Rotary Kiln

F.L.
SMIDTH
INSTRUKTIONE
R INSTRUCTIONS INSTRUCTION
S
INSTRUCCIONE 39461-24 1/66
ANWEISUNGE INSTRUCÕES
S
N
ROTARY KILN PLANT (ILC) CEMENT

Process instructions
EWEKORO, NIGERIA
Enclosures:
Sketch of heating and start-up procedures 39461-20-I
Text reference is made to the

following instruction manuals:
Flow sheet. Symbols 24771

Flow sheet. Item numbers, machine codes,
flow codes and signal codes 28581
Cross Bar SF 3 x 4 F
Oil and gas products, safety regulations 33011
Reference is also made to:
Flow sheet (FLS) 5.946010

_______________________________________________________________
Contents: Page:
1. GENERAL NOTES 3
2. CONSTRUCTION AND OPERATING PRINCIPLE 4
3. DRYING AND HEATING OF LINING PRIOR TO
START-UP 11
4. STARTING OF THE KILN PLANT 22
5. STOPPING OF THE KILN PLANT 31
6. OPERATION OF THE KILN PLANT 36
7. INTERLOCKINGS, PROGRAMMING AND CONTROL
CIRCUITS 44
8. PREVENTION OF FIRES AND EXPLOSIONS 55
9. BARRING 57
10. CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS
March/2000/LPAn/HLy
______________________________________________________________
F.L. SMIDTH & Co. A/S, VIGERSLEV ALLÉ 77
DK-2500 VALBY, DANMARK
39461-24
AND ALARM LIMITS 60
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 enumera-
tion 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 in-
struction 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.
39461-24
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 stated in the manual

are of a generalised character given that a range
of relevant factors of a specific or localised
nature is involved. 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.
39461-24
2. CONSTRUCTION AND OPERATING PRINCIPLE
2.1 Construction main elements
The kiln plant construction is schematically shown

in flow sheet 5.946010.
The clinker producing plant is a FLS-ILC Low NOx

(In-Line Calciner) installation incorporating the
following elements:
Kiln tube:
Diameter 4.15 meters
Length 64 meters
No. of supports 3
Inclination 4%
Size of kiln drive

and max. speed 1 x 500 kW, 3.6 r/min
1 pre-heater string with 4 stages
Size of cyclones in 2 of 4.8 m LP

pre-heater string 1 of 6.6 m LP
1 of 6.6 m LP
1 of 6.6 m LP
Two-stage calciner:
Low NOx part 3.0 m x 3.0 m
In-line part 7.2 m x 22.0 m
Grate cooler type SF 3 x 4 F Cross bar
Burner type Duoflex
Kiln feed system Elevator
Kiln exhaust gas fan type Oelde DHRVB –40.1600K

1800 kW
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2.2 Operating principle
The ILC Low NOx calciner kiln system is installed.

The calciner is placed in-line with the kiln riser
duct.
The system is a single string 4 stage ILC-kiln.
The combustion gas for the calciner is hot

atmospheric air drawn from the Smidth/Fuller Cross
Bar grate cooler through a separate tertiary air
duct mixed with the combustion gas from the kiln.
The Low NOx calciner, which is the bottom part of
the in-line calciner, is dimensioned for a gas
retention time of approximately 0.2 seconds, and
the in-line calciner is dimensioned for the
remaining 3.47 seconds. The calciner fuel is
introduced to the calciner in two locations, to the
reduction zone below the entrance point of the
tertiary air thus creating a sub-stochiometric
combustion zone for abatement of NOx formed in the
kiln, and the other in the inlet part of the
tertiary duct to the calciner.
The kiln and calciner are provided with a single

string pre-heater.
The kiln main burner is the new Duoflex burner. The

primary air consumption of this burner is lower as
compared with traditional burners.
The burner is provided with a gas burner for

heating-up of the kiln.
The raw meal feed - the kiln feed - is extracted

from the raw meal feed bin, and via a dozing valve
fed to the pre-heater by and air slide, an
elevator, another air slide with a split, and a
material sluice system.
The feed can be split and fed partly to the top

stage – two cyclones - and partly to the second
stage in order to achieve as high a gas temperature
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- 400C – as possible in order to optimise the

drying capacity in the raw mill. The fuel split
between the calciner and the kiln will be
approximately 59/41 when the kiln system is
operated as a ordinary 4 stage pre-heater and 60/40
when operated with feed split.
The filter dust from the Electrostatic Precipitator

(ESP) and dust from the Gas Conditioning Tower
(GCT) are fed to the CF silo system or directly to
the pre-heater.
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 exhaust fan.
Having passed 3 pre-heater stages, then the raw

meal reaches a duct split, where the raw meal flow
can be divided to the calciner vessel, and to the
riser pipe from the kiln. How the material
distribution is to be, will be supervised by a
thermal sensor placed in the reducing zone of the
Low NOx calciner. The thermal sensor is the tool -
which the operator can use - in order to optimise
the distribution of raw meal between the riser pipe
and calciner. Try to monitor the tendency of
coating formation in the riser pipe.
The above mentioned thermal sensor is to be placed

