Process problems & trouble shooting in cement kiln
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Transcript of Process problems & trouble shooting in cement kiln
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RNB CEMENTS (P) LIMITED DEPARTMENT- PROCESS Presented By- Akshay Kumar Si DGM (Process)05/01/23 1
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WHAT ARE THE MAIN PROCESS PROBLEMS IN CEMENT PLANT?In Pyroprocessing- Cyclone Jamming Kiln inlet jamming Big clinker ball formation Coating formation in kiln Feed rushes and dusty kiln Snow man formation in cooler Red river in clinker cooler
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PROCESS PROBLEMS IN GRINDING Mill jamming Residue problems Blaine problems
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Cyclone JammingWhy cyclone jamming happens in Preheater?
Main Reasons-Insufficient suction due to low rpm in PH fan.Flap valve failure & blockage in material pipe.Refractory failure.High Iron % in Raw mix.High Sulfur % in fuel(i.e- coal)
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KILN INLET JAMMINGWhy kiln inlet jamming happens?
Main Reasons- High Iron % in Raw mix. High Sulfur % in fuel(i.e- coal)
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BIG CLINKER BALL FORMATION
Why big size clinker ball formation happens?
Main Reasons-High Iron % in Raw mix.High Sulfur (S)% in fuel(i.e- coal).Kiln running with slow rpm & % filling is more.High BZ temperature.% liquid is more.Higher % of Magnesia (MgO).
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HEAVY COATING FORMATION IN KILNWhy heavy coating formation in kiln?
Main Reasons- High Iron % in Raw mix. High Sulfur (S)% in fuel(i.e- coal). Kiln running with slow rpm & % filling is more. % liquid is more. Higher % of Magnesia (MgO).
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FEED RUSHES & DUST KILN
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Why Feed rushes and dust kiln happens?Main Reasons- High lime in Raw mix or high LSF.Very less % of liquid.High AR.Less iron% in raw mix.Blockage of hot meal due to clinker ball
occasionally.
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SNOWMAN FORMATION IN COOLER
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Why snowman is formed in cooler?Main reasons-Higher % of liquid, may be iron % is more in
raw mix so hot meal will be sticky and viscous.Shorter cooling zone; so may be shortage of
adequate quenching .Higher BZ temperature, may be due to short
flame.Failure of air blaster in cooler 1st grate if any.
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RED RIVER IN COOLER
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Why red river is shown in cooler?Main reasons-Uneven distribution of cooling air.Mis alignment of kiln & cooler.
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RED RIVER
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THANK YOU
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