Operator Development

Kiln Control Best Practices

K i ln S tart-u
rt-up
p P rocedures
rocedures
P res ent
entation & Ins tructor Notes
Notes
BP Objectives
Kiln Start-up Procedures
 Master procedure for heating up the pyro-line
 s tandard, safe & efficient manner
 minimum transition periods

 no failed s tart-ups

 as s ure the integ rity of equipment & refractory

 s tay in environmental compliance

 rapid compliance with clink er quality objectives

Each plant must customize to the specific

characteristics of their equipment & develop
more detailed checklists & SOP’s

Pyro-processing: Kiln Control 2

BP Deliverables

 Preheat curve & kiln turning schedule

 adjus tment for different refractory work
 Procedure to reach full production
 Recommended record keeping
 Start-up after short shutdowns (<48 hrs)
 Information required for customization of SOP
 Indicators required

Pyro-processing: Kiln Control 3

Kiln Start-up Procedures
Learning Objectives

 At the end of this session you should be:

 familiar with the s tart-up B P
 able to lis t the major s teps involved

 name the required proces s indicators

 able to explain the cus tomization differences with

 your plants S OPs

Pyro-processing: Kiln Control 4

Kiln Start-up Procedures

 End-users: Production Operators/technicians

 Content:
 C hecks prior to s tart-up
 K iln preheat preparation: B urner pipe, R efractory
 K iln Preheat schedule:
 Parameters to monitor
 Tire Creep
 Turning schedule
 Start-up Process data sheet
 Kiln lining preheat schedule
 Feeding raw mix
 What to do in case of deviations
 S tart-up Pos t-audit
Pre Start-up Checks

 Dry run & complete check sheets

 Feed S ys tem
 Cooler & Clinker Handling

 ID fan

 Coal Conveying S ys tem

 K iln B ag house E S P

 Pre-heat s ys tem

 Pre-heater tour

 B urner P ipe alig nment

 Common & auxi liary equipment

Check sheets should include room for comments

& assigned responsibility
Pyro-processing: Kiln Control 6
Feeding of Raw Material

 Raw material feed “ON”

 when burning zone is ready

 Start of feed and arrival in sintering (burning) zone is

critical to tyre creep
  fuel supply mus t be increas ed

 compens ate for heat abs orbed by raw material

 Close attention to tyre slip

 if s lip ceas es, counter meas ures must be taken

 Limited feed may be introduced prior to optimal

temperature to assist coating

Pyro-processing: Kiln Control 18

Start-up Post Audit

 Analyze deviations from the planned schedule to

continuously improve operational performance
  production coor dinator, kiln coach & operators

 identify reas ons for deviations

 make joint recommendations

 corr ect SOP s and circulate among all operators

 Develop a table of variances and explanations

Use our collective knowledge & experience to

become the world’s best cement producer!

Pyro-processing: Kiln Control 20