300 mm under the transition line between the
cylindrical part of the reducing zone and the
bottom zone of the calciner, just before the
tertiary air duct (seen in the horizontal level).
In the calciner vessel, approximately 50-60% 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 temperatures of more than 1000C,
which increases the combustion rate. The excess air
at the top of the calciner is foreseen to be
approximately 20% corresponding to an oxygen level
of 3% in the gas duct out of the calciner. These
39461-24
measures should ensure complete combustion of the

fuel applied.
The total amount of combustion air to the kiln

system is controlled by the ID-fan, whereas the
correct ratio between the combustion air to the
kiln and the calciner is assured mainly by the
relative dimensions between the riser pipe and the
tertiary air duct. It can further be adjusted by
operating the hoisting damper in the tertiary air
duct and the split of material between the riser
pipe and the calciner.
The combustion gas used in the calciner is a

mixture of hot atmospheric air ~900C drawn from
the grate cooler through the tertiary air duct, and
the kiln gases from the rotary kiln proper.
The material is leaving the top of the calciner and

is then passing onwards to the 4th 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 downstreams 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 to a temperature of maximum 85C above the
ambient temperature.
2.2.1 SF 3 x 4F cross bar cooler
The SF cooler has nearest to the kiln an inclined

grate (Controlled Impact System Air Distribution
Plates = CIS-ADP) which consists of 5 ADP´s wide
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and five rows long placed in a 16 degree sloped

step pattern in the longitudinal direction.
After this section the major 4 horizontal

compartments follow.
The cross bar sections are constructed in modular

form. Each module is four ADP plates wide and
fourteen ADP plates long. The modules are set side-
by-side and end-to-end.
The cooler is identified as a 3 x 4 unit, this is

three modules (12 plates) wide and four modules (56
plates) long.
The cross bar modules consist of an undergrate

chamber with the grate line at the top. Each set of
3 modules placed side-by-side forms an undergrate
compartment (UGC). Thus, there are 4 UGC´s in
total.
Each compartment is (12) air distribution plates

wide and fourteen rows long.
Each of the (4) UGC´s has a fan supplying cooling

air. The fans are K21, K31, K41 and K51. The CIS-
ADP has its own cooling fan K11.
The amount of air used for cooling in the CIS-ADP

and the first UGC sections is approximately equal
to the combustion air used in the kiln system. It
is anticipated that the first 22 rows of the cooler
are the so-called recuperation zone.
The rest of the cooler is referred to as the after

cooling zone.
The excess air is extracted from the outlet end of

the cooler and de-dusted in a dedusting cyclone
before it flows to raw mill to used for drying
purposes or to the gas conditioning tower.
39461-24
Each ADP in the cross bar sections, just as for the

CIS-ADP, is equipped with a MFR. The MFR-regulators
will open or close to provide a constant flow of
cooling air to each ADP plate. Importantly, the
mechanical flow regulators maintain the constant
flow of cooling air by compensating for changes in
the resistance of the clinker layer without adding
to the static pressure requirements of the fan. The
regulators will provide flow as long as cooling air
is available irrespective of the clinker bed
height, particle size distribution, temperature,
etc.
This gives the following advantages
- reduced dust circulation between cooler and

kiln
- improved heat recuperation
- no sealing air
- less excess air
The kiln hood is supplying combustion air for the

kiln and a separate out take at the first
horizontal UGC is supplying combustion air to the
tertiary air duct. The hood and the out take are
made so large that minimum clinker dust is recycled
to the kiln and calciner.
2.2.2 Gas treatment and distribution
Whenever the kiln is in operation and the raw mill

is stopped, the exhaust gases are treated in the
gas conditioning tower (GCT), i.e. this gas is
conditioned to a temperature at approximately 150C
which is acceptable to the common main ESP-filter.
The kiln gas is de-dusted in this filter before
released to the atmosphere.
The dust precipitated in the conditioning tower and

the kiln filter installation can be returned to the
homogenising silo or directly to the pre-heater.
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10
If the raw mill is in operation, then a major part

or in most situations all, of the kiln gases will
be used for drying purposes in the mill.
A part of the excess air from the grate cooler is

also used in the raw mill for drying purposes. All
the excess air from the grate cooler is pre-
dedusted in a de-dusting cyclone. After the excess
air fan, the excess air is joining the kiln gas
flow to either the raw mill or to the GCT.
A thermal sensor is placed after the de-dusting

cyclone. The thermal sensor, measuring the
temperature of the clinker dust, will start the
water injection in the cooler at 350°C. If the
clinker dust temperature rises to 450C then the
excess air fan stops. The clinker dust is returned
to the clinker transport.
The gasses, used and cooled in the raw mill,

together with the remaining mix of gas from the
kiln pre-heater and the clinker cooler passing the
GCT will as a combined cooled gas flow be de-dusted
in the main common ESP.
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11
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,

which provides information about heating and start-
up procedures in graphical form.
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 indicating 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.
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 testing under load, where
possible.
The trial run of the kiln should only comprise

of the kiln drive, without turning the kiln.
Trial run of machines loaded with material
should be performed over a prolonged period. For
39461-24
12
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
interlocking, 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 also 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.
5. Prior to the production of clinker, an

appropriate amount of correct quality raw meal
must be available. Raw meal for at least 1 day’s
consumption must be available.
6. Ignition burner, and the production burner

equipment must have been prepared for start-up.
7. The chemical laboratory at the plant should be

on standby 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 optimise the regulation of the

primary air volume in the kiln, for optimisation
of the flame structure, it is advisable to
measure the airflow supplied to the burner by
the primary air fan at different valve openings
and pressures. Hence, it is possible to
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13
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, the description in section 7 of inter-
locking, programming and control should be read
through.
CHECK
- that all tools and all foreign objects have been

removed from all kiln plant machines
- that potential coating formation has 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 motorised dampers function properly
- that the device for barring, with brake, is

ready to be operated
39461-24
14
- that all plant machinery has been lubricated in

strict accordance with directions given in
separate instruction manuals
- 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, gas analyser

and GCT 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.
Place the electrostatic precipitator in state of

readiness as directed in separate instruction
manual.
Start the heating elements at the bottom of the

chambers in the electrostatic precipitator 2-3
hours ahead of the anticipated start time of the
heating-up of the kiln.
Start the dust transport for kiln dust.
Start the rapping gear of the precipitators.
Place the gas analysis equipment in the kiln system

in state of readiness.
Mount the burner of the kiln and prepare the

ignition burner for operation. See separate
instructions.
Prepare the cooler and the clinker transportation

system. Place a portion of cold clinker or possibly
39461-24
15
crushed limestone on the SF coolers’ first grates.

