INSTRUKTIONER INSTRUCTIONS INSTRUCTIONS

70002363-1 1/65
ANWEISUNGEN INSTRUCCIONES INSTRUCÕES

ROTARY KILN PLANT (ILC) CEMENT

Process instructions

SHARGH CEMENT – IRAN

Enclosures:

Sketch of heating and start-up procedures Page 63-65

Reference is also made to:

Flow sheet (FLS): 10053073, 10053074 & 10053075

_______________________________________________________________

Contents: Page:

1. GENERAL NOTES 3
2. CONSTRUCTION AND OPERATING PRINCIPLE 4
3. DRYING AND HEATING OF LINING PRIOR TO
START-UP 8
4. START OF KILN PLANT 21
5. STOP OF KILN PLANT 29
6. OPERATION 34
7. INTERLOCKING, PROGRAMMING AND CONTROL
CIRCUITS 42
8. PREVENTION OF FIRES AND EXPLOSIONS 51
9. BARRING 54
10. CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS
AND ALARM LIMITS 57

August/2005/RLA/HLy
______________________________________________________________

FLSMIDTH, VIGERSLEV ALLÉ 77

DK-2500 VALBY, DENMARK
 70002363-1

NOTE!

The present instruction manual is dealing with the

situations which, according to the experience of
FLS, are the most likely to occur. An exhaustive
enumeration of all conceivable situations which may
occur during the erection/operation/maintenance of
the plant/machine/equipment cannot be provided.

Consequently, if a situation should arise, the

occurrence of which is not foreseen in the
instruction manual, and which the operator is/or
feels unable to handle, we would recommend that FLS
is contacted without undue delay for advice on
appropriate action.

SEPARATE INSTRUCTION MANUALS

The plant under review also comprises several other

instruction manuals containing detailed information
about the single machines or arrangements.
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3
1. GENERAL NOTES

This manual is intended as a reference guide, which

can be used in connection with start-up, normal
operation and stoppage of the plant.

The majority of the directions given in the manual

are of a generalized character. A range of relevant
factors of specific or local nature are involved,
and it would be impossible to provide a detailed
evaluation of all these factors in this manual
without sacrifice of clarity.

The manual must be regarded as a tool for

optimisation of the kiln plant, and it can also be
used to support judgements made by the operator in
a given operative situation.

In this manual it is a fundamental condition that

the control panel equipment has been installed,
tested and made fully operational.

This manual should be thoroughly studied prior to

start-up, so as to permit detailed planning of this
phase.
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2. CONSTRUCTION AND OPERATING PRINCIPLE

2.1 Construction main elements

The kiln plant construction is schematically shown

in flow sheet 10053074. The clinker producing plant
is an FLS-ILC (In-Line Calciner) installation
incorporating the following elements:

Kiln tube: Rotax-2

Diameter 4.55 meters
Length 54.0 meters
No of supports 2
Inclination 3.5 %

Size of kiln drive and max. speed

Required motor power on rollers 450 kW
nominal consumption 278 kW
Nominal speed 3.6 r/min
Maximum speed 5.0 r/min

Single pre-heater string with 5 stages

Size of cyclones in pre-heater 1 LP of 7.20 m

1 LP of 7.20 m
1 LP of 7.50 m
1 LP of 7.50 m
1 LP of 7.50 m

Calciner:
In-line calciner vessel 7.2 m x 27.6 m

Grate cooler type SF 3x5 F

Burner type Duoflex

Fuel type Gas (oil)

Kiln feed system Elevator

Kiln ID-fan type Solyvent.

Motor ~2000 kW
Volume 193.6 m3/s
Pressure 6790 Pa
Gas temperature 286°C
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2.2 Operating principle

The ILC calciner kiln system is installed. The

calciner is placed in-line with the kiln riser
duct.

The combustion gas for the calciner is hot

atmospheric air drawn from the SF Cross Bar cooler
through the separate tertiary air duct mixed with
the combustion gas from the kiln. The in-line
calciner is dimensioned for a retention time of 3.6
seconds.

The kiln main burner is the well proven Duoflex

burner.

The burner is provided with an ignition burner for

igniting of the fuel admitted to the kiln.

The raw meal feed - the kiln feed - is extracted

from the CF-silo and transported to the pre-heater
via an air slide and subsequently an elevator. The
feed system to the pre-heater is supplied with a
feed split which makes it possible to feed in
required ratio to 4th or 5th stage of the pre-
heater. This is due to possible increased moisture
content in the raw materials during the winter
period, thus supplying the adequate drying gas
amount and temperature to the raw mill.

The pre-heater is operating as a counter current

heat exchanger with the raw meal passing downwards
through the pre-heater stages by gravity, and the
gas moving upwards drawn by the ID-fan.

Having passed 4 pre-heater stages, then the raw

meal reaches a duct split, where a part of the raw
meal flow can be guided to the lower part of the
calciner vessel and to the riser pipe from the
kiln. Which way to guide the material is depending
very much on the fuel used and the tendency of
coating formation in the riser pipe. In the
calciner vessel approximately 55% of the fuel is
burnt. The raw meal will be calcined to a degree of
about 90-95%. The calciner can be operated at high
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temperatures of ~1000°C, which increases the
combustion rate. The excess air in the calciner is
foreseen to be approximately 30% corresponding to
an oxygen level of ~2.5%. These measures should
ensure complete combustion of the fuel applied.

The combustion gas used in the calciner is a

mixture of hot atmospheric air ~925°C drawn from
the SF cooler through the tertiary air duct and the
kiln gases (~1150°C) from the rotary kiln proper.

The material is leaving the top of the calciner and

is then passing onwards to the 5th pre-heater
stage. From this last pre-heater stage the material
slides to the rotary kiln inlet.

Due to the inclination and rotation of the kiln,

the raw meal is transported downstream through the
kiln. Simultaneously, the raw meal is gradually
heated and fully calcined by the heat supplied to
the kiln by the firing installation at the outlet
end of the kiln.

Clinkerization - clinker formation - takes place

when the raw meal passes through the burning zone
of the kiln.

The clinker formed enters the grate cooler for

cooling.

2.2.1 SF Cross Bar Cooler 3x5F

The clinker cooled are discharged through the ham-

mer crusher. Clinker coarser than 25-30 mm are
crushed by the clinker crusher, from where the
crushed clinker joins the clinker transport.
Clinker finer than 30 mm passes through an outlet
grid to the clinker conveyor. The total clinker
flow is then transported to the clinker silo or to
the off standard clinker hopper.

The excess air is extracted from the outlet end of

the cooler is de-dusted in a cooler ESP. The
clinker dust from the cooler ESP is returned to the
clinker transport.
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The extended kiln hood is supplying combustion air
for the kiln and supplying combustion air to the
calciner through the tertiary air duct. The kiln
hood and the outtake are designed so that the ma-
jority of the clinker dust stays in the cooler, and
only a minor part of the clinker dust is recycled
to the kiln and calciner.

2.2.2 Gas treatment and distribution

Whenever the kiln is in normal operation, the

exhaust gases are supplied to the raw mill at a
temperature of ~310°C. The kiln/raw mill gasses are
subsequently de-dusted in the main Kiln/Raw Mill
filter before released to the atmosphere.

The dust precipitated in the above mentioned filter

installation is returned to the dust hopper from
where it can be routed back to the process via the
kiln feed elevator. The possibility of dumping the
dust to a truck also exists.
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8
3. DRYING AND HEATING OF LINING PRIOR TO START-UP

3.1. Preconditions and criteria for start-up

This section must be compared with enclosure 1

(page 63), which in graphical form provides
information about heating and start-up procedures.

3.1.1 Personnel

Operators and operating personnel must be fully

familiarised with the instruments and functions of
the control panel.

Furthermore, the personnel must be well informed

about the layout and operating principle of the
motor control system, especially all interlocking
diagrams which indicate protective, safety and
operational interlocking.

See also: Instruction manual for programming of the

process control system.

3.1.2 Raw materials

Prior to start-up, raw materials must be available

in sufficient quantities and with a well-known
quality in order to ensure continuous, stable kiln
operation. In order to produce raw meal, hot gas to
the raw mill can be supplied by the start burner
placed when pre-heating the kiln system. The hot
gasses are drawn up to the pre-heater.

