Kiln # 2 cyclic issue rectification and optimization

Process Department
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Problem statement – Kiln # 2
Sr # Operational problems *Standard deviation Comment
1 TAD temperature fluctuation (cyclic) ± 31 C – 17 degree High
2 Hot meal temperature fluctuation (cyclic) ± 24C – 8.2 Degree High
3 Kiln hood pressure fluctuation against SP ± -0.1 mbar – 0.05 High
mbar
4 EP Inlet temperature fluctuation (cyclic) ± 50 C High
5 Cooler EP Speed ± 15 rpm – 6 rpm High
*Standard deviation measured on the basis of 24 hours normal operation from CCR

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Summary:

 Kiln # 2 cyclic issue observed with a sinusoidal change with in regular intervals of the following
parameters.
1. TAD temperature
2. Hot Meal temperature
3. Kiln hood pressure
4. Mid air temperature
5. Cooler EP Fan RPM
6. Pan conveyor ampere variation
7. Cooler drive ampere variation

Cyclic issue disturb plant operation, process team conducted detail study to find out the route
cause for the given problem and steps were taken to optimize the cooler operation.

Presentation name or chapter 3

Operational Problems

Presentation name or chapter 4

 1. TAD temperature fluctuation (cyclic)
• Below graph shows the TAD cyclic issue - Standard deviation ± 50 Degrees
• Important observation was that during the same 24 hours operation it show a straight trend. Therefore
there is some trigging point in the system for this change

Fluctuation ± 50 degree Fluctuation stop Fluctuation start again

2. Hot Meal temperature (cyclic)
• Below graph shows the HOT meal C5 cyclic issue - Standard deviation ± ___ Degrees
• Important observation was that during the same 24 hours operation it show a straight trend. Therefore
there is some trigging point in the system for this change. Also when fluctuation stop we observe
increase in Hot meal temperature

Increase in hot meal

temperature at same fuel

Fluctuation ± __ degree Fluctuation stop

Fluctuation start again
 3. Kiln hood pressure fluctuation against SP

• Below graph shows the Kiln Hood cyclic issue - Standard deviation ± 50 Degrees
• Important observation was that during the same 24 hours operation it show a straight trend. Therefore
there is some trigging point in the system for this change

Fluctuation ± 50 degree Fluctuation stop Fluctuation start again

 4 . EP Inlet temperature fluctuation
• Below graph shows the EP Inlet temperature cyclic issue - Standard deviation ± __Degrees
• Important observation was that during the same 24 hours operation it show a straight trend. Therefore
there is some trigging point in the system for this change

Fluctuation start again

Fluctuation ± 50 degree Fluctuation stop
 5 . Cooler EP Speed (RPM)
• Below graph shows the Cooler EP cyclic issue - Standard deviation ± __Degrees
• Important observation was that during the same 24 hours operation it show a straight trend. Therefore
there is some trigging point in the system for this change

Fluctuation ± 50 degree Fluctuation start again

Fluctuation stop
6.Conclusion

• Fluctuation during stable operation of Kiln hood, Cooler EP fan and EP inlet temperature.
• Possible disturbance of the cyclic is therefore not from soot variation but from the cooler operation. A
stable cooler operation was achieving best operational parameter and reduced the cycle.
• Therefore we find for the possible route cause in the cooler to rectify the issue.
Cooler operation overview.
1. Fan flow PID control through change in RPM - Every thing is linked with RPM of the fan
2. Cooler EP fan on PID with Kiln Hood
3.Cooler speed constant