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.
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 and pre-heater
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 in
instances 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 plant management and FLS are
needed, before any modifications are introduced.
For practical reasons, drying-out of the kiln

lining should not take place, until erection of
installation has advanced so far that the kiln can
be started in immediate aftermath of the drying-out
operation. The initial heating-up/drying-out
operation should stretch over a time period of
approximately 72 hours as shown in the enclosed
diagram.
In connection with subsequent kiln starts, the

heating period can normally be reduced to 24 hours,
39461-24
16
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.
3.3 Initiation of heating-up operation
See also the separate instruction manuals related

to the individual equipment mentioned.
Heating-up operation is started as follows:
3.3.1 Kiln and pre-heater
Check the pressure of the natural gas at the gas

firing station.
Check that the hydraulic system is ready for

start. The hydraulic pump of the thrust device and
the hydraulic pump of the kiln drive are started
automatically, please confirm.
Start the filter fan with closed damper.
Start the kiln exhaust fan at min. speed and closed

damper.
Gradually open the damper for the kiln exhaust fan

and the damper for the filter fan in order to keep
a constant under-pressure after the ID-fan. Start
the excess air fan, so that a slight negative
pressure in the kiln hood is obtained.
Start the primary air fan and close the primary air
damper to 0-10%.
Start the ignition burner.
Start the gas burner and open the gas valve for the
nozzle used for heating-up of the kiln.
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17
Check that the gas is ignited. If necessary, adjust

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
indication of kiln position gives alarm, barring
must be continuous until the alarm can be
cancelled. Continuous barring is also required if
the kiln is subject to cooling, for instance due to
heavy rain.
Soon after the start of the burner, the gas

analyser in the riser duct should be put into
operation.
Start the first two fans of the SF Cross Bar cooler

K11 and K21. In case of much material remaining in
the front of the cooler, this must be started to
move any accumulation of material. Start the nose
ring fan when the kiln has reached a temperature
where continuous barring is necessary.
Set the air volume in manual mode to set points of

approximately 25-35% r/min for K11 and K21 and 15-
25% r/min for the remaining fans, when started.
Start the dust transport from the cooler de-dusting

cyclone.
Start the excess air fan for the cooler with closed
damper.
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18
Set the automatic negative pressure control in the

kiln hood to a set point of -0.2 mbar.
Open the hoisting damper in the tertiary air pipe

10-20%.
Regulate the kiln exhaust gas fan damper so an

oxygen content of 8-10% in the kiln inlet is
achieved. When the kiln has become more hot after
some hours this level can be reduced to 4-5%.
3.3.2 Air supply during the heating-up phase
During the heating-up period, the maximum amount of

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

for the combustion process.
It could be necessary to start K11 and K21 cooling

air fans and to start the excess air fan to be able
to control the negative pressure in the kiln hood.
Often, this would require that the oxygen content

indicated by exit gas analysis in the riser duct is
8-10%. When the kiln has become hotter after a
couple of hours, the oxygen content can be reduced
to about 4-5%.
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.
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19
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.
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 to ensure retention of

the supplied heat inside the kiln, as previously
mentioned.
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
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20
Inspect the kiln lining at regular intervals. The

lining in the burning zone must not be exposed to
fast and local overheating.
The lining temperature must not exceed 1000C.
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 400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.
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. However, in the event that an
alarm is tripped by the thrust device equipment
indicating the position of the kiln, the kiln must
be barred continuously until the alarm can be
cancelled.
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Continuous barring is also needed if the kiln is

subject 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. To ensure effective cooling
at the cooler inlet, it may be necessary to start
the first fans of the cooler, as previously stated.
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22
4. STARTING OF THE 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.
In this way the preheating is performed initially

by using gas as fuel and gradually as the system
becomes warmer, the gas flow is increased.
In this way the heating is continued using solely

gas as fuel.
The gas is ignited by the igniter gas burner and

the heating-up process continues until the desired
temperature profiles are achieved, as indicated
below. Gradually admit increased draught through
the kiln concurrently with increased fuel
consumption.
Start the transport lines for dust and clinker

after the kiln, if not already running.
Check that the dividing gate after the 2 nd lower

most cyclone is adjusted so all the raw meal is
directed to the riser pipe.
4.2 Starting of kiln main drive
Stop the barring drive, disengage the barring gear

and start the kiln main drive at the lowest speed.
Reduce the damper opening of the exhaust gas fan.
It is necessary to adjust the main burner fuel
flow, 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
exhaust gas fan.
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Please make sure that the damper opening is

adjusted to maintain sufficient suction in the kiln
hood and after the kiln pre-heater.
Start the clinker transport system, with clinker

crusher, and the cooler drives and fans (refer to
separate manual for the SF cross bar cooler).
4.3 Starting of kiln feed
When the temperature at the top of the 2 nd lower

most cyclone stage is about 750C, and assuming
compliance with the heating programme, as outlined
in the enclosure, is obtained, the kiln is ready to
accept feed material.
When feed is supplied to the pre-heater the dust

transport from the GCT is started, if not already
running.
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 is passing
through. The risk of plugging in the cyclones is
particularly 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 by the supervising
personnel to the control room in event that
plugging symptoms in cyclones are observed.
4.4 Establishing normal production rate
Perform the following operations in RAPID, but

CORRECT, sequence:
- The filter fan is started.