3.1.3 Preparations

The following activities must be carried out prior

to the initial start-up:

1) All kiln plant machinery should be subjected to

no-load testing and where possible testing under
load.

The trial run of the kiln should only comprise

the kiln drive without turning the kiln.
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9
Trial run of machines loaded with material
should be performed over a prolonged period, for
instance for 24 hours with the kiln feed in
circulation.

Water and/or air must be available where

necessary. See separate instruction manuals and
diagrams.

2) The entire electrical and electronic control

system must be tested to ensure that all inter-
locking, i.e. safety, protective and operational
interlocking are active, and that they function
as intended.

3) Ensure that all alarm limits have been set.

(Refer to section 10 in this instruction
manual).

4) The raw meal must be recycled to sustain the

operation of the feed arrangement and for
calibration of the load cells. The recycling
must start at 10% level in the CF-silo.

5) Prior to the production of clinker an appro-

priate amount of correct quality raw meal must
be available. The consumption of raw meal for at
least one day must be available.

6) Ignition burner, start burner placed in the kiln

hood, burner for heating-up of the kiln and the
production burner equipment must be prepared for
start-up.

7) The plant laboratory should be on standby and

prepared to perform the necessary analyses of
the kiln feed and clinker, particularly to
determine the content of free lime, the litre
weight of the clinker, and the kiln feed
analysis.

8) In order to optimize the regulation of the

primary air volume in the kiln for optimization
of the flame structure, it is advisable to
measure the airflow supplied to the burner by
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the primary air fan at different valve openings
and pressures. Hence it is possible to ascertain
what valve position should be used during
operation.

NOTE!

Where specific demands for initial drying procedure

of the concrete are stipulated by the supplier of
the castable for the grate cooler, account must be
taken of such criteria during the start-up phase
or, if this is not possible, it may be necessary to
dry out the grate cooler on a separate basis.

3.1.4 Preparations prior to heating

Before the below mentioned start-up sequence is

followed and before any machines are put into
operation, then please study carefully the
description in section 7 concerning interlocking,
programming and control.

CHECK

- that all tools and all foreign objects have been

removed from all kiln plant machines

- that potential coatings have been removed from

cyclones, flue ducts and riser ducts
(see separate instruction manual for safety)

- that all doors and clean-out hatches are closed

- that the motorized dampers function properly

- that the barring device, with brake, is ready to

be operated

- that all plant machinery has been lubricated in

strict accordance with directions given in the
separate instruction manuals
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11
- oil must be applied to the journals of the
supporting rollers to ensure that they are
covered by oil when barring operation is started
(see separate instruction manual)

- the water supply to kiln bearings, and gas

analyser is functioning

- that all instruments in the control system are

functioning

- that all alarm limits have been set

Start the compressed-air supply and check that

compressed air is present at the points of
consumption at the correct pressure.

Start the heating elements at the bottom of the

chambers in the bag house filter 2-3 hours ahead of
the anticipated start time of the heating-up of the
kiln.

Start the dust transport for kiln dust.

Place the gas analysis equipment in the kiln system
in state of readiness. Check that the thrust roller
device and the lubrication and hydraulic oil for
the kiln drive are at their respective recommended
sleeves. Refer to separate instruction manual.

Mount the burner for heating-up of the kiln and

prepare the ignition burner, and the start burner
for operation. See separate instructions.

Prepare the cooler and the clinker transportation

system. Place cold clinker on the grates on the
cooler (50-100 mm). See separate instruction
manual.

If special requirements for the initial drying of

the castable are stipulated by the supplier of the
castable for the grate cooler, these requirements
must either be met during the start-up procedure
or, if this is not possible, the grate cooler must
be dried out separately.
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12
Once these checks and activities have been
completed, both the electrical and the mechanical
department must ensure that the installation is
reported ready for start-up.

3.2 Drying-out procedure

3.2.1 Kiln, preheater and cooler

The heating and drying-out of the lining must be

performed very slowly in order to avoid the lining
to crack and spall. This especially applies where
large zones equipped with castable are to be dried
out.

It may be necessary to modify the outlined drying

out procedure in case the brick supplier recommends
a different code of practice. However, consul-
tations between the plant management and FLS are
needed before introducing any modifications.

For practical reasons the drying-out of the kiln

lining should not take place until the erection of
the installation has advanced so far that the kiln
can be started in immediate aftermath of the
drying-out operation. The initial heating-up/dry-
ing-out operation of the kiln should, depending on
the amount of available start-up burners stretch
over three phases. A total heating period of up to
192 hours should be expected, as shown in the
enclosed diagrams.

In connection with subsequent kiln starts, the

heating-up period can normally be reduced, though
it depends on the type of lining repairs conducted
during the intervening periods.

As mentioned previously, it is recommended to

extend the heating-up period if concrete castable
has been used for casting operations inside the
kiln system.
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13
3.3 Initiation of heating-up operation

See also the separate instruction manuals related

to the individual equipment mentioned.

Heating-up operation is started and performed in

three phases:

Phase 1: Cross bar cooler.

Portable start-up burner placed in kiln
hood, and in back of cooler if available.
72-96 hours
Phase 2: Preheater (kiln riser), Tertiary Air
Duct(TA).
Calciner burner and portable burner placed
in kiln hood and kiln riser pipe.
48 hours
Phase 3: Rotary kiln and Preheater.
Main kiln burner and calciner burner.
48 hours

If more than 2 portable start-up burners are avail-

able phase 1 and 2 can be done at the same time,
and time consumption reduced.

3.3.1 Phase 1

Note! This is only possible if portable start-up

burners are available.

Before this phase is started insert a wooden or

brick wall in the kiln inlet and/or outlet, this is
to avoid hot gasses to be drawn through the kiln
tube.

This phase has a duration of 72-96 hours.

Place the portable start-up burners in the kiln

hood and back end of cooler respectively.

Check the pressure and temperature of the fuel.

For the first 24 hours the temperature must be kept

≤ 220°C. The wall in the kiln inlet mentioned
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14
above, should be in place in order to prevent heat
to escape, flowing via the kiln tube.

Open the TA damper to 100% open position.

If necessary open one or more man doors for supply

of extra combustion air.

Start the excess air fan and open the damper of the
excess air fan.

Adjust the kiln hood under-pressure to –0.5 mbar

and set the control loop in automatic mode.

If the burners are not already in operation start

them and maintain reasonable stable flames.

MAKE SURE THAT THE DRAFT IS TOWARDS THE EXCESS AIR

FAN!

Control the temperature in the kiln hood, cooler

roof and cooler filter inlet.

Make sure to follow the heating-up programme phase

1 during the whole period (72-96 hours).

3.3.2 Phase 2

Remember to maintain the separation wall in the

kiln, this to avoid hot gasses to be drawn through
the kiln tube.

Make sure that fuel is ready to be supplied to the

portable burner now placed at the bottom of the
kiln riser pipe. The start-up burner in the kiln
hood is kept at its location.

Check the pressure and temperature of the fuel.

Start the lubricator for the smoke chamber seal.

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15
Start the transport in the bottom of the GCT and
set the water injection system in a ready for start
mode.

Start the filter fan at minimum speed with closed

damper.

Start the kiln ID-fan with barring drive and closed

damper and utilise the fan when additional
combustion air is required.

Open the TA damper to ~12% open.

Maintain in general minimum draft in the kiln

inlet.

Start the portable burner in the bottom of the kiln

riser and the calciner burner at an absolute
minimum. If not already running also start the
burner in the kiln hood.

Check that the fuel is ignited. If necessary,

adjust the draft conditions to facilitate the flame
formation.

Adjust the draft in the riser.

Make sure to avoid local overheating close to the

flame formation.

Soon after start of the burner, the gas analysers

should be put into operation.

Increase slowly the temperature of the kiln riser

pipe to 120°C and keep the temperature at this
level during the first 24 hours followed by an
increase to approximately 500°C during the next 24
hours, see enclosure.

The drying of the TA and the first part of the

drying of the riser pipe is finalised after 48
hours.
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3.3.3 Phase 3

Remove the separation wall in the kiln inlet and

open the slide dampers in the riser to 100% open
position. Also remove all the start-up burners
(kiln hood and riser)

Maintain the clinker layer as mentioned in phase 1.

