Professional Documents
Culture Documents
70002363-1 1/65
ANWEISUNGEN INSTRUCCIONES INSTRUCÕES
Enclosures:
Contents: Page:
1. GENERAL NOTES 3
2. CONSTRUCTION AND OPERATING PRINCIPLE 4
3. DRYING AND HEATING OF LINING PRIOR TO
START-UP 8
4. START OF KILN PLANT 21
5. STOP OF KILN PLANT 29
6. OPERATION 34
7. INTERLOCKING, PROGRAMMING AND CONTROL
CIRCUITS 42
8. PREVENTION OF FIRES AND EXPLOSIONS 51
9. BARRING 54
10. CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS
AND ALARM LIMITS 57
August/2005/RLA/HLy
______________________________________________________________
NOTE!
3
1. GENERAL NOTES
4
2. CONSTRUCTION AND OPERATING PRINCIPLE
Calciner:
In-line calciner vessel 7.2 m x 27.6 m
5
2.2 Operating principle
6
temperatures of ~1000°C, which increases the
combustion rate. The excess air in the calciner is
foreseen to be approximately 30% corresponding to
an oxygen level of ~2.5%. These measures should
ensure complete combustion of the fuel applied.
7
The extended kiln hood is supplying combustion air
for the kiln and supplying combustion air to the
calciner through the tertiary air duct. The kiln
hood and the outtake are designed so that the ma-
jority of the clinker dust stays in the cooler, and
only a minor part of the clinker dust is recycled
to the kiln and calciner.
8
3. DRYING AND HEATING OF LINING PRIOR TO START-UP
3.1.1 Personnel
3.1.3 Preparations
9
Trial run of machines loaded with material
should be performed over a prolonged period, for
instance for 24 hours with the kiln feed in
circulation.
10
the primary air fan at different valve openings
and pressures. Hence it is possible to ascertain
what valve position should be used during
operation.
NOTE!
CHECK
11
- 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)
12
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.
13
3.3 Initiation of heating-up operation
3.3.1 Phase 1
14
above, should be in place in order to prevent heat
to escape, flowing via the kiln tube.
Start the excess air fan and open the damper of the
excess air fan.
3.3.2 Phase 2
15
Start the transport in the bottom of the GCT and
set the water injection system in a ready for start
mode.
16
3.3.3 Phase 3
Start the primary air fan and close the primary air
damper to 10%.
17
continuous until the alarm can be cancelled. Con-
tinuous barring is also required if the kiln is
subjected to cooling, for instance due to heavy
rain.
18
However, an adequate air surplus must be present
for the combustion process.
Start the cooling air fans and the excess air fan
to be able to control the negative pressure in the
kiln outlet.
19
Kiln lining
20
Bearings for supporting rollers
Barring
Clinker transport
21
4. START OF KILN PLANT
22
4.3 Starting of kiln main drive
23
24
for clinker formation, the kiln system will
gradually be heated.
25
4.5 Starting and operation of the grate cooler
26
Gradually as the production increases, the cooling
air will increase. Also the cooler grates can from
early beginning be maintained in continuous
operation. An interlock is applied between the
first grate drive and the kiln drive, which means
that the grate drive must be in operation before
the kiln drive can be started. This interlock can
be overruled during the heating-up period.
27
- If the CO and/or CH4 content in the gases after
the pre-heater rises to MAX I level 0.5% then
the operator must take action to increase the
amount of combustion air. If the CO and/or CH4
concentration still increases to Max II (0.9%)
level for more than 10 seconds, then the fuel
rate to the calciner must automatically be
reduced by minimum 20%. If the above situation
has occurred then the burner is automatically
changed to manual control mode. If MAX III level
has been reached 1.2%, then the interlocking
will force the fuel for calciner and main burner
to a preset minimum.
28
temperature should be maintained automatically by
the PLC-control system.
29
5. STOP OF KILN PLANT
30
Where the stoppage period of the kiln extends over
a prolonged period of time, then all machinery not
required for barring of the kiln and cooling of the
burner pipe must be stopped i.e.:
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.
31
5.2.1 Total power failure
32
5.2.5 Blockage of cyclones
33
5.2.7 Failure of clinker transport
34
6. OPERATION
35
6.2.1 Exit gas analysis
36
The alarm limits should be set as follows:
37
The following alarm limits should be set:
6.2.5 Filters
38
6.2.6 Blockage in cyclones
39
NOTE!
40
41
kiln burning zone should be kept under continuous
supervision.
42
7. INTERLOCKING, PROGRAMMING AND CONTROL CIRCUITS
7.1 Interlocking
- bearing temperature
- vibrations
- winding temperature
- minimum oil level
- speed monitors
- maximum material level, etc.
Examples:
43
Special interlocking
7.2 Programming
44
The following programs are proposed:
1) CF-silo
2) Kiln feed
3) Mill/kiln filter fan
4) Dust transport
5) Kiln ID-fan
6) Gas analysers
7) Kiln auxiliaries
8) Kiln drive
9) Device for barring
10) Kiln burner fans
11) Kiln burner
12) Calciner burner
13) Clinker transport system
14) Cooler excess air fan
15) Cooler drive
16) Cooler fans
Fan dampers.
Changeover gates and dividing gates.
Position of valves – gas valves and feed valves.
Motors with speed regulation, such as kiln drive.
45
1) CF-silo
2) Kiln feed
46
5) Kiln ID-fan
6) Gas analysers
7) Kiln auxiliaries
8) Kiln drive
47
11) Kiln burner
48
13) Clinker transport
49
During start-up special permission can be given
for operating of the cross bars to remove any
accumulation of material at the kiln outlet.
50
During start-up special permission can be given
for operation of the fans individually.
51
8. PREVENTION OF FIRES AND EXPLOSIONS
52
8.2 Precautionary measures relating to the burners
53
The test permission for analysers must be separated
in test permissions, one for each analyser. The
test mode must always be clearly indicated to the
operator.
8.3 Fuels
54
9. BARRING
55
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 the
installation is required, before the kiln is
restarted on the main drive.
56
9.2.3 Barring during stoppage of the kiln
9.3 Braking
57
10. CAUSE/EFFECT DIAGRAMS, OPERATING PARAMETERS AND
ALARM LIMITS
58
SHARGH CEMENT
KILN PLANT
IRAN
CF silo % + + x
Total feed t/h 256 + 4)
ID-fan kW x
r/min x
Preheater out mbar 49 + 70
5 stage °C 309 + 370 450
Operation A1 3.4 + 2.0
A2 0.0 + 0.5 0.9 1.2
1) 2)
A3 x +
A4 0 + 0.5 0.9 1.2
1) 2)
A1 = O2 % 1) MAX II reduces the fuel to the calciner by 20%.
A2 = CO% 2) MAX III fuel automatically set to preset minimum.
A3 = NOx ppm
A4 = CH4 %
70002363-1
59
SHARGH CEMENT
KILN PLANT
IRAN
Cyclone 1 T1 311 c)
Cyclone 2 T1 493
T2 488 c)
P2 34
Cyclone 3 T1 648
T2 643 c)
P2 29
Cyclone 4 T1 775
T2 765 c)
P1 27
P2 22 10
Cyclone 5 T1 890 + c) 920 980 3)
T2 870
P1 21
P2 18 10
Top of lower T 1000 750 820
part calciner
3) Temperature controlled by fuel feed rate.
T1 = Top temperature in cyclone.
T2 = Bottom temperature in cyclone.
P1 = Pressure in cyclone roof.
P2 = Pressure in cyclone bottom.
70002363-1
60
SHARGH
CEMENT
KILN PLANT
IRAN
61
SHARGH
CEMENT
KILN PLANT
IRAN
62
SHARGH CEMENT
KILN PLANT
IRAN
Speed monitor
Motor bearing temperature
Motor winding temperature
Bearing temperature
Pressostate (air pressure control)
Oil flow control
Oil level control
Oil temperature
Hydraulic oil pressure
Hydraulic oil temperature
Hydraulic oil level
---oOo---
70002363-1
63
°C
1000
900
TEMPERATURE
800
700
100
0
0 12 24 36 48 96 HOURS
0 12 24
70002363-1
64
°C
1000
900
TEMPERATURE
800
700
Tertiary Air Duct.
600 and Riser Pipe
500
400
300
200
100
0
0 12 24 36 48 96 HOURS
0 12 24
70002363-1
65
S H A R G H C E M E N T - IR A N
P R E H E A T IN G / D R Y IN G - O U T , P H A S E 3
K IL N S T A R T W IT H C A L C IN E R , T Y P E IL C
°C START FEEDING
1000
900 Stage 5.
TEMPERATURE
800
700
600
500
400
300 Stage 1.
200
100
0 2 4 6 8 10 12 14 16 HOURS
0 12 24 36 48
8 16 24
100
Kiln feed.
90
FEEDING / FUEL
80
70
60 Fuel to calciner.
50
Fuel to kiln.
40
30
20
10
0 2 4 6 8 10 12 14 16 HOURS
0 12 24 36 48
8 16 24
100
Kiln Speed
90
KILN SPEED
80
70
2-3% O2 Kiln Outlet
60
50
40
Tert. air damper
30
3-4% O2 Kiln Outlet
20
10
0 2 4 6 8 10 12 14 16 HOURS
0 12 24 36 48
8 16 24