Professional Documents
Culture Documents
Kiln Audit Training Details PDF
Kiln Audit Training Details PDF
ATC
SMO / 02/09/2008 - 1
Kiln Audit - ATC
• Benchmark
• Past performance
• Supplier guarantees
• Type of equipment / system
• Anticipated performance
SMO / 4-Jun-2007 - 2
Kiln Audit - ATC
SMO / 4-Jun-2007 - 3
Kiln Audit - ATC
• Kiln
• Size (Diameter x Length)
• No. of supports (2 / 3)
• Slope (3.5 / 4%)
• Maximum speed, rpm
• Lining thickness, mm
• Installed motor power
SMO / 4-Jun-2007 - 4
Kiln Audit - ATC
SMO / 4-Jun-2007 - 5
Kiln Audit - ATC
• Miscellaneous
• Fuels used (with proportions, way of preparation)
• Sketch showing gas & material flows
• Present performance (Production, heat / power consumption)
• Present constraints
• Sketch indicating measurement / sampling point locations
• Modifications done w.r.t. original supply (e.g. changed to
Lafarge Burner, installation of Hurrivanes in preheater cyclone)
SMO / 4-Jun-2007 - 6
Kiln Audit - ATC
• Fuel, as fired
• Moisture
• Fineness (Residues on 90 and 212µ)
• Temperature
• Heat value
• Proximate analysis
• Ultimate analysis
SMO / 4-Jun-2007 - 7
Kiln Audit - ATC
• With in Process
• Bottom stage exit material
• LOI
• Temperature
• Chemical analysis (incl. minor oxides)
• Un-burnt Carbon
SMO / 4-Jun-2007 - 8
Kiln Audit - ATC
SMO / 4-Jun-2007 - 9
Kiln Audit - ATC
• Calciner exit
• Temperature
• Static Pressure
• Gas analysis (O2, CO, CO2, SO2, NOx)
• Each cyclone inlet and outlet
• Temperature
• Static pressure
• Gas analysis (O2, CO, CO2)
SMO / 4-Jun-2007 - 10
Kiln Audit - ATC
SMO / 4-Jun-2007 - 11
Kiln Audit - ATC
• Secondary air
• Temperature
• Kiln hood
• Pressure
SMO / 4-Jun-2007 - 12
Kiln Audit - ATC
• Surface temperatures
• Kiln shell
• All components of preheater (cyclones incl. risers, material pipes, smoke chamber,
kiln riser pipe, calciner vessel)
• Tertiary air duct
• Kiln hood
• Cooler walls
SMO / 4-Jun-2007 - 14
Kiln Audit - ATC
SMO / 4-Jun-2007 - 15
Kiln Audit - ATC
SMO / 4-Jun-2007 - 16
Kiln Audit - ATC
• Look for sources of air leakages / false air entry in to the system
• Monitor safety
SMO / 4-Jun-2007 - 17
Kiln Audit - ATC
• Air Distribution
• Compare cooler flows w.r.t. recommended
SMO / 4-Jun-2007 - 18
Kiln Audit - ATC
• KFUI <14
• CaO standard deviation < 0.11
SMO / 4-Jun-2007 - 19
Kiln Audit - ATC
• Power Consumption
kWh/t cli.
• Preheater fan 6.5
• Cooling air fans 5 – 5.2 (beam aeration w/ fixed speed fans)
• Cooler vent fan 0.6 – 0.8
• Cooler Performance
Conventional Beam aeration Modern (cross bar)
• K-Factor > 1.5
• Recovery ratio > 70
• Sp. cooling air (Kg/Kg cli.) 3.0 2.5 – 2.6 2.3
SMO / 4-Jun-2007 - 20