Rotary Kiln Plant: Operating Manual en-D000091-4C-4V

Operating manual
en-D000091-4C-4V
Rotary kiln plant
Code word
SAMANFA
Order no.
D000091
POLYSIUS Order Code (POC)

4C - 4V
Operating manual Contents
Rotary kiln plant
Contents
1 Technical Data......................................................................................... 1-1
1.1 Technical data of the plant........................................................................ 1-1
1.2 List of machines ........................................................................................ 1-2
2 Safety ....................................................................................................... 2-1
3 Components and mode of functioning ................................................. 3-1
3.1 Process technological functions of the plant components........................ 3-1
3.2 DOPOL® preheater ................................................................................... 3-2
3.3 Calciner ..................................................................................................... 3-4
3.4 Rotary kiln ................................................................................................. 3-5
3.5 Reciprocating grate cooler REPOL® ....................................................... 3-10
3.6 Exhaust gas and cooler exhaust air conditioning ................................... 3-17
3.7 Flaps and dampers in the kiln plant ........................................................ 3-18
3.8 Clinker storage and conveyance............................................................. 3-19
3.9 Electrical interlock ................................................................................... 3-20
3.10 Operating modes .................................................................................... 3-20
3.11 Control loops in the kiln plant.................................................................. 3-21
4 Commissioning ....................................................................................... 4-1
4.1 Checks prior to commissioning ................................................................. 4-1
4.2 Test run ..................................................................................................... 4-3
4.3 Drying the refractory lining in the preheater.............................................. 4-4
4.4 Drying the refractory lining in the cooler and in the kiln hood................. 4-13
4.5 First commissioning ................................................................................ 4-15
4.6 Checking the plant and correcting the settings....................................... 4-16
5 Starting the plant..................................................................................... 5-1
5.1 Heating up the kiln plant ........................................................................... 5-1
5.2 Starting the REPOL® clinker cooler .......................................................... 5-6
5.3 General information about starting the kiln plant ...................................... 5-7
5.4 Start sequence of the kiln plant............................................................... 5-12
6 Operation ................................................................................................. 6-1
6.1 Preheater .................................................................................................. 6-1
6.2 Calciner ..................................................................................................... 6-3
6.3 Kiln ............................................................................................................ 6-4
6.4 REPOL® clinker cooler .............................................................................. 6-4
6.5 Safety interlocks of the kiln plant .............................................................. 6-9
6.6 Operation in the case of a power failure ................................................. 6-10
6.7 Deviations from normal operation ........................................................... 6-14
6.8 Checks during operation ......................................................................... 6-16
6.9 Limit values of the cooler ........................................................................6-17
6.10 Safety interlocks of the cooler................................................................. 6-18
6.11 Checking the process parameters .......................................................... 6-19
6.12 Typical operating data............................................................................. 6-21
6.13 Optimising the plant ................................................................................ 6-21
6.14 Operating the shock blowers .................................................................. 6-22
7 Shutting down the plant ......................................................................... 7-1
7.1 Shutting down the kiln plant under normal circumstances ....................... 7-1
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Contents Operating manual
4 Rotary kiln plant
7.2 Shutting down the cooler .......................................................................... 7-3

7.3 Shutting down the kiln plant in case of emergency................................... 7-4
7.4 Shutting down the plant in the case of certain malfunctions..................... 7-5
8 Trouble shooting..................................................................................... 8-1
8.1 Kiln and preheater..................................................................................... 8-1
8.2 Safety recommendations for eliminating blockages in the preheater ....... 8-1
8.3 Reciprocating grate cooler REPOL® ......................................................... 8-7
9 Cleaning, inspection and maintenance ................................................ 9-1
9.1 Work during operation............................................................................... 9-1
9.2 Work during stoppage............................................................................... 9-4
10 Appendix................................................................................................ 10-1
10.1 Flowsheets .............................................................................................. 10-1
Operating manual Technical Data
Rotary kiln plant 1-1
1 Technical Data
NOTE
For the technical data of the individual machines, refer to the machine manuals or
operating instructions of the respective machines. The machines are listed with
reference to their item numbers at the end of this section. To find the
documentation for an individual machine, use the Table of contents in the first
folder of the overall documentation. The table of contents lists the machines and
units in accordance with their positioning in the plant. However, the table of
contents does not contain all sub-items that are in the flowsheets. For information
on the sub-items, refer to the respective main items.
For the technical data of machines not supplied by POLYSIUS AG Beckum,
consult the technical documentation of the respective manufacturer or supplier.
1.1 Technical data of the plant
NOTE
All data and values given in this operating manual are to be regarded as
recommended values only. They are not to be understood as warranty figures.
The relevant warranty data are contained in the contractual documents.
Information regarding the compilation of records and notes, as well as the
performance of analyses, is to be regarded as a recommendation only. The
information must not be understood as a basis for the preparation of acceptance
reports for the verification of performance figures.
Basic data
Year of manufacture.............................................................................. 2007 / 2009

Preheater............................... DOPOL® 90 type 20-20-19-18-20 / 1 string / 5 stage
Calciner ................................................................................................PREPOL-AS
Cooler .......................................................................................REPOL RS 18021-2
Rotary kiln ..................................................................... 4.6 x 70 m, 3 roller stations
Output.......................................................................................................... 3500 t/d
Energy consumption............ 745 kcal/kg of clinker when operated with natural gas
.................................................730 kcal/kg of clinker when operated with heavy oil
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Technical Data Operating manual
1-2 Rotary kiln plant
1.2 List of machines
NOTE
For a correct description of the plant and of the plant operation it is also
necessary to consider plant components and machines not included in the scope
of supply of POLYSIUS AG.
Figure 1 Kiln feed control system
POLYSIUS
Qty. Designation
Order Code
Raw meal conveying equipment and kiln feed

1 control system 4C1
1 AEROPOL vertical conveyor 4C1.AC01
1 Bucket elevator 4C1.BE01
4 Bag filter 4C1.BF01 - BF04
1 Continuous feeder 4C1.CD01
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POLYSIUS
Qty. Designation
Order Code
1 Diverter gate 4C1.CF01
1 Compressor 4C1.CP01
2 Discharge devices 4C1.DD01 - DD02
1 Monorail trolley 4C1.MC01
1 Sampling system 4C1.QS01
4 Rotary blower 4C1.RB01 - RB04
1 Pneumatic screw pump 4C1.SP01
4C1.TC01
2 Fluidor pneumatic trough conveyors 4C1.TC03
POLYSIUS
Qty. Designation
Order Code
Raw meal conveying equipment and kiln feed

1 control system 4C2
1 AEROPOL vertical conveyor 4C2.AC01
1 Bucket elevator 4C2.BE01
4 Bag filter 4C2.BF01 - BF04
1 Continuous feeder 4C2.CD01
1 Diverter gate 4C2.CF01
1 Compressor 4C2.CP01
2 Discharge devices 4C2.DD01 - DD02
1 Monorail trolley 4C2.MC01
1 Sampling system 4C2.QS01
4 Rotary blower 4C2.RB01 - RB04
1 Screw pump 4C2.SP01
4C2.TC01
2 Fluidor pneumatic trough conveyors 4C2.TC03
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Figure 2 Raw mill dedusting system
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POLYSIUS
Qty. Designation
Order Code
1 Dedusting and interconnected system 4E
1 Electrostatic precipitator 4E1.EL01
1 Evaporation cooling tower 4E1.ET01
1 Fan 4E1.FN01
1 Stack 4E1.SK01
1 Electrostatic precipitator 4E2.EL01
1 Evaporation cooling tower 4E2.ET01
1 Fan 4E2.FN01
1 Stack 4E2.SK01
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Figure 3 Interconnected system dust conveyance
POLYSIUS
Qty. Designation
Order Code
1 Interconnected system dust conveyance 4F1
1 Bucket elevator 4F1.BE01
1 Bag filter 4F1.BF01
1 Bin weighing device 4F1.BN01
1 Continuous feeder 4F1.CD01
1 Dust hopper 4F1.DH01
2 Flat slide valves 4F1.FG01 - FG02
1 Rotary blower 4F1.RB01
1 Rotary airlock 4F1.RF01
3 Trough screw conveyors 4F1.SC01 - SC03
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POLYSIUS
Qty. Designation
Order Code
1 Interconnected system dust conveyance 4F2
1 Bucket elevator 4F2.BE01
1 Bag filter 4F2.BF01
1 Bin weighing device 4F2.BN01
1 Continuous feeder 4F2.CD01
1 Dust hopper 4F2.DH01
2 Flat slide valves 4F2.FG01-02
1 Rotary blower 4F2.RB01
1 Rotary airlock 4F2.RF01
3 Trough screw conveyors 4F2.SC01 - SC03
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Figure 4 DOPOL preheater
POLYSIUS
Qty. Designation
Order Code
1 Preheater system 4G1
2 Firing systems in calciner (oil) 4G1.BU01 -BU02
2 Firing systems in calciner (gas) 4G1.BU03 -BU04
1 Calciner 4G1.CA01
1 Compressed air cleaning system 4G1.CG01
1 Fresh-air flap 4G1.FA01
1 Fan 4G1.FN01
3 Gas analysis systems 4G1.GA01 - GA03
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POLYSIUS
Qty. Designation
Order Code
1 Kiln inlet housing 4G1.KJ01
1 Preheater inlet stage 4G1.PJ01
3 Preheater system stages 4G1.PS01 - PS03
1 Preheater dust collection stage 4G1.PT01
1 Tertiary air duct 4G1.TD01
1 Damper 4G1.TV01
POLYSIUS
Qty. Designation
Order Code
1 Preheater system 4G2
2 Firing systems in calciner (oil) 4G2.BU01 - BU02
2 Firing systems in calciner (gas) 4G2.BU03 - BU04
1 Calciner 4G2.CA01
1 Compressed air cleaning system 4G2.CG01
1 Fresh-air flap 4G2.FA01
1 Fan 4G2.FN01
3 Gas analysis systems 4G2.GA01 - GA03
1 Kiln inlet housing 4G2.KJ01
1 Preheater inlet stage 4G2.PJ01
3 Preheater system stages 4G2.PS01 - PS03
1 Preheater dust collection stage 4G2.PT01
1 Tertiary air duct 4G2.TD01
1 Damper 4G2.TV01
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Figure 5 Rotary kiln
POLYSIUS
Qty. Designation
Order Code
1 Kiln 4K1
1 Firing system, clinkering zone 4K1.BU01
1 Kiln shell cooling device 4K1.KC01
1 Rotary kiln 4K1.KN01
1 Kiln shell temperature measuring instrument 4K1.KT01
3 Roller station 4K1.KT01.RST01-03
2 Fans for cooling air 4K1.KT01.FNC01-02
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POLYSIUS
Qty. Designation
Order Code
1 Kiln 4K2
1 Firing system, clinkering zone 4K2.BU01
1 Kiln shell cooling device 4K2.KC01
1 Rotary kiln 4K2.KN01
1 Kiln shell temperature measuring instrument 4K2.KT01
3 Roller stations 4K2.KT01.RST01-03
2 Fans for cooling air 4K2.KT01.FNC01-02
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Figure 6 Clinker cooler
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Figure 7 Aeration system for clinker cooler
POLYSIUS
Qty. Designation
Order Code
1 Cooler 4R1
1 Compressed air cleaning system 4R1.CG01
10 Cooler fans 4R1.FN01 -FN10
1 Reciprocating grate cooler REPOL 4R1.GQ01
1 Hammer crusher (cooler) 4R1.HR01
1 Cooling air fan for hammer crusher 4R1.FNJ01
1 Inlet 4K1.CQ01.JNT01
1 Fan 4R1.CQ01.FNJ01
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POLYSIUS
Qty. Designation
Order Code
1 Cooler 4R2
1 Compressed air cleaning system 4R2.CG01
10 Cooler fans 4R2.FN01 -FN10
1 Reciprocating grate cooler REPOL 4R2.GQ01
1 Hammer crusher (cooler) 4R2.HR01
1 Cooling air fan for hammer crusher 4R2.FNJ01
1 Inlet 4K2.CQ01.JNT01
1 Fan 4R2.CQ01.FNJ01
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Figure 8 Clinker cooler dedusting system
POLYSIUS
Qty. Designation
Order Code
1 Cooler dedusting system 4S
1 Bag filter 4S1.BF01
1 Electrostatic precipitator 4S1.EL01
1 Fan 4S1.FN01
1 Trough screw conveyor 4S1.SC01
1 Shut-off flap 4S1.SF01
1 Stack 4S1.SK01
1 Water injection system 4S1.WJ01
1 Bag filter 4S2.BF01
1 Electrostatic precipitator 4S2.EL01
1 Fan 4S2.FN01
1 Trough screw conveyor 4S2.SC01
1 Shut-off flap 4S2.SF01
1 Stack 4S2.SK01
1 Water injection system 4S2.WJ01
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Figure 9 Clinker silo and conveyors
POLYSIUS
Qty. Designation
Order Code
Conveyors to clinker store 4T
2 Steel apron feeders 4T1.AY01 - AY02
1 Distribution box 4T1.DB01
1 Drag chain conveyor 4T1.DZ01
2 Steel apron feeders 4T2.AY01 - AY02
1 Distribution box 4T2.DB01
1 Drag chain conveyor 4T2.DZ01
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Figure 10 Clinker silo
POLYSIUS
Qty. Designation
Order Code
Clinker storage 4V
3 Bag filters 4V1.BF01 - BF03
2 Clinker silos 4V1.KL01 - KL02
1 Loading device 4V1.LD01
1 Clam shell valve 4V1.SV01
1 Vibrating trough conveyor 4V1.VC01
1 Bag filter 4V2.BF01 - BF03
2 Clinker silos 4V2.KL01 - KL02
1 Loading device 4V2.LD01
1 Clam shell valve 4V2.SV01
1 Vibrating trough conveyor 4V2.VC01
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Operating manual Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the supplement Important
notes on the documentation.
Use
• The plant is exclusively intended for producing clinker from raw meal.
Be sure to comply with the specification of the intended use in section
Technical data.
• Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use.
Any other use is at the owner's own risk.
• The intended use also includes compliance with the instructions in the
operating manual, the machine manuals, and the operating instructions.
Operation
General
• Hearing protectors have to be worn in the area of the fans the blowers and the
compressors, as the noise level can exceed 90 dB(A).
• Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
• If changes in the plant or its operating behaviour occur that are relevant to
safety, shut it down immediately.
• Before starting up the kiln plant, check and activate all necessary interlocks
required for safety reasons.
• Be sure to stay at an adequate safety distance from all moving plant
components.
• During the heating-up and cooling-down phases, all surfaces are extremely
hot and may only be touched on the condition that suitable protective clothing
is worn.
• Only use 24 Volt lamps for illuminating the interior.
• At the flap valves, parts of the body may be mangled or cut off. Make sure that
the entire swinging range of the pendulum counterweights is covered by the
protection cover.
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Safety Operating manual
• In the case of a power failure in the kiln plant, overpressure in the entire
preheater may occur. Do not open the doors or poke holes until there is no
overpressure in the preheater.
• Existing platform openings must be closed or properly safeguarded.
Preheater
• During the heating up phase and during operation, all doors and covers in the
preheater must be securely closed. It is strictly forbidden to open doors and
covers.
• Before opening the poke holes, interrupt the compressed air supply to the
shock blowers in the neighbouring area and trigger and thus depressurise the
shock blowers.
• During operation, manually clean the inside of the preheater only through the
provided poke holes. Wear the suitable protective clothing, such as safety
boots, heat protection clothing, safety helmet with face shield. Only clean the
preheater with the provided equipment (such as long lances).
• Make sure that no raw meal or other loose objects can fall down on you when
you are working inside the machine. Make absolutely sure that persons in
subsequent plant components are not endangered.
NOTE
Make sure that all electric cables in the vicinity of the preheater are protected with
covers against contact with hot raw meal.
Elimination of blockages in the preheater