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- Start kiln exhaust fan.
- The control loop maintaining the underpressure

after the exhaust gas fan by regulating the inlet
damper of the filter fan is in automatic mode.
- Start the raw meal feed at a rate of 50% of

nominal feed to the pre-heater.
- Increase the draught level by opening the damper

for the exhaust gas fan.
- Start the dust transport.
- Increase the fuel rate accordingly.
- Increase the feed rate to 55% of full production,

with simultaneous increase in kiln speed to 1.75
r/min.
- Open the tertiary air damper 15%.
- Start the fuel supply to the calciner at minimum

rate. Increase the fuel rate step wise in order
to maintain the temperature of this lower most
stage of 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 425C.
The gas analysis after the pre-heater will

typically indicate an oxygen level of 6-8% during
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start-up. However, the oxygen level should be in

the range of 3-5% at the kiln inlet.
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 3.25 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
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 3-5 hours.
4.5 Starting and operation of the grate cooler
Se also separate instruction manual.

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4.5.1 Cooler operation
The two prime objectives of the grate cooler are as

follows:
A. To cool the clinker to a temperature which

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

cross-bar movement is started stepwise with the
increasing material flow from the kiln.
Start the clinker crusher and the clinker conveying

system after the cooler.
Gradually as the production increases, the cooling

air will increase. Also the cross-bars must be
maintained in operation more frequently, and,
eventually, the cross-bars must be maintained in
continuous operation. An interlock is applied
between the cross-bar and the kiln drive, which
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means that the cross-bar must be in operation

before the kiln drive can be started. This
interlock can be overruled during the heating-up
period.
The overall target concerning a clinker bed is a

bed with a thickness of 500 mm, and a uniform flow
of clinker across the entire grate area.
An adjustment of the cooling air volume to each

sector and the cross-bar speed is needed as
outlined below in order to meet the following
criteria:
1. A uniform clinker bed of 500 mm on the grates.
2. A differential pressure across the first grate

sectors of ~80 mbar.
3. More air is supplied to areas with fine clinker

and less air to sectors with coarse clinker. The
MFR´s regulates this airflow.
4. At the discharge point of the cooler, the

clinker temperature should be kept as close to
the designed temperature as possible, in order
to protect the subsequent clinker transport
system and clinker storage facilities.
5. Maintenance of a negative pressure of 0.1-0.3

mbar in the hood between the kiln and cooler.
After the kiln has been run up to full production

capacity, the secondary air temperature to the kiln
will typical be ~1100C.
The grate plate temperature in the front of the

cooler must normally be less than 75C. Otherwise,
an adjustment of the cooling air volume is needed.
The amount of cooling air should be the maximum

possible without making the clinker bed unstable.
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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 is fed to
the pre-heater. However, the following interlocking
must be fulfilled:
- Kiln main burner in operation with exhaust fan

in operation.
- Kiln main drive in operation.
- The temperature in the lower most cyclone stage

must be higher than minimum (650C) and lower
than Max II (950C).
- The feed to the pre-heater is on.
- CO and CH4 content in the gases after the pre-

heater must not be higher than Max II (0.8%) for
more than 10 seconds, then the fuel rate to the
calciner must automatically be reduced by
minimum 20%. In order to cancel the alarm and
introduce full fuel rate to the calciner the O 2
content in the gases after the pre-heater must
be  5%.
If the above situation has occurred, the burner

is automatically changed to manual control mode.
The combustion gas/air to the calciner is

controlled both by adjustment of the exhaust fan
damper and by changing the position of the damper
in the tertiary air duct.
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The CO and CH4 content at the kiln inlet must be

maintained lower than 0.1% and at an oxygen level
between 3-4%.
Always increase draught before fuel rate is

increased to prevent formation of explosive gases.
The fuel to the calciner is entered in the very top

end of the riser pipe where the diameter is 3 m.
Shortly after the diameter widens to 6.80 m.
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 lower

most cyclone stage is maintained at approximately
890C, which would correspond to a degree of
calcination of 90-95%. This calcining temperature
should be maintained automatically by the PLC-
control system. Adjust the dividing gate after the
3rd cyclone in order to achieve correct distribution
of the raw meal between the riser pipe and the
calciner. The thermal sensor positioned in the
reducing zone of the calciner will supervise the
thermal conditions, related to the raw meal
distribution.
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).
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- Check whether a change of the kiln fuel is

needed.
(Depending of free lime level, litre weight and
torque).
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5. STOPPING OF THE 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 gas fuel to the calciner.
- Stop the kiln exhaust gas fan and close the

damper (automatically).
This automatically involves as follows:
- The kiln burner is stopped.