Check the gas pressures.

Start the hydraulic pump of the thrust device.

Start the hydraulic pump of the kiln drive.

Start the filter fan with closed damper.

Open the filter fan damper gradually, so that a

slight negative pressure in the kiln hood is ob-
tained.

Start the primary air fan and close the primary air
damper to 10%.

Start the ignition burner.

Start the gas burner.

Make sure that the gas is ignited, if necessary ad-

just the primary air valve to facilitate the flame
formation.

Adjust the draught in the kiln.

Start the barring of the kiln in accordance with

the barring programme outlined in section 9.

Check lubrication of supporting rollers. The

journals must not become dry. During barring it may
be required to pour additional oil directly on the
journals.

The specified barring program must be adhered to,

however, if the thrust device equipment for indica-
tion of kiln position gives alarm, barring must be
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continuous until the alarm can be cancelled. Con-
tinuous barring is also required if the kiln is
subjected to cooling, for instance due to heavy
rain.

Soon after start of the burner, the gas analyser in

the riser duct should be put into operation, if not
already in operation.

Start the cooling fans. In case of much material

remaining in the front of the grate, it must be
started in order to move possible accumulation of
material.

Start the ESP-fan for excess air from the cooler

with closed damper if not already started.

Set the automatic under pressure control in the

kiln hood to a set-point of -0.5 mbar.

Adjust the hoisting damper in the tertiary air pipe

to ~10% open.

Regulate the kiln ID-fan damper so an oxygen

content of 8-10% in the kiln inlet is achieved.
When the kiln has become hot after some hours, this
level can be reduced to 4-5%.

The ignition burner can be extinguished after

approximately 8 hours, or as soon as the lining is
hot enough for the burner to burn without support.

Adjust the TA damper to ~12% open.

Follow the heating curve shown in the enclosure.

Kiln feed is expected to be started after
approximately 48 hours.

3.3.4 Air supply during the heating-up phase

During the heating-up period, maximum amount of the

heat input should be utilized for heating of the
kiln; i.e. only the necessary air volume should be
drawn through the kiln.
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However, an adequate air surplus must be present
for the combustion process.

Start the cooling air fans and the excess air fan
to be able to control the negative pressure in the
kiln outlet.

THE FLAME MUST NOT CAUSE SOOTING (If oil firing in

portable burners).

Often, this would require that the oxygen content

indicated by the exit gas analysis in the riser
duct is 8-10%. When the kiln has become warm enough
after a couple of hours, then the oxygen content
can be reduced to about 4-5%. An oxygen content
smaller than this might cause a soothing flame.

An exit gas analysis performed after the pre-heater

is not of much use during the heating-up phase,
since air infiltration from the pre-heater would
influence the oxygen analysis.

3.4 Inspection during heating-up period

The programme for the heating-up period is

graphically indicated in the enclosure.

Following major lining repairs, a heating-up period

of approximately 72 hours is recommended, whereas
for normal starting of cold-state kiln the period
should be approximately 24 hours.

IT IS VERY IMPORTANT THAT NO ATTEMPT IS MADE TO

SPEED UP THE PROGRAMME.

In case of interruptions during the heating-up

period, compensation is needed by extending the
time period so that the actual heating period has
the stipulated duration.

The speed of heating-up, as measured at the kiln

inlet and the outlet from the pre-heater tower,
should follow the curves very closely as indicated
in the enclosure.
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19

It is advisable to record operational experience

gained during initial heating-up periods, so that
the curves in the enclosure can be adjusted in
accordance with the local conditions.

A regulation of fuel rate, draught level and oxygen

level is needed to ensure strict adherence to the
curves for the temperature rise.

Overall, the prime aim is, as previously mentioned,

to ensure retention of the supplied heat inside the
kiln. Any increase in the draught level will
rapidly cause the temperature in the cyclone tower
to rise at the expense of the temperature in the
kiln, and this is not desirable.

THE FOLLOWING INSPECTION AND CHECK-UP MUST BE MADE

DURING THE HEATING-UP PERIOD:

Kiln lining

Inspect the kiln lining at regular intervals. The

lining in the burning zone must not be exposed to
fast and local overheating.

If the lining temperature rises too quickly and/or

becomes too high, reduce the amount of fuel.

Kiln shell temperature

Check the kiln shell temperature. Special attention

must be focused on the burning zone where high
surface temperatures may occur. Temperatures of up
to 420°C will be acceptable.

If the kiln should become too hot in the burning

zone, and the temperature after the pre-heater is
relatively low, i.e. it permits that surplus heat
is drawn from the kiln upstream to the pre-heater
by increasing the draught.

Alternatively the flame shape must be adjusted by

regulating the air volume to the main burner.
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20
Bearings for supporting rollers

Check the lubrication. Dry running of the bearing

journals must not occur. When the kiln is barred,
it may be necessary to apply additional oil
directly to the bearing journals.

Barring

Strict observance of the specified barring

programme is needed, but in the event that an alarm
is tripped by the thrust device equipment
indicating the position of the kiln, then the kiln
must be barred continuously until the alarm can be
cancelled.

Continuous barring is also needed if the kiln is

subjected to cooling, for example due to heavy
rainfall.

Clinker transport

If the kiln has been filled with raw materials, it

may, from time to time, be necessary to start the
grate cooler and the clinker conveying system in
order to transport away the materials, however, do
not empty the cooler.
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4. START OF KILN PLANT

4.1 Getting ready for operation

Operational status must be prepared approximately 3

hours in advance of the anticipated time for start-
up with feed.

Start the transport lines for dust and clinker

after the kiln.

Check that the dividing gate after the second

lowermost cyclone is adjusted so all the raw meal
is directed to the riser pipe.

4.2 Starting of kiln feed

Start the kiln feed in recycling mode recycling to

the CF silo in a feed rate of 70% of nominal feed
rate.

When the temperature at the top of the lowermost

cyclone stage is about 750°C, and assuming
compliance with the heating programme as outlined
in enclosure, the kiln is ready to accept feed
material.

Personnel must be stationed in the cyclone tower in

order to watch the raw meal as it passes through
the cyclone pre-heater.

Supervision is performed at the sluice flaps under

each cyclone. The flaps must move freely. This is
done to ascertain that the raw meal passes through.
The risk of plugging in the cyclones is particu-
larly high during start-up.

The control room must have the possibility to

contact the supervising personnel via mobile
communication equipment, radio or telephone, so
that early warning can be given from the
supervising personnel to the control room in event
that plugging symptoms in cyclones are observed.
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4.3 Starting of kiln main drive

Stop the barring drive and start the kiln at the

lowest speed.

Cancel interlock between kiln and cooler.

Reduce the damper openings of the ID-fan. It is

necessary to adjust the burner if it takes a long
time to establish the correct draught. However, it
should be possible to operate the burner at minimum
rate.

Therefore the draught and fuel rate must be reset

to levels applicable prior to the starting of the
ID-fan.

Please make sure damper openings are adjusted to

maintain sufficient suction in the kiln hood and
after the kiln pre-heater.

Start the dust transport to the kiln feed elevator

Start the clinker transport system with clinker

breaker, and the cooler drives and fans.

4.4 Establishing normal production rate

Perform the below operations in RAPID but CORRECT

sequence:

- Open the ID-fan dampers to 100 % and increase

the draught by speeding up the ID-fan (pay
attention to that the bag house fan controller
can cope with the extra air, (pressure after ID-
fan must not become positive)

- Kiln feed operating in recycle mode, select kiln

feed mode to feed the raw meal at a rate of
approximately 70% of nominal feed to the pre-
heater.

- The TA damper is adjusted to 18-20% open level

- Start the calciner burner at minimum fuel rate

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23

- Increase the kiln fuel rate accordingly.

- Increase the feed rate to 75% of full

production, with simultaneous increase in kiln
speed to.

- Increase the TA damper to 30% open.

- As soon as the kiln feed has reached the

lowermost cyclone stages, then increase the
fuel rate in order to maintain the temperature
of these lowermost stages at about 890°C.

- Set the draught level and fuel rate so the fuel

supply rate is 5-10% in excess of the normal
operational level at the same production rate.
The reason is that the kiln system is colder at
start-up as compared with normal operation.