Shut down the rotary kiln immediately if blockage of a preheater cyclone is
detected.
All persons must immediately leave the danger areas.
The danger areas are:
• preheater tower and adjacent ground area

(take wind direction into account)
• rotary kiln (kiln platforms and adjacent area)
• clinker cooler
• clinker conveyor
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Inform the following persons:

• control room personnel
• production manager or his deputy
• plant manager or his deputy
Do not take any measures until at least one person with appropriate authority
has arrived.
The elimination of the blockage must be directly supervised by a person with
appropriate authority.
Only assign appropriately skilled employees for eliminating the blockage.
Cordon off the entire danger area to prevent unauthorised persons from
gaining access. Ensure that the emergency escape routes are free.
Only the necessary experienced technicians may be present in the preheater
tower.
The personnel responsible for elimination of the blockage
• must wear the necessary protective clothing,
• must use blasting lances of maximum length so that they remain outside
the range of spurting hot raw meal,
• must not work on platforms with raw meal on them or onto which raw meal
may fall down.
Only the person in charge who supervised the elimination of the preheater
blockage is entitled to give the signal that the danger is over.
When cleaning a blocked cyclone, you must clean the meal chute first, in order to
ensure that the raw meal can flow away unhindered. You can then clean the
cyclone using compressed air blasting lances from below through the lateral
cleaning slots or from above through the poke holes. If the cyclone cannot be
cleaned using this method, you will have to clean it via the access door in the gas
inlet of the cyclone. Open this door with great caution. If there are still
incrustations in the cyclone which you are unable to blast away when working
from the access door in the gas inlet of the cyclone, you must clean them out
through the round access hatch in the conical section of the cyclone. Also open
this door with great caution. Do not open the door before you have looked
through the access door in the gas inlet of the cyclone and made sure that there
is no loose material which could flow out when you open the round access door in
the conical cyclone section. During the cleaning period, the exhaust gas fan must
operate at low speed. The slight negative pressure prevents hot gases from
flowing out. Carefully check the meal chutes and the cyclone after the cleaning.
They must be completely free of incrustations, as these may be the starting point
for new cyclone clogging.
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Rotary kiln
• Be sure to stay at an adequate safety distance from all rotating plant
components during operation.
• Wear a face shield with a cobalt glass and gloves as well as a tough jacket for
observing the flame at the main burner and looking through the provided
opening in the kiln hood. Be sure to stay at an adequate safety distance from
the opening as hot air may escape.
• Touching the kiln shell and the kiln hood during the periods of heating up,
operation and cooling is strictly forbidden (danger of suffering burns).
Cooler
• Be sure to wear the proper protective clothing for work at the hot clinker
cooler!
• Hearing protectors have to be worn in the vicinity of the clinker cooler because
the noise level can exceed 90 dB (A).
• When using automatic shock blowers, let the residual pressure escape after
the shock blower has been electrically switched off before opening the doors
and poke holes. Danger of unintentional shooting, due to residual pressure.
• Directly after the machine has been shut down, you are only allowed to enter
the interior wearing breathing apparatus with independent ventilation. You are
not allowed to enter the interior without breathing apparatus until you have
sufficiently purged it with fresh air. Make sure that there is sufficient oxygen
inside the machine and that no hot gases can enter it.
• Doors and sealing covers may only be opened by specially authorised and
trained personnel on the express orders of the plant manager!
Make sure that all doors and sealing covers are secured with padlocks.
• When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents. Aeration with pure oxygen is
forbidden.
• Make absolutely certain that nobody can gain access to the clinker cooler
while the preheater or the rotary kiln is being cleaned. It is possible that raw
meal could flush through the kiln and into the clinker cooler. Danger of being
buried alive and dying of suffocation.
• Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.
• Switch off the power supply to the electrical components before beginning any
maintenance work.
• The hydraulic system has been specially designed for the supplied machine
and must, therefore, not be used for any other machine without the express
consent of POLYSIUS AG.
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• Make absolutely sure that the hydraulic piping is relieved of pressure before
disconnecting it.
• Never use the main pumps of the hydraulic system for emptying or filling the
oil tank.
• If you drain hydraulic oil at operating temperature, you risk scalding yourself.
• After all maintenance work, check that there are no leaks in joints and
connections.
• Strictly observe the welding instructions when performing any welding work.
• When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
• Never situate the source of the welding current in a confined space where
walls have conductive properties. Only use 24-Volt lamps for illuminating the
interior of the machine.
• If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
• Remount all protection devices when maintenance work has been finished.
Make absolutely sure that no persons are inside the plant component before
you properly close the inspection and service covers.
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Inspection
• Be sure to comply with all warning signs and safety instructions on the
machines as well as in the machine manuals and operating instructions.
• Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the inspection work.
• Ensure that all rotating parts of the machines have come to a complete
standstill before you remove any protection devices or open any covers.
• Before starting work on the machines, make absolutely sure that there is no
danger of suffering burns when touching the machines. Before opening any
inspection and service covers, make absolutely sure that there is no longer
any hot material inside the machines.
• Make absolutely sure that the interior of the machines has cooled down so far
that the personnel will not suffer any burns on entering.
• Make sure that there are no material accumulations that could fall down onto
personnel entering the machines.
• Make sure that the personnel use adequate safety equipment, such as
abseiling harness in the preheater.
• Remount all protection devices and properly close all inspection and service
covers when inspection work has been finished.
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Operating manual Components and mode of functioning
3 Components and mode of functioning

3.1 Process technological functions of the plant components
The rotary kiln plant consists of the main plant components preheater, calciner,
tertiary air duct, rotary kiln and cooler, each machine having a specific process
technological function (see Figure 11).
•Vaporisation of water
•Dehydration of clay
Gas, dust Raw meal
•Preheating of raw meal Emission
•Cooling of exhaust gas
• Meal and gas conveyance
• Partial decarbonation of the raw meal
Dedusting
Preheater system
Tertiary air duct
Fuel
Fuel Calciner Kiln
Clinker
Clinker cooler
To clinker silo
• Heating of the raw meal • Meal and gas conveyance
• Combustion • Residual decarbonation Air
• Decarbonation • Granulation of meal / clinker
• Meal and gas conveyance • Formation of clinker minerals
• Combustion • Cooling the clinker
• Preheating the combustion air
• Transporting clinker and air
Figure 11 Process technological functions
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Components and mode of functioning Operating manual
3.2 DOPOL® preheater

The preheater is used for effective heat transfer between the exhaust gas from
the kiln or the calciner and the raw meal that flows in the opposite direction. Due
to the balance that becomes established in each stage, the most effective heat
transfer takes place in a multistage process. Each stage mainly consists of a gas
duct section with the raw meal feed system and the collection cyclone. This
cyclone has two functions:
• it heats up the raw meal in the gas stream
• it collects the raw meal and discharges it via the raw meal chute.
The raw meal collected in the cyclone flows through a meal chute into the next
lower stage of the preheater, while the gas flows into the next higher stage.
Within one cyclone stage the heat transfer between raw meal and hot gases is
thus effected in parallel flow. However, when all 5 stages are considered, the raw
meal is heated up in counterflow. The raw meal is continuously heated from one
stage to the next, while the gas temperature continuously decreases on its way to
the topmost cyclone stage. This preheater is a single string preheater with 5
cyclone stages.
Between cyclone stages 4 and 5, the single string cyclone preheater DOPOL® 90
is constantly and uniformly fed with homogenised raw meal. In each cyclone
stage, the raw meal is distributed and dispersed in the gas stream in so-called
dispersing boxes (splash boxes). These are refractory-lined box-shaped
constructions made of steel plate that are welded onto the outside of the
respective gas duct and are open towards the gas duct. Due to the energy of fall,
a good distribution effect is achieved during impact of the raw meal onto the
bottom plate of the dispersing box. To prevent deposits forming in the dispersing
boxes and causing poor dispersion of the raw meal, all dispersing boxes are
connected to a cleaning system that operates by means of compressed air
pulses.
The raw meal is collected in the cyclones and is conveyed through meal chutes
into the gas ducts of the cyclone stage below. The upward flowing gas carries the
meal in the gas ducts to the next higher cyclone stages. The heat is transferred
from the gas to the raw meal. This procedure is repeated in the individual stages
until the raw meal flows from the second cyclone stage at a temperature of
approximately 760 - 780 °C into the calciner.
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Figure 12 Preheater
NOTE
For further information about the raw meal conveying equipment see the
operating manual for the raw grinding plant.
Pneumatic cleaning devices are mounted in all stages for cleaning the cyclone
outlets and dispersing boxes regularly or as necessary. In this way, incrustations
or deposits of raw meal are largely avoided. In addition, shock blowers are used
in the area of critical zones where incrustations of raw meal can form. Size,
number and arrangement of the shock blowers to be used are determined by:
• position and form of the incrustations,
• temperature ranges,
• local conditions.
The cyclones and gas ducts are lined with refractory material.
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3.3 Calciner
The primary function of the calciner is to decarbonate the raw meal (90 - 93 %). A
portion of the energy required for this purpose is derived from the exhaust gas of
the rotary kiln, to which the calciner is connected in gas flow direction. The main
portion of the required energy comes, however, from the calciner firing system.
The exhaust gas from the kiln passes through the kiln inlet housing and into the
calciner. The calciner begins with the calciner nozzle. The nozzle is a
constricted piece of the gas duct which has the function of compensating the
different pressure drops of the kiln and the tertiary air duct. This constriction of
the main gas duct ensures that both the clinkering zone firing system and the
calciner firing system operate under optimum burning conditions, the combustion
air flow rate and the oxygen content being controllable by means of the dampers
in the tertiary air duct. Directly above the calciner nozzle (in gas flow direction) is
the infeeding point for meal of the second stage of the preheater. The two
calciner burners for natural gas and the two lateral tertiary air inlets at the calciner
are installed below the meal infeed points.
The two calciner burners for heavy oil are mounted above the meal infeed point.
The arrangement of the gas burner and the tertiary air supply below the meal
feeding system ensures that the natural gas, which is not easily inflammable, can
ignite in a hot and oxygen-rich zone before it comes into contact with the colder
meal curtain. As heavy oil is more easily inflammable, the burners are installed
above the meal feeding system in order to prevent thermal overloading. The two
fuels can either be used together or separately.
In case the inflammability of the fuel is so bad that, in spite of the above-
described measures, it does not fully burn out before reaching the end of the
calciner during operation with natural gas, a meal splitting system has been
installed. This means that a partial flow of the preheated raw meal from the
second preheater stage can be diverted via a splitter flap to a dispersing box at a
higher position in the calciner. This creates a second hot zone in the area
between the two infeeding points of the raw meal from the second stage, which
improves the inflammability of the natural gas.
From the calciner, the meal is conveyed into the lowest cyclone stage of the
preheater, is collected and is conveyed via meal chutes at a temperature of 840 -
860 °C via the kiln inlet housing into the rotary kiln.
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3.4 Rotary kiln
Rotary kiln inlet

