LAFARGE PAKISTAN CEMENT

Kiln Audit Report-2015

Internal Audit Report
Process Team
4/8/2015

It is kiln audit report in which system is analyzed for its critical parameters clinker factor SHC &
SPC. To improve and optimize the system reliability and productivity.
Contents

Kiln Operation during trial…………………………………………………………………………..03

Specific Heat Consumption………………………………………………………………………….08

Specific Power Consumption…………………………………………………………………………10

Clinker Factor………………………………………………………………………………………………..10

System Gas Balance……………………………………………………………………………………… 11

Clinker Quality……………………………………………………………………………………………..11

Action Plans…………………………………………………………………………………………………..12

Prepared By Process Team Page 2

Kiln Audit-2015
Kiln drop test trial was started from 08-April-2015 at 09:00 AM to 09-April-2015 at 09:00 AM,
during 24 Hrs clinker weighment was done and net clinker weight was 7195 ton. During this trial
all the process measurements of entire pyroline system were taken and calculated the system gas
balance, heat balance, SHC, & SPC.

1.1 Kiln Operation during Trial

Kiln Operation mimics during the trial are as under

Kiln Operation mimic view

Prepared By Process Team Page 3

 Kiln ID Fans & GCT operational mimic view

Grate Cooler Operational mimic

Prepared By Process Team Page 4

 Kiln Feed Operation mimic

Grate Cooler & Cooler ESP mimic view

Prepared By Process Team Page 5

Kiln shell scam scanner view during trial

Prepared By Process Team Page 6

C5 A&B Temperatures and set point
During trial cyclone-05 A&B side temperatures trend with set point. It can be clearly seen that
temperatures peaks variations from its set points and loss of fuel. It needs to be fine control tune
for saving the fuel.

Prepared By Process Team Page 7

1.2 Specific Heat Consumption
The fuel used during the trial was South Africa Coal & Carbon powder, the ratio between the
being approximately 85:15 in the duration of trial for both Kiln and Calciner firing.

The raw coal feeders are running in proportion. Feeders A01 and B01 were utilized respectively for
South Africa Coal and Carbon powder. Total consumption of coal and Cp on both sides is

Total Coal towards Kiln: 322.2 ton

Total Coal towards Calciner: 601.8 ton

Prepared By Process Team Page 8

During trial the Pfisters error by LOW method is as below and these are the fuel tonnage by
hourly loss of weight method

Main PC
Description (ton) (ton)
-0.39 -0.13
-1.02 -0.12
-0.67 0.37
Hourly
Average (ton) -0.69 0.04
Day Average -16.64 0.96
Consumption
after Error 305.6 602.8

Specific heat consumption by Heat Balance Tool: 746 Kcal/Kg clinker

Prepared By Process Team Page 9

1.3 Specific Power Consumption
SPC up to Clinker: 62.88 Kwh/ton clinker

SPC up to Kiln area: 32.39 Kwh/ton clinker

1.4 Clinker Factor

Kiln Feed consumed during trial: 11524 ton

Clinker weighed: 7195 ton

Clinker Factor: 1.602

Clinker Factor by adding Kiln Feed scale error: 1.67

Raw mill dust was fed directly to the kiln through-out the trail. Kiln feed scale error requires
LOW calibration during shutdown.

Prepared By Process Team Page 10

1.5 System Gas Balance Sheet
Gas balance around the whole system is as below and false air across the Preheater is 33395
Nm3/hr or 14.8% which is higher than its target value <7%.

1.6 Clinker Quality

The free lime average during the trail was well within the plant operations target. The results
from the hourly laboratory results is listed as

Average Free Lime: 1.39%

Average Clinker Temperature: 158 C

Clinker Ltr Wight: 1210 g/Ltr

Clinker C3S: 58.53 %

Prepared By Process Team Page 11

1.7 Action Plans

Sr # Description Who When

1 Kiln Inlet analyzer remained out of order Ch Asif/Sohail 29-April-2015
throughout the trial, need to be improved its
reliability for accurate fuel mix control in kiln and
Calciner.
2 Kiln ID fans J1T06 & J1T12 sealing work is required Pervaiz Iqbal 28-April-2015
specially shafts sealing, expansion joints and casing
joints.
3 Preheater dust losses increased due C4-A bended Fahim-Ul-Ehsan Scheduled
dip tube and missed dispersion plates of C3B, C4A,
C2B which Affecting the cyclone efficiencies,
Shutdown
clinker factor and productivity, Need to be
maintenance work for improving KPI’s.
4 CO observed at the bottom cyclone exit gas up to Fahim-Ul- 29-April-2015
0.5%. This not only a safety hazard but also a waste
of fuel due to incomplete combustion. 0.1% CO=
Ehsan/Sajjadullah
4Kcal/Kg clinker, total waste is 20 Kcal/Kg clinker,
so need to be optimized the Calciner combustion
by low moisture fuel (AF), small particle size, and
good distribution of fuel w.r.t retention time. It
also needs the C05 gozze neck cleaning in
shutdown.
5 Mechanical flaps were missed and stuck at Cyclone Muhammad Scheduled
4 & 5 both A and B side, need to be placed Ali/Fahim-ul-
modified flaps with good sealing to stop the gases Ehan
Shutdown
reversible path and good material flow.

6 Preheater Cyclones temperature difference Muhammad Scheduled

indicating the poor heat transfer b/w material and
gases need to be placed all the missing dispersion
Ali/M Sajjadullah Shutdown
plates e.g. C3B, C4A, and C4B & C2B.

7 Need to be replacing the cyclone-04 A-side bended Muhammad Scheduled

dip tube because it effecting cyclone dust
separating efficiency and pressure drop.

Prepared By Process Team Page 12

 Ali/M Sajjadullah Shutdown

8 Older generation sluice flaps are source for false air Pervaiz Scheduled
entry in the system at stage 5, 6, 7 and 8. These are
to be replaced with new generation flaps for better
Iqbal/Sohail Shutdown
sealing.

9 Error in Kiln Feed scale -4.41%, need to be Ch Asif/Fahim- Scheduled

calibrating the LOW kiln feed weigh system in
shut down to remove the error.
ul-Ehsan-Sohail Shutdown

10 False air across the Preheater is 67427 Nm3/hr or Pervaiz 29-April-2015

14.8% which is higher than its target value <7%.
Need to be sealed properly the leakages points of
sliding gates, Calciner outlet expansion joint, Iqbal/Sohail
expansion joints, main doors, pocking holes and
eye holes for saving heat & power

11 Pfister online calibration errors are beyond the Ch Asif/Sohail 27-April-2015

acceptable limits specially Calciner side, need the
Pfisters reliability regarding calibration error
12 Cooler water spray flow meter is out of order, need Ch Asif/Sohail 29-April-2015
to be replacing it with reliable meter.

13 Required validation of LOW method of fine coal Ch Asif/Fahim- Scheduled

bin to calculate SHC. ul-
Ehsan/Sajjadullah
Shutdown

14 Kiln thermal loading is 5.54 MW/m2, standard is < Fahim-Ul- 29-April-2015

5.5 MW/m2, its need to be down by optimizing the
main side fuel
Ehsan/Sajjadullah

15 Needs to be fine control tune of cyclone-05 set Imran Haider 29-April-2015

point for saving the fuel.

Prepared By Process Team Page 13