calculated to be only 27.4
mbar. The pressure drop of the three shaft stages was determined to be only 4.0 mbar. This low
pressure drop is apparently normal for this preheater process. The first cyclone stage after the
shaft stages has a pressure drop of approx. 13.0 mbar, which is excessive.

The pressure drop of the dust collection stage is 6 - 7 mbar, which is a low figure. The following
Table 2 shows the pressure drops and temperatures of the individual stages.

In material
flow direction
String right / left
Kiln inlet pstat mbar -2.0
t c 1100
After shaft stage 3 pstat mbar -5.2 / -5.9
t c 740-778 / 765-795
After cyclone stage 2 pstat mbar -18.9 / -19.0
t c 580-605 / 647
After cyclone stage 1 pstat [mbar] -24.9 / -26.1
t c 370-420 / 390-403
After preheater pstat mbar 29.4
t °C 390-410
Table 2: Temperature/pressure profile

The temperature differences between string A and B are a consequence of the difference in ma-
terial feed rates to each string, which in turn causes a non-uniform gas distribution.

The temperatures show that the heat transfer in the shaft stages is not optimal. After the 3 shaft
stages, the measured gas temperatures of 770 °C were still very high. Very probably, heat is
being carried through by high dust circulations. For the purpose of comparison, a normal cyclone
preheater already achieves this heat transfer figure after the second cyclone stage.

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5.8 Velocity profile of the preheater tower

On the basis of the calculated exhaust gas quantity (see Table 6.8) and the temperature and
pressure profile (see Fig. 6.13), it is possible to calculate the velocities in the individual stages
under consideration of the false air and conveying air quantities.

The kiln output of 1504 tpd results in the velocities that are shown in Figure 6.14. The cross-
sections of the individual gas ducts and cyclone inlets relate to the refractory lining dimensions
and have been obtained from the available drawings. Changes in the cross-sections due to the
formation of incrustation are of course possible.

In order to keep the pressure drop of a preheater, and thus also the electrical energy require-
ment, as low as possible, low velocities are necessary. However, to ensure that the material is
conveyed through the gas duct, these velocities must not fall below certain limit values. On the
other hand, excessive velocities have a negative effect on the cyclone collection rate and in-
crease the dust circulations inside the preheater. This is reflected in the high quantity of exhaust
gas dust of 22.93 % related to clinker.

The calculated velocities in the shaft stages are approx. 9 m/s in the narrowest cross-section and
2.3 m/s in the extended cross-section. The calculated gas velocity in the gas duct of cyclone
stage 2 is 8.9 m/s. This velocity is relatively low and can result in material falling into cyclone
stage 2 from the cyclone stage above. The 19 m/s velocity in the inlet of cyclone stage 2 is nor-
mal, while the approx. 13 m/s velocity in the dust collection stage is relatively low.

5.9 False air

Fig. 6.15 shows a compilation of the measured and calculated gas and air conditions in the kiln
plant.

The false air inleak rate of the lower section of the preheater cannot be measured because an
unknown amount of the carbon in the kiln feed meal burns out in the lower shaft stages. The cal-
culated total quantity of false air leaking in via the preheater is 0.0555 Nm³/kg of clinker, which
equals 4 % related to the exhaust gas quantity, which is within the normal range. The amount of
conveying air for the kiln feed meal was appropriately taken into consideration for this calculation.
However, between the measuring points “After preheater“ and “After exhaust gas fan“ a very
large false air quantity of 0.153 Nm³/kg of clinker leaks in, which equals 9% related to the ex-
haust gas quantity in the exhaust gas interconnection system.

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5.10 Cooler balance / operation

Fig. 6.17 also shows the air flow volumes in the cooler system. The air flow volume supplied to
the cooler by the five fans is 1.6308 Nm³/kg of clinker. With this air flow volume, the clinker dis-
charged from the kiln is cooled down from approx. 1360 °C to 250 °C.

The cooler exhaust air volume measured at the chimney was 1.133 Nm³/kg of clinker. The theo-
retically calculated cooler exhaust air volume is 0.9089 Nm³/kg of clinker. This difference shows
that enormous sources of false air exist in the area of the cooler and/or the kiln hood, as well as
in the gas interconnection system of the filter. The estimated inleakage of false air in the kiln
hood at the area of the kiln inlet seal, due to the gap width of 10 – 20 mm between the seal and
the rotary kiln shell, is 0.092 Nm³/kg of clinker. On the basis of the air quantity balance of the
cooler, the calculated remaining quantity of false air is 0.2241 Nm³/kg of clinker. A part of this
false air leaks into the cooler through the cooler roof. A visual inspection revealed that there are
cracks in the cooler roof. Some of these cracks are so big that it was possible to look through
them and see the bed of clinker on the grate. It is not possible to make a quantitative assessment
of the air inleak rate through these cracks. However, it was possible to measure negative pres-
sure in the area of the cracks. This confirmed that false air is leaking into the cooler. This inleak-
ing false air does not participate in the heat transfer between the clinker and the air, but only re-
duces the temperature level of the secondary air and of the cooler exhaust air. The cooler ex-
haust air temperature was determined directly after the cooler by means of several system
measurements over the cross-section of the cooler exhaust air duct. The result was compared to
the cooler exhaust air temperatures displayed in the control room for the zone before the air-air
heat exchanger. This comparison showed that the manually measured cooler exhaust air tem-
perature was 46 °C higher than the mean temperature displayed in the control room. For the cal-
culation of the heat losses via the cooler exhaust air, an exhaust air temperature of 319 °C was
assumed (mean control panel display 273 °C, + 46 °C). When the heat balance of the cooler and
the overall plant was prepared, the possibility of inleakage of false air in the area of the filter was
not taken into account.

Table 6.16 shows the heat balance of the cooler. On the heat expenditure side, a cooler efficien-
cy of only 53.8% relative to the total heat inputs was calculated on the basis of the measured
cooler losses. The calculated secondary air flow volume is 0.7219 Nm³/kg of clinker. The balance
result for secondary air temperature is only 804 °C. For the cooler balance it was not assumed
that there are any clinker dust circulations in the cooler/kiln outlet area, because the kiln atmos-
phere was seen to be relatively clear.

Fig. 6.17 shows a compilation of the measured and calculated air and gas flow volumes in the
cooler system. The cooling air flow volume brought into the cooler compartments by the individu-
al cooling air fans is depicted in Tables 6.18 and 6.20. Table 6.20 also includes the cooling air
flow rates of the individual fans, as well as the compartment pressures, that were displayed in the
control room. A comparison of the measured air flow volumes (calculated from the suction flow of
the fan nozzles) with the flow rates displayed in the control room reveals very large differences.
The biggest percentage difference was 86.9% for fan 1. Here the measured suction flow rate in

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the inlet nozzle was 11041 m³/h, compared to 20633 m³/h according to the control panel display.
The first the cooling air fans show a positive deviation, while fans 3 to 5 show a negative devia-
tion of up to -50 % (fan 3), meaning that the displayed air flow volumes are too low. The total the
measured suction flow rate is 115000 m³/h, which means that the displayed cooling air flow rate
of 95300 m³/h has a deviation of -17.1 %. Such large discrepancies in the indicated cooling air
flow rates are not acceptable and must be correspondingly corrected. In the case of the com-
partment pressures, the differences between measured and displayed pressures are not so ex-
treme. Here, the biggest deviation is 11 mbar, equalling 41 %, in the indication of the pressure in
compartment 5b. The measured pressure was 26.8 mbar while the control panel display value
was 37.8 mbar.

Fig. 6.19 shows a compilation of the compartment pressures and the specific cooling air flow
rates in Nm³/m²h for the individual compartments. As a rule, Polysius design criteria specify that
the highest specific cooling air flow rate must be supplied to the first compartment. This specific
cooling air flow rate is then reduced from compartment to compartment, so that a graduated
pressure development is achieved over the length of the cooler.

This Figure also shows the cooler efficiency as a function of the secondary air flow volume. The
K factor calculated from the cooler balance and the balanced secondary air flow volume is 1.07.
Coolers that are operating well achieve cooler efficiency rates of 70 % at a secondary and tertiary
air flow volume of 0,8 Nm³/kg of clinker. This results in a K factor of 1.5. If the existing cooler had
this K factor, the secondary air flow volume would be 0.722 Nm³/kg of clinker and the cooler effi-
ciency rate would be 66.1%.