The calciner and the rotary kiln are connected to each other by the kiln inlet
housing. The rotating kiln and the static kiln inlet housing are sealed by the kiln
inlet seal. Essential elements of the seal are two ring-shaped and lubricated
sealing surfaces that are pressed against each other by a number of pneumatic
cylinders. The rotating ring is permanently connected to the kiln whereas the
other ring can shift axially on the support ring. The supporting ring is sealed by a
sealing cord.
Figure 13 Rotary kiln inlet
The meal chute from the bottommost cyclone stage (1 in Fig. 13) opens into the
kiln inlet housing. The special design of the meal chute connection and the shape
of the kiln inlet housing ensure that the hot and largely decarbonated raw meal
flows into the rotary kiln (4) with very little formation and whirling up of dust.
The kiln inlet trough (3) forms the transition between the end wall of the kiln inlet
housing and the kiln. The trough is indirectly air-cooled in order to protect it
against the very high temperatures in this area. The cooling air is supplied by the
cooling air fan installed in the immediate vicinity of the kiln inlet.
Shock blowers are also installed in the area of the kiln inlet. The nozzles of the
shock blowers are located where, according to experience, coating formation
occurs very often.
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Rotary kiln
The rotary kiln is fundamentally a refractory-lined steel plate cylinder with a 4 %
inclination and on 3 supports. The kiln shell has a diameter of 4.6 m and a length
of 70 m, with the kiln inlet reduced in diameter to 4.8 m.
The kiln shell is supported via three tyres on supporting rollers. The tyres,
together with the rollers and their bearings, form the kiln tyre stations. The
function of the kiln tyre stations is on the one hand to support the rotary kiln shell
and on the other hand to transmit the occurring loads into the foundations.
The driving power is supplied via the girth gear installed between tyres 1 and 2.
The main drive consists of an electric motor and a gear unit.
The main motor is a frequency-controlled electric motor. Its speed range is
between 150 and 1500 rpm.
When the kiln is being driven by the main motor, the kiln rotation speed is 0.35 -
3.5 rpm. When it is being driven by the auxiliary motor, the kiln rotation speed is
0.11 rpm. The direction of rotation is constant, provided that the kiln is not in the
process of swinging to a complete stop. There is no force direction reversal.
The preheated and mainly decarbonated raw meal from the lower preheater
stage of the preheater tower is conveyed via the kiln inlet into the rotary kiln. Due
to the slope and rotation of the kiln, the feed material moves in opposite direction
to the hot gas towards the outlet and then into the cooler.
On its way through the kiln, the raw meal is first completely decarbonated, then it
is heated to clinkering temperature and is finally sintered into clinker. In the
clinkering zone, the clinker mineral formation is concluded. The clinker produced
in the kiln falls at a temperature of 1250-1400 °C into the downstream clinker
cooler.
The energy required for clinker formation is supplied to the rotary kiln via the main
burner. The main portion of the combustion air is preheated air from the clinker
cooler (secondary air), while a minor portion is primary air and conveying air
required for forming the flame shape and cooling the burner (in the case of coal
firing). The heat is transferred to the raw meal by means of the contact between
hot gas and material and the contact with the refractory lining.
Secondary and tertiary air 90 – 92 %
Primary air 5–6%
Conveying air 3–4%
Table 1: Constituents of the combustion air
The necessary combustion air quantities (secondary and tertiary air) are
approximately 0.8 to 1.1 Nm3/kg of clinker, depending on the fuel used and the
necessary specific heat quantity.
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The high-temperature flue gases are discharged from the kiln at the kiln inlet and
enter the calciner. The kiln hood is the end of the kiln and the connecting link to
the cooler. The tertiary air is extracted at the kiln hood together with the
secondary air and is guided through the tertiary air duct along the kiln to the
calciner. The tertiary air slide dampers control the gas flow rate and prevent the
content of oxygen in the kiln exhaust gases in the kiln inlet from falling below 2-
3% O2.
The clinker passes a cooling zone at the end of the rotary kiln which is longer or
shorter depending on the position of the burner. The clinker then falls at a
temperature of approx. 1300 to 1400 °C into the downstream cooler.
The rotational speed of the kiln must be adapted to the clinker burning conditions.
A higher rotational speed normally produces better results due to the low filling
ratio and more intensive agitation of the raw meal. Moreover, the material flow is
then more uniform and flushing of raw meal, which is known from kilns with a
higher filling ratio, practically no longer occurs.
Kiln hood
The outlet end of the rotary kiln extends into the kiln hood. The gap between the
rotating kiln and the static kiln hood is sealed by the kiln outlet seal. This seal has
a similar design to the kiln inlet seal described earlier. The end of the rotary kiln
consists of kiln outlet segments. These segments are made of highly heat
resistant cast steel and are cooled by 2 blowers in order to extend their service
life.
Tertiary air duct

The tertiary air duct is connected to the upper part of the kiln hood. This
refractory-lined duct is mounted on supports and is routed above the centre line
of the kiln. A special axial-radial seal is installed to absorb the kiln expansions,
which can vary greatly due to the often very high temperatures of the tertiary air,
and to seal the kiln against the outside (see Fig. 14). The seal is installed
between the guide duct (1) and the tertiary air duct (2). It consists of an axially (3)
and a radially (4) self-adjusting seal. It has the function of sealing between the
guide duct and the tertiary air duct while absorbing axial and radial displacements
that occur due to thermal expansions. The seal is held by a floating suspension
(5). The guide duct (1) has a double shell and is indirectly cooled by a cooling air
fan.
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Figure 14 Axial/radial seal between tertiary air duct and kiln hood
In the area of the calciner, the tertiary air duct divides into 2 strands leading to the
firing points of the calciner burners. A damper is installed in each of the two ducts
for controlling the air flow rate. The damper is provided with a plate made of
refractory material (see Figure 15). This is necessary because the loading due to
clinker dust and high temperatures is particularly great at this point.
Figure 15 Damper in the tertiary air duct
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Main burner
The burner is mounted on a suspended burner carriage. With the aid of this
burner carriage, the burner can be moved into the rotary kiln and its angle
adjusted relative to the axis of the rotary kiln.
The main burner is designed for the burning of natural gas and heavy oil. When
the burner is started up, the heavy oil or the natural gas is ignited by an ignition
device.
The flame shape is determined by the exit velocities and the flow rates of fuel and
primary air at the burner tip. During operation, the flame shape is infinitely
variable. The special properties of the fuel can therefore be adapted to the
conditions in the combustion space.
Combustion air for the kiln system

The major part of the combustion air is introduced into the kiln plant by the
cooling air fans. The set values for the cooling air flow rate are kept constant by
control loops. The cooling air flow rate is set in accordance with the kiln output.
The combustion air required for the combustion in the calciner flows through the
tertiary air duct from the cooler (kiln hood) to the calciner. The air flow rate is set
by the position of the dampers in the tertiary air duct. The calciner burners are
supplied with additional combustion air by the primary air fans.
The combustion air for the main burner flows from the cooler through the cooler
shaft into the kiln. This air is the so-called secondary air. The pressure in the kiln
hood is kept constant with the cooler exhaust air fan. The normal values lie
between -0.3 mbar and -0.1 mbar.
The portion of the cooling air which is not required as combustion air leaves the
cooler as exhaust air and is dedusted in the connected electrostatic precipitator.
Combustion gases
The combustion gases flow through the kiln to the kiln inlet. Along the way, they
transfer heat to the kiln charge material. The temperature of the gas in the kiln
inlet is approximately 1000 to 1200 °C.
The combustion gases from the kiln and the tertiary air from the cooler form a
collective gas stream at the firing point in the calciner. Additional combustion air
is brought in by the primary air fans.
The combustion gases flow upwards through the preheater and transfer a large
part of their thermal energy to the kiln charge material. After the last cyclone
stage, the gases flow at a temperature of approx. 320 to 340 °C to the exhaust
gas fan.
Set the speed of the exhaust gas fan and the position of the two existing exhaust
gas fans and the position of the tertiary air dampers so that the pressure in the
kiln inlet is approximately between -4 and -6 mbar and the oxygen content in the
gas after the precalciner is approx. 2 to 3 %. The oxygen content of the gas at the
kiln inlet should also be 2-3 %.
The exhaust gas fan conducts the gases or a portion of the gases to the grinding
plant for raw meal (interconnected operation) or direct to the exhaust gas
dedusting system (mill bypass operation).
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Fuel
Fuel is fed into the process at two points: in the main burner and in the calciner
burner.
Burner Fuel
Main burner Oil / gas
Calciner burner Oil / gas
3.5 Reciprocating grate cooler REPOL®

In the grate cooler, the hot clinker discharged from the kiln is cooled and then
broken in the hammer crusher. The cooler is a REPOL® RS 10081-2 cooler.
Installed downstream of the cooler, the existing clinker conveying equipment
conveys the cooled clinker to the clinker silo.
To cool the clinker, cooling air is blown from underneath as a crosscurrent
through the cooler grate and the clinker bed. Above the bed of material, the
cooling air divides into the following 3 partial flows:
A. Secondary air,
B. Tertiary air,
C. Cooler exhaust air.
Secondary air and tertiary air contain the recuperable heat and are used as
combustion air. The combustion air flows through the cooler shaft and is divided
into secondary air for the rotary kiln and tertiary air for the calciner. The cooler
exhaust air comes from the rear part of the cooler. It is subsequently dedusted in
the electrostatic precipitator and is then discharged into the atmosphere.
In the cooler, the clinker is cooled down from the initial approx. 1400 °C to the
cooler outlet temperature of approx. 95 °C. The hot clinker discharged from the
kiln first falls onto the static pre-grate. It is then conveyed onwards by two moving
grates. The grates are hydraulically moved in thrusts so that the material is
conveyed in the direction of the outfeeding clinker conveyor. The thrust speed of
the grate influences the clinker bed depth on the grate. The Jet-stream plates
installed on the grates guide the air uniformly into the bed.
The hammer crusher for breaking the rough clinker is installed behind the grates.
After the hammer crusher, the broken and cooled clinker falls onto the clinker
conveyor belt.
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Principle of functioning of the reciprocating grate cooler
Grate drives
A local/remote selector switch with the switch steps Central, OFF, Flushing, Local
and Local start is installed in the immediate vicinity of the hydraulic cylinders of
each grate. Two inching switches for each grate are also installed in the same
place.
It is important to distinguish the following operating modes:
Automatic operation Start from the central control room
Inching operation Start from Local
Local operation Start from Local
Flushing operation Start from Local
Automatic operation
In the Automatic mode of operation the local/remote selector switch must be in
the Central position. All commands for starting and stopping the grate come from
the central host computer. The stroke frequency of the grate is set in the control
room. In automatic operation, a flushing cycle is started at regular intervals in
accordance with the set time. When the grate is stopped, the grate drive is moved
into the lower end position.
Local operating modes