- The kiln feed is stopped.
- Note, the dust transport is stopped, if the
ESP-fan stops.
- 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 grates 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.
Where the stoppage period of the kiln extends over

a prolonged period of time, then all machinery not
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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.
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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 bar the ID-
fan, to close the fan dampers, to cool down the
burner pipe, to start the nose-ring fan for cooler
grate cooling, and to start the following fans, K11
and K21 of the cooler. 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 imme-

diately, the exhaust gas fan must be stopped,
wherefore 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

immediately, then there is a possibility of
restoring stable operation. If possible, the kiln
operation can be continued on the kiln main burner
alone. If the draught in the pre-heater is causing
drop-through of material, then the kiln has 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.
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5.2.4 Kiln feed failure
If the kiln feed cannot be restarted immediately,

it will be necessary to stop the kiln. Stop the
exhaust gas fan and follow the stoppage procedure
outlined in subsection 5.1.
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 an 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 400C.
An attempt can be made to maintain the kiln in

operation in order 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.
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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.
5.2.7 Failure of clinker transport
In 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, which

should 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.
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6. OPERATION OF THE KILN PLANT
6.1 General notes
The kiln performance is optimised 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 bottom cyclone,

ensuring a constant degree of calcination.
- The pressure at the kiln hood, this contributes

towards stable cooler operation, and stable
secondary and tertiary air conditions. The
damper of the excess air fan is regulated.
- The pressure after the exhaust gas fan for

stabilisation of draught, by regulating the
inlet damper of the filter fan.
- The operation of the cooler, with regulators

providing uniform cooling by adjustment of air
flows and cross-bar speeds.
- Ensuring that the temperature of the excess air

will not exceed 350oC.
- Ensuring that the temperature of the gas flow

from the GCT is maintained at 150C by
regulating of the water valve to the GCT.
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
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potential presence of coating formation or other

operational disorders recently encountered.
The amount of cooling air to the cooler is

automatically reduced by 20-40% of the actual flow
when the kiln stops.
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.
6.2.1 Exit gas analysis
The exit gas analysis constitute 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. CH4 (methane) or CO (carbon mono-
xide).
Presence of such gases may, under adverse

circumstances, cause fires or explosions and
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 an

added calorie consumption in the kiln of
approximately 40 kcal/kg clinker.
Any presence of unburned gases would indicate

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

combustion process.
As previously mentioned, the exit gases from the

pre-heater should contain 3-5% of oxygen. It is
possible to set a lower alarm limit for the oxygen
level. For example, a limit of 2% can be applied.
This alarm will inform the operator about the risk
of unburned gases in the exit gases.
After the pre-heater the CO-meter will continuously

monitor the CO level in the exit gases.
The alarm limits should be set as follows:
MAX I : 0.3% CO & CH4

MAX II : 0.8% CO & CH4
MAX III : 1.5% CO & CH4
MAX I will signal alarm. Then the operator must

make the necessary adjustments to the combustion
process.
MAX II will signal alarm and after 10 seconds
automatically reduce the fuel rate to the calciner
by minimum 20%. The calciner burner is then in
manual control mode. MAX II will also reduce the
voltage rate to the ESP. The voltage can
automatically return to the normal level 3 minutes
after the CO & CH4 level is  than MAX I.
MAX III will cause that the high tension will be
switched off, when this alarm has signalled.
An analyser fault (CO & CH4) and equipment alarm

will immediately switch off the rectifiers.
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.
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6.2.3 Temperatures after cyclone pre-heater
The exhaust gas fan are designed to withstand

operating temperatures up to 400C. However, short
term temperature rises up to 450C can be
tolerated.
The following alarm limits should be set:
MAX I: Giving alarm which is 25C above the

highest normal exit temperature, (410C).
MAX II: Causing alarm tripping and stoppage of the

exhaust gas fan at a temperature level
which is 40C above the MAX I level,
(450C).
6.2.4 Bearing temperatures
An excessive temperature in any fan bearing will

cause alarm tripping and automatic switch off the
fan. This applies to the exhaust gas fan, the grate
cooler excess air fan and the filter fan.
An excessive temperature in any supporting roller

bearing will only cause alarm indication, but the
operator must ensure that immediate action is taken
to remedy the situation, if kiln operation is
continued.
6.2.5 ESP-filter
The operating temperature of the filter must never

exceed the maximum temperature specified by the
supplier. A stop of the filter fan will cut the ESP
rectifiers.
The pyrometer at the inlet and outlet of the ESP-

filter casing are connected to electrical
interlocking, that will stop the filter fan in case
the temperature exceeds a certain maximum
temperature specified by the supplier.
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The gas conditioning tower will adjust the water

injection and in this way adjust the temperature
level of the gases coming to the filter to an
acceptable level. A stop of the exhaust gas fan
will stop the water injection to the GCT.
6.2.6 Blockage in the cyclones
Changes in the temperatures of the material at the

discharge point from the cyclones may be signs of
incipient - the beginning stages of a blockage in
the cyclones.
Negative pressure meters are installed at the

bottom of all the cyclones. 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. 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 blockage in a cyclone has been ascertained,

the operator must ensure that the kiln is stopped,
wherefore the blockage is removed manually.
Normally, air lances in appropriate lengths are

effective tools. Extreme caution must be exercised
during the clean-out operation.
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NOTE!
The temperature of the material caking formation

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.
A number of precautionary measures to be taken in a

cement plant are outlined in a separate instruction
manual.
6.2.7 Caking formation in the riser duct and kiln

inlet
It is possible to detect major caking formation in

the riser duct and kiln inlet by checking the
difference between the negative pressures at the
kiln outlet and at the lower most cyclone.
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 formation 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.
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6.2.8 Kiln position
The axial position of the kiln on the supporting

rollers is monitored by the thrust device. 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 thrust
device and/or the position of the supporting
rollers. A MAX I alarm must NOT be active before
start.
The MAX II alarm automatically stops the kiln drive

for prevention of damage to the smoke chamber seal,
kiln hood seal or thrust roller.
It may be necessary to check the thrust direction

of the supporting rollers. See separate instruction
manual.
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, but 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 which consists 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
importance.
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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,

but, generally, replacement is recommended in case
the thickness of bricks has been reduced to half
the original size owing to wear.
Any damage to the lining involves risk that the

kiln shell will be overheated. Particularly the
kiln burning zone should be kept under continuous
supervision.
If the kiln shell temperature should rise to 400-

450C, the affected area must be cooled by means of
external fans.
In 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
450C.
Whenever access to the kiln is possible during a

stoppage period, the opportunity should be taken to
inspect the lining, so that appropriate time
schedules for replacement or repair can be worked
out.
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7. INTERLOCKINGS, 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, are

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.

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Examples:
- If the speed monitor of an air sluice does not

indicate any rotations, the motor for this air
sluice will stop.
- If the vibration level of the kiln exhaust gas

fan is high, the motor of this fan will stop.
- If the bearing temperature of the clinker crusher

is above the maximum temperature allowed, then
this 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 (CAUSE/EFFECT
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 motors.
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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).
The following programs are proposed:
1. CF silo
2. Kiln feed
3. Dust transport with conditioning
tower
4. ESP filter fan
5. Kiln exhaust gas fan
6. ESP control
7. Gas analysers
8. Kiln auxiliaries
9. Kiln drive
10. Device for barring
11. Kiln burner fans
12. Kiln burner
13. Calciner burner
14. Clinker transport system
15. Cooler excess air fan
16. Cooler drive
17. Cooler fan CIS-section
18. Cooler fan Compartment 1
The following equipment can be operated

individually:
Fan dampers.
Changeover gates and dividing gates.
Position of valves - gas valves and feed valves.
Motors with speed regulation, such as kiln drive
and cross-bar drives.
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7.3 Comments to programs
For details of 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.
1. CF silo
Conditions to be fulfilled before start:

The blowers and the silo extraction sequence can
be started at any time.
Conditions to be fulfilled in order to produce:

The de-dusting of the CF silo must be in
operation. The extraction sequence will be
stopped whenever the kiln feed hopper reaches
maximum level.
2. Kiln feed

The air compressors are in operation or ready for
operation.

Same as for start.
The exhaust gas fans must be operational.
The transport direction must be defined before
the kiln feed is started, either to pre-heater or
recycling to the homogenising silo.
3. Dust transport from conditioning tower
Selection of which way to send the dust:

The dust from the GCT can be directed either to a
stockpile on the ground/to a truck, or together
with the filter dust to the homogenising silo via
the transport system.
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The transport direction must be selected, and the
subsequent transport equipment must be in
operation. The dust transport system for the
conditioning tower must have no alarms.

Program 2 in operation, can be bypassed during
heating-up period.
Same as for start.
NOTE, delayed stop for emptying.
4. ESP filter fan

Damper to be closed, and filter inlet and outlet
temperature lower than the maximum allowed.

Same as above.
5. Kiln exhaust gas fan

Pre-heater outlet temperature lower than MAX I.
Damper to be closed.
Conditioning tower operational, or ready for
start.
Program 3 is operational.

Damper to be closed.
Pre-heater outlet temperature lower than MAX II.
Conditioning tower operational.
Program 2 is operational, or is ready for start.
Program 3 is operational.
6. ESP control

Program 3,4 & 5 in operation. Program 5 can be
cancelled during heating-up period. Program 12 in
operation if selected, or not selected.
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No alarm from the gas analyser system

No CO-alarm from the gas analyser.

Same as above.
7. Gas analysers

availability of compressed air and cooling water.

Same as for start.
8. Kiln auxiliaries

None.

None.
9. Kiln drive

Program 8 in operation or in “no alarm” status
Device for barring disconnected.
No alarm for kiln position.
Cooler cross-bar drive in operation.
(These interlocking can be bypassed during kiln
start-up).

Program 8 in operation or in “no alarm” status
Device for barring disconnected.
No MAX II alarm for kiln position.
Cooler cross-bar drive in operation or not
stopped for more than 3 minutes.
Cooler fan CIS-section and compartment 1 are in
operation.
39461-24
50
10. Device for barring incorporated in the

hydraulic system drive

Main kiln drive stopped.

Main kiln drive stopped.
11. Kiln burner fans

None

Once the kiln burner -program 12- has been put
into operation, then the emergency fan must start
automatically when the primary air fan stops.
12. Kiln burner

Rectifiers of the ESP must NOT be in operation.
Kiln exhaust 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 fans in operation is
allowed. However, when the fan have been started,
this special interlocking is automatically
cancelled.
Primary air fan in operation -program 11.
The oxygen content in the pre-heater exit gases
must be  5% and the CO & CH4 < MAX 1.
Analysers for CO & CH4 must not be in test mode.

Same as for start up.
13. Calciner burner

Kiln burner in operation -program 12.
Kiln exhaust gas fan in operation -program 5.
39461-24
51
Kiln feed is on program 2.

CO & CH4 < MAX I.
O2  5%.
Gas analyser must be in operation, not in test
mode, and no alarms.

Same as for start. However, if the calciner
temperature rises above MAX II or the CO & CH4
level, or one of them, after the pre-heater has
been above MAX II (0.8%) for more than 10
seconds, then the fuel rate to the calciner is
reduced by minimum 20%.
14. Clinker transport system
Transportation selected to either,
A. 200 t Clinker hopper

B. Off standard clinker open pile
NB. From A the clinker are transported to the

existing factory.

Clinker storage area must not be full.
Transportation route defined.

Same as for start.
15. Cooler excess air fan

Damper is closed. Main ESP inlet temperature
below MAX I.

Same as for start. Damper is closed.
The water injection will start when the tem-
perature of the excess air will pass 350oC. The
cooler excess air fan will be switched off
automatically at temperatures above 435C
39461-24
52
provided the cooler excess air fan is in

operation.
NOTE that the exhaust gas fan will stop when the
excess air fan stops.(To avoid excess outlet of
hot dust).
16. Cooler drives
(Please also refer to cooler instruction manual)

Clinker crusher and clinker transport are in
operation - program 14 in operation.
Cooler fans for the SF cooler are in operation,
programs 17, 18, 19, 20 and 21.
Air flow  60% of nominal.

The clinker transport after the cooler is in
operation or stopped for a period of maximum 15
minutes.
Clinker crusher is in operation.
Cooler fans for the SF cooler are in operation.
17. Cooler fan CIS/ADP section

Cooler excess air fan in operation.

Cooler excess air fan in operation.
If cooler excess air fan stops, then the flow
from the cooler fans must quickly be reduced to a
minimum level in order to avoid dust emission.
During start-up special permission can be given
for operation of the fans individually.

Same as for program 17.
39461-24
53


Same as for program 17





7.4 Control circuits
The following control circuits are foreseen.
1. The kiln feed is synchronised with the kiln

speed.
2. The fuel to the kiln burner is maintained to a

pre-set value.
3. The inlet temperature of the ESP filter is

controlled by conditioning the gas mixture from
pre-heater, raw mill circuit and grate cooler
excess air, in the gas conditioning tower.
39461-24
54
4. The temperature in the top of the lower most

cyclone controls the fuel supply to the calciner
burner.
5. The pressure after the kiln ID-fan is kept

constant by regulating the inlet damper of the
filter fan.
6. The pressure in the kiln hood is maintained by

the speed of the cooler excess air fan.
7. The cross-bar speed of the SF cooler is

controlled by the under-grate compartment
pressure under the first module(Compartment 1).
8. The cross-bar speed will be increased if the

power demand measured is above a certain limit.
9. For all cooler fans the measured air flow will

be reduced by 20-40% when the kiln stops.
10.The temperature of the excess air is maintained

below 350oC by the water injection system.
7.5 Cause/effect diagram
In section 10, cause and effect diagrams are shown.

All instrumentation related to process parameters
are listed. The handling and the use of these
signals are presented.
39461-24
55
8. PREVENTION OF FIRES AND EXPLOSIONS
8.1 General precautions
On no account must soot nor combustible, incomplete

combusted exit gases, be allowed to accumulate in
the kiln, the cyclones, the flue ducts etc. since
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, the kiln must be
lit in the normal manner, using the igniting
equipment, heating-up of the kiln, 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, i.e. with a nozzle velocity for the
primary air of about 160 m/s.
4) Burners must always be started at minimum fuel

rate.
5) Never increase the fuel supply rate too suddenly

or excessively at any one 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.
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. Whenever working with
fuels, these risks are present. Although measures
39461-24
56
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 at least one of the gas
analysers after the pre-heater is in operation
without any unit alarms or without analyser fault
on the CO & CH4 channel.
Further, it is conditional for the calciner burner

operation that the CO & CH4 level has not been over
MAX II (0.8% CO & CH4) for more than a few seconds
(less than 10 seconds). In this case the fuel rate
must automatically be reduced by minimum 20%. The
rectifiers are switched off immediately when MAX
III alarm is activated.
If the CO & CH4 level is above MAX I (0.3% CO &

CH), 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.
8.3 Fuels
For precautionary measures to be taken when using

gas, see separate instruction manuals.
Reference is also made to the regulations of the

local authorities.
39461-24
57
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 following guidelines apply to a situation where

the kiln is stopped in a hot condition and is to be
barred:
1. As long as the kiln is hot, the barring ope-

ration 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.
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
this installation is required, before the kiln is
restarted on the main drive.
39461-24
58
9.2 Barring programmes
The barring programmes are divided into stages of

100 deg. rotation. This is done to ensure
variations in the position of the kiln during
standstill.
9.2.1 Barring during drying of the lining before

initial start-up
0 - 24 hours: About 100 degrees every 30 minutes

68 - 72 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-state

kiln

20 - 24 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.
9.2.3 Barring during stoppage of the kiln
0 - ½ hour : Continuous barring

½ - 24 hours: About 100 degrees every 15 minutes
48 - hours: Bar as required, if some of the
conditions mentioned in subsection
9.1 make it necessary
39461-24
59
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 may
still 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. Therefore, the kiln may 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.
39461-24
60
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
a 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 too will have to be adjusted according to
local conditions, as factors like the lubrication
oil selected, the ambient temperature, etc. will
affect the values.
In every single case, the mechanical and/or the

electrical departments must 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.
SEE ALSO INSTRUCTION MANUAL 28581 AS WELL AS FLOW

SHEET FOR CODES AND INSTRUMENTATION.
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 range of instrument.
39461-24
61
EWEKORO
KILN PLANT
NIGERIA
UNIT
Storage silo % + + x%
Total feed t/h 195* + 135 5)
Feed bin % + x%
ESP inlet C 105 a) 1) 2)
Temperature a)
Exhaust fan kW X +
C 360 450 2)
3)
Pre-heater mbar 43 +
out
4-stage C 365 + 425 450
Operation O2% 4 + 2.0
CO% 0.1 + 0.3 0.8 1.5
4) 4)
CH4% 0.0 + 0.3 0.8 1.5
4) 4)
NOx X +
1) The inlet temp. is controlled by the conditioning temperature.
2) If inlet temp. is above MAX II, then exhaust gas fan must stop.
3) Max II temperature stops exhaust gas fan.
4) MAX II CH4 & CO-alarm reduces the fuel rate by 20%, and reduces the
voltage of the rectifiers.
MAX III switches off the rectifiers
5) Manually controlled, however, synchronised with kiln speed.
* Dry feed
C1 = Top temperature in cyclone.
C2 = Bottom temperature in cyclone.
Mbar1 = Pressure in cyclone roof.
Mbar2 = Pressure in cyclone bottom.
39461-24
62
EWEKORO
KILN PLANT
NIGERIA
UNIT
Cyclone 1 C1 365 425 450
Cyclone 2 C1 585