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6. Process data of SHARRCEM

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6.1 Heat balance of the SHARRCEM

Dep. 150 complete kiln at 20°C

1. Inputs kcal/kg cl. kJ/kg cl. %

Fuel, sintering zone burner
from sensible heat t = 58,0 °C 0,9 3,9 0,10
from combustion K = 9,66 % 808,1 3383,4 88,50
Raw meal
from sensible heat R = 1,7633 kg/kg cl. 15,3 64,2 1,68
t = 62,0 °C
from combustible constituents Ceffec = 0,0104 kg C/kg cl. 84,0 351,8 9,20
Cooling air V = 1,6308 Nm³/kg cl. 3,2 13,2 0,35
from sensible heat t = 26,2 °C
Primary air V = 0,1028 Nm³/kg cl. 1,1 4,5 0,12
from sensible heat t = 54,0 °C
Conveying air V = 0,0393 Nm³/kg cl. 0,5 1,9 0,05
from sensible heat t = 58,0 °C
from fuel 808,1 3383,4 88,50
Total inputs 913,1 3823,1 100,0
2. Expenditures kcal/kg cl. kJ/kg cl. %
Theoretical heat requirement 393,9 1649,3 43,14
for clinker burning
Water evaporation, kiln feed H2O = 0,80 % 8,3 34,6 0,91
Exhaust gas losses V = 1,5260 Nm³/kg cl. 209,7 878,1 22,97
t = 395 °C
Losses by CO CO = 0,15 % 6,6 27,5 0,72
Losses by exhaust gas dust s = 22,9 % 21,5 90,0 2,35
Decarbonation of exhaust gas dust  = 0,7 % 0,8 3,1 0,08
Losses by cooler exhaust air V = 1,1330 Nm³/kg cl. 107,5 450,3 11,78
t = 319,0 °C
Clinker waste heat losses t = 250 °C 46,5 194,5 5,09
Radiation and Convection 94,8 396,9 10,38
Remainder 23,6 98,7 2,58
Total Expenditures 913,1 3823,1 100,00

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6.2 Specific loadings SHARRCEM

Dep. 150

No Designation

1 Thermal sintering zone loading kJ*106/m²h 15,60

2 Kiln volume loading t/m³ 24h 1,65
3 Cross-sectional loading t/m² 24h 110,66
4
5 Cooler grate loading t/m² 24h 44,24
6 Cooler width loading t/m 24h 616,39
7

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6.3 Clinker SHARRCEM

Dep. 150

No Designation mean max min

1 Testing time
2 Clinker quantity produced t/testing time
3 kg/h 62667
4 t/24h 1504
5 Litre weight 1,41
6 Clinker temperature at cooler outlet °C 250
7 Clinker temperature at kiln outlet °C 1360
8
9 Grain analysis > 40 mm % 5,37
10 31,5 - 40 mm %
11 16 - 31,5 mm % 20,81
12 12,5 - 16 mm % 12,15
13 8 - 12,5 mm % 6,68
14 5,6 - 8 mm % 13,15
15 2 - 5,6 mm % 23,76
16 1 - 2 mm % 3,73
17 0,5 - 1 mm % 0,52
18 < 0,5 mm % 0,21
19 Silica ratio 2,19
20 Aluminia ratio 1,77
21 Limestandard 98,38
22 Liquid phase by Lea (1400°C) % 27,36
23 Free lime % 1,12
24 C3S = 3 CaO * SiO2 )* % 56,93
25 C2S = 2 CaO * SiO2 )* % 14,26
26 C3A = 3 CaO * Al2O3 )* % 9,88
27 C4AF = 4 CaO * Al2O3 * Fe2O3 )* % 10,01
28

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6.3.1 RRSB-Diagram SHARRCEM

Dep. 150 of clinker

Rückstand [%]
435
6
10
20
30
40
50
60
70

99,5

1 2 3 4 5 6 8 10 20 30 40
[mm]

Kennwort Probe Datum/Zeit d [mm] n [--]

Sharrcem Klinker 21.09.2013 16,75 1,62

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6.4 Raw meal SHARRCEM

Dep. 150

No Designation mean max min

1 CaCO3 and MgCO3-Content (Titration) %
2 Loss on ignition % 34,6
3 CO2-content % 33,8
4 Fineness Residue on 200µm % 3,2
5 Residue on 90 µm % 9,2
6 Temperature of raw meal °C 62,0
7 Water content % 0,8
8 Testing time h 24
9 Quantity for clinker t/testing time 2652,00
10 consumed and dust t/h 110,50
11 moist kg/kg Kl. = R )** 1,7633
12 dry kg/kg Kl. = R )** 1,7491
13 for clinker only kg/kg Kl. = R' )** 1,5196
14
)** calculated

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6.4.1 RRSB-Diagram SHARRCEM

Dep. 150 of kiln feed
Residue [%]

2
3
4
5
6

30 40 50 60 80 100 200 300 400 500600 800 1000

Particle Size [µm]

Kennwort Probe Datum/Zeit d [µm] n [--]

Sharrcem Kiln feed 20/21.09.13 11,37 0,40

Sharrcem Kiln feed 19.09.2013 7,671 0,30

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6.5 Petcoke SHARRCEM

Dep. 150 Sintering zone burner, fuel 1

No Designation as fired
1 Gross calorific value kJ/kg
2 Net calorific value kJ/kg 35010
3 Water content % 0,5
4 Ash content % 0,7
5 Volatiles % 14,8
6 Fixed Carbon %
7 Temperature °C 58,0
8 Fineness Residue on 212 µm %
9 Residue on 90 µm %
10 Minimum air requirement Nm³/kg 8,67
11
12 Minimum flue gas volume Nm³/kg 8,92
13
14 Consumption
15 Fuel 1 of sintering zone burner t/test time
16 kg/h 6056
17 kg/kg cl.
18 %=K 9,66
19 kJ/kg Kl. 3383,4
20 Part of total fuels of sintering zone burner % 100,00
21 Total fuels of sintering zone burner t/test time
22 kg/h
23 kg/kg cl. 0,0966
24 %=K 9,66
25 Total energy consumption kJ/kg cl. 3383,4

Analysis of fuel as fired

1 Ash % 0,70
2 Water H2O % 0,46
3 Oxygen O/O2 % 1,40
4 Nitrogen N/N2 % 1,99
5 Carbon C % 84,90
6 Hydrogene H % 3,81
7 Total sulphur S % 4,98
8 Chlorine Cl %
9
10
11
12 Total % 98,24

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6.6. Chemical Analysis SHARRCEM

Dep. 150

Kiln feed Ash Clinker EP-dust Bypassdust

No Component
ignited ignited ignited ignited
a b c d e f g h i
1 Insoluble residue
2 SiO2 12,48 19,09 12,88 19,94 20,00 11,75 18,34
3 Al2O3 3,62 5,54 2,93 5,83 5,85 3,68 5,74
4 TiO2 0,42
5 P 2O5
6 Fe2O3 2,08 3,18 3,13 3,29 3,30 1,97 3,07
7 Mn2O3 0,10
8 CaO 41,39 63,33 14,76 63,50 63,69 42,20 65,87
9 MgO 1,93 2,95 2,99 3,00 3,06
10 SO3 0,32 0,49 16,85 1,37 1,37 0,44 0,69
11 Na2O 0,09 0,14 0,80 0,09 0,09 0,08 0,12
12 K2O 0,54 0,83 0,59 0,83 0,83 0,60 0,94
13 Cl
14 Loss on ignition 34,64 0,30 35,93
15 Total 1-14 97,09 95,55 98,14 98,13 98,61 97,83
16 Non volatile compo- 61,50 94,09 95,55 95,84 61,56 96,08
nents (1-9)
17 C )** 0,66 0,51
18 CaOfree 1,12
19 CO2 33,84 32,93
20 H2O<110°C 0,80
21 H2O>110°C 0,14
22 Liquid phase 26,30 27,36
by Lea (1400°C)
23 Silica ratio 2,19 2,19 2,08
24 Alumina ratio 1,74 1,77 1,87
25 Limestandard 102,50 98,38 110,11
26
27

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6.6.1. Chemical analysis SHARRCEM

Dep. 150 Hot meal

hot meal
No Component kiln inlet

a b c d e f g h i
1 Insoluble residue
2 SiO2 13,41 18,37
3 Al2O3 3,78 5,18
4 TiO2
5 P 2O5
6 Fe2O3 2,20 3,01
7 Mn2O3
8 CaO 42,12 57,70
9 MgO 2,07 2,84
10 SO3 1,50 2,05
11 Na2O 0,11 0,15
12 K2O 0,81 1,11
13 Cl 0,04 0,05
14 Loss on ignition 27,00
15 Total 1-14 93,04
16 Non volatile compo-
nents (1-9)
17 C
18 CaOfree
19 CO2 26,00
20 H2O<110°C
21 H2O>110°C
22 Liquid phase
by Lea (1400°C)
23 Silica ratio 2,24
24 Alumina ratio 1,72
25 Limestandard 97,40
26 Decarbonation 30,95
27

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6.7 Gas- and air conditions SHARRCEM

Dep. 150

No Designation Temperature Quantity Quantity Quantity

°C m³/h Nm³/h Nm³/kg cl.
1 Primary air sintering zone burner 54,0 7998 6439 0,1028
2 Conveying air sintering zone burner 58,0 3096 2462 0,0393
3 Primary air precalciner burner
4 Conveying air precalciner burner
5 Primary air kiln inlet burner
6 Conveying air kiln inlet burner
7 Primary air top air burner
8 Conveying air top air burner
9 Secondary air 803,7 184958 45238 0,7219
10 Tertiary air
11 Theoretical combustion air 58346 0,9311
12 Cooling air (total) 26,2 102195 1,6308
13 Cooler exhaust air (measured) 319,0 160073 71001 1,1330
14 Cooler exhaust air (calculated) 319,0 128410 56957 0,9089
15 False air cooler (calculated) 14044 0,2241
16 Fresh air for Utility air
17 Exhaust gas preheater (measured) 395,0 249867 95632 1,5260
18 Exhaust gas preheater (calculated) 395,0 231245 88505 1,4123
19 Bypass hot gas
20 False air at kiln hood (estimated) 5758 0,0919
21 False air at kiln inlet (estimated)
22 Conveying air raw meal 5985 0,0955
23 False air kiln hood to precalciner (calc.)
24 False air preheater (calculated) 3481 0,0555
25
26
27
28
29
30

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6.8 Exhaust gas quantity SHARRCEM

Dep. 150 summary

a) Measuring point: kiln inlet

from from raw from from false
No combustion material excess air air Total
and dust Nm³/kg cl. % moist % dry % MRU
1 CO2 0,1530 0,1822 0,3352 28,86 30,14 41,00
2 CO 0,0002 0,0002 0,01 0,01 0,02
3 SO2 0,0034 0,0034 0,29 0,30 in CO2 incl.
4 N2 0,6636 0,0867 0,7503 64,59 67,46 57,21
5 O2 0,0001 0,0230 0,0231 1,99 2,08 1,77
from H H2O<110°C
6 0,0409
from H 2O comb. H2O>110°C
7 H2O 0,0006 0,0495 --- ---
from Lmin
8 0,0071
Total 1-8
9 (moist) 0,8688 0,1822 0,1106 1,1616 100,00 --- ---
Total 1-5
10 (dry) 0,8202 0,1822 0,1097 1,1121 --- 100,00 100,00

b) Measuring point: behind preheater

from from raw from from
No combustion meal and excess air false air Total
dust Nm³/kg cl. % moist % dry % MRU
1 CO2 0,1707 0,2604 0,4311 30,52 32,15 33,60
2 CO 0,0019 0,0019 0,14 0,14 0,15
3 SO2 0,0034 0,0034 0,24 0,25 in CO2 incl.
4 N2 0,7371 0,0132 0,1183 0,8686 61,50 64,78 63,61
5 O2 0,0010 0,0035 0,0315 0,0359 2,54 2,68 2,64
from H H2O<110°C
6 0,0409 0,0175
from H 2O comb. H2O>110°C
7 H2O 0,0006 0,0030 0,0001 0,0013 0,0714 5,05 --- ---
from Lmin from SNCR
8 0,0079
Total 1-8
9 (moist) 0,9634 0,2810 0,0169 0,1510 1,4123 100,00 --- ---
Total 1-5
10 (dry) 0,9140 0,2604 0,0167 0,1498 1,3409 --- 100,00 100,00

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6.9 Gas-analysis, air excess SHARRCEM

Dep. 150 H2O-contents and dew points

CO2 O2 CO N2 n H2O in dew point

No Designation % % % % --- % ref. to g/Nm³ °C
moist gas dry Gas
a b c d e f g h
1 kiln inlet mean 41,00 1,77 0,02 57,21 1,1309 35,79 31,2
2 max
3 min
4 mean
5 max
6 min
7 behind preheater mean 33,60 2,64 0,15 63,61 1,1788 42,79 33,7
8 max
9 min
10 mean
11 max
12 min
13 mean
14 max
15 min
16 mean
17 max
18 min
19 mean
20 max
21 min
22 mean
23 max
24 min
25 mean
26 max
27 min

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6.10 Dust SHARRCEM

Dep. 150

No Designation mean min max

1 EP-dust kg/h 14370
2 % of production 22,93
3 g/Nm³ 150,26
4 g/m³ 57,51
5 Bypassdust kg/h
6 % of production
7 g/Nm³
8 g/m³
9 kg/h
10
11 g/Nm³
12 g/m³
13 kg/h
14 % of production
15 g/Nm³
16 g/m³
17 kg/h
18 % of production
19 g/Nm³
20 g/m³
21 kg/h
22 % of production
23 g/Nm³
24 g/m³

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6.11 Radiation SHARRCEM

Dep. 150 and Convection

No Designation kJ*106/h kcal/kg cl. kJ/kg cl.

1 Cooler 1,6 6,3 26,2
2 Kiln 17,3 66,0 276,5
3 Tertiary air duct
4 Preheater 5,5 21,1 88,5
5 Kiln head 0,4 1,4 5,7
6 Cooler exhaust gas duct
7
8
9
10
11
12 Total 24,9 94,8 396,9

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6.12 Kilnshell Temperatures SHARRCEM

Dep. 150

60
50 L [m]
40
30
20
10
400

350

300

150

100
250

200

50
T [°C]

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Dept. 150 6.14 Gas Velocities at Preheater SHARRCEM

Kiln Production 1.504 tato

Ambient Pressure 977 mbar
Point Number Width Height Diameter Area Temperature Pressure Gas Volume Velocity Min. velocity Max. velocity
actual design design

m m m m² °C mbar Nm³/kgcli Nm³/h m³/h m/s m/s m/s

Kiln shell 1 4,160 13,59 1100 -2 1,162 72819 380427 7,8 10,0

Narrowest area kiln inlet chute approx.1 4,81 1100 -2 1,162 72819 380427 22,0 25,0

Gas duct after kiln inlet approx. 1 2,4 5,43 13,03 1000 -2,5 1,162 72819 352903 7,5

Stage 5 narrowest cross section 2 2,500 9,82 900 -3 1,162 72819 325351 9,2

Stage 5 inlet cross section 2 4,950 38,49 830 -3,5 1,212 75952 319266 2,3

Stage 4 narrowest cross section 2 2,500 9,82 830 -3,5 1,212 75952 319266 9,0

Stage 4 inlet cross section 2 4,950 38,49 800 -4 1,261 79041 323384 2,3

Stage 3 narrowest cross section 2 2,500 9,82 800 -4 1,261 79041 323384 9,1

Stage 3 inlet cross section 2 4,950 38,49 770 -5 1,261 79041 314667 2,3

Gasduct 2 (before meal shut) 2 2,500 9,82 770 -5,6 1,261 79041 314861 8,9 12,0 16,0

Cycl. 2 Inlet approximate 2 1,115 1,850 4,13 620 -7,6 1,317 82519 282029 19,0 15,0 22,0

Gas duct 1 (before meal chute) 2 1,900 5,67 620 -19 1,317 82519 285385 14,0 12,0 16,0

Cycl. 1 Inlet 2 1,280 1,920 4,92 396 -20 1,412 88504 229557 13,0 15,0 22,0

Cycl. 1 dip pipe 2 1,850 5,38 396 -25 1,412 88504 230763 11,9

DOPOL Waste gas duct 1 2,210 3,84 400 -29,4 1,412 88504 233220 16,9 20,0

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6.16 Heat balance of SHARRCEM

Dep. 150 cooler at 20°C

1. Inputs kcal/kg cl. kJ/kg cl. %

from clinker t = 1360 °C 343,9 1439,8 99,09

from cooling air V = 1,6308 Nm³/kg cl. 3,2 13,2 0,91

t = 26,2 °C

Total Inputs 347,0 1453,0 100,00

2. Expenditures kcal/kg cl. kJ/kg cl. %

Clinker waste heat losses t = 250,0 °C 46,5 194,5 13,39

Losses by cooler exhaust air V = 1,1330 Nm³/kg cl. 107,5 450,3 30,99
t = 319,0 °C
Losses by radiation 6,3 26,2 1,80
and convection
Secondary air V = 0,7219 Nm³/kg cl. 186,8 782,0 53,82
t = 803,7 °C

Total Expenditures 347,0 1453,0 100,00

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Date 20.09.2013 Engineer BERU/TLA cooler width loading [t/24h m] 616,4

Time 14:00 Clinker Production [t/24h] 1504,0 cooler grate loading [t/24h m²] 44,2

secondary air [Nm³/kg cli.] 0,7219 calc. false air cooler[Nm³/kg cli.] 0,2241 calc. cooler waste air [Nm³/kg cli.] 1,1330 meas.
temperature [°C] 803,7 temperature [°C] 20,0 temperature [°C] 319,0
heat gas [kJ/kg cli.] 782,0 heat [kJ/kg cli.] 0,0 heat [kJ/kg cli.] 450,3
% of Outputs 53,8 % of Intputs 0,00 % of Outputs 31,0
dust [% ]
ThyssenKrupp Industrial Solutions

heat dust [kJ/kg cli.]

% of Outputs

Radiation & Convection

heat [kJ/kg cli.] 26,2
% of Outputs 1,8

input clinker [kg/kg cli.] 1,00

Business address: ThyssenKrupp Industrial Solutions GmbH, ThyssenKrupp Allee 1, 45143 Essen
temperature [°C] 1360 clinker temp. [°C] 703,7
heat [kJ/kg cli.] 1439,8
% of Inputs 99,09

clinker beh. cooler [kg/kg cli.] 1,0

Registered office: Beckum Registration court: Local Court of Münster HRB No. 7717 VAT ID No.: DE811152653
recuperation zone cooling zone temperature [°C] 250,0

Management Board: Dr. Hans Christoph Atzpodien (Chairman), Martin Hilbig, Dr. Joachim F. Panek, Jörg Schönewolf
= 54,31 % = 69,05 % heat [kJ/kg cli.] 194,5
% of Outputs 13,39

cooling air [Nm³/kg cli.] 1,6308 meas. Summary

temperature [°C] 26,2 cooler efficiency [% ] 54,31
heat [kJ/kg cli.] 13,2 cooling air [Nm³/kg cli.] 1,6308
meas. = measured % of Intputs 0,91 combustion air from cooler [Nm³/kg cli.] 0,7219

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calc. = calculated temperature of clinker behind cooler [°C] 250,0

57 / 95

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6.18 Cooling Air Flows SHARRCEM

Dep. 150

T p VB p VN vs vs
meas. meas. meas. Chamber
[°C] [mbar] [m³/h] [mbar] [Nm³/h] [Nm³/kgKl.] [Nm³/m²h]
A 41,0 90,4 10712 9812
C
Chamber 1 90,4 0,157 2031
D
B
A 28,0 80,9 7308 6921
C
Chamber 2 80,9 0,110 2149
D
B
A 26,0 18424
C
Chamber 3 37,6 0,269 4184
D
B
A 24,0 37,2 24103 22177
C
Chamber 4 37,2 0,354 3443
D
B
A 24,0 34,8 19323 17737
C
Chamber 5 a 34,8 0,283 2753
D
B
A 24,0 26,8 31519 28703
C
Chamber 5 b 26,8 0,458 3241
D
B
A
C
Chamber 6
D
B

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6.19 Cooler Diagrams SHARRCEM

Dep. 150

90 Chamber Pressures
2031
100 81 2149
Chamber Pressure [mbar]

90 38 4184
80 37 3443
70 35 2753
60 27 3241
50 0 0
40
#BEZUG! ######
30
#BEZUG! ######
20
10 #BEZUG! ######
0 #BEZUG! ######
1 2 #BEZUG!
3 ######
4 5a
5 5b
6 67 8 9 10 11 12
Chamber

Volume Flow per m²

Spec. Volume Flow [Nm³/m²h]

5000
4000
3000
2000
1000
0
1 2 3 4 55a 65b 76 8 9 10 11 12

Chamber

Rekuperation Efficiency in Relation to Sekundary and Tertiary Air Flow

80
Efficiency [%]

Garantie
70 Erreicht

60
0,5 41,8736
50 0,7 53,2133
0,9 62,3407
40 1,1 69,6875
1,3 75,6011
30

20 0,72189 54,311

0
0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3
Sekundary and Tertiary Air Flow [Nm³/kg Kl.]