Local operation facilitates exact positioning of the grates and also a continuous
mode of operation for commissioning or repair work on the REPOL®.
The control oil and feed oil pump and the respective main pump must be in
operation (start from the higher-ranking control system or via an own local/remote
selector switch).
• In the operating mode inching operation the local/remote selector switch is in

the Local position. With the inching buttons, the grate can be positioned
forward and backward at minimum speed (5 strokes per minute).
• When you turn the local/remote selector switch in the operating mode Local
operation past the Local position into the Local Start position, the drive starts
continuous operation. The local/remote selector switch returns from Local
Start to the Local position. In this position you can change the grate operating
speed using the inching buttons. In this operation mode, it is also possible to
specify the setpoint value for the stroke frequency via the operator panel. In
local operation, the grate drive is immediately stopped when the local/remote
selector switch is set to OFF.
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• The operating mode Flushing operation is started for the first commissioning
or after repairs to the hydraulic system. To start the flushing operation, the
local/remote selector switch must be set to the position Flushing. The control
oil and feed oil pump and the respective main pump must be in operation
(start from the higher-ranking control system or via an own local/remote
selector switch). When you press the inching button Forward, the hydraulic
cylinder travels into the upper end position and the discs of the main pump are
pivoted to the set pivot angle. You set the pump disc pivot angle via the
operator panel. Flushing in the lower end position of the hydraulic cylinder is
started with the inching button Backward.
You terminate the flushing process by turning the local/remote selector switch
from the Flushing position to the OFF position.
Cooler housing
The cooler housing is one of the largest components of the cooler. It consists of a
steel plate housing reinforced by girders and ribs. The complete housing is
provided with refractory lining as protection against the high temperatures of the
clinker and the recuperated cooling air. The kiln outlet housing is a major
component. Connected to the outlet housing, the next component in the upper
section is the tertiary air duct for carrying part of the heated cooling air to the
calciner as combustion air. The rotating end section of the rotary kiln extends into
the kiln outlet housing. The rotating part and the stationary part are sealed by a
special kiln outlet seal. The main burner is arranged centrally in the kiln outlet
section of the rotary kiln shell. An indirect cooling system with own cooling air fan
for cooling the refractory lining is installed on the side below the main burner in
order to increase the service lives of the refractory lining in the transition zone
between the kiln outlet housing and the cooler housing. The transition zone is
called the bullnose and the cooling device is called the bullnose cooling system.
Static pre-grate
The inlet zone of the REPOL® is equipped with a static pre-grate. A static pre-
grate is a step-like arrangement of fixed rows of grate plates. The static pre-grate
consists of a total of 5 rows. Like the two movable grates, the static pre-grate is
also 10 plates wide. Part of the static pre-grate is, however, covered with a so-
called Horse Shoe made of refractories. The function of the Horse Shoe is to
initiate, in coaction with the static pre-grate, uniform distribution of the clinker onto
grate 1 and to force the cooling air in this area as a concentrated flow into the
rotary kiln zone of piled up discharged material. Without the Horse Shoe, the
cooling air would escape less effectively through the shallower and relatively cold
bed in the upper corners and sides of the static pre-grate. Cooling air is supplied
to the static grate by 2 cooling air fans.
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Shock blowers
To prevent snowmen from forming on the static grate or on the Horse Shoe, or to
eliminate them, shock blowers have to be used.
The static pre-grate is equipped with a total of 10 shock blowers. 4 of them are
installed in the end wall above the Horse Shoe. A further 6 units (3 on each side)
are connected via a special structural component to the fronts of the grate plates
of the pre-grate. The air from these shock blowers is discharged through specially
designed nozzle openings in the direction of material flow. Activation of these
shock blowers at intervals to be defined during commissioning prevents the
formation of clinker incrustations (snowmen) in this area.
Figure 16 Shock blowers for static pre-grate
Grate 1
From the static pre-grate, the clinker is conveyed onto the first reciprocating
grate. A reciprocating grate consists of 19 fixed and 18 moving, alternately
arranged rows of grate plates. This makes a total of 37 rows of grate plates,
resulting in an effective cooling area of 39 m2. As the ends of each row of grate
plates at the walls of the cooler are liable to particularly heavy wear, they are
protected by so-called cover strips. The wall areas are lined with refractory
material.
The grate plates are mounted on grate plate supports. While the supports of the
fixed rows are each directly and rigidly connected to the housing, the movable
supports have a common connection via the oscillating beams. These oscillating
beams are connected to the hydraulic cylinders of the drive.
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In order to improve the adjustability of the air distribution in the cooler

compartment, flow resistance elements in the form of simple replaceable orifice
plates are installed in almost all the grate plates. The function of these plates is to
counteract differences in air permeability at different zones of the clinker bed,
which may occur due to, for instance, particle-size segregation effects caused by
the kiln discharge.
Grate 2
Grate 2 directly follows grate 1. Grate 2 is of similar setup to grate 1 and consists
of 21 fixed and 18 moving rows. This grate thus has an effective cooling area of
41.6 m2.
Clinker crusher
The clinker crusher is installed after grate 2. It is a so-called hammer crusher,
which consists of a rotor fitted with swinging hammers.
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Aeration system
The clinker cooler is aerated by compartment-type aeration. This applies to the
static pre-grate and also to the grates 1 and 2. One cooling air fan is installed in
each compartment except for the static pre-grate, under which 2 fans are located.
This results in the following compartment allocation:
Static pre-grate One central compartment for the kiln discharge zone
and one for the remainder (a total of 5 plate rows
long)
Grate 1 5 compartments (6, 6, 8, 8, 9 plate rows long)
Grate 2 3 compartments (12, 12, 15 plate rows long)
This arrangement requires 10 cooling air fans, which are arranged along the two
sides of the cooler. All fans are equipped with an inlet measuring nozzle for
measuring the flow rate. The flow rate is set via motorised inlet vane controllers
or a flow rate controller. All fans are equipped with a silencer on the suction side.
The following air distribution diagram shows the distribution of the fans for
aerating the different compartments.
Figure 17 Air distribution diagram and aeration diagram
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Cooling air fans

All cooling air fans can be operated in Automatic or in Local mode.
In Automatic operating mode, the commands for start, stop and any changes of
the volume flow rate (by changing the speed or altering the position of the vane
controller) are issued from the central control desk. Both the mechanical and the
process technological interlocks are active in this operating mode.
When local operation is enabled from the central control panel, only the
mechanical interlocks, such as the torque limiting switches of the inlet vane
controller, are effective. The volume flow of the fan can also be changed in the
Local mode of operation e.g. by adjusting the inlet vane controller.
The following figure shows the design values for the specific air flow rate in
m3/m2/min and also indicates the actual range in later operation.
Kühlluftverteilung
100
Auslegung
Betrieb
90
80
70
Kühlluft [m³/(m²*min)]
60
Saman Gargh Cement Co., Iran
SAMANFA
3500 tato
50
40
30
20
10
0
0 5 10 15 20 25 30
Kühlerlänge [m]
Figure 18 Cooling air distribution
Clinker conveying
A drag chain conveyor installed beneath the cooler conveys the grate riddlings to
a steel apron feeder. A steel apron feeder then conveys the grate riddlings
onward, together with the crushed clinker.
A distribution box installed at the end of this steel apron feeder provides the
possibility to remove the clinker from the system by conveying it to a special silo.
Under normal circumstances, the clinker is conveyed onto the second steel apron
feeder, which takes it to a large clinker silo.
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3.6 Exhaust gas and cooler exhaust air conditioning
Distributing the exhaust gases

The exhaust gas from the preheater is conveyed via a system of ducts, shut-off
valves or changeover flaps and fans either entirely or in part to the following
plants:
• Raw mill,
• Exhaust gas filter (stack)
After leaving cyclone stage 5 of the preheater, the exhaust gases are conveyed
via a corresponding duct to the exhaust gas fan. The motorised damper is
installed in this duct. Upstream of this damper, the motorised fresh-air flap is
installed in the exhaust gas duct.
The double-flow exhaust gas fan is equipped with a variable speed drive. The
function of this fan is to suck the combustion air required for the combustion
process, as well as the produced exhaust gases, through the kiln, calciner and
preheater.
In gas flow direction immediately downstream of the exhaust gas fan, the gas is
distributed to the following gas ducts:
• branch taking the exhaust gas to the raw grinding plants for combined grinding
and drying
• branch taking the kiln exhaust gases (mill bypass operation) to the
evaporation cooling tower and then to the exhaust gas filter
Depending on the operating mode, i.e. interconnected operation or mill bypass
operation of kiln and grinding plant (raw mill), the gas routes are either opened or
closed by dampers. Depending on requirements, these dampers have a simple
open/close function, a control function or even a quick-closing function.
Conditioning the exhaust gas

Depending on the operating mode, the exhaust gas from the preheater is either
used in the downstream grinding plants (raw mills) or is conveyed directly to the
dust collection filters. In mill bypass operation, the exhaust gas temperature is too
high for the bag filter or the electrostatic precipitator and corresponding
conditioning is necessary. This is generally effected by injecting water into a
cooling tower. In addition, the raw mill exhaust air is merged with the kiln exhaust
gas. This normally leads to a lower temperature of the mixed gas.
Dedusting
The dust-laden exhaust gas from the kiln and/or the raw grinding plant is
dedusted in the exhaust gas filter. The dust collected in the filter falls into the
collecting bins of the filter housing and is discharged from there via trough screw
conveyor and rotary airlocks. In mill bypass operation the dust is conveyed by a
chain bucket elevator to the filter dust bin. From there, the filter dust is conveyed
together with the kiln feed meal to the kiln feed system. In interconnected
operation, the filter dust is mixed with the raw meal in a blending silo.
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Cooler exhaust air dedusting

The cooler exhaust air fan sucks the exhaust air out of the cooler, through a
connecting duct and through the electrostatic precipitator. After the cooler
exhaust air fan, the cleaned exhaust air is discharged via a stack into the
atmosphere.
A fresh-air flap is installed in order to protect the bag filters against operating
temperatures exceeding the maximum permissible temperature.
The dust collected in the electrostatic precipitator is conveyed by trough screw
conveyors and rotary airlock feeders to the clinker conveyor, which takes it to the
clinker silo.
3.7 Flaps and dampers in the kiln plant

The following table gives an overview of the flaps/dampers in the kiln plant.
Ope
Place of Positiona Adjustabl
Designation Item no. n/clo
installation ble e
sed
Exhaust gas duct

Shut-off flap 3F1.SF01 X X X
from raw mill to filter
Circulating air duct

for the raw mill
Exhaust gas duct

Shut-off flap from kiln to 3F1.SF03 X X X
evaporation cooler
Exhaust gas duct

from kiln to raw mill
Kiln exhaust gas

Fresh-air flap duct to kiln system 4G1.FA01 X X
fan
Kiln exhaust gas

Damper duct to kiln system 4G1.TV01 X X
fan
4G1.TD01.
Flat slide valves Tertiary air duct X X
FGJ01-02
Cooler exhaust air

Shut-off flap duct to electrostatic 4S1.SF01 X X X
precipitator
Table 2 - Overview of flaps/dampers
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3.8 Clinker storage and conveyance

The clinker conveyor conveys the clinker to the clinker silo or - if necessary - to
the silo for underburnt clinker.
Clinker conveying
A drag chain conveyor installed beneath the cooler conveys the grate riddlings to
a steel apron feeder. A steel apron feeder then conveys the grate riddlings
onward, together with the crushed clinker.
A distribution box installed at the end of this steel apron feeder provides the
possibility to remove the clinker from the system by conveying it to a silo for
under-burnt clinker. Under normal circumstances, the clinker is conveyed onto
the second steel apron feeder, which takes it to a large clinker silo.
Silo for under-burnt clinker

Corresponding setting of the distributing chute enables inadequately burnt clinker
(export clinker) to be conveyed into the silo for underburnt clinker. The export
clinker is either loaded onto trucks via the discharge device and the loading
device or is supplied via the discharge device to the troughed belt conveyor for
conveyance to the cement grinding plant.
Figure 19 Clinker conveying equipment and clinker silo
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3.9 Electrical interlock

The drives of the machines in the plant or in a plant section are interlocked with
one another. If one machine fails (e.g. due to overloading), then all drives in the
process sequence upstream of the failed machine are switched off automatically.
This arrangement prevents blockages and machine damage.
Refer to the process functional diagrams for information on the start-up and
shutdown sequences for the individual drives.
3.10 Operating modes
Exhaust gas conditioning
Mill bypass operation