Presentation name or chapter 11

7. Cooler Operation Overview
Design Average Running Standard Deviation
Name Static Pressure
RPM m3/hr compartment RPM mbar RPM mbar
mbar
Cooler Grate 1
FN01/V1L 2585 22,500 1 100 2372 92.2 24 1.5
FN02/V1R 1562 22,500 1 100 1329 93 16 1.7
FN03/V2 1366 54,000 2 100 1146 70 19 2.1
FN04/V3 1542 46,000 3 95 1280 64.7 28 2.3
FN05/V4 1496 44,000 4 90 1287 69.8 18 2.8
FN06/V5 1448 42,000 5 85 1278 61.3 24 2.9
FN07/V6 1400 40,000 6 80 1250 57.6 0 2.5
FN08/V7 1274 76,000 7 75 1200 37.4 0 2
347,000
Cooler Grate 2
FN09/V8 1473 37,000 8 65 1400 64 50 4.3
FN010/V9 1485 62,000 9 60 1310 51 40 4.1
FN011/V10 1348 54,000 10 50 1250 48 30 3.5
153,000
500,000
 Continue…
• Cooler # 1st and 2nd grate fan have high standard deviation of RPM against the set point. With the change
in RPM plus or minus from mean point the quantity of air changes resultantly increase/decrease in air
flow and static pressure.
• Since the speed of the grate cooler is constant so the change in under grate control is coming from poor
control of RPM by cooler PID. This change disturbing the operation and cycle in the kiln.

Fan - 9
Fan - 10 Fan - 11
 Continue…
• Cooler # 1st and 2nd grate fan have high standard deviation of RPM against the set point. With the change
in RPM plus or minus from mean point the quantity of air changes resultantly increase/decrease in air
flow and static pressure.
• Since the speed of the grate cooler is constant so the change in under grate control is coming from poor
control of RPM by cooler PID. This change disturbing the operation and cycle in the kiln.

Fan - 9
Fan - 10 Fan - 11
8.Corrective Actions
1. Last 03 fans on fixed speed on the basis of running average.
(08 days operational trend of all parameters are shown in next slide)

Presentation name or chapter 15

Corrective action -
Design Average Running Standard Average Running Standard
Deviation Deviation
Name Static
RPM m3/hr compartment Pressure RPM mbar RPM mbar RPM mbar RPM mbar
mbar
Cooler Grate 1
FN01/V1L 2585 22,500 1 100 2372 92.2 24 1.5
FN02/V1R 1562 22,500 1 100 1329 93 16 1.7
FN03/V2 1366 54,000 2 100 1146 70 19 2.1
FN04/V3 1542 46,000 3 95 1280 64.7 28 2.3
Corrective action 2
FN05/V4 1496 44,000 4 90 1287 69.8 18 2.8
FN06/V5 1448 42,000 5 85 1278 61.3 24 2.9
FN07/V6 1400 40,000 6 80 1250 57.6 0 2.5
FN08/V7 1274 76,000 7 75 1200 37.4 0 2
347,000

Cooler Grate 2
FN09/V8 1473 37,000 8 65 1400 64 50 4.3 1400 64 0 1.3
FN010/V9 1485 62,000 9 60 1310 51 40 4.1 1310 51 0 1.2
FN011/V10 1348 54,000 10 50 1250 48 30 3.5 125 48 0 1.1
153,000
500,000
Cooler grate 2 – Fan 9 constant RPM

03 days 05 days
Cooler Fan 9 Chamber pressure stabilized

03 days 05 days
Cooler EP Fan(08 Days trend)

03 days 05 days
Kiln Hood Pressure (08 Days trend)

03 days 05 days
TAD Temperature(08 Days trend)

03 days 05 days
Conclusion
Sr # Operational problems UOM Before After
1 Average TAD temperature Degrees 845 875 30
2 Cooler Efficiency % 72 73 1
3 Cooler standard losses MJ/Kg clinker 492 480.9 12.33
4 SPC Reduction MJ/Kg clinker 12.33 12.33
5 Kiln hood pressure standard
deviation mbar -0.10 -0.05 0.05

3 Cooler EP fan speed standard

RPM 23 9 14
deviation
4 EP Inlet temperature standard
Degrees 40 13 27
deviation
5 TAD temp standard deviation Degrees 45 10~18 20~25
6 Clinker temperature standard Degrees 15 7 8
deviation

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Heat Balance of Cooler (Basis Secondary temperature constant)

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