C2 580
Mbar2 34 15
Cyclone 3 C1 775
C2 770
Mbar2 27 10
Cyclone 4 C1 890 750 980 6)
C2 870
Mbar1 20
Mbar2 20 8
6) Temperature controlled by fuel feed rate.
EWEKORO
KILN PLANT
NIGERIA
UNIT
39461-24
63
Tert. Air C 900 +

Mbar 10
Calciner C 1100
Reducing zone
Tert. Damper Poss. X +
Kiln inlet Press 3 +
O2% 3 + 1.0
CO% 0.1 + 0.3 0.8 1.5
CH4% 0.0 0.3 0.8 1.5
NOx x
Kiln drive Speed 3.2 + 5)
Roller Temp. a) a)
Bearings
Kiln position Poss. + a) a) a) a)
Kiln hood Mbar 0.3 7)
C 1100
Grate temp. C X a)
Cross-bar 1 Amps. X a) 8)
Cross-bar Speed X 11)
1,2,3
5) Manually controlled, however, synchronised with
kiln feed.
7) Cooler excess air fan speed control.
8) Cross-bar 1 speed control to prevent overload.
11) Cross-bar speed maintains Compt. 1 under-grate
pressure.
39461-24
64
EWEKORO
KILN PLANT
NIGERIA
UNIT
Primary air Mbar X c) + 12)
KW X
Under-grate Mbar 95 + 11)
Compartment 1
Pressure
Cooling fan Mbar 100 + +
K11 3
M /mi 410 350 + 13)
Amps. X
K21 3
M /mi 1015 865 + 13)
Amps. X
K31 3
m /mi 495 420 + 13)
Amps. X
K41 3
m /mi 680 580 + 13)
Amps. X
K51 m3/mi 680 580 + 13)
Amps. X
12) Pressure could be controlled by inlet damper.
13) Flow regulation by inlet damper control and
motor frequency control.
39461-24
65
EWEKORO
KILN PLANT
NIGERIA
UNIT
Gas to Kiln Nm3/h 4730 + 4) +
^
Gas to Calc. Nm3/h 6700 + 4) + 6)
# 7030
Excess air % X 7)
Fan Amps. X
Excess air a) a) 14)
Temperature C 270 400 435 450
Clinker crush Amps. X
Clinker buckt Amps. X
Conveyor
Drag chain Amps. X
^Gas fuel consumption at 3300 tpd
#High gas fuel consumption at 3300 tpd + feed split.
14) MAX 3 stops excess air fan.
39461-24
66
EWEKORO
KILN PLANT
NIGERIA
UNIT
Below measurements are used for protection of the
Individual equipment.
Speed monitor
Motor bearing temperature
Motor winding temperature
Bearing temperature
Pressostate (air pressure control)
Gas 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---

Rotary Kiln

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F.L.

ROTARY KILN PLANT (ILC) CEMENT

Sketch of heating and start-up procedures 39461-20-I

Text reference is made to the

Flow sheet. Symbols 24771

Reference is also made to:

Flow sheet (FLS) 5.946010

AND ALARM LIMITS 60

The present instruction manual is dealing with the

Consequently, if a situation should arise, the

SEPARATE INSTRUCTION MANUALS

The plant under review also comprises several other

This manual is intended as a reference guide, which

The majority of the directions stated in the manual

The manual must be regarded as a tool for

In this manual it is a fundamental condition that

This manual should be thoroughly studied prior to

2. CONSTRUCTION AND OPERATING PRINCIPLE

2.1 Construction main elements

The kiln plant construction is schematically shown

The clinker producing plant is a FLS-ILC Low NOx

Size of kiln drive

1 pre-heater string with 4 stages

Size of cyclones in 2 of 4.8 m LP

Grate cooler type SF 3 x 4 F Cross bar

Burner type Duoflex

Kiln feed system Elevator

Kiln exhaust gas fan type Oelde DHRVB –40.1600K

2.2 Operating principle

The ILC Low NOx calciner kiln system is installed.

The system is a single string 4 stage ILC-kiln.

The combustion gas for the calciner is hot

The kiln and calciner are provided with a single

The kiln main burner is the new Duoflex burner. The

The burner is provided with a gas burner for

The raw meal feed - the kiln feed - is extracted

The feed can be split and fed partly to the top

- 400C – as possible in order to optimise the

The filter dust from the Electrostatic Precipitator

The pre-heater is operating as a counter current

Having passed 3 pre-heater stages, then the raw

The above mentioned thermal sensor is to be placed

In the calciner vessel, approximately 50-60% of the

measures should ensure complete combustion of the

The total amount of combustion air to the kiln

The combustion gas used in the calciner is a

The material is leaving the top of the calciner and

Due to the inclination and rotation of the kiln,

Clinkerization - clinker formation - takes place

The clinker formed enters the grate cooler for

2.2.1 SF 3 x 4F cross bar cooler

The SF cooler has nearest to the kiln an inclined

and five rows long placed in a 16 degree sloped

After this section the major 4 horizontal

The cross bar sections are constructed in modular

The cooler is identified as a 3 x 4 unit, this is

The cross bar modules consist of an undergrate

Each compartment is (12) air distribution plates

Each of the (4) UGC´s has a fan supplying cooling

The amount of air used for cooling in the CIS-ADP

The rest of the cooler is referred to as the after

The excess air is extracted from the outlet end of

Each ADP in the cross bar sections, just as for the