The shut-off flap in the hot gas duct to the raw mill is closed and all kiln exhaust
gases are carried directly via the evaporation cooling tower and the gas duct to
the filter.
The occurring filter dust (only pure kiln dust) is conveyed directly to the preheater
meal feed unit or to the filter dust silo.
Interconnected operation
In interconnected operation, i.e. when the grinding plant for raw meal is in
operation, the shut-off flap in the hot gas duct to the raw mill and the shut-off flap
in the gas duct from the mill fan to the filter are open, and a large proportion of
the kiln exhaust gases is carried to the combined grinding and drying process via
the raw mill.
The filter dust is collected together with the raw meal in the filter. This mixture of
raw meal and filter dust is conveyed to the silo. Optimum mixing of the two
constituents is thus assured, in order to avoid fluctuations in the homogeneity of
the raw meal.
Rotary kiln
Main drive
The main drive is used in normal operation. The kiln is rotated by the main drive.
Auxiliary drive
When the main drive is either not available, or e.g. during servicing or repairs, the
kiln can be rotated using the auxiliary drive.
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3.11 Control loops in the kiln plant
Exhaust gas system

With regard to the control loops, there is a general difference between the
operating modes mill bypass operation and interconnected operation.
In mill bypass operation, the raw mill is not in operation, and all kiln exhaust
gases are conducted direct to the dust collection filter.
In interconnected operation, a portion of the kiln exhaust gases is required for
the combined grinding and drying process in the raw mill and only a small portion
of the kiln exhaust gases is conducted direct to the filter.
A kiln plant requires at least the following control loops:
®
DOPOL preheater and rotary kiln
The following control loops are provided for the exhaust gas side of the kiln:
• Control loop 1: pressure downstream of the DOPOL® fan

• Control loop 2: pressure upstream of the electrostatic precipitator
REPOL® clinker cooler
• Control loop 3: kiln hood pressure

• Control loop 4: cooling air flow rate
• Control loop 5: grate operating speed
• Control loop 6: temperature upstream of the cooler exhaust air filter
Aim of the control loop Controlled variable Manipulated variable
1 Pressure downstream of DOPOL® Pressure downstream Speed of the filter fan

= constant (mill bypass operation) of DOPOL®
2 Pressure upstream of exhaust gas Pressure upstream of Speed of the filter fan
filter = constant (interconnected exhaust gas filter
operation)
The pressure after the kiln exhaust
gas fan is kept constant via the
damper position in the return air
duct of the raw mill
3 Kiln hood pressure = constant Pressure in the kiln Speed of the cooler
hood exhaust air fan
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Aim of the control loop Controlled variable Manipulated variable
4 Cooling air flow rate = constant Air through-flow rate Position of the inlet
at inlet metering vane controller of the
nozzles of the cooling cooling air fans
air fans
5 Uniform clinker layer in clinker Pressure in Stroke frequency of

cooler compartment 1 or 2 or the cooler grates
hydraulic pressure of
grate 1
6 Protection of the electrostatic Temperature Fresh-air flaps in the

precipitator against excessively upstream of the cooler cooler exhaust air
hot exhaust air exhaust air filter duct
Preheater and kiln
Control loop 1: Pressure downstream of the kiln exhaust gas fan

In order to ensure safe and uniform plant operation with the minimum dust
possible, overpressure downstream of the kiln exhaust gas fan must be
prevented. This is achieved by constantly controlling the pressure downstream of
the fan. The pressure downstream of the fan is therefore the controlled variable
and the speed of the filter fan the manipulated variable. This control loop is only
active during mill bypass operation.
Control loop 2: Pressure upstream of the exhaust gas filter

This control loop is not active during mill bypass operation.
In interconnected operation, the major portion of the hot gases is conveyed via
the raw mill. The pressure downstream of the kiln exhaust gas fan is no longer
controlled by the filter fan. But as the pressure upstream of the tube mill is almost
identical to the pressure downstream of the kiln exhaust gas fan and this
pressure is kept constant by means of the control damper in the return gas duct
of the raw mill, overpressure downstream of the fan cannot occur during
interconnected operation.
Upstream of the electrostatic precipitator, the remaining kiln exhaust gases and
the mill exhaust air are merged again. In order to ensure constant draught
conditions, the pressure upstream of the electrostatic precipitator is kept constant
by means of the controller. The pressure upstream of the filter serves as the
controlled variable for this purpose. The speed of the filter fan downstream of the
electrostatic precipitator is the manipulated variable.
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Control loop 3: Kiln hood pressure

To ensure continuous combustion, the pressure conditions in the kiln plant and
also the pressure at the kiln hood must be kept constant. The pressure at the kiln
hood is therefore controlled via the speed of the cooler exhaust air fan. In this
way, the fan discharges the air from the cooler that is not needed as combustion
air.
Control loop 4: Cooling air flow rate

The operator sets the setpoint value for the cooling air flow rate depending on the
kiln output. The cooling air streams of the individual cooling air fans are kept
constant by means of control loops, independently of the current cooler loading,
in order to provide constant air flow rates for the cooling process and combustion.
The differential pressure signal of the inlet measuring nozzles at the individual
fans serves as the controlled variable, while the opening of the inlet vane
controller is the manipulated variable. PID controllers are installed for controlling
the air flow rate in the individual cooling air fans.
Control loop 5: Stroke frequency of the cooler grates

The aim of operation at different stroke frequencies is to keep the clinker bed
depth on the grate constant by means of a constant compartment pressure. For
this purpose, a control loop with the compartment pressure as the controlled
variable and the stroke frequency of the grates as the manipulated variable is
installed in the control system.
Take the static pressure for controlling the grate operating speed of grate 1 from
the first or second compartment under the moving grate of the clinker cooler. A
specific compartment pressure must be set as setpoint value for the control loop.
With this pressure, you can define the clinker bed depth on the grate, which may
have to be altered depending on the clinker grain size.
As an alternative, the hydraulic pressure of grate 1 is available as controlled
variable for optimisation purposes.
For grate 2, control via a separate pressure control loop for compartment 1 of this
grate has not proved advantageous in our experience. The speed of grate 2 is
therefore controlled by a cascade control system that sets a fixed speed ratio
between the grates. Grate 2 generally operates at a speed that is approx. 10 to
20% higher than that of grate 1.
Control loop 6: Temperature upstream of the cooler exhaust air filter

During normal operation, the cooler exhaust air passes into the electrostatic
precipitator at a temperature of approx. 250 - 300 °C.
To prevent overheating of the filter, a fresh-air flap which is controlled via the
temperature control loop, is installed upstream of the filter. The temperature
controller upstream of the filter is parameterised with a setpoint value of e.g.
320 °C.
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Operating manual Commissioning
4 Commissioning
4.1 Checks prior to commissioning
NOTE
Be sure to also perform the checks specified in the machine manuals of
POLYSIUS AG and in the operating instructions of the respective manufacturers.
After completing the assembly work and prior to the first test run, be sure to
remove all material remnants, tools and assembly appliances and check and/or
adjust the plant components again. Be sure to carry out the following particularly
important checks and actions:
Prepare measurement records (log books) as specified in the machine
manuals.
Fill the machines and installation components with the required consumables
(e. g. oils, greases).
The qualities and quantities are specified in the respective machine manuals.
Visually inspect all piping, screwed connections and welds for leaks
Check all drive motors for correct direction of rotation.
Check that all the necessary protection devices (e.g. guards) and warning
signs have been properly mounted.
Check all flaps, dampers and discharge devices for proper functioning and
adjust them as necessary.
Check the compressed air supply system (e.g. water separator, lubricator).
Check the anti-runback devices for correct installation (blocking direction).
Check that all manholes, inspection doors and covers are correctly closed.
Check the refractory lining.
Have all projections and wide joints (except the expansion joints specified in
the refractory lining drawing) and all roughness been eliminated?
Check the compressed air blasting pipes.
The compressed air blasting pipes must be flush with the wall.
Inspect the cyclones, gas ducts and riser pipes.
Remove all incrustations from the kiln system. Incrustations disintegrate after
a short time, but they can form again in other areas in the preheater and
cause blockages.
Check the flap valves in the meal chutes.
Do all flap valves move easily in both cold and hot condition?
Check all conveyor systems.
Remove any foreign bodies or large lumps of material which may be present
in the conveyor systems.
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Commissioning Operating manual
Check the direction of rotation of all fan impellers.

Check whether the exhaust gas fans can oscillate in all directions (no stressed
connection to any other parts).
Compare the position of every flap indicated at the control panel with the
actual flap position.
Check whether water pipes, overflows and drains have been cleaned and are
ready for operation.
Check all machines for firm anchorage.
Have the contact surfaces of the rollers and tyres been carefully cleaned?
Check the specified distance between the refractory lining of the end kiln
section and the inlet trough. Check the specified distance between the
refractory lining of the end kiln section and the inlet trough. Unless otherwise
stated in the drawing, this measurement must be between 30 and 35 mm.
Check that the kiln inlet seal has sufficient clearance.
Check the electrical control systems and interlocks.
Conduct a special check at the burners:
Check that all solenoid valves open and close properly. If pneumatically
controlled valves are used, check their opening and closing times (3 seconds).
In the case of oil firing, check the system for leaks at a feed pressure of 1.5
times the operating pressure (with oil gun withdrawn).
Check all measuring devices and indicators for proper functioning.
Prepare and check bought-in equipment according to the suppliers'
instructions.
Check the voice communication between the control room and the burner
platform.
Check the voice communication between the control room and the preheater
tower.
Calibrating
Calibrate all flow regulating devices.
Adjust all measuring devices and indicators.
Signal check
Check the monitoring devices (e.g. Check the monitoring devices (e.g. speed
monitors, true-run switches, filling level monitors) for proper functioning
Check and calibrate all measuring points (e.g. pressures, temperatures,
speed).
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NOTE
Be sure to also perform the checks specified in the machine manuals of
POLYSIUS AG and in the operating instructions of the respective manufacturers.
4.2 Test run
NOTE
The first test run must be carried out in the presence of specialists from
POLYSIUS AG and in accordance with their instructions.
CAUTION
There is potential danger for both the personnel and the plant.
Do not start the test run before all checking and adjusting work has been
completed.
During the test run, pay special attention to the following:

• abnormal noise at plant components
• higher temperatures than normal at bearings, gear units, motors or other plant
components
• severe vibrations at rotating plant components
After completion of the preparations and checks of all plant components, a 24-
hour test run is carried out. All machines – with the exception of the kiln – are
switched on and must operate continuously under the supervision of the
commissioning and erection personnel. Check all plant components for correct
functioning.
Check the temperature of the bearings.
Check the electrical interlocks (e.g. of the firing system, raw meal and clinker
conveyor) several times.
Set the thermal tripping device of the electric motors to rated current.
CAUTION
Do not rotate the kiln in cold condition.
Otherwise, the refractory lining may suffer damage.
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If necessary, the test run can be continued during the drying time. Subsequently,
close all the doors and flaps of the plant with the exception of the doors/flaps that
are needed for evaporation during the drying operation. Do not close these
doors/flaps until shortly before commissioning, i.e. before the heating up phase.
CAUTION
The plant may suffer serious damage.
Interrupt the test run immediately if one of the abnormal conditions
mentioned above occurs.
Eliminate the cause without delay.
During the test run, also pay attention to

• correct interlocking and proper functioning of individual plant sections and
machine groups which are started up together
• tightness of all piping and screwed pipe joints
4.3 Drying the refractory lining in the preheater
CAUTION
The refractory lining may suffer damage.
For the drying process and the heating up, be sure to comply with the
instructions of the supplier of refractory lining and the documentation of the
company responsible for the drying.
General
The drying of the refractory lining and heating of the plant must be carried out in
accordance with the relevant instructions of the refractories supplier.
The following preconditions must be fulfilled before the drying process can be
started:
• All flap valves must be completely open to ensure that the meal chutes and
cyclone cones are also thoroughly dried.
• To prevent condensation water from entering the pneumatic feeding system,
the meal ducts must be sealed off with blind flanges during the drying phase.
The blind flanges must be located just before the points where the meal ducts
enter the preheater .
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The drying of the refractory lining takes place independently of the heating up of
the kiln refractory lining. The magnesite lining partially installed in the kiln must be
continuously heated, and must not be exposed to low temperatures for prolonged
periods as occurs when preheater and kiln are dried simultaneously.
It takes approximately 5 days to dry the preheater, calciner, kiln and cooler.
However, the drying period may be longer if a lot of castable was used. It is
important that the preheater is completely dry at every location because any
residual moisture can lead to material incrustations in the first operating phase
and thus to operational failures, in particular in the topmost cyclone stage.
Ensure adequate ventilation during the drying operation so that the moisture can
escape from the plant without hindrance through the evaporation openings
mounted before.
Various types of burners can be used to dry the refractory lining of the preheater.
• monoblock burner, several ones if necessary, installed in the different

preheater stages.
• hot gas blowers operated with light oil,
• an additional burner (auxiliary light oil burner) which is installed in the inlet
housing of the kiln (see Figure 20 and Figure 21),
The refractory lining should only be dried using light oil auxiliary burners in
exceptional cases. The main reasons for this are as follows:
• Safety - the burner in the form shown does not have a flame monitor with
automatic fuel shut-off.
• Temperature adjustment - temperature adjustment is only possible to a limited
extent within the specifications of the supplier of the refractory material.
• In order to achieve an optimal result for the drying process, it is recommended
that this activity be delegated to an appropriate drying company. Details
regarding the drying process (arrangement and number of drying burners,
ventilation openings, steam extraction connections, temperature profile, etc.)
must be coordinated in good time with the supplier of the refractory lining, the
drying company and the machinery supplier.
If an auxiliary light oil burner is installed in the inlet housing of the kiln, the burner
draws the required combustion air through the kiln. In that case, a partition must
not be installed in the inlet housing.
If possible, the preheater has to be dried by means of the natural negative
pressure in the kiln
• with open fresh-air dampers in the exhaust gas duct