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Dept.150 6.20 Cooling Air Fans SHARRCEM

Date 20/21.09.2013 Clinkerproduktion 1504 tato (Design: 1500 tato)

Operator 150-BERU/TLA Ambient pressure 977 mbar

FAN Chamber Air temp. Pressure Air Air Meas. air Air Pressure Air Design Deviation
after fan after fan Volume Volume volume Volume after fan Volume static CCR -
bef. cham. bef. cham. meas. meas. calculated CCR CCR design pressure Measured
after fan inlet nozzle indic. indic.

°C mbar m³/h Nm³/h m³/h m³/h mbar m³/h mbar

1 1 41 90,4 10.712 9.812 11041 20.633 92,5 24.000 114,5 86,9%

2 2 28 80,9 7.308 6.921 7788 13.742 82,5 15.000 114,4 76,5%
3 3 26 37,6 18.424 16.845 18955 15.790 42,7 16.800 71,7 -16,7%
4 4 24 37,2 24.103 22.177 24955 18.988 41,1 30.000 56,4 -23,9%
5 5a 24 34,8 19.313 17.737 52256 26.156 34,6 79.200 40,4 -49,9%
5b 24 26,8 31.519 28.703 37,8

27,8 111.379 102.195 114.995 95.309 165.000 -17,1%

Specific Air Volume 1,777 1,631 1,835 1,521 2,633

m³/h Nm³/h m³/h m³/h m³/h

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7. Gas interconnection system

During the plant situation audit, the gas interconnection system of the raw grinding system and the
kiln plant was examined in interconnected operation mode. The pressure and temperature profiles
were recorded and the volume flows were measured. A detailed report on this examination and the
recommendations and measures for optimising the raw material grinding are presented in a sepa-
rate report No. 150/11 – 008/2014.

The following Figure shows the raw material grinding plant configuration.

From Kiln Line

As described in the above-mentioned report, the major portion of the total exhaust gas flow rate
after the preheater is supplied to the grinding and drying process. At this point the hot gas from the
preheater is split. One part of the hot gas is used in the dryer as drying gas and the other part of the
hot gas is fed to the double rotator. Depending on the raw material moisture content, a separate hot
gas producer can be connected in. The impact dryer and the double rotator have their own exhaust
gas fan, with which the hot gases can be sucked through the system.

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The exhaust air from the dryer and mill is supplied to the lower section of the former cooling tower
and mixes with the remaining kiln exhaust gas, which is fed to the cooling tower inlet via the direct
duct. At the cooling tower inlet there are an additional three fresh air fans, which quench the pre-
heater exhaust gas from approx. 400 °C to approx. 180 - 200 °C when the plant is in mill bypass
operation mode. As a rule, two fresh air fans, which are controlled by defined temperature limit val-
ues, are in operation for this quenching process in mill bypass operation. The former cooling tower
only serves as a mixing chamber for the supplied gas volume flows. After the mixing chamber, the
dust-laden gas stream is dedusted in the downstream filter and then discharged into the atmos-
phere via the chimney.

The following Figure shows the operating parameters displayed in the control room during mill by-
pass operation at an indicated kiln feed meal input rate of 100 t/h.

Fig. 52: Kiln/mill exhaust gas filter, mill bypass operation

The exhaust gas flow rate measured after the preheater had a mean value of 96000 Nm³/h at a hot
gas temperature of 400 °C. Up to the measuring point after the exhaust gas fan, this exhaust gas
flow rate increases to 105200 Nm³/h due to the inleaked false air, and a temperature of 365 °C is
reached. In order to quench this gas flow volume with fresh air and/or false air to a temperature of
200 °C, an air volume of 123100 Nm³/h with a fresh air temperature of 21 °C is required. Due to
radiation and convection losses, and to approx. 3 % of additional false air inleaking via the kiln/mill
exhaust gas filter, the exhaust gas temperature falls by a further 12 °C to 188 °C. Given these op-
erating data, the calculated gas flow volume after the kiln/mill exhaust gas filter is 235400 Nm³/h,
equalling 423500 m³/h at a static pressure of -24.3 mbar. If the mixed gas temperature after the

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mixing chamber is increased from 200 °C to 230 °C, a calculated quantity of fresh air and false air
amounting to approx. 86500 Nm3/h would have to be supplied. In this operating state, the gas flow
volume after the filter is 197600 Nm3/h, equalling 376400 m³/h at a temperature of 217 °C.

The following Figure shows the characteristic curve of the filter fan at an exhaust gas temperature
of 230 °C. The original design characteristic curve relates to a fan speed of 1051 rpm. As the drive
motor of the fan can only be operated with a speed of 990 rpm, according to information provided
by the customer, an additional characteristic curve was drawn up for this speed and entered in the
characteristics field.

Fig. 53: Characteristic curves of filter fan in mill bypass operation

The shown filter fan speed in mill bypass operation is logged as approx. 830 rpm, while die power
consumption of the drive motor is logged as approx. 390 kW. However, to deliver the calculated gas
volume flow rate of 423500 m³/h after the kiln/mill exhaust gas filter, the fan speeds must be higher
than those indicated on the control room panel. The indicated fan speeds therefore have to be
checked. The calculated shaft output at the fan is 323 kW and the calculated power consumption of

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the drive motor is 351 kW at a motor efficiency of 92 %, which is within the range of the displayed
figure of 390 kW.

Fig. 54 shows the characteristics field of the calculated operating data. To adjust these characteris-
tic curves to "mill bypass operation", a fan speed of approx. 960 rpm is needed. The speed re-
serves of the filter fan would then be almost totally used up.

Fig. 54: Characteristic curves of filter fan in mill bypass operation

In interconnected operation, the major amount of the total exhaust gas quantity after the exhaust
gas fan is supplied to the combined grinding and drying process. A small portion of the exhaust gas
is conveyed via the direct duct to the mixing chamber. This gas volume is not significantly different
from that of the operating mode with or without connection-in of the hot gas producer. In operation
"with hot gas producer", the total exhaust gas flow rate after the kiln/mill exhaust gas filter increases
by approx. 7000 Nm³/h from the figure of 280000 Nm³/h in operation "without hot gas producer" to
287000 Nm³/h. There is presumably a shifting of the volume flows between the impact dryer and
the double rotator. The additionally brought in hot gas flow volume from the hot gas producer is
supplied to the impact dryer. The following Figures show the typical filter unit operating data dis-
played in the control room during interconnected operation with and without hot gas producer.

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Fig. 55: Kiln/mill exhaust gas filter, interconnected operation with hot gas generator

Fig. 56: Kiln/mill exhaust gas filter, interconnected operation without hot gas generator

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After the drying and grinding process, the exhaust gases are fed to the lower section of the former
cooling tower and mix with the remaining kiln exhaust gas. From the mixing chamber, the total ex-
haust gas quantity is fed to the kiln/mill exhaust gas filter, dedusted and then discharged into the
atmosphere with the aid of the filter fan. An comparison of the volume flow after the kiln exhaust
gas fan and the volume flow after the kiln/mill exhaust gas filter reveals that a very big increase in
the volume flow takes place. This volume flow increase is mainly due to the inleakage of false air in
the gas interconnection system (impact dryer and grinding plant).

In operation without hot gas producer, the calculated quantity of false air is 161700 Nm³/h. If the
inleakage of false air "after preheater" up to "after kiln exhaust gas fan" is also taken into ac-
count, this quantity of false air increases by an additional 9600 Nm³/h to 171300 Nm³/h. In opera-
tion with hot gas producer, the inleakage of false air is 150000 Nm³/h in the area of the drying
and grinding system including kiln/mill exhaust gas filter. If the 9600 Nm³/h of false air from the
exhaust gas interconnection system of the kiln exhaust gas duct are also taken into account, the
total quantity of false air increases to 159600 Nm³/h. Related to the measured exhaust gas flow
rates, this is equal to a false air rate of 55.4 % in the case of operation with hot gas producer and
61.2 % in the case of operation without hot gas producer. A detailed compilation of the false air
inleaks in provided in the report about raw material grinding.

There is also a characteristic curve for the filter fan in interconnected operation. This shows a char-
acteristic for a fan speed of 868 rpm. As the drive motor can be run at 990 rpm, a further character-
istics field was also drawn up for this case. On the basis of the existing data, the calculated power
consumption at the fan shaft at a speed of 990 rpm is 497 kW. At a motor efficiency of 0.92, the
drive motor needs a power of 540 kW. However, as the drive motor is only designed for a power of
500 kW, it is highly likely that this operating point cannot be reached.

The following Figure shows these characteristic curves at this fan speed and a gas temperature of
95 °C.