The draught must always be increased prior to any

increase in the fuel rate in order to avoid CO-
formations. Also remember to regulate the damper in
the tertiary air duct for the calciner.

The temperature after the pre-heater must not

exceed 450°C.

When it has been ascertained that the clinker in

the burning zone is well-burned, the kiln speed can
gradually be increased to match the production
level. The kiln feed rate and the kiln speed r/min
should be synchronised to maintain constant
material level, for instance 3.6 r/min corresponds
to 100% production level.

It is of critical importance that the first

material is well burned in order to avoid
circulation of dust between kiln and cooler. Dust
circulation may cause cooling of the burning zone
so more time is needed to stabilise the kiln
operation.

Since, as mentioned above, the heat input to the

kiln at the beginning exceeds the amount required
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for clinker formation, the kiln system will
gradually be heated.

When there is solid evidence of satisfactory

clinker formation at low free lime levels, the kiln
output can gradually be increased with simultaneous
increase of draught level, feed rate and fuel rate.

Especially the kiln torque and visual inspection of

the clinker are useful parameters to use in order
to judge whether the clinker are well burned.
Further analyses of the clinker litre weight and
content of free lime are useful for judgement of
the clinker quality. The duration of the period
from starting of the kiln feed to full production
level is reached, will normally be ~4-5 hours.

Tertiary fixed obstruction at Damper position.

During normal operation the tertiary damper is very

seldom fully opened thus restricting some of the
duct area. If it is found by experience that in
most situations ~15-20% of the duct area is
restricted by the damper it could be advantageous
to substitute the damper with a fixed obstruction
taking up a similar area ~20% of the duct area. The
fixed obstruction can be constructed in the bottom
of the tertiary pipe at the damper position. The
damper will when and if it closes, close towards
this obstruction “wall”, formed as a damper seat.
This obstruction is making it possible to withdraw
the tertiary air damper fully from the hot air
flow, thus eliminating any possible wear to the
damper from the clinker dust suspended in the
tertiary air.
 70002363-1

25
4.5 Starting and operation of the grate cooler

See also separate instruction manual.

4.5.1 Cooler operation

The two prime objectives of the grate cooler are as

follows:

A. To cool the clinker to a temperature that

prevents damage to the subsequent conveying
system.

B. To recuperate the maximum amount of thermal

energy to ensure efficient operating economy of
the kiln system.

Additional to these two prime objectives, a number

of physical and transport related factors are
involved, making it very difficult to give exact
guidelines with respect to air volumes etc.

The clinker granulometry is a factor of great

significance.

The clinker should flow evenly over the entire

grate area.

A visual inspection of the grates is recommended

during the running-in of the cooler.

Gradually as the clinker begins to leave the kiln,

the grate cooler must be put into operation.

To avoid a build-up of clinker on the grates, the

grate movement is started stepwise with the
increasing material flow from the kiln.

If not already started, start the clinker breaker

and the clinker conveying system after the cooler.
 70002363-1

26
Gradually as the production increases, the cooling
air will increase. Also the cooler grates can from
early beginning be maintained in continuous
operation. An interlock is applied between the
first grate drive and the kiln drive, which means
that the grate drive must be in operation before
the kiln drive can be started. This interlock can
be overruled during the heating-up period.

The pressure in the kiln hood should be maintained

in the range of -0.3 to -0.5 mbar by the speed of
the cooler excess air fan, control loop is set in
automatic.

The amount of cooling air should be the maximum

possible without making the clinker bed unstable.
If the clinker bed starts to fluidize, then the
cooling efficiency is destroyed.

The kiln speed must be reduced if the temperature

rise is due to “surge of material” from the kiln.

4.6 Preparations for and calciner operation

As mentioned above the firing in the calciner must

be started at the same time as the feed to the pre-
heater. However, the following interlocking must be
fulfilled:

- Kiln main burner in operation with ID-fan in

operation.

- Kiln drive in operation.

- The temperature in the top of the lower part of

the calciner must be higher than minimum (750°C)
and the temperature in the top of the lowermost
cyclone must be lower than Max II (980°C).

- The feed to the pre-heater is on.

- The O2 content in the gases after the pre-heater

must be > 4%.
 70002363-1

27
- If the CO and/or CH4 content in the gases after
the pre-heater rises to MAX I level 0.5% then
the operator must take action to increase the
amount of combustion air. If the CO and/or CH4
concentration still increases to Max II (0.9%)
level for more than 10 seconds, then the fuel
rate to the calciner must automatically be
reduced by minimum 20%. If the above situation
has occurred then the burner is automatically
changed to manual control mode. If MAX III level
has been reached 1.2%, then the interlocking
will force the fuel for calciner and main burner
to a preset minimum.

The combustion gas/air to the calciner is

controlled both by adjustment of the dampers of the
exhaust gas fan and by changing the position of the
damper in the tertiary air duct and the split
distribution of material between the riser pipe and
the calciner.

The CO content at the kiln inlet must be maintained

lower than 0.1% at an oxygen level between 3-4%. At
the same time the CH4 concentration must also
remain below 0.1%.

Always increase draught before fuel rate is

increased to prevent formation of explosive gases.

The fuel to the calciner is entered in the kiln

riser and the tertiary air duct.

4.6.1 Achieving nominal capacity

During the first couple of hours after the

production has been started the feed rate is
increased gradually, however, only concurrently
with production of well burnt clinker.

Adapt feed and fuel so the temperature in the

lowermost cyclone stage is maintained at
approximately 890°C, which would correspond to a
degree of calcination of 90-95%. This calcining
 70002363-1

28
temperature should be maintained automatically by
the PLC-control system.

Consequently the kiln production is increased as

follows:

- Increase the draught.

- Increase the feed

(synchronously with the kiln speed).

- Increase the fuel supply to the calciner

(possibly automatically).

- Check whether a change of the kiln fuel is needed

(depending of free lime level, litre weight and
torque).

The temperature of the hot air from the cooler to

the calciner through the tertiary air duct will
increase progressively as the clinker volume is
increased.
 70002363-1

29
5. STOP OF KILN PLANT

5.1 Normal stoppage of the plant

It is advisable to stop the kiln plant in a

controlled manner by following the sequence
outlined below:

- Reduce the total air flow to the cooler.

- Stop the fuel to the calciner.

- Stop the ID-fan and close the dampers

(automatically).

This automatically involves that:

- The kiln burner is stopped

- The kiln feed is stopped.
- The dust transport is stopped with delay.

- Stop the kiln drive.

- Reduce the amount of primary air to a minimum.

However, a certain amount of primary air is needed

to cool down the burner pipe, if the burner remains
in the kiln.

- Reduce the cooler cross bar speed. After a few

minutes the cooler drives can be stopped.

- The cooling air fans can be stopped one by one

gradually as the temperatures of the grates are
reduced.

Start barring operation as outlined in section 9.

BARRING.
 70002363-1

30
Where the stoppage period of the kiln extends over
a prolonged period of time, then all machinery not
required for barring of the kiln and cooling of the
burner pipe must be stopped i.e.:

- Withdraw the gas analyser from the riser duct.

- Stop the compressors.

- Draw up plans for subsequent clean-up operation

in the cyclones, flue ducts and riser ducts.

- Make sure that the cooling water supply for the

kiln bearings is functioning as long as the kiln
is barred.

After the kiln has cooled off:

- Stop the primary air fan and retract the burner.

- Stop the clinker conveying system.

- Inspect the kiln, the cooler, the hot gas ducts

and the pre-heater.

- Planning of the maintenance and repair work

required prior to renewed start-up.

NOTE!
The kiln must always be cooled off slowly to
prevent too rapid cooling of the lining in relation
to the kiln shell. Otherwise, the lining may work
loose, involving attendant risk of twisting and
drop-out of bricks.

5.2 Unscheduled stoppages

In the following a description is given of the most

common types of operational disorders.
 70002363-1

31
5.2.1 Total power failure

All machines and motors are stopped.

The emergency power generator must be started,
making it possible to bar the kiln, to close the
fan dampers, to cool down the burner pipe, to start
the nose-ring fan. Cooling water for cooling of the
support roller bearings must be available as long
as the kiln is barred.

