Preheater Tower Best Safety Practices

Tom Spaits Josh FredlakeVice President Production Manager

ATD Pressure Gas System Giant Cement7634 Southrail Road, Unit 601 654 Judge StreetNorth Charleston, SC 29420 Harleyville, SC 29488tom.spaits@atd-pgs.com josh.fredlake@gcpv.com

Preheater Tower

• Prepares feed for the kiln

• Meal can be heated to 1500 F in 30 seconds

• Tons of material can be present at one time

• Material can be sticky and buildup or can suddenly plug

Monitoring The Process

• Kiln operation can effect build up

• Chemical composition can effect build up

• Monitoring or the process is critical

Detection of Buildup

• Pressure and temperature sensors can help determine a problem

• Nuclear density gauges work very well

• Tipping valves• Thermal Imaging

Accountibility

• Know who is on the preheater tower and where they are

• Control room log• Radio communication

Checking The Tower

• Regular inspections and follow up plans to address issues

• Identify Cleaning ports

Preheater Tower Inspection

• Notify control room• Proper PPE required• Exit Strategy• Situational awareness• Hazard recognition

Air Cannons

• Can be located almost anywhere

• Remotely activated• Low Energy (in

comparison)• Stationary

Cardox

• Very Powerful• Can be installed/used

online• Must be used by trained

personnel• Risk of refractory

damage

High Pressure Water

• Powerful spray can be directed as needed

• Can be used on line• Low operating cost• Versatility• Exposure hazards• Specially designed ports• Risk of refractory

damage

Air Lancing

• Low cost• High potential of blow

back• Low energy • Fugitive dust

Preheater Tower Plugs

• How do you know?– Nuclear density monitor– Pressure spike– Temperature spike– Tipping valve

• What next?– Shutdown– Secure the area

• Entire pyro processing line

Preheater Tower Plug

• Barricades warning signs, lights, signs

• Put on proper PPE• Locate the plug

– Small doors– Start at the bottom– Cardox is the best tool

Before A Kilns Start

• New cleanout ports needed?

• Check cyclones before preheat

• Check again before feed• Check again when feed

starts

Thank You!

Questions?