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Fig. 57: Characteristic curves of filter fan in interconnected operation

As already described, in interconnected operation with hot gas producer an exhaust gas flow vol-
ume of 287000 Nm³/h was measured after the kiln/mill exhaust gas filter. This equals 419875 m³/h
at a temperature of 99 °C and a static pressure of -31.9 mbar.

In operation without hot gas producer, the exhaust gas flow volume after the kiln/mill exhaust gas
filter is 280000 Nm³/h, equalling 392435 m³/h at a temperature of 84 °C and a static pressure of -
29.6 mbar.

The following Figure shows these two operating points and the calculated power consumption at
the fan shaft. In order to draw up the complete characteristic curve, the associated fan speed is
required. The point of intersection of the characteristic curve and the operating point corresponds to
the fan speed. For interconnected operation with hot gas producer a fan speed of approx. 950 rpm
is determined in this way, while for operation without hot gas producer the fan speed is approx.
890 rpm. According to the control panel display, the fan speed is approx. 830 rpm in operation with
hot gas producer and 790 rpm in operation without hot gas producer.

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The calculated power consumption of the motor is 474 kW, compared to 460 kW according to con-
trol panel display in operation with hot gas producer and a calculated 411 kW compared to dis-
played 420 kW in operation without hot gas producer. In respect of the power consumption, there is
a very close correspondence between the calculated value and the indicated value, but for the mo-
tor and fan speeds there are large discrepancies.

Fig. 58: Characteristic curves of filter fan in interconnected operation

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After evaluation of the recorded and calculated operating data, the exhaust gas, fresh air and false
air quantities can be summarised as follows:

Measuring point Dimension Mill bypass oper- Interconnected opera- Interconnected opera-
ation tion with hot gas pro- tion without hot gas
ducer producer
Exhaust gas after Nm³/h 95632 95641 96753
preheater m³/h 249867 243559 253597
°C 395 378 395
mbar - 28.4 - 26.5 - 29.4
Exhaust gas after Nm³/h 237814 286843 280039
kiln/mill exhaust gas m³/h 423460 419875 392435
filter °C 188 99 84
mbar - 24.3 - 31.9 - 29.6
Fresh air / false air Nm³/h 139804 159600 171300
% 58.8 55.4 61.2
Table 3: Operating data for mill bypass operation and interconnected operation

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8. Catalogue of measures – service package II

The customer Sharrcem wishes to increase the output of the kiln plant to 1650 t/24h. The measures
proposed in the following are based on the plant measurement campaign, the evaluation of all
available measurement results and the energy balance created on this basis for the kiln plant. The
considerations are made from a process-technological point of view. Clarification of whether the
stated measures can be implemented from a design point of view has to be established in the
scope of a separate investigation. This point is not covered by this report.

8.1 Elimination of false air sources

Evaluation of the measurement results revealed serious air inleaks at the kiln outlet seal and in the
exhaust gas duct after the preheater up to the kiln system fan. It is not possible to precisely allocate
the inleakage of false air for the zone between the kiln inlet seal and after the shaft stages, and for
the zone between the shaft stages and after the preheater, because it is not possible to exactly de-
termine either the burnout location of the carbon brought in with the kiln feed meal or the amount of
carbon being burnt out. To achieve this, it will be necessary to determine the carbon content of the
hot meal in the individual stages. However, for further considerations in this report, those data are
not relevant.

The gas analyses provide a means of determining the total quantity of air leaking into the preheater
system between the kiln inlet and the measuring point in the exhaust gas duct after the preheater.
However, it is a prerequisite that the carbon brought into the system is burnt out within the preheat-
er. Under this precondition, the calculated total air flow rate is 9466 Nm³/h, equalling 0.151 Nm³/kg
of clinker. However, this air flow volume also includes the conveying air for the kiln feed meal. Be-
cause of the high conveying air pressure, it was not possible to measure the conveying air flow rate,
and it was therefore estimated. On the basis of the delivered quantities of kiln feed meal and taking
account of the conveying pipe diameter, the estimated flow volume of conveying air for the kiln feed
meal is 5985 Nm³/h. Using these data, the calculated quantity of false air leaking in via the preheat-
er is 3481 Nm³/h, equalling 0.0555 Nm³/kg of clinker or 4.0% related to the exhaust gas quantity
after the preheater. For the entire preheater, this quantity of false air is within the normal range.
However, if the main quantity of the false air is entering the system via the kiln inlet seal, the above
figure is too high.

We ascertained that there is a large proportion of false air entering between the exhaust gas flow
rate measuring point after the preheater and the measuring point after the kiln exhaust gas fan. This
false air volume is 9600 Nm³/h, equalling 0.153 Nm³/kg of clinker. This false air may be inleaking
through defective expansion joints in the exhaust gas duct, shaft seals at the dampers, leaky fresh-
air flap, shaft seal at the exhaust gas fan and the dust collection cone just after the exhaust gas fan.

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Inleakage of false air into the kiln system is not acceptable from either a process-technological or
an economical point od view, because they

- reduce the kiln output

- increase the heat consumption
- overload the exhaust gas fan and the gas interconnection system
- and increase the specific electrical energy consumption.

The is also a serious inleakage of false air at the kiln outlet seal. The following photo shows the gap
between the outlet seal and the rotary kiln shell.

False air

Fig. 59: Gap between kiln and kiln hood

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The false air volume flow can be approximately calculated using Bernoulli's equation. According to
the VDZ (Association of German Cement Works) this equation therefore has to be multiplied by a
non-dimensional coefficient, which is between 0.6 and 0.9. The information leaflet Vt 10 "Perfor-
mance and Evaluation of Rotary Kiln Tests", issue May 1992, of the VDZ's process technology
committee defined this coefficient as 0.75.
The equation for calculating the false air volume flow is:

0,75  A
VIA   2  p  L
L , N

VLA Inleaking air flow (Nm³/s)

A: Open cross section = 0.2175 m²
L,N: Air density at normal conditions = 1.293 kg/m³
L: Air density at local conditions = 1.148 kg/m³
p: Differential pressure = 70 Pa

0,75  0,2175
VIA   2  70  1,148 = 1,599 Nm³/s = 5758 Nm³/h
1,293

This approximate calculation of 5758 Nm³/h of false air, equalling 0.0919 Nm³/kg of clinker, is very
high and correspondingly reduces the secondary air flow volume from the cooler, as well as causing
a lower cooler efficiency rate. It is even possible that the quantity of false air could be still higher,
because the segment cooling air is guided until a point immediately before the described gap area.
In this connection, also see Fig. 31 (Kiln outlet seal). This means that a portion of the segment cool-
ing air is forced through this gap in the kiln outlet. The measured gap width between the kiln outlet
seal and the kiln shell was 15 mm. At a kiln diameter of 4.6 m, the calculated total cross-sectional
area of the gap all around the periphery is 0.2175 m². The calculated static pressure before the gap
is + 50 Pa and the calculated static pressure in the kiln outlet is - 20 Pa. The total calculated pres-
sure gradient is thus approx. 70 Pa.

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There are further sources of false air in the cooler roof. These are cracks in the refractory lining that
allow false air to leak in. It is, however, not possible to assess the false air volume flow involved.
The following photos document this cooler roof damage.

False air

Fig. 60: Cracks in clinker cooler roof

In the vicinity of the cracks, negative pressures of around 20 Pa were measured. These negative
pressures show that false air is penetrating into the cooler.

This amount of false air of course mainly affects the kiln process, but also increases the load on all
downstream units (cooling tower, fans, filter etc.)

It will hardly be possible to completely eliminate false air, but the identified sources of false air must
be systematically remedied. Regular gas analyses (around twice per month) performed at the vari-
ous measuring points with a portable gas analyser from MRU will provide a basis for detecting
sources of false air.

These analyses can also be used for the purpose of checking the installed gas analysis system.
With minimum extra work (max. 3 hours including sampling), this will achieve optimal monitoring.

This is the only way to achieve sustained minimisation of false air. Moreover, these check meas-
urements provide a means of quickly detecting any damage, such as cracks in weld seams, so that
they can be preventively eliminated.

The following are possible sources of false air with the respectively recommended repair or modifi-
cation proposal:

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Possible source of false air Eliminate by

Kiln outlet and kiln inlet seals - Check the mechanical components
- Replace the axial sealing cord (if in-
stalled)
- Replace the springs
Doors, inspection ports,poke holes, flange con- - Replace the seals (ceramic fibre
nections and expansion joints in the preheater seals)
meal chutes - Retighten the bolts
Inspection ports at the flap valves - Replace the seals (ceramic fibre
seals)
Cracked plates and welds in preheater and ex- - Re-weld
haust gas interconnection system
Fabric expansion joints in the exhaust gas duct, - Replace defective fabric expansion
at the exhaust gas fan and in the gas intercon- joints
nection system
Fabric expansion joints above the flap valves - Replace defective fabric expansion
joints
Table 4: False air sources and elimination

In particular, we wish once again to emphasise that the false air entering the lower preheater sec-
tion and the kiln inlet seal has a strong influence on the heat consumption.

The following Figure presents theoretical considerations regarding the effect of false air on the ex-
haust gas flow rate and the fuel consumption. The exhaust gas temperature curve can rise or fall
due to the influence of false air, depending on which stage is the inleak source of false air (see Fig.
1). In these illustrations, stage 1 is the bottom stage and stage 4 is the topmost stage (dust collec-
tion stage), which is the Polysius method of counting.

Every inleakage of false air has a negative effect on the heat consumption of the overall plant, but
to different degrees, depending on which preheater stage is affected (see Fig. 2).

If reducing combustion is taking place in the kiln, i.e. combustion in air deficiency conditions, an
inleakage of false air can cause postcombustion with local overheating in the kiln inlet area. If this
false air is substituted by hot secondary air, the result must be an improvement of the heat recovery
from the cooler. The cooler efficiency rate increases in line with the rising quantity of secondary air,
which is dependent on

- the heat requirement of the kiln,

- the minimum air requirement for the fuel,
- the air excess and
- the amounts of primary and conveying air.

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Fig. 61: False air effects

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If the heat calculations only take account of the cooler efficiency rate, the heat consumption and
exhaust gas temperature figures result as shown in Fig. 3.

Trend calculations show that if the present false air at the kiln outlet is reduced, the cooler efficiency
rate will rise by approx. 5 percentage points, which would reduce the heat consumption of the kiln
plant by approx. 2.8% and lower the exhaust gas flow rate by 2.2%.
An additional reduction of the false air between the measuring point after the preheater and the
measuring point after the kiln system fan by 9%, to normal values of 1-2%, would either provide an
additional capacity reserve for the exhaust gas fan, or with the same exhaust gas fan capacity
would increase the kiln output by up to 10% (150 tpd).

8.2 Optimisation of the combustion conditions

As shown by the air excess factors in the kiln inlet, the fuel is being burnt with a low CO concentra-
tion of 0.02%. However, during the measurements CO peaks of up to 0.5% also occurred.

In order to continuously check the combustion conditions in the kiln and adjust them to obtain the
optimum oxygen content, reliable and correct analysis values are required. However, dur to the fact
that no measuring device is installed at the kiln inlet, the combustion process in the kiln is uncon-
trolled. The CO-free conversion of the fuel is dominated by fuel parameters such as granulometric
distribution and burnout performance. The average grinding result of the petcoke is 4.8% R on the
90 µm screen. Even finer grinding would not be likely to result in any improvement for the investi-
gated kiln plant. To burn cement clinker with the normal composition, an oxidising kiln atmosphere
is required. Otherwise, the hardening capability decreases and the cement tends to set faster.

As the kiln feed meal brings a significantly high amount of carbon (0.66%) into the preheater, the
gas analysers in the exhaust gas show an average CO concentration of 0.15%. Some of this car-
bon does not burn out completely in the preheater, resulting in the formation of CO. As the occur-
rence of incomplete combustion cannot be detected, due to the lack of gas analysis, it is important
to install a combined oxygen and carbon monoxide measuring device in the kiln inlet.

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8.3 Kiln / preheater efficiency

On the basis of the calculated exhaust gas quantities and the temperature and pressure profile in
the preheater, it is possible to calculate the velocities in the kiln and preheater under consideration
of the false air and conveying air quantities. At an output of 1504 tpd, the figures result that are
shown in Table 6.14.

The following statements can be made regarding the present preheater situation:

 The velocitiesof 7.8 m/s in the kiln, and 22 m/s in the narrowest cross-section of the kiln inlet
housing are in the normal range.
 We are not able to make or definitively evaluate any velocity recommendations for the 3
shaft stages, because the type of design and construction of these stages does not corre-
spond to the Polysius engineering. This report therefore cannot specify any limit values or
recommendations. In the narrowest cross-section, i.e. in the transition to the shaft stages,
the calculated velocities are 9 – 9.2 m/s, while in the extended cross-section the velocities
are 2.3 m/s. The pressure drop of the three shaft stages was determined to be 4.0 mbar,
which is very low.
 The calculated velocity in gas duct 2 is 8.9 m/s and that in the cyclone inlet is 19 m/s. The
velocity in the gas duct is relatively low. This could cause material to fall directly into the
shaft stage from the above cyclone stage 1. This directly falling meal inevitably misses the
heat transfer between gas and material and therefore increases the exhaust gas tempera-
ture. For this section of the preheater, we recommend velocities of between 12 and 16 m/s.
The velocity in the cyclone inlet is in the normal range, but the approx. 13 mbar pressure
drop of this entire stage is too high.
 With 14 m/s in the gas duct, the velocities in the first stage are normal, while the 13 m/s in
the cyclone inlet is somewhat too low. As the collection efficiency of the dust collection cy-
clone is partly dependent on the inlet velocity, this low velocity figure could have the effect of
high dust discharge rates. It is essential for the dust collection cyclone and the dip pipes to
be checked. With 6 mbar, the pressure drop of this stage is in the low range.
 The calculated velocity in the exhaust gas duct is 16.9 m/s, which is in the normal range.

If the kiln plant output is increased by 10%, i.e. from 1504 tpd to 1650 tpd the calculated velocities
will be as shown in the following Table, provided that there is no significant change in the specific
exhaust gas flow rates. The static pressure after the preheater would be approx. -36 mbar. The
velocities in the kiln and kiln inlet housing would still be below our limit values.

Whether or not the velocities in the shaft stages would reach critical limit values can only be found
out in practical operation. If the velocities get too high, there is the risk that the high material loading
in the shaft stages could lead to fluctuation of the exhaust gas volume. If these conditions occur,
they would make it difficult to achieve uniform and stable kiln operation.

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Dept. 150 Gas Velocities in Preheater at 1650 t/d SHARRCEM

Kiln Production 1.650 tato

Ambient Pressure 977 mbar
Point Number Width Height Diameter Area Temperature Pressure Gas Volume Velocity Min. velocity Max. velocity
actual design design

m m m m² °C mbar Nm³/kgcli Nm³/h m³/h m/s m/s m/s

Kiln shell 1 4,160 13,59 1100 -2,4 1,162 79888 417528 8,5 10,0

Narrowest area kiln inlet chute approx.1 4,81 1100 -2,4 1,162 79888 417528 24,1 25,0

Gas duct after kiln inlet approx. 1 2,4 5,43 13,03 1000 -3 1,162 79888 387360 8,3

Stage 5 narrowest cross section 2 2,500 9,82 900 -3,6 1,162 79888 357155 10,1

Stage 5 inlet cross section 2 4,950 38,49 830 -4,2 1,212 83325 350511 2,5

Stage 4 narrowest cross section 2 2,500 9,82 830 -4,2 1,212 83325 350511 9,9

Stage 4 inlet cross section 2 4,950 38,49 800 -4,8 1,261 86714 355068 2,6

Stage 3 narrowest cross section 2 2,500 9,82 800 -4,8 1,261 86714 355068 10,0

Stage 3 inlet cross section 2 4,950 38,49 770 -6 1,261 86714 345568 2,5

Gasduct 2 (before meal chute) 2 2,500 9,82 770 -6,8 1,261 86714 345853 9,8 12,0 16,0

Cycl. 2 Inlet approximate 2 1,115 1,850 4,13 620 -9,2 1,317 90530 309918 20,9 15,0 22,0

Gasduct 1 (before meal chute) 2 1,900 5,67 620 -23 1,317 90530 314401 15,4 12,0 16,0

Cycl. 1 Inlet 2 1,280 1,920 4,92 396 -24,2 1,412 97096 252951 14,3 15,0 22,0

Cycl. 1 dip pipe 2 1,850 5,38 396 -30,3 1,412 97096 254581 13,2

DOPOL waste gas duct 1 2,210 3,84 400 -35,6 1,412 97096 257545 18,6 20,0

Table 5: Gas velocities in preheater at 1650 tpd

The velocity in gas duct 2 will still be relatively low in spite of an increase in output, while the other
velocities are all within the range recommended by Polysius.

An optimising of the entire kiln plant will reduce the heat consumption and the exhaust gas flow
rate. This means that a further slight decrease can be expected in the exhaust gas flow rates and
velocities stated here.

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8.4 Kiln feed meal finenesses

The mean samples of the kiln feed meal taken on 19.09.2013 and 20/21.09.2013 showed fineness-
es of 11.2 %R and 9.2 %R on the 90µm screen. The particle size distribution slope of 0.4 and 0.3 in
the RRSB particle size distribution diagram is relatively flat (see 6.4.1), which means that, with 3-
5 % R on the 200 µm screen, a high proportion of coarse particles is present. An excessively large
proportion of coarse particles can negatively affect the burnability of the material and lead to a high
heat consumption. However, no order had been placed for burnability analyses (BI-analysis) of the
kiln feed meal.

The relatively fine kiln feed meal can also have a negative effect on the collection efficiency of the
dust collection cyclone. It is a known fact that kiln plants with low preheater meal finenesses suffer
from a high dust discharge rate. The dust discharge of the investigated kiln plant was weighed in
mill bypass operation and found to be 22.9% related to clinker. In order to further optimise the kiln
operation, a kiln feed meal should be produced that has residues of approx. 15 – 18 % R on 90µm,
and the proportion of coarse particles should be reduced. The production of this coarser kiln feed
meal should be undertaken step by step, to provide the possibility of quickly making corrections if
the fineness setting turns out to be too coarse. The influence of an excessively coarse kiln feed
meal can be quickly detected by checking the content of free lime in the clinker.

8.5 Kiln rotation speed

During the test period, the kiln was operated at a speed of approx. 1.6 rpm. In order to further
improve the uniformity of the material being burnt in the kiln and of the clinker discharged from
the kiln, a higher kiln rotation speed of 2.5 – 3.0 rpm should be attempted. A higher kiln rotation
speed will also reduce the filling ratio in the kiln and positively influence the heat transfer between
gas and material.

8.6 Cooler optimisation

The evaluations of the measurements at the cooler show that a cooler efficiency of only 53.8% is
being achieved at present. For the heat consumption of the complete plant, however, it is im-
portant that the cooler operates with the maximum possible efficiency.

The calculated secondary air flow volume is only 0.7219 Nm³/kg of clinker. Observations and
measurements show that there is a serious inleakage of false air in the cooler zone. This is re-
ducing the secondary air flow volume. By reducing the false air at the kiln outlet seal, the sec-
ondary air flow volume will be increased and will contribute significantly to improving the cooler
efficiency. There are other inleakages of false air through the cooler roof. This inleaking false air
does not participate in the heat transfer between the clinker and the air, but only reduces the
temperature level of the secondary air and of the cooler exhaust air (also see section 8.1)

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The supplied cooling air flow rate of 1.6308 Nm³/kg of clinker is a relatively low flow rate and
cools the clinker discharged from the kiln from the average entry temperature of 1360 °C to an
average ultimate temperature of 250 °C. Sometimes, ultimate clinker temperatures of up to
600 °C were measured (also see photos in section 3.2; Figs. 38 and 40). It was also observed
that in certain operating situations red-hot clinker falls out of the side of the cooler in the front
cooler zone and lands in the dust discharge equipment underneath. This presumably means that
the end zone between the refractory lining and the side plates is open. This must be checked and
repaired if necessary.

In order to optimise the cooler operation, we recommend firstly an increase in the cooling air flow
rate of the cooling air fans for compartments 1 and 2. According to the manufacturer's specifica-
tions, cooling air fan 1 is designed for an inlet-side cooling air flow rate of 24000 m³/h at an out-
let-side pressure of 114.5 mbar. Evaluation of the cooling air volume flow shows that the inlet-
side volume flow is only 11041 m³/h at a pressure of 90.4 mbar. According to the control panel
display, the inlet nozzle volume flow is 20633 m³/h and the outlet-side pressure is 92.5 mbar. The
difference between the displayed volume flow and the measured volume flow is enormous, in this
case being as high as +86.9%.

The conditions at cooling air fan 2 are similar. The fan is designed for a flow rate of 15000 m³/h at
an outlet-side pressure of 114.4 mbar. Measurements showed that the volume flow at the inlet
side is only 7788 m³/h at an outlet-side static pressure of 80.9 mbar. However, the control panel
indicates a volume flow of 13742 m³/h and a static pressure of 82.5 mbar. The difference be-
tween the measured volume flow and the indicated volume flow is +76.5 % in this case.

In the case of cooling air fans 3 to 5, there are negative differences between the indicated vol-
ume flows and the measured volume flows. This means that higher volume flows were measured
than those indicated on the control panel. In the case of cooling air fan 5, the calculated differ-
ence is -49.9 %.

Such large discrepancies in the indicated cooling air flow rates are not acceptable and must be
correspondingly corrected. The differences in compartment pressures are not so high. The pres-
sures measured in the first two compartments correspond closely to the figures indicated on the
control panel. In the case of compartment 3, the difference is already 5 mbar and in compart-
ments 5a and 5b it is 10 to 11 mbar. Table 6.20 lists the measured values and the design data of
the cooling air fans.

Conspicuous feature of the measurements at cooling air fans 1 and 2 are also the very high static
pressures in relationship to the relatively low cooling air flow rates supplied to the compartments.
At only 46% of the installed cooling air volume flow in compartment 1, a static pressure of
90.4 mbar was measured, equalling 79% of the design pressure. Given the low cooling air flow
rate, we suspect that the pressure drop is not caused by the bed of clinker but by the grate
plates. Our experience leads us to believe that the aeration air supply piping leading to the grate
plates has filled up with clinker dust. This should be checked during the next inspection. The sit-

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uation in compartment 2 is similar. Drilling holes in the aeration air supply piping might help. We
would recommend a total of 4 drill holes measuring approx. 18 mm over the width of the cooler.

The following Figure shows the measured specific cooling air flow rates and those indicated on
the control panel and converted. The values are m³/m²h in the individual compartments. This
Figure also shows the design air volumes. According to Polysius design criteria, the highest spe-
cific cooling air flow rate must be supplied to the first compartment. This specific cooling air flow
rate is then reduced from compartment to compartment, so that a graduated pressure develop-
ment is achieved over the length of the cooler, as illustrated in this Figure.

Fig. 62: Cooling

With the specific compartment air volume flows that we recommend, the following cooling air flow
volumes occur at the inlet side of the cooling air fans:

 Cooling air fan 1 : 22800 m³/h

 Cooling air fan 2 : 14250 m³/h
 Cooling air fan 3 : 16000 m³/h
 Cooling air fan 4 : 25250 m³/h
 Cooling air fan 5 : 48900 m³/h

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This scheme involves a total cooling air flow volume of 126200 m³/h, equalling 112650 Nm³/h
being supplied to the cooler. Related to a kiln output of 1500 tpd, the specific cooling air flow vol-
ume would be 1.8 Nm³/kg of clinker.

According to Polysius design criteria, the reciprocating grate cooler would be designed for a spe-
cific compartment air flow volume of 7000 m³/m²h, which is 2000 m³/m²h higher than the specific
cooling air flow volume installed at this cooler. The first cooling air fans could be replaced with
higher-performance fans or reconditioned.

In the case of an increase in output to 1650 tpd, the grate loading would be 48.5 t/m²24h, which
is close to the upper limit. If designed to our design criteria, new coolers have a grate loading of
45 t/m²24h. In the case of the higher kiln output, the specific cooling air flow volume would have
to be readjusted to 1.8 – 2.0 Nm³/kg of clinker. As the first cooling air fans would be practically at
their upper performance limit if our recommendations are followed for 1500 tpd, it would only be
possible to increase the flow volume of the fans further along the cooler. However, only increas-
ing the flow volume of the fans further along the cooler is not so effective and would possibly
have a negative effect on the cooler efficiency. The cooling air fans are designed for a total cool-
ing air flow volume of 165000 m³/h. At a kiln output of 1650 tpd, this would correspond to 2a spe-
cific cooling air flow volume of approx. 2.1 Nm³/kg of clinker.

8.7 Kiln exhaust gas fan

At a kiln output of 1650 tpd, the exhaust gas flow volume at the kiln exhaust gas fan would be
102500 Nm³/h with a temperature of approx. 395 °C if all the sources of false air are properly
eliminated and if the cooler operation is optimised. This flow volume is equal to a gas flow vol-
ume of approx. 272000 m³/h at a static pressure of -42 mbar. According to information provided
by the customer, the exhaust gas fan is designed for a gas flow volume of 384000 m³/h at a static
pressure of -540 mmWS and a gas temperature of 360 °C. The measured gas flow volume at the
fan was 262515 m³/h at a temperature of 365 °C. The fan speed indication was 77 %. This corre-
sponds to a speed of 732 rpm. According to operating personnel, the speed of the exhaust gas
fan is limited to 85 %. The cause of this limitation is the fact that if this speed is exceeded, over-
pressure occurs downstream of the kiln exhaust gas fan. This means that the filter fan cannot
cope with this high gas flow volume and/or the pressure drop of the duct system is too high. For
an increase in output to 1650 tpd, the kiln exhaust gas fan is adequately dimensioned.

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8.8 Instrumentation

Some of the operating and performance data displayed in the control room are full of errors and do
not correspond to the data actually measured at the plant components. In order to quickly produce
approximate balance sheets and make necessary operating decisions, accurate and reliable indica-
tions are necessary.

Examples for the erroneous indications are the coal flow volume to the main burner and the quantity
of kiln feed meal dosed by the Pfister machines. A weigher error of 16.2% was determined in the
case of the coal dosing system. By means of weighing the bulk transporter vehicles and weighing
the remaining quantity of fuel in the coal dust silo mounted on load cells, we calculated that the av-
erage coal consumption rate is 6.056 tph. But the control panel display indicates that the average
coal consumption rate is 5.075 tph.

On the basis of the loss on ignition of the kiln feed meal, clinker, exhaust gas dust and ash of the
supplied quantity of coal, as well as the weighed quantity of exhaust gas dust, a raw meal/clinker
factor of 1.763 kg/kg of clinker was calculated (see table 6.4). The quantity of clinker produced
during the investigation period was also determined by vehicle weighbridge and found to be
1504 tpd. From this figure, the average supplied quantity of kiln feed meal was calculated to be
110.5 tph. But according to the control panel display, the average supplied quantity of kiln feed
meal was 100 tph. The difference between these figures means that there is a negative error of
9.5% in the Pfister weigher indications.

The cooling air flow volumes displayed in the control room are also erroneous and do not corre-
spond to the air flow volumes actually measured at the cooler. Differences of up to 87% were
ascertained. Table 6.20 shows the measured cooling air flow volumes of the individual cooling air
fans and the displayed cooling air flow volumes.

The indicated speed of the filter fan is also questionable. According to the display, speed re-
serves are still available. When we compared the measured exhaust gas flow volume after the
kiln/mill dust collection filter against the existing characteristic curve of the filter fan, we found
discrepancies of 10 to 15% between the indicated fan speed and the fan speed calculated ac-
cording to the characteristic curve.

In order to obtain reliable data, all of the control panel indications should be checked and cor-
rected if necessary.

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8.9 Duct arrangement

As stated in section 5.6, the calculated efficiency of the kiln exhaust gas fan is only approx. 43%. In
order to improve this fan's efficiency, the fan intake flow and the gas routing after the fan must be
optimised.

The intake flow optimisation is aimed at assuring uniform gas volume loading of the suction box, in
order to ensure a consistent flow of gas through the inlet nozzle of the impeller. Disturbances in the
intake flow, such as a one-sided flow to the inlet nozzle, lead to a decrease in fan capacity (signifi-
cantly lower efficiency) and thus to a reduced performance. In the case of double-flow fans, it is
also extremely important that both suction boxes receive the same air volume. Different air volumes
in the suction boxes of double-flow fans also result in a lower efficiency.

Fig. 63 shows the present situation. Approximately 3 m before the suction box inlet there is a duct
bend of approx. 25°. It would be ideal if the distance between this bend and the suction box inlet
was 4 to 5 times the diameter of the duct, and if baffle plates were additionally installed in the duct
bends to force a uniform gas flow into the downstream duct. The suction bushes would also have to
be correspondingly shifted and adapted.

- 0.3 mbar

Fig. 63: Fan

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Moreover, no diffuser is present or visible on the delivery side of the fan. The purpose of a diffuser
is to slow down the flow and thus convert dynamic pressure into static pressure. By this means, a
pressure recuperation is achieved. A static pressure of -0.3 mbar was measured at the delivery side
of this fan. From a flow point of view, this design is not optimal because the volume flow has to pass
a 90° bend after leaving the fan. The further gas duct routing to the double rotator for interconnect-
ed operation is also very disadvantageous, as it again contains a 90° bend. After the inlet to the
duct for interconnected operation, there are further bends on the way to the dryer and to the mill
inlet. Fig. 64 shows the present situation of this gas duct routing. At the mill inlet, a static pressure
of -8.2 mbar was measured, which means that the pressure drop of this duct arrangement is
8 mbar.

Due to such high negative pressures at the mill inlet and the dryer, there is the risk that the amount
of false air will also drastically increase.

- 0.3 mbar

-8.2 mbar

Fig. 64: Duct arrangement

Perhaps it would be possible to turn the kiln system fan by 180° on its axis, so that the outlet open-
ing of the fan is at the bottom. With this arrangement, a suitable diffuser should also be installed. In
diffusers widening at one side, the angle should be restricted to 15°, while in diffusers widening at
both sides the angle is restricted to 7-10° at each side. If the respective opening angle is larger than
specified here, the flow no longer follows the duct wall smoothly, but breaks up into areas of turbu-
lence which significantly decrease the efficiency.

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In this report we cannot state whether the above solution is actually technically possible; this must
be clarified with the fan manufacturer.

Fig. 65 sketches the configuration of the turned-around fan.

4–5xD

Fig. 65: Modified fan

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8.10. Gas interconnection system

In the case of an increase in output to 1650 tpd, the calculated exhaust gas flow volume after the
kiln system fan is 102500 Nm³/h with an exhaust gas temperature of 395 °C. The prerequisite for
this is that all sources of false air are eliminated and that the cooler and kiln plant are operated
under optimum conditions.

In mill bypass operation, this exhaust gas flow volume has to be cooled down with fresh air in the
mixing chamber to an acceptable filter inlet temperature. If the same filter inlet temperature level
is assumed as that measured during the investigation, it will be necessary to feed a fresh air flow
volume of approx. 138500 Nm³/h with a temperature of 21 °C to the mixing chamber. On this
basis the resultant gas flow volume will be 241000 Nm³/h and the gas temperature will be
200 °C. Due to radiation and convection at the filter unit and a false air inleakage rate of 3%, we
expect a gas flow volume of 248500 Nm³/h with a temperature of approx. 190 °C before the filter
fan. This corresponds to an operating gas flow volume of 450000 m³/h. This gas flow volume is
approx. 25000 m³/h higher than that during the plant situation audit. It is questionable whether
the existing filter fan will be able to handle this gas flow volume. In principle, it would be possible
to raise the speed of the filter fan from 990 rpm to 1051 rpm. There is a characteristic curve for
the filter fan for this speed. Also see section 7 regarding this point. According to the characteristic
curve, the operating point for this speed was 459515 m³/h at 230 °C and a static pressure of
27 mbar. The drive motor would have to be modified to cope with this speed increase.

As already described in section 7, the gas flow volume can be reduced by a higher filter inlet
temperature. The kiln/mill exhaust gas filter is designed for a gas temperature of 240 °C. The
filter can also tolerate brief peak temperatures of up to 260 °C. If the limit value for the inlet tem-
perature in mill bypass operation is set to 230 °C, the calculated gas flow volume before filter fan
is approx. 209000 Nm³/h with a gas temperature of approx. 220 °C. This corresponds to an oper-
ating gas flow volume of 402000 m³/h. This gas flow volume is thus 20000 m³/h lower than that
during the plant situation audit.

If even lower temperatures are required after the dust collection filter, the cooling tower will have
to be reactivated and the water injection will have to be put back into operation.

In interconnected operation, the amount of kiln exhaust gases available for the combined grind-
ing and drying process is approx. 87500 Nm³/h of the occurring 102500 Nm³/h with a tempera-
ture of 390 °C. The remaining kiln exhaust gases of approx. 15000 Nm³/h will be routed via the
direct duct to the mixing chamber. To allow quick reaction in the case of a malfunction, the
damper in the direct duct will not be closed completely, but generally left approx. 15-20% open.
With this damper setting, a corresponding portion of the kiln exhaust gas flow volume is routed
through the direct duct.

In a detailed report (see Report No. 150/11 – 008/2014; Investigation of raw mill at Sharrcem) the
recommendations and measures for optimising of the grinding and drying plant are described.
That report states the gas flow volumes to the double rotator and to the dryer for a grinding and

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drying capacity of 135 tph. At a 25 % false air inleakage rate in the grinding system section, a
calculated mill exhaust air flow volume is 79500 Nm³/h with a temperature of 100 °C will be fed to
the mixing chamber. The calculated dryer exhaust gas flow volume is 97000 Nm³/h, also with a
gas temperature of 100 °C. This calculation takes account of a false air inleakage of 20%.

With these assumptions, a total gas flow volume of 191500 Nm³/h will be fed to the kiln/mill ex-
haust gas filter with a mixed gas temperature of 125 °C. On this basis the resultant gas flow vol-
ume for the filter fan will be 197300 Nm³/h with a gas temperature of 115 °C. This corresponds to
an operating gas flow volume of 304000 m³/h.

When investigating the gas interconnection system the ascertained gas flow volume for the filter
fan during grinding plant operation with hot gas producer was 420000 m³/h with a temperature of
99 °C, and in operation without hot gas producer the ascertained gas flow volume for the filter fan
was 392500 m³/h with a temperature of 84 °C. These gas flow volumes are significantly higher
than the calculated gas flow volume after optimisation of the grinding and drying system, at a
grinding capacity of 135 tph.

After systematic elimination of the existing sources of false air, implementation of the proposed
measures and optimisation of the mode of plant operation, the gas interconnection system
(kiln/mill exhaust gas filter and filter fan) would be adequately dimensioned for the achievement
of a kiln output of 1650 tpd.

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Appendix
Chemical analyses

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SHARRCEM analyses

HANDLING AND PROCESSING OF FUELS

FUEL ANALYSIS AS RECEIVED

Date Fuel Carbon Hydrogen Nitrogen Oxygen Total Sulfur HHV kcal/kg HHV kJ/kg LHV kcal/kg LHV kJ/kg Ash (%) Volatiles Moisture Sieve
Avg PET-COKE 84,9 3,81 1,99 1,4 4,98 8562 35791 8362 34955 0,70 14,80 0,46 4,84

Daily Report: Test report From: 18-Sep-13 07:00:30

Package: Test report To: 25-Sep-13 07:00:30
Type: Daily First: 34543
Description: Test report Last: 35006

SmpNo Smp Grp Time Comment SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O SO3 LSF SIM ALM HM C3S C2S C3A C4AF LOI Cl 90 µm

34700 Test 20-Sep-13 12:13:39 HOT MEAL 19/09/13 13,70 3,93 2,22 41,56 2,11 0,12 0,88 2,11 93,53 2,23 1,77 2,09 -- -- -- -- 25,13 0,04 18,90
34701 Test 20-Sep-13 12:18:34 KILN FEED 19/09/13 12,47 3,62 2,12 41,35 1,94 0,09 0,56 0,34 101,91 2,17 1,71 2,27 -- -- -- --
34702 Test 20-Sep-13 12:26:58 CLINKER comp. 19/09/2013 (09:00-19:00 h) 19,84 5,88 3,21 63,49 2,99 0,08 0,87 1,32 98,30 2,18 1,83 2,19 63,50 9,03 10,30 9,75
34782 Test 21-Sep-13 12:33:16 HOT MEAL 21/09/2013 (10:50 h) 13,41 3,78 2,20 42,12 2,07 0,11 0,81 1,50 96,98 2,24 1,72 2,17 -- -- -- -- 27,00 0,04
34946 Test 23-Sep-13 13:40:41 CLINKER 20-21.09.2013 19,94 5,83 3,29 63,53 2,99 0,09 0,83 1,37 97,95 2,19 1,77 2,19 63,15 9,58 10,03 9,99
34947 Test 23-Sep-13 13:47:33 KILN FEED 20-21/09/2013 12,48 3,62 2,08 41,39 1,93 0,09 0,54 0,32 102,06 2,19 1,74 2,28 -- -- -- --
34960 Test 23-Sep-13 17:37:51 FILTER DUST 17:30 (5 kg) 11,75 3,68 1,97 42,20 1,96 0,08 0,60 0,44 109,54 2,08 1,87 2,43 -- -- -- --

7 7 7 7 7 7 7 7 7 7 7 7 2 2 2 2 2 1
Mean:
Min:
Max:
S.dev:
R.Dev:
Sum:

Weighted mean:

Clinker Sample

Passing percentual (%)

Sieves
0,063 0,090 0,125 0,25 0,5 1 2 5,6 8 12,5 16 31,5 40
Clinker 0,08 0,10 0,12 0,15 0,21 0,73 4,46 28,22 41,37 48,05 60,20 81,01 94,63

Filter Dust LOI=35.93 %

TOC in Kiln Feed is 0.72 %

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Polysius analyses

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