5.2.2 The kiln main burner stops functioning

If operational status cannot be restored immedi-

ately, the ID-fan must be stopped and then the stop
procedure outlined in subsection 5.1 must be
initiated.

5.2.3 The calciner burner stops functioning

If the calciner burner can be restarted immedi-

ately, then there is a possibility of restoring
stable operation. Otherwise, the kiln may have to
be stopped.

Until the burner can be restarted the kiln feed as

well as the draught should be reduced. The draught
in the calciner and the pre-heater is likely to be
too low causing drop-through of material from one
pre-heater stage to another. So if the calciner
burner is not restarted fairly quickly then kiln
operation must stop, and the stoppage procedure
outlined in subsection 5.1 must be initiated.

5.2.4 Kiln feed failure

If the kiln feed cannot be restarted immediately,

it will be necessary to stop the kiln. Stop the ID-
fan and follow the stoppage procedure outlined in
subsection 5.1.
 70002363-1

32
5.2.5 Blockage of cyclones

Blockage symptoms are normally indicated by a drop

in the negative pressure at the bottom of the
cyclone or a drop in the temperature of the
material after the cyclone. If blockage is
ascertained in a cyclone, it is essential that the
kiln is brought to immediate standstill in order to
avoid overfilling.
Stop the exhaust gas fan and the kiln drive. The
feed is stopped by interlocking.

Then follow the stop procedure outlined in

subsection 5.1.

Before the clean-up operation is started, a

negative pressure must be generated by means of the
exhaust fan.

5.2.6 Hot spots on the kiln shell

A stoppage of the kiln will normally be required if

the kiln shell temperature is higher than 420°C.

An attempt can be made to maintain the kiln in

operation to postpone the stoppage to a more
appropriate time, provided the temperature can be
lowered by means of cooling fans with concentrated
cooling at the hot spot(s).

It is prudent practice to keep the kiln drive

running on minimum speed until the temperature of
the hot spot has been substantially reduced.

If, however, it is not possible to cool the hot

spot, then a kiln stoppage for repairs of the
lining is described in subsection 5.1.

It may be advantageous to make a partial discharge

of material from the kiln by prolonged barring
before the repair of the lining is initiated.
 70002363-1

33
5.2.7 Failure of clinker transport

In the event of clinker transport failure, the kiln

can normally be maintained in operation for a
couple of minutes before it must be stopped.

During this period of time an attempt to restart

the clinker transport must be made, but if
operation cannot be resumed, it will be necessary
to stop the kiln in accordance with the procedure
outlined in subsection 5.1.

5.2.8 Failure of the grate cooler

In this case, the precautionary measures to be

taken are identical to those outlined in subsection
5.2.7.

5.2.9 Failure of dust handling system

Normally, kiln operation may continue up to 30

minutes without dust transport. If it is not
possible to restart the dust transport within 30
minutes the kiln must be stopped in accordance with
procedure outlined in subsection 5.1.
 70002363-1

34
6. OPERATION

6.1 General notes

The kiln performance is optimized by ensuring that

operational kiln adjustments are restricted to an
absolute minimum. The necessary adjustments must be
phased in gradually.

Once all control loops are active, these will

ensure maintenance of:

- The top temperature of the lowermost cyclones,

ensuring a constant degree of calcination.

- The pressure at the kiln outlet. This con-

tributes towards stable cooler operation, as
well as stable secondary and tertiary air
conditions.

- The pressure after the ID-fan for stabilization

of draught.

The fuel supply rate to the kiln installation is

determined on the basis of an evaluation of the
clinker quality, i.e. the litre weight, free lime
content, and the general appearance of the clinker.

Another determinant is the current status of the

kiln, i.e. the trend of the torque curve, the
potential presence of coating formation, or other
operational disorders recently encountered.

The feed rate and the kiln speed are synchronised.

However, the operator can change the synchronising
ratio.

6.2 Specific conditions related to kiln operation

In the following a review is made of a range of

specific factors affecting the kiln operation.
 70002363-1

35
6.2.1 Exit gas analysis

The exit gas analysis constitutes the most

important source of information for the evaluation
of the combustion process. Therefore, it is of
crucial importance to ensure that the analysis
equipment is functioning properly.

The smoke gases must not contain any unburned

substances, i.e. C (carbon), CO (carbon monoxide)
or CH4 (methane).

Presence of such gases may, under adverse

circumstances, cause fires or explosions. Further,
the loss incurred by wasting the latent heat of the
unburned part of the gases may be quite
substantial.

A CO level of 1% in the smoke gases may entail

additional calorie consumption in the kiln of
approximately 40 kcal/kg clinker.

Any presence of unburned substances would indicate

inadequacy of air for the combustion of the fuel.
Even with an adequate air volume, the smoke may
contain unburned substances due to the fact that
the mixture of fuel and air is not ideal.
Therefore, a certain air surplus should be applied
during the combustion process.

As previously mentioned, the exit gases from the

pre-heater should contain 3-4% of oxygen. It is
possible to set a lower alarm limit for the oxygen
level. A limit of 2% can e.g. be applied. This
alarm will inform the operator about the risk of
unburned substances in the exit gases.

After the pre-heater the CO & CH4-analyser will

continuously monitor the CO & CH4 levels in the
exit gases.
 70002363-1

36
The alarm limits should be set as follows:

MAX I : 0.5% CO, CH4

MAX II : 0.9% CO, CH4
MAX III : 1.2% CO, CH4

MAX I will signal alarm. Then the operator must

make the necessary adjustments to the combustion
process.

MAX II when this alarm signals, the fuel rate to

the calciner will be reduced by 20%. The fuel
control is now in manual mode. The operator must
make further adjustments to the combustion process
in order to restore the oxygen level. CH4 MAX II
concentration will signal alarm and the interlock
is as described for CO MAX II alarm.

MAX III if the CO or CH4 concentration reaches or

exceeds 1.2% in the smoke gases, then this alarm is
activated and total fuel rate will be reduced to a
preset minimum.

6.2.2 Primary air volume

The primary air is supplied through the burner

pipe, ensuring an effective mixture of air and
fuel. Normally the primary air volume supplied by
the fan constitutes 8-10% of the air volume needed
for combustion.

6.2.3 Temperatures after cyclone pre-heater.

The ID-fan is designed to withstand operating

temperatures up to 435°C. However, short term
temperature rises up to 450°C can be tolerated.
 70002363-1

37
The following alarm limits should be set:

MAX I: Giving alarm at approximately 50°C above

the highest normal exit temperature,
(370°C).

MAX II: Causing alarm tripping and stoppage of the

ID-fan at 450°C.

6.2.4 Bearing temperatures

An excessive temperature in any fan bearing will

cause alarm tripping and automatic switch the fan
off. This applies to the ID-fan and the grate
cooler excess air fan.

An excessive temperature in any supporting roller

bearing will only cause alarm indication. The
operator must ensure that immediate action is taken
to remedy the situation, if kiln operation is
continued.

6.2.5 Filters

The operating temperature of the filters must never

exceed the maximum temperature specified by the
supplier.
 70002363-1

38
6.2.6 Blockage in cyclones

Changes in the temperatures of the material at the

discharge point from the cyclones may be signs of
beginning stages of a blockage in the cyclones.

Negative pressure meters are installed at the

bottom of all the cyclones (except the 1st
cyclone).

If the negative pressure should drop during normal

operation this is, combined with a possible change
in temperature, a sure sign of blockage.

The pressure gauges will cause alarm indication, if

the negative pressure should drop below the set
minimum value. It is then up to the operator to
assess, on a case by case basis, whether a kiln
stoppage is required.

A drilled hole, with a diameter of about 2 mm, must

be present in the connecting bushings for the
negative pressure meters, and it is very important
to keep this hole clean. In case of blockage in the
cyclones, the pressure measurement will gradually
move towards zero as the tube is filled with
atmospheric air.

Once a blockage in a cyclone has been ascertained,

the operator must ensure that the kiln is stopped
and the blockage removed manually.

Normally, air lances in appropriate lengths are

effective tools. Extreme caution must be exercised
during the clean-out operation.

A number of precautionary measures to be taken in a

cement plant are outlined in a separate instruction
manual.
 70002363-1

39

NOTE!

The temperature of the material caking may be as

high as 800°C, with attendant risk of sudden
outflow of hot raw meal, flowing as if it were a
liquid.

Therefore, it is essential that extreme caution and

care are being exercised during the operation, and
it is advisable that the operators involved are
equipped with heat-insulated protective suits
during the clean-out operation.

6.2.7 Caking in riser duct and kiln inlet

It is possible to detect major caking in the riser

duct and kiln inlet by checking the difference
between the negative pressures at the kiln outlet
and at the lowermost cyclones.

The safety precautions, which must be taken during

the clean-up operation, are similar to those
stipulated for the cyclones.

Operational experience will show whether the extent

and locations of potential caking would make it
appropriate to equip the installation with
additional clean-out hatches.

It may also be practical to install air chock

blasters at appropriate locations.

6.2.8 Kiln position

The axial position of the kiln is monitored on the

supporting rollers. The alarm limits must be set as
directed in the instruction manual for the thrust
device.

The MAX I alarm is a signal instructing the

operator to undertake inspection of the position of
the supporting rollers.
 70002363-1

40

The MAX II alarm automatically stops the kiln drive

for prevention of damage to the smoke chamber seal
or kiln hood seal.

In a critical situation, it may be necessary to

apply oil directly to the supporting rollers, if
the rollers tend to thrust the kiln upwards.
However it is very important to ensure that the oil
is removed as soon as possible following the re-
alignment of the supporting rollers.

The lubrication between the supporting rollers and

the kiln tyre must be provided by means of dry
graphite lubrication. See separate instruction
manual.

6.2.9 Kiln lining

The temperatures in the kiln system are so high

that most of the system is protected by means of a
lining consisting of bricks and concrete.

It is a prerequisite for smooth kiln operation that

the kiln lining is intact. Consequently, proper
maintenance of the lining is of paramount import-
ance.

Normally, the lining in the pre-heater, hot-air

duct and in most parts of the cooler will have a
lifetime of several years with no need for
replacements.

However, especially the lining installed in the

burning zone of the kiln will require more frequent
replacement of bricks.

The exact frequency depends on a range of factors.

Generally, replacement is recommended in case the
thickness of bricks - owing to wear - has been
reduced to half the original size.

Any damage to the lining involves the risk that the

kiln shell will be overheated. Particularly the
 70002363-1

41
kiln burning zone should be kept under continuous
supervision.

If the kiln shell temperature should rise to 420-

450°C, the affected area must be cooled by means of
fans.

In the event of a further rise in temperature, the

kiln must be stopped for repair of the lining.

During operation the condition of the kiln lining

can be checked by installing a radiation pyrometer
(scanner) for monitoring of the kiln shell
temperature. This alarm level should not exceed
420°C.

Whenever access to the kiln is possible during a

stoppage period, the opportunity should be taken to
inspect the lining. Then appropriate time schedules
for replacement or repair can be worked out.
 70002363-1

42
7. INTERLOCKING, PROGRAMMING AND CONTROL CIRCUITS

The various motors, machines, dampers and other

equipment are operated and controlled by the
central control system. In the following the
proposed structure of the control system is
described seen from the operational and process
point of view. A proposal for grouping of the
motors is given below. The general and special
rules of interlocking are listed. A survey of all
process related measurements and their treatment is
given in section 10.

Finally the list of control loops is presented.

7.1 Interlocking

The detailed interlocking, as programmed, is

described in the interlocking diagrams. However,
the main philosophy is given below.

The general rule of operational interlocking is

that no machine can be started before the
subsequent machine has been started. Inversely,
stop of any machine will cause the stop of the
machine ahead. This follows the process order.

Protection interlocking like

- bearing temperature
- vibrations
- winding temperature
- minimum oil level
- speed monitors
- maximum material level, etc.

will stop the machine in question immediately

Examples:

- If the speed monitor of an air sluice does not

indicate any rotations, then the motor for this
air sluice will stop.
- If the vibration level of the kiln ID-fan is
high, then the motor of this fan will stop.
 70002363-1

43

- If the bearing temperature of the clinker hammer

crusher is above the maximum temperature allowed,
then the crusher will stop.

Special interlocking

The special interlocking will be described in the

section of programming as well as in the diagrams
giving the process instrumentation. (DIAGRAMS as
described in section 10).

In the control system the various motors and

machines will be arranged in a number of groups for
common start and stop.

7.2 Programming

From the central control room the kiln department

can be operated by selection of a number of
programs and a number of direct functions.

The programs installed in the control system will

perform the start and stop procedures for the
machines divided into groups. Further the operation
is automatically supervised, checking constantly
all interlocking for operation, protection and
safety.

The direct functions consist of opening and closing

the dampers and speed control of the motors.

The following programs are proposed. (Please note

that the groupings of machines may be carried out
differently to the proposal, but the main ideas
should be kept).
 70002363-1

44
The following programs are proposed:

1) CF-silo
2) Kiln feed
3) Mill/kiln filter fan
4) Dust transport
5) Kiln ID-fan
6) Gas analysers
7) Kiln auxiliaries
8) Kiln drive
9) Device for barring
10) Kiln burner fans
11) Kiln burner
12) Calciner burner
13) Clinker transport system
14) Cooler excess air fan
15) Cooler drive
16) Cooler fans

The following equipment can be operated indi-

vidually:

Fan dampers.
Changeover gates and dividing gates.
Position of valves – gas valves and feed valves.
Motors with speed regulation, such as kiln drive.

7.3 Comments to programs

For details of the programming reference is made to

the separate documentation for the PLC system.
However, in the following some important notes are
pointed out in relation to each program. In general
all bag filters should stop with a minimum delay of
15 minutes to empty the system.
 70002363-1

45
1) CF-silo

Conditions to be fulfilled before start:

The filter, the blowers and the extraction
sequence from the silo can be started any time.

2) Kiln feed

Conditions to be fulfilled before start:

The air compressors are in operation or ready for
operation. The ID-fan must be in operation. If
the feed stops (program 2) then the ID-fan must
be stopped to prevent over-heating of the pre-
heater and the ID-fan. This interlock can be
bypassed during heating-up before feeding the
kiln.
The transport direction must be defined before
the kiln feed is started, either to the pre-
heater or recycling to the CF-silo. (remember to
start this recycling as soon as the CF-silo has
reached a raw meal level of 10%.)

3) Mill/kiln filter fan (Not FLS scope)

Conditions to be fulfilled before start:

Damper to be closed, and filter inlet
temperatures lower than the maximum allowed.
Program 4 must be in operation.

4) Dust transport (Not FLS scope)

The dust from the kiln can be directed to the kiln

pre-heater or to the CF-silo via the dust hopper.

Conditions to be fulfilled before start:

The transport equipment must be in operation. The
dust transport system must have no alarms.
Program 2 in operation, can be bypassed during
heating-up period. NOTE, delayed stop for
emptying.
 70002363-1

46
5) Kiln ID-fan

Conditions to be fulfilled before start:

Dampers to be closed.
Pre-heater outlet temperature lower than MAX II.
Program 3 is operational.

6) Gas analysers

Conditions to be fulfilled before start:

Availability of compressed air and cooling water.

7) Kiln auxiliaries

Conditions to be fulfilled before start:

None.

8) Kiln drive

Conditions to be fulfilled before start:

Program 7 in operation or in “no alarm” status.
Barring is stopped and dis-engaged.
Kiln drive ready for start and engaged.
No alarm for kiln position.
Cooler drives in operation or not stopped for
more than 5 minutes. (This interlocking can be
bypassed during kiln start-up).
Cooler fans are in operation.

9) Device for barring

Conditions to be fulfilled before start:

Main kiln drive stopped and dis-engaged.
Barring drive engaged.

10) Kiln burner fans

Conditions to be fulfilled before start:

None, however, once the kiln burner - program 11
- has been put into operation, then the emergency
fan must start automatically when the primary air
fan stops.
 70002363-1

47
11) Kiln burner

Conditions to be fulfilled before start:

Kiln ID-fan - program 5 - is in operation, during
heating-up of the kiln. A special interlock
permission can be given that a start-up of the
burner without the exhaust fan is in operation.
However, when the fan has been started this
special interlocking is automatically cancelled.
Primary air fan in operation - program 10.
The oxygen content in the pre-heater exit gases
must be ≥ 4%.
CO and/or CH4 < MAX I.
Analysers for CO and CH4 must not be in test
mode.

12) Calciner burner

Conditions to be fulfilled before start:

Kiln burner in operation - program 11.
Kiln ID-fan in operation - program 5.
Calciner outlet temperature must be above minimum
level and below MAX II level.
Kiln feed is on - program 2.
CO and/or CH4 < MAX I.
O2 ≥ 4%.
Gas analyser must be in operation, not in test
mode, and no alarms active. If the CO and/or CH4
level after the pre-heater rise above MAX II
(0.9%) then the fuel rate to the calciner burner
is automatically reduced by 20%. The burner is
then in manual mode.

If the CO and/or CH4 level later is above MAX III

(1.2%)(400 ppm) then the calciner fuel supply
will be stopped (delayed 2 minutes).
 70002363-1

48
13) Clinker transport

Transportation selected to either,

A. Clinker silo
B. Off standard clinker silo

Conditions to be fulfilled before start:

Clinker storage area must not be full.
Transportation route defined.
The clinker dust transport will stop if the
clinker transport stops.

14) Cooler excess air fan

Conditions to be fulfilled before start:

Damper of excess fan is closed.
The excess air is expected to be ~300°C.
The cooler excess air fan will be switched off
automatically at temperatures above 450°C
provided the cooler excess air fan is in
operation.
NOTE that the ID-fan will stop when the excess
air fan stops.

15) Cooler drives

Conditions to be fulfilled before start:

The clinker transport after the cooler is in
operation.
Clinker crusher is in operation.
Cooler fans for the grate cooler are in
operation.
 70002363-1

49
During start-up special permission can be given
for operating of the cross bars to remove any
accumulation of material at the kiln outlet.

Stoppage: Stop to the clinker crusher, clinker

transport, excess air fan or ID-fan will cause a
kiln stop, which will cause the cooler drives to
be reduced to minimum speed and to be stopped
within an adjustable time 0-5 minutes.

If one cooler cross-bar stops, then the kiln will

stop after 0-8 hours delay. If more than one
cross-bar stops the kiln will stop after 0-5
minutes delay.

If the dust transport from the cooler ESP is

stopped, then the cooler drive is stopped within
0-20 minutes delay. This will cause a kiln stop
with related interlock stops.

If any of the cooler fans are stopped,

then the cooler drives must be stopped

immediately.

This must then immediately be proceeded by

stoppage of the kiln if the fans remain stopped
for more than 0-5 minutes.

The cooler drives must NOT be started until

cooling air has been re-established.

16) Cooler fans

Conditions to be fulfilled before start:

Cooler excess air fan in operation.

If cooler excess air fan and or the ID-fan stop,

then the flow from the cooler fans must
automatically be reduced by 40% capacity in order
to avoid dust emission (reduction can be set
individually for each fan).
 70002363-1

50
During start-up special permission can be given
for operation of the fans individually.

7.4 Control circuits

The following control circuits are foreseen.

1) The kiln feed is synchronised with the kiln

speed.

2) The temperature in the top of the lowermost

cyclone controls the fuel supply to the
calciner burner.

3) The pressure after the kiln ID-fan is kept

constant by regulating the inlet speed of the
filter fan.

4) The temperature of the gasses at the inlet of

the main filter is controlled by the position
of the bleed air damper located in the duct
from the ID-fan to the bag filter.

5) The pressure in the kiln hood is maintained by

the speed of the cooler excess air fan.

6) The water injection to the clinker cooler is

regulated in order to protect the clinker
cooler de-dusting filter and excess air fan
against high temperatures.

7) The speed of the cooler drive is controlled by

the average grate pressure of the cooler (4
grates in the central part after the inclined
inlet).

7.5 Operating parameters and alarms

In section 10. operating parameters and alarms are

shown. All instrumentation related to process
parameters is listed. The handling and the use of
these signals are presented.
 70002363-1

51
8. PREVENTION OF FIRES AND EXPLOSIONS

8.1 General precautions

On no account must soot nor combustible, unburned

exit gases be allowed to accumulate in the kiln,
the cyclones, the flue ducts etc. This would
involve a serious risk of explosion or fire.

Therefore strict adherence to the following rules

is needed:

1) In connection with renewed light-up of the kiln,

following a temporary stoppage, it must be
firmly established that the kiln heat (material
surface temperature) is sufficient to ignite the
fuel.

If the kiln is too cold, the kiln must be lit in

the normal manner, using the light-up equipment,
and using a procedure similar to that applied
during the normal heating-up phase prior to
start-up.

2) Always ensure that the burner is not operating

with an air deficiency.

3) Inject the fuel at sufficient primary air

velocity.

4) Burners must always be started at minimum fuel

rate.

5) Never increase the fuel supply rate too suddenly

or excessively at the same time. In any case,
the draught must always be increased first and
the upward adjustment of the fuel supply must
take place evenly and slowly.
 70002363-1

52
8.2 Precautionary measures relating to the burners

In the following the interlocking for the burners

and the gas analysers are summarised. The main
purpose of the interlocking is to reduce the risk
of any fire or explosion. These risks are always
present when working with fuels. Although measures
are taken to prevent the dangers, the operator
should always observe and act carefully when
working with fuels and firing equipment.

It is therefore an important interlocking that a

burner can only operate, if the gas analysers after
the pre-heater are in operation without any unit
alarms or without analyser fault on the CO and the
CH4 channels.

Further it is conditional for the calciner burner

operation that the CO and/or CH4 levels have not
been over MAX II (0.9% CO/CH4).

If the CO and/or CH4 levels is/are above MAX I

(0.5% CO/CH4), then the operator must take actions
to reduce this immediately. Depending on the
circumstances these actions could be either to
reduce fuel rate or increase draught.

PROCEDURE FOR GAS ANALYSER TEST MODE

The analyser has a digital input for permission to

test mode. This input must be set before any local
test can be performed.

The test permission is selected by the operator in

the central control room. It is automatically de-
selected whenever the analyser is put in test mode
or if not, de-selected after 10 minutes by a timer.
 70002363-1

53
The test permission for analysers must be separated
in test permissions, one for each analyser. The
test mode must always be clearly indicated to the
operator.

For further safety, test permission should only be

possible for one analyser at a time.

8.3 Fuels

For precautionary measures to be taken when using

fuel, see separate instruction manuals.

Reference is also made to the regulations of the

local authorities.
 70002363-1

54
9. BARRING

9.1 General instructions

If the kiln is stopped while hot, barring of the

kiln is required to avoid kiln shell deformation.

Normally, barring should always be restricted to an

absolute minimum to prevent damage to the lining.

The hydraulic thrust device and the spray

lubrication system of the kiln drive must be in
operation while barring operation is being
performed.

The following guidelines apply to a situation where

the kiln is stopped in a hot condition and has to
be barred:

1) As long as the kiln is hot, the barring

operation must be continuous the first half hour
after stoppage.

2) If the axial position of the kiln should cause

the alarm to be tripped, then barring must be
continued until the correct position has been
re-established.

3) If the kiln shell is exposed to strong external

cooling, for example due to heavy rainfall, then
continuous barring is required.

4) Cooling water supply to the kiln roller bearings

must be uninterrupted during the entire barring
period.
 70002363-1

55
NOTE
If accidentally for some reason the kiln has not
been barred for 2 hours after the kiln has stopped
- though this should never take place - then the
first priority in this situation is to bar the kiln
as soon as possible. A mechanical inspection of the
installation is required, before the kiln is
restarted on the main drive.

9.2 Barring programmes

The barring programmes are divided into stages of

200 degrees rotation. This is done to ensure
variations in the position of the kiln during
standstill.

9.2.1 Barring during drying of lining before

initial start-up

0 - 24 hours: About 200 degrees every 30 minutes

24 - 68 hours: About 200 degrees every 15 minutes
68 - hours: Continuous barring

Keep a close check on the longitudinal expansion of

the kiln and its position on the supporting rollers
during the entire period.

See separate instruction manual for thrust device.

9.2.2 Barring during normal start of cold kiln

0 - 8 hours: About 200 degrees every 30 minutes

8 - 20 hours: About 200 degrees every 15 minutes
20 - hours: Continuous barring

Keep a close check on the longitudinal expansion of

the kiln and its position on the supporting rollers
during the entire period.

See separate instruction manual for thrust device.

 70002363-1

56
9.2.3 Barring during stoppage of the kiln

0 - ½ hour : Continuous barring

½ - 12 hours: About 200 degrees every 10 minutes
12 - 24 hours: About 200 degrees every 15 minutes
24 - 48 hours: About 200 degrees every 30 minutes
48 - hours: Bar as required, if some of the
conditions mentioned in subsection 9.1 makes it
necessary.

During the final period the kiln must be barred for

a few minutes, if the axial migration of the kiln
exceeds the maximum value for normal kiln
operation.

This barring operation is required to prevent

damaging or possibly rupturing of the thrust roller
shaft during the kiln tube contraction, which still
may take place up to the 72nd hour.

Proper graphite lubrication of the supporting

roller surfaces must be ensured. The graphite
blocks must rest loosely in their holders so that
the pressure against the supporting roller surfaces
is not hampered.

To protect the surfaces of the supporting rollers

and live-rings against damage as the live-ring
slides over the supporting rollers during the axial
movement of the kiln, it is essential that the
mentioned dry matter lubrication is in order.

9.3 Braking

If the barring operation is stopped, the kiln is

automatically braked and maintained in an arbitrary
position and may therefore be side heavy. This fact
must be taken into account when the brake is
slackened.

Reference is also made to the instruction manual

for the barring device.
 70002363-1

57
10. CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS AND
ALARM LIMITS

The following tables are a survey of the expected

normal operating parameters and the normal alarm
limits.

The operating parameters stated are for guidance

only and apply to the normal, stable operating
situation. The operating limits stated are meant as
guidance for start-up. It will be possible to
adjust many of these with advantage later on in
order to make them more suitable for the actual
operation. Concerning many of the alarm limits they
will also have to be adjusted according to local
conditions as factors like the lubrication oil
selected, the ambient temperature, etc. will affect
the values. The mechanical and/or the electrical
departments must, in every single case, approve the
change and fixing of the alarm limits for
protection of the machines.

Normally, the alarm limits for the operating

parameters will be the responsibility of the
production management.

The following notes refer to the tables listed

below:

a) To be fixed in accordance with the specifi-

cations in separate machine instruction.
b) To be fixed in accordance with the electrical
documentation.
c) To be fixed empirically so the alarm is not
activated under normal operating conditions.
x) The normal value is either given in above text
or has to be evaluated during commissioning.
+) Indication given according to the range of
instrument.
 70002363-1

58
SHARGH CEMENT

KILN PLANT

IRAN

CF silo % + + x
Total feed t/h 256 + 4)
ID-fan kW x
r/min x
Preheater out mbar 49 + 70
5 stage °C 309 + 370 450
Operation A1 3.4 + 2.0
A2 0.0 + 0.5 0.9 1.2
1) 2)
A3 x +
A4 0 + 0.5 0.9 1.2
1) 2)
A1 = O2 % 1) MAX II reduces the fuel to the calciner by 20%.
A2 = CO% 2) MAX III fuel automatically set to preset minimum.
A3 = NOx ppm
A4 = CH4 %
 70002363-1

59

SHARGH CEMENT

KILN PLANT

IRAN

Cyclone 1 T1 311 c)
Cyclone 2 T1 493
T2 488 c)
P2 34
Cyclone 3 T1 648
T2 643 c)
P2 29
Cyclone 4 T1 775
T2 765 c)
P1 27
P2 22 10
Cyclone 5 T1 890 + c) 920 980 3)
T2 870
P1 21
P2 18 10
Top of lower T 1000 750 820
part calciner
3) Temperature controlled by fuel feed rate.
T1 = Top temperature in cyclone.
T2 = Bottom temperature in cyclone.
P1 = Pressure in cyclone roof.
P2 = Pressure in cyclone bottom.
 70002363-1

60
SHARGH
CEMENT

KILN PLANT

IRAN

Tert. air °C 925 +

mbar 10
Tert. damper % x +
Kiln inlet mbar -2 +
A1 4.0 + 1.0
A2 0.0 + 0.5 0.9 1.2
A3 X + x
A4 0 + x 0.5 0.9 1.2
Kiln drive r/min 3.6 + 4)
Roller °C a) a)
bearings
Kiln Poss. + a) a) a) a)
position
Kiln hood mbar -1 5)
°C 1050
Grate temp. °C x a)
Primary air mbar x c) + 6)
kW x
Grate press. mbar x + 7)
Cooler drive st/min x

A1 = O2 % 4) Manually controlled, however, synchronized with

A2 = CO% kiln feed.
A3 = NOx ppm 5) Cooler excess air fan speed control.
A4 = CH4 % 6) Pressure could be controlled by inlet damper.
7) Average grate pressure maintained by speed of
cross bars.
 70002363-1

61
SHARGH
CEMENT

KILN PLANT

IRAN

Cooling fan mbar 72 +

3
K11 m /min 520 210 310 +
kW x
speed % 0-100 8)

Cooling fans mbar 73 +

K21 m3/min 1220 490 735 +
kW x
speed % 0-100 8)

Cooling fans mbar 70 +

3
K31 m /min 1220 490 735 +
kW x
speed % 0-100 8)

Cooling fan mbar 60 +

K41 m³/min 1065 425 640 +
kW x
speed % 0-100 8)

Cooling fans mbar 55 +

K51 m³/min 905 360 540 +
kW
speed % 0-100 8)

Cooling fan mbar 50 +

K61 m³/min 705 280 425 +
kW x
speed % 0-100 8)

8) Flow regulation by damper control.

9) Excess air fan stops at 450°C.
 70002363-1

62

SHARGH CEMENT

KILN PLANT

IRAN

Excess air r/min x 6)

fan
kW x 5)
Excess air °C ~300 430 450
temperature 9)
Clinker crush Amps. x
3
Gas to kiln Nm /h 5750 + +
3
Gas to calc. Nm /h 7220 + 3) +
Below measurements are used for protection of the
individual equipment.

Speed monitor
Motor bearing temperature
Motor winding temperature
Bearing temperature
Pressostate (air pressure control)
Oil flow control
Oil level control
Oil temperature
Hydraulic oil pressure
Hydraulic oil temperature
Hydraulic oil level

Alarm settings to be in accordance with separate

instructions.

---oOo---
 70002363-1

63

SHARGH CEMENT- IRAN

PREHEATING / DRYING-OUT, PHASE 1
SF CROSS-BAR COOLER

°C

1000

900
TEMPERATURE

800

700

600 Kiln Hood.

500 Cooler Roof.
400

300 Cooler Filter Inlet.

200

100

0
0 12 24 36 48 96 HOURS

0 12 24
 70002363-1

64

SHARGH CEMENT - IRAN

PREHEATING / DRYING-OUT, PHASE 2
PREHEATER (KILN RISER) & TERTIARY AIR DUCT

°C

1000

900
TEMPERATURE

800

700
Tertiary Air Duct.
600 and Riser Pipe
500

400

300

200

100

0
0 12 24 36 48 96 HOURS

0 12 24
 70002363-1

65
S H A R G H C E M E N T - IR A N
P R E H E A T IN G / D R Y IN G - O U T , P H A S E 3
K IL N S T A R T W IT H C A L C IN E R , T Y P E IL C
°C START FEEDING

1000

900 Stage 5.
TEMPERATURE

800

700

600

500

400

300 Stage 1.

200

100

0 2 4 6 8 10 12 14 16 HOURS
0 12 24 36 48
8 16 24

100
Kiln feed.

90
FEEDING / FUEL

80

70

60 Fuel to calciner.
50
Fuel to kiln.
40

30

20

10

0 2 4 6 8 10 12 14 16 HOURS
0 12 24 36 48
8 16 24

100
Kiln Speed
90
KILN SPEED

80

70
2-3% O2 Kiln Outlet
60

50

40
Tert. air damper
30
3-4% O2 Kiln Outlet
20

10

0 2 4 6 8 10 12 14 16 HOURS
0 12 24 36 48
8 16 24

BARRING ACCORDIN G TO PROG RAM

KILN ON MAIN DRIVE