• with open inspection doors and dampers in the exhaust gas duct and in the
covers of the topmost cyclone stage
If electrical cables or measuring transducers are installed in the areas of the
doors or covers, make sure that these are covered and protected against all
escaping hot gases.
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If the natural suction in the kiln is not sufficient, the kiln exhaust gas fan has to be
operated at the lowest speed.
Inlet housing of additional burner
Figure 20
A = tank, at least 20 m higher than the burner lance

B = auxiliary burner
C = access door
D = distance approx. 1 m
E = ignition wall, approx. 50 cm high
F = standard bricks
G = possibly 2nd burner
H = only so much compressed air that the flame does not burn away from the
nozzle
I = 1 layer standard lining bricks
K = steel plate, approx. 6 mm thick
L = 2 times 16 C/I
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Light oil auxiliary burner
Figure 21 Light oil auxiliary burner
A = light oil
B = shut-off valve
C = control valve
D = Ermeto pipe, Ø10
E = pipe, 1 1/2”
F = control valve
G = compressed air, 4 to 6 bar
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To monitor the drying process, the temperature of the working lining of the
cyclones and the gas duct is measured (Figure 22). For this purpose, holes with
11 mm diameter are drilled through the steel casing and the insulation to the
surface of the working lining:
• into each cyclone cone 1 hole at the bottom and 1 hole at the top
• into each cyclone cover 1 hole
• into each gas duct 1 hole
• into each meal chute 1 hole
Figure 22 Inspection borehole
A = working lining
B = cyclone inside
C = insulation
D = measuring point
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Drying the tertiary air duct by means of the auxiliary burner

You can dry the tertiary air duct also by means of the auxiliary burner at the kiln
inlet. With this procedure, the cooler exhaust gas fan draws the hot gases
through the kiln and the tertiary air duct. For this, a temporary intermediate wall of
square timbers and insulation plates is installed in the cooler between the inlet
shaft and the tertiary air duct (see Figure 23).
• drying time: approx. 48 hours.

• maximum temperature in the tertiary air connection: 285 °C
• maximum temperature of the steel casing: 90 °C
temperature measuring
point
temporary diaphragm
Figure 23 Installation of a provisional partition wall
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Temperature measurements
You must number all the measuring points and measure the temperature of the
refractory lining with thermocouples every 4 hours, making a written record of the
measured values. The temperature measuring points for normal plant operation
monitoring (display in the control room) are also used for monitoring the drying
process, whereby the measured values are again recorded every 4 hours. The
maximum temperature increase is approx. 10 °C/h. Increase the fuel quantity for
the first time when the temperature with the initial rate of fuel supplied no longer
increases. Subsequently, increase the fuel quantity continuously. The slower the
drying proceeds, the better is the result and the lower is the risk that the
refractory lining is damaged during the drying procedure, or that parts of the lining
spall off.
The aim of the drying is to attain a temperature of at least 100 °C in the refractory
lining in the topmost cyclone stages and to exceed this temperature if possible.
Keep the temperature in the refractory lining stable for 24 hours. Normally, this is
sufficient to ensure that no more water exists within the refractory lining.
However, as a temperature of 100 °C or more cannot be attained everywhere
during the drying process, thorough drying of the refractory lining is sometimes
only possible during continuous operation.
After completion of the drying process, close the holes with 12 mm bolts.
During the drying procedure, the following must be ensured:
Install open flames in the centre of the open cross-section of the gas ducts so
that the flames do not come into contact with the refractory lining, at least not
at the beginning.
Possibly install an ignition wall.
Monitor the flame to ensure that it burns without smoking.
Make sure that local overheating of refractory lining or machine parts can not
occur (also when using hot air fans or monoblock burners).
Attempt to reach a temperature of 350 °C in the area of the auxiliary burner
and check the temperature regularly with an optical total-radiation-pyrometer.
Open the evaporation ports at all points of possible concentration of water
vapour between the refractory lining and the steel casing (e.g. cyclone
covers, top side of bends of the calcining loop).
If evaporation ports were not installed, cut evaporation openings into the steel
casing.
Example:
per cyclone cover 8 openings with Ø 50 mm or 2 - 4 openings with 100
x 100 mm;
after the drying process, close the evaporation openings with caps or by welding.
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The drying has to be carried out as follows:
1st day
Predry the preheater from the kiln inlet at low temperature and at high air flow
rates by means of a burner of the auxiliary firing system.
2nd and 3rd day

Slightly increase the temperatures, slowly increase the fuel quantity.
4th day
Slowly continue the drying operation with the main burner of the rotary kiln.
Increase the temperature slowly but continuously.
5th day
Continue the heating, slowly increase the fuel quantity.
6th day
Slowly increase the fuel quantity until the end of the drying operation.
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During the drying procedure, the following gas temperatures in the

preheater are approximately attained:
1st day 2nd day 3rd day 4th day 5th day 6th day
Gas temperature 100 200 300 400 450- End of drying

in the kiln inlet 650 process
*Calciner “I“ 50 60 110 260 380
Cyclone stage “I“ 50 60 110 200 300
*Gas duct “II“ 50 50 110 200 300
Cyclone stage “II“ 50 50 100 160 250
*Gas duct “III“ 50 50 100 160 250
Cyclone stage "III" 40 50 100 160 250
Gas duct "IV" 40 40 90 150 200
Cyclone stage "IV" 40 40 90 150 200
*Gas duct “V“ 30 40 80 150 200
Cyclone stage “V“ 30 40 80 140 200
NOTE
If the manufacturer of the refractory lining stipulates a drying curve, be sure to
comply with it during the drying process.
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4.4 Drying the refractory lining in the cooler and in the kiln hood
The drying of the refractory lining and heating of the plant must be carried out in
accordance with the relevant instructions of the refractories supplier. It is always
recommended that the drying of the refractory mixes be performed by a
specialised drying company.
Monitor the drying process by monitoring the installed temperature measuring
instruments and by carrying out additional manual temperature measurements. If
there is a danger of overheating, take suitable countermeasures such as
supplying cooling air, installing heat shields or removing sensitive components.
In order to prevent heat from escaping from the cooler, suitable insulation must
be installed in the kiln outlet and the cooler exhaust air duct. The dampers and
gate valves in the tertiary air duct must be closed.
Suitable burners for generating the drying heat can be installed in the area of the
access doors at the cooler and the kiln hood.
In addition to drying the refractory lining in the cooler and the kiln hood, the
refractory insulation of the burner lance can also be dried during this step. For
this purpose, the burner lance is inserted until just before the barrier installed in
the kiln outlet. During the drying process, a low volume flow of cooling air must be
supplied to the burner by means of the primary air fan. This flow rate is specified
by the supplier of the burner.
Figure 24 is a schematic of the arrangement for the drying of the cooler and kiln
hood.
CAUTION
The refractory lining may suffer damage.
For the drying process and the heating up, be sure to comply with the
instructions of the supplier of refractory lining and the documentation of the
company responsible for the drying.
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Flaps to be closed in Tertiary Air Duct and MiddleAir Duct
Bulkheadin CoolerExit Air Duct

Bulkheadin the Kiln
150mm Insulationon the grates
or at least 500mmClinkerbed
Thermocouplesabove and below the grates
Dry out burner
Figure 24 Drying out the refractory lining in the cooler (example only!)
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4.5 First commissioning

When the kiln plant has dried out, produce the raw meal required for starting the
kiln plant. To ensure a safe start, fill the raw meal silo approx. 30 %.
Make sure that the necessary quantity of raw meal and a basic amount of heavy
oil are available for starting the kiln plant. The main burner is so designed that
gas can also be used as fuel. A gas burner and a heavy oil burner are installed in
the calciner.
A short time before raw meal feeding may be started, the clinker conveying
equipment is started in the interlock sequence. The other cooling air fans of the
cooler and the cooler exhaust air fan are then switched on. A control loop keeps
the pressure in the kiln hood at a constant ±0 mbar with the cooler exhaust air
fan. Subsequently, the clinker crusher and the cooler grates are started. The
cooler grates are temporarily operated at the lowest speed.
The rotary kiln, calciner and preheater must be sufficiently heated up and the
clinkering zone must be hot enough for clinker to form. Suitably open the tertiary
air dampers and set the exhaust gas fans so that there is at least 2 % oxygen in
the gas at the kiln inlet and at least 4.5 % oxygen in the gas downstream of stage
2.
You can then feed in raw meal. Check for the formation of clinker through the
sight glass at the kiln outlet. The gas temperature at the kiln inlet should be 900
to 1000 °C. If the fresh air dampers are open, close them and then increase the
negative pressure downstream of the preheater to approx. -12 to -15 mbar by
raising the speed of the exhaust gas fan and feed in approx. 30% of the raw meal
quantity required for the rated throughput of the plant. Increase the fuel quantity
at the main burner if necessary or feed fuel into the precalciner. Rotate the kiln
continuously at low speed.
Make sure that the exhaust gas temperature at the exhaust gas fans does not
exceed the maximum permissible value. In the further course of the process, the
exhaust gas temperature is regulated via the raw meal quantity, so that finally the
normal operating values of between approx. 320 and 340 °C are attained for the
gas temperature after cyclone stage 5.
As long as no coating has formed on the kiln's refractory lining, only feed 30 % of
the raw meal quantity required for rated capacity to the preheater.
As soon as clinker is produced which has been sufficiently cooled down in the
cooler (max. 100 °C), fill so much of this clinker into the silo for underburnt clinker
that the silo's floor is completely covered with clinker even after subsequent
emptying or until a natural slope has built up. This ensures that in later operation,
when situations arise where hot underburnt clinker may have to be filled into the
silo for underburnt clinker (if installed), the hot clinker does not fall directly onto
the silo floor but onto an existing layer of cold clinker. This prevents stress cracks
in the silo as a result of excessive temperatures.
NOTE
Hot clinker must not be filled into the completely emptied and well-swept silo for
underburnt clinker. The silo floor must always be covered with a layer of cold
clinker.
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4.6 Checking the plant and correcting the settings
Take care particularly in the start-up phase that the flap valves in the meal
chutes operate perfectly and that the meal flows unhindered. Correspondingly
adjust the counterweights of the flap valves and later correct them at rated
throughput and fix them if necessary.
The temperature and pressure conditions, as well as the gas analyses,
provide information about the operating conditions.
Check the values shown on all indicators. If there are unacceptable
deviations, immediately investigate the cause. Immediately eliminate any
faults.
Check the clearance at the kiln inlet seal and the kiln outlet seal and adjust it if
necessary.
Check the bearing temperatures.
It is advisable not to alter the settings in the first hours after feeding in meal.
To increase the throughput, first raise the speed of the kiln. A little later (e.g.
after 15 minutes), raise the speed of the exhaust gas fans and then increase
the fuel and raw meal feed rates. Any alteration that is effected too early may
cause flushing of raw meal through the kiln.
Carry out any increase in the raw meal feed rate step by step. Adjust the
negative pressure and the fuel quantity so that no CO forms, the oxygen
content in the gas after the precalciner is not lower than 2 % and overheating
of the preheater is prevented. The content of oxygen in the gas at the kiln inlet
must not be below 2 % either.
NOTE
Before increasing the fuel quantity by metered amounts, wait until the content of
oxygen in the gas after the precalciner has clearly risen (e.g. to 4.5 %) due to the
increase in speed of the exhaust gas fans.
After short stoppages from full kiln operation, which means that the kiln is hot,
the raw meal feed rate may be approx. 2/3 of the required flow rate at nominal
capacity. Even when lower feed rates are being used, restart the plant with the
precalcination running right from the outset. The kiln output can then be
increased far more quickly than is possible if it is started from cold condition.
If raw meal nevertheless flushes through during the starting procedure,
operate the plant at constant operating parameters and wait until clinker forms
and kiln operation is normal. To further reduce the already low kiln rotation
speed during the startup is wrong.
Heat up the plant again if the kiln is too cold.
After kiln operation has stabilised, try to set higher speeds as soon as
possible.
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After the start-up, you must check the clinkering zone burner. Make sure that
the burner nozzle of the clinkering zone burner is horizontal. It must project far
enough into the kiln for the last section of the kiln to be used as a cooling
zone, so that the clinker is not too hot when entering the cooler. Align the
nozzle tip with the kiln axis, so that the flame burns at the centre of the rotary
kiln without overheating the kiln refractory lining.
You will possibly have to slightly correct the position and inclination of the
burner nozzle later during normal kiln operation at nominal capacity. The
burning conditions that occur as a result of the raw meal properties are
decisive. Direct the flame slightly towards the slope of the kiln charge material.
Evaluate the combustion quality on the basis of the content of CO and O2 in
the kiln exhaust gases.
NOTE
Make sure that combustion takes place with air excess; there must be no CO in
the exhaust gas.
If necessary, you can alter the clinkering zone by taking the following measures:
by axially shifting the burner nozzle;
by varying the primary air. More swirl air than axial air results in a short wide
flame and more axial air than swirl air in a long narrow flame.
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Operating manual Starting the plant
5 Starting the plant
NOTE
Start the constant-speed fans only when the dampers are closed. Otherwise the
drive motors of the fans will be overloaded.
NOTE
Be sure to also comply with the data stated in section Commissioning.
The start-up, stoppage and operation are linked with the following 3 types of
condition:
• Starting conditions:
a starting condition must be fulfilled before a group or operating mode can be
started.
• Permanent conditions:
the permanent condition must be fulfilled in order for the group to remain in
operation.
• Stopping conditions:
the corresponding group is stopped when a stopping condition is fulfilled.
5.1 Heating up the kiln plant

As soon as the kiln plant has dried out, you can start to heat it up.
Close all covers, doors and flaps in the preheater.
Shortly before starting to feed in raw meal, close the openings (if any) drilled
in the cyclone walls for moisture evaporation.
Start the filter and exhaust gas fans,
Start the primary air fans (clinkering zone burner and calciner burner) and the
oil treatment system,
Start the cooling air fans.
Adapt the position of the fresh-air dampers in the preheater to the pressure
conditions,
Ignite the clinkering zone firing system.
For heating up the kiln plant, use gas or oil as fuel. Carefully check all conveying
and feeding devices before commissioning the firing system. Only then may you
switch on the plant.
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Starting the plant Operating manual
O ti
Electrostatic precipitator
The electrostatic precipitators must not be switched on until the following
conditions are met:
• The preconditions specified by the supplier of the electrostatic precipitators

must be fulfilled.
• The fuel must burn properly, i.e. without forming CO and with air excess.
• A timeout of at least 5 minutes must have been observed in order to ensure
that the last CO vapours have been expelled.
• The filters must be dry.
• It must be ensured that the CO shutdown and the electrostatic precipitator
earth connection are functioning.
• The locking mechanisms in the exhaust gas paths must function properly with
the firing system.
The electrostatic precipitators must be switched off immediately and

automatically earthed under the following circumstances:
• If faults occur that could lead to the formation of CO, or that could make it
necessary to switch off the kiln
• If the CO limit value automatic shut-down facility fails, or if it cannot be
guaranteed that the CO analyser is working properly
Before starting raw meal feeding, you must adjust the pressure conditions in the
kiln so that the fuel is burnt with the lowest possible combustion air volume
without CO formation, and so that as much heat as possible remains in the
clinkering zone. The flame must be short, compact and steady.
The temperature after Stage 5 and at the exhaust gas fan must not exceed 450
°C. At a temperature of 430 °C, an alarm message is issued and at 450 °C, the
kiln plant is shut down.
The combustion air is supplied by operating the first cooling air fans.
When the flame has been ignited, turn the kiln for the first time by 180° after
approximately 2 hours and then by 120° every 30 minutes for 3 to 5 hours. As
heating up progresses, rotate the kiln more frequently and rotate it continuously
when the operating temperature is reached.
Great care is necessary when the kiln is heated up for the first time and the
refractory lining must be constantly monitored.
The turning of the kiln prevents distortion. It is performed with the lowest speed in
order to prevent loosening of the refractory brick lining.
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NOTE
When rotating the kiln at low speed, ensure that the bearings in the supporting
roller stations are supplied with sufficient quantities of lubricating oil. If the
lubricating oil pump fails, oil must be poured onto the bearing trunnions through
the filling nozzles by hand. Especially after a prolonged stoppage, make sure that
lubricating oil is poured onto the bearing trunnions.
The auxiliary drive is used for vibration free turning at low speed, also in the case
of main drive failure. It must always be ready for operation so that the hot kiln can
be rotated even in the case of power failures.
The entire heating-up process takes approximately 48 hours.
Heating-up diagrams
The diagrams for heating up the plant with gas and fuel oil are only examples.
Heating-up curve for gas
Heating up curve Gas

Start up of kiln feed
10.000
9.000
Gas quantity in [Nm³/h]
8.000
7.000
6.000
5.000
4.000
3.000
2.000
1.000
0
0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 45,0 50,0
Time in hours
Figure 25 Heating-up curve for gas
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Heating-up curve for oil
Heating up curve Oil

Startup of kiln feed
10.000
9.000
Oil quantity in [l/h]
8.000
7.000
6.000
5.000
4.000
3.000
2.000
1.000
0
0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 45,0 50,0
Time in hours
Figure 26 Heating-up curve for oil
During the heating up phase, twice feed a raw meal quantity of approx. 30 t into
the preheater. This promotes the formation of coating in the clinkering zone and
additionally provides a covering layer on the first cooler grate. Stability of the
flame is thus attained sooner due to the availability of slightly heated combustion
air.
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Figure 27 Heating-up curves
Explanations regarding the diagrams

Increase the fuel quantity at the main burner so that the temperatures increase
continuously. Before starting raw meal feeding, adjust the pressure conditions so
that the following combustion conditions are achieved:
• the combustion air volume is as small as possible,
• CO does not form,
• the heat largely remains in the clinkering zone,
• the flame is short, compact and steady.
The time required for heating up the kiln plant depends on the kiln temperature. If
the kiln has completely cooled down, the heating up to operating temperature
takes approx. 44 - 48 hours.
NOTE
Follow the temperature : time curve in Figure 27 when heating up the kiln.
But also strictly observe the instructions of the manufacturers of the refractory
lining material.
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Inching and turning the kiln

While heating up the kiln, inch and rotate it continuously. Be sure to comply with
the recommended values for a cold kiln in the following table:
Time Turning
after approx. 2 hours 180°
up to the 12th hour by 120° every 30 minutes
13th to 26th hour by 120° every 20 minutes
27th to 40th hour by 120° every 15 minutes
41st to 46th hour by 120° every 10 minutes
47th to 48th hour continuously by means of the auxiliary drive
5.2 Starting the REPOL® clinker cooler

Always put the various control loops as early as possible into the Automatic
operating mode in order to facilitate the operator's work and allow him to
concentrate on essential matters. The cooler is started in combination with the
kiln plant. After the heating up and immediately before meal feeding, the plant is
in the following status:
Automatic operation,
Kiln hood pressure control
set pressure value: -0.2 mbar
"Automatic", V=min, or = secondary air

Cooling air fans
flow rate
Grate 1 "Manual", stop
Grate 2 "Manual", stop
When raw meal feeding starts, you must

• abruptly increase the fuel quantity,
• increase the amount of secondary air and tertiary air and
• increase the rotational speed of the kiln.
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Depending on the amount of raw meal in the kiln, you have to expect the first
clinker feed into the cooler immediately or delayed by the material retention time
(approx. 0.5 h) and start the reciprocating tracks. At first, keep the stroke
frequency of the reciprocating grates as low as possible in order to quickly attain
a high secondary air temperature and protect the grate plates against
overheating. Increase the cooling air flow rate and the grate operating speed step
by step in accordance with the increasing raw meal and fuel feed rate. When the
rated capacity is achieved, also switch the reciprocating grates into Automatic
operating mode and bring them up to the respective setpoint values.
Like the entire plant, the clinker cooler incl. clinker conveying equipment and
cooler exhaust air dedusting system are started up and shut down in successive
groups.
5.3 General information about starting the kiln plant
Starting and stopping the cooler

After drying the refractory lining and before starting up, you must fill the cooler
with cold pyroprocessed material to a bed height of approx. 500-700 mm. This
layer of cold material protects the aeration units against overheating and protects
the concrete of the HORSE SHOE against heating up too quickly. Start the cooler
before starting the preheater feed meal unit and move the reciprocating grates at
minimum stroke frequency.
A minimum pressure below the aeration floor is necessary for starting the cooler.
If this pressure is not reached, tightness of the aeration floor is not ensured.
The reciprocating grates cannot be switched on until there is a pressure of at
least 10 mbar in compartments 1-6 and 5 mbar in compartments 7 to 9.
NOTE
Make absolutely sure that the aeration floor is always covered with a material
layer of sufficient height!
During the first starting period, the secondary air consumption is so low that you
can throttle down the fans for the first chambers. As the kiln output increases,
successively switch on the other fans. When you switch on the fans, make sure
that all throttle devices are closed.
When starting up the cooler take special care that the transport tracks do not
overheat, in order to prevent damage. The temperature of the transport tracks is
monitored. If the infed air flow rate is not sufficient to keep the transport track
temperature below the alarm temperature, you have to increase the air supply by
increasing the motor speed for the fans or by opening the throttle devices. The
cooling air not required for the rotary kiln is then discharged into the atmosphere
with the exhaust air.
Set the pressure in the compartment of the static pre-grate at least 2-5 mbar
higher than the pressure in the following compartment in order to prevent clinker
from entering into the compartment below the static pre-grate. This applies to all
cooler operating modes.
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As the quantity of material to be cooled increases, raise the cooling air flow rate
accordingly.
The specified values are reference values and have to be adapted according to
requirements and further experience. You must adjust the forward stroke speed
to suit the incoming quantity of material to be cooled.
The depth of the bed of cooling material on the aeration floor is thus dependent
both on the incoming quantity and on the stroke frequency of the reciprocating
grates.
Always control the clinker cooler manually during the starting up phase. Do not
switch on the automatic control system until the normal operating state has been
attained.
Under normal circumstances, the compartment pressure of one of the front
cooling air compartments is used for controlling the stroke frequency.
Alternatively, the stroke frequency can be controlled via the clinker bed depth
measurement.
If kiln operation is interrupted, make sure that the clinker cooler remains in
operation as long as material to be cooled is discharged from the rotary kiln. You
must adjust the stroke frequency to suit the decreasing quantity of incoming
material.
As long as the kiln is being turned with the main drive, you must keep the
reciprocating grates operating, as otherwise the main drive of the rotary kiln fails
via the interlock.
At the end, the reciprocating grates must be operated manually at the lowest
stroke frequency. If the kiln is only being rotated with the auxiliary drive, the
reciprocating grates must be operated at intervals. For this purpose, start the
grate from the control room in individual operation.
Never allow the cooler to run until it is empty, except as preparation for the
performance of repair work. You must adjust the stroke frequency to suit the
decreasing quantity of incoming material. Furthermore, you must prevent
excessive dust formation by throttling the cooling air flow correspondingly, but
only to a degree which still ensures that the reciprocating grates are not damaged
by overheating. Before shutting down, set the fans to minimum speed.
Never shut down the fans until the reciprocating grates have been stopped and
the material on the grate has sufficiently cooled down. The aeration floor could
otherwise be damaged.
If the clinker cooler was emptied for repair work, restart the plant as described
previously.
Note that the rotary kiln can also discharge material to be cooled while it is being
turned until cold and inched. If this happens, you must switch the clinker cooler
on again for a short time.
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Starting the kiln plant

The preheater, kiln, kiln feed system and exhaust gas filter form a single unit as
regards the start sequence. . The REPOL® cooler is already in operation with the
grates running at minimum speed.
To protect the kiln plant against damage during the heating up or during
operation, all plant component groups are interlocked with one another. This
means that the plant component groups can only be started in accordance with
the following scheme (start sequence). The scheme results from the safety
interlocks of the kiln plant.
After the heating up and immediately before meal feeding, the plant is in the
following status:
1. Cooler grates Minimum stroke frequency
2. Main kiln drive Kiln speed approx. 0.6 to 0.8 min-1
3. Cooling air fans Increase the cooling air flow rate to

approx. 30% of the normal air flow rate
4. Cooler exhaust air fan Pressure at the kiln hood approx. -0.1 to
-0.3 mbar
5. Main burner Gas: approx. 5000 m³/h or

oil: approx. 5500 kg/h
6. Start of meal feed equipment 30 % to 40 % of rated capacity,

tertiary air damper 20 % open
As it takes approx. 30 seconds from the start of raw meal feeding to entry of the
raw meal into the gas duct (so-called dead time), do not change the pressure
after the preheater until you observe a reduction in the gas temperature in the
preheater. If you increase the draught in the preheater too quickly (without
adequate raw meal feed rate), there is the danger that the plant will fail
because of excessive exhaust gas temperatures.
7. Pressure after preheater Set to approx. -15 mbar by

opening the shut-off flaps,
closing the fresh-air flaps,
increasing the speed of the fans
8. Fuel quantity increase Entire heat consumption approx. 1300 to

1700 kcal/kg clinker
The initial heat consumption will be 1300 to 1700 kcal/kg of clinker, which will
decrease to normal values (approx. 725 kcal/kg of clinker) as the temperatures
of secondary air and tertiary air rise and the throughput increases.
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Fuel distribution: Main burner approx. 65 %,

Calciner burner approx. 35%
Kiln inlet temperature approx. 1050 °C
Temperature after Stage 1 approx. 860 °C
Temperature in meal chute 1 approx. 840 °C
As soon as the raw meal feed system is started and the temperatures in the
lower meal chutes have reached approx. 860°C, you can start the calciner
burner with minimum fuel quantity. Make absolutely sure that the content of O2
after stage 2 is at least 4.5% O2 before the calciner burner is started.
Do not start the calciner burner until you observe a temperature drop in the
lower meal chutes, which indicates that raw meal is flowing.
9. Start of the calciner burner Increase the fuel quantity so that the
temperature in meal chute 1 rises to
above 800 °C as quickly as possible.
10. Cooling air flow rate Set the cooling air flow rate in
accordance with the raw meal feed rate
(normally approx. 1.8 Nm³/kg clinker).
Operate the plant with the above-mentioned setting until clinker forms in the
clinkering zone (visual inspection by means of the kiln camera). A further
indication for clinker formation is an increasing power consumption of the kiln
main drive. If you cannot detect this, you should increase the fuel quantity at the
main burner.
Because of the small quantity of raw meal that is fed in during the start-up phase,
pay particular attention that the maximum permissible temperatures in and
downstream of the preheater are not exceeded. The fuel quantity to be fed in
depends on these temperatures. If the temperatures increase too high, the raw
meal feed should be increased as quickly as possible in order to prevent failure of
the plant.
Maximum permissible temperatures in and downstream of the preheater
Upstream of fans approx. 450 °C
Downstream of preheater stage 5 approx. 480 °C
In meal chutes of stage 1 approx. 880 °C
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Increasing the plant throughput

As soon as clinker forms in the clinkering zone, you can increase the throughput
of the plant as follows:
1. Increase the speed of the filter fan and the exhaust gas fans. The guide
value is the content of O2 downstream of the preheater or downstream of
stage 2. Before you increase the fuel supply, the oxygen content should
be at least 3 - 4%. The speed of the filter fan depends on the pressure
after the exhaust gas fan (-5 mbar).
2. Open the tertiary air dampers step by step. The O2 concentrations in the
kiln inlet and downstream of stage 2 are the relevant process variables.
Each O2 content should be approx. 2 - 3%.
3. Increase the cooling air flow rate keeping the kiln hood pressure at -0.1
mbar.
4. Increase the fuel supply at the clinkering zone burner and the calciner
burner (fuel distribution at rated capacity: clinkering zone burner approx.
45%, calciner burner approx. 55%).
5. Increase the meal feed in accordance with the fuel supply.
6. Increase the rotational speed of the kiln. The rotational speed is

increased in accordance with the raw meal feed rate. It is advantageous
to keep the filling ratio of the kiln as low as possible.
Every increase of the throughput causes a rise in the quantity of clinker

discharged from the kiln and leads to an increase in the temperatures of
secondary air and tertiary air. For each increase of the throughput, you must
increase the stroke frequency of the cooler. You must also suitably adjust the
cooling air flow rate at the cooling air fans of the cooler (approx. 1.8 Nm³/kg of
clinker).
NOTE
The heat requirement of the kiln decreases with increasing secondary and tertiary
air temperature. The danger of overheating is avoided by reducing the fuel
quantity and/or by increasing the raw meal feed rate. The relevant process
variables are the temperatures in the kiln inlet, in meal chute 1 and downstream of
the preheater.
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Manually operate the cooler grates until the pressure in compartment 1 is approx.
50 to 60 mbar. Then switch on the cooler control system and optimise. The cooler
control system keeps the pressure constant via the stroke frequency of the
grates. If the pressure decreases, the stroke frequency is reduced; if the pressure
increases, the stroke frequency is increased. But a constant pressure under the
clinker bed does not necessarily mean a uniform bed depth. Rather, the bed
depth on the grates depends on the air permeability of the clinker bed. Given the
same pressure below the grates, coarse clinker causes a deep clinker bed to
form and fine-grained clinker causes a shallow clinker bed to form.
Starting after a short stoppage

After short stoppages from full kiln operation, which means that the kiln is hot, the
raw meal feed rate may be approx. 2/3 of the required raw meal quantity at
nominal capacity. Even when lower raw meal feed rates are being used, restart
the plant with the calcination running right from the outset. The kiln output can
then be increased far more quickly than is possible if it is started from the cold
condition.
If raw meal nevertheless flushes through during the starting procedure, operate
the plant at constant operating parameters and wait until clinker forms and kiln
operation is normal. To further reduce the already low kiln rotation speed during
the startup is wrong.
If the kiln becomes too cold, you must heat up the plant again.
After kiln operation has stabilised, try to set higher speeds as soon as possible.
5.4 Start sequence of the kiln plant

The plant is automatically started in starting groups via a programmed control
system. The following is an overview of the starting sequence of the individual
machines. For detailed information on the start-up sequence and start-up
conditions, refer to the process functional diagrams.
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Operating manual Operation
6 Operation
NOTE
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
6.1 Preheater
The function of the preheater is to optimally carry out the heat transfer from the
gas to the material. This optimum is attained if the following individual conditions
are fulfilled:
• the exhaust gas temperature after preheater is at a minimum,
• the exhaust gas flow volume after preheater is at a minimum,
• the pressure drop of the preheater is at a minimum,
• the raw gas dust content in the exhaust gas after preheater is at a minimum,
• the temperature of the raw meal at the calciner inlet is at a maximum.
The exhaust gas consists of the following components:

• combustion air
• false air,
• carbon dioxide from the raw meal,
• water vapour from the residual moisture content of the raw meal,
• other volatile gas components from the raw meal (e.g. SO2).
At the given raw meal composition, the portion of exhaust gas originating from
heating and decarbonation of the raw meal is largely constant. The portion of
false air also does not fluctuate greatly if the plant is well-maintained and tight.
However, the combustion air flow volume is variable and depends on the type of
fuel, the heat consumption and on an operating mode that is more or less
optimal.
The above-mentioned optimal operating points such as minimisation of the
exhaust gas flow volume and temperature or the pressure drop are primarily
attained with a given fuel by minimisation of the heat consumption and by
optimum combustion. The preheater is so designed with regard to the cross-
sections of gas ducts and cyclones that the gas velocities occurring during an
optimum mode of operation are sufficient for carrying the dispersed raw meal and
ensuring good separation of gas and raw meal in the cyclones.
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Operation Operating manual
The main optimisation target when operating the preheater is to set an air excess
that is as constant as possible and adequate for combustion both in the calciner
and in the clinkering zone. An adequate air excess is achieved when specific
oxygen concentrations are observed; the required gas analysis is performed after
stage 2 or after the exhaust gas fan. The target values are from 3 to max. 5% O2.
The optimum is achieved when the oxygen concentration is as low as possible
and no significant carbon monoxide formation results from the combustion.
The following points are important for operating a cyclone preheater:
• good dispersion of the raw meal in the gas stream (function of the dispersing
boxes),
• collection performance of the cyclones,
• prevention of gas flows through meal ducts (flap valves),
• prevention of incrustations and blockages.
The above are, however, factors that depend on the design and on the operating
conditions and can therefore not be directly regarded as operating parameters.
But it is absolutely essential to regularly inspect the devices installed for ensuring
proper operation, such as shock blowers, compressed air cleaning systems, flap
valves etc., and to service them as necessary.
The preheater is equipped with a large number of temperature and pressure
measuring points in order to monitor its proper functioning. Possible clogging of
the critical cyclones is detected by gamma ray emitters. Visual inspection can be
carried out through inspection and cleanout ports.
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6.2 Calciner
Decarbonation of the raw meal

The calciner has two primary functions. First, it serves to largely decarbonise the
raw meal preheated in the preheater, i.e. to expel the carbon dioxide bound in the
calcium carbonate and convert the Ca(CO)3 into calcium oxide (CaO). Secondly,
the nitrogen oxides formed in the clinkering zone have to be reduced and new
production of nitrogen from the fuel in the calciner has to be largely prevented.
Decarbonation of the calcium carbonate already begins at relatively low
temperatures of approx. 700 °C. However, for this process to be performed on a
large scale within a few seconds in a calciner, temperatures of approx. 850 to
900 °C are required.
In industrial practice, calciners are operated as a function of the temperature.
Suitable master process variables are the temperature of the raw meal in the hot
meal chute of stage 1 or the gas temperature after cyclone stage 1.
The temperature required for achieving a specific degree of decarbonation
depends, to a certain extent, on the raw meal properties. The general rule is that
a temperature of approx. 850 - 860 °C is necessary at the end of the calciner or
after cyclone 1 in order to obtain a degree of decarbonation of approx. 90 to 95
%. The temperature in the meal chute will then be similar. It is good policy to
prepare a diagram that shows the achieved degrees of decarbonation as a
function of the master process variable (e.g. of the gas temperature after cyclone
stage 1 or the temperature in the meal chute).
The energy input into the calciner mainly originates from the following sources:
• the combustion heat of the fuel for the calciner burner,
• the kiln exhaust gas and the dust it contains,
• the tertiary air and dust it contains.
The largest portion and also the one which is easiest to control is the combustion
heat from the fuel for the calciner burner. This variable is therefore used for
controlling or regulating the temperature in the calciner. As a rule, operation in
accordance with the a.m. principles results in a fuel quantity split of 55 % to the
calciner burner and 45 % to the clinkering zone burner. A deviation of approx.
± 5 % serves as margin for consideration or optimisation of further important
parameters such as clinker quality or formation of incrustation in the kiln inlet or
calciner.
Using the tertiary air damper as final control element thus enables distribution of
the combustion air flow rates to the clinkering zone firing system and the calciner
firing system. An important setting parameter is the oxygen content measured at
the kiln inlet. The target values are from 2 % to 4 % in order to prevent reducing
conditions with all their associated disadvantages from occurring in the rotary kiln.
It is also important that the content of carbon monoxide and sulphur dioxide is
low. High values of these gas components indicate a lack of oxygen in the
clinkering zone firing system.
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6.3 Kiln
In the rotary kiln, the preheated and decarbonated raw meal is burnt to cement
clinker. During this process, clinker minerals are formed from the main oxides
CaO, SiO2, Fe2O3 and Al2O3. Also, the fine-grained raw meal agglomerates to
form the much coarser cement clinker.
The energy required for the clinker formation is mainly supplied via the main or
clinkering zone burner into the rotary kiln. A smaller portion comes with the
secondary air into the system and contains the heat quantity recuperated from
the cement clinker during the cooling process. Important operating and setting
parameters in this plant section are the supplied quantity of fuel and the rotation
speed of the kiln. The fuel quantity supplied through the clinkering zone burner is
approx. 45% of the total quantity. Minor changes are necessary during normal
operation as a result of normal control variables such as the temperature in the
clinkering zone, current or power consumption of the main drive and temperature
at the kiln inlet. At rated capacity, the kiln rotation speed must be close to the
maximum value. In the case of varying meal feed, a useful measure is to keep
the kiln rotation speed and the raw meal feed rate directly proportional to each
other as this helps to obtain an approximately constant filling ratio in the kiln.
6.4 REPOL® clinker cooler

The following requirements must be optimally fulfilled by the clinker cooler:
• Cooling of the clinker

• Recuperation of the clinker heat
• Ensuring a good clinker quality
• Reliable and troublefree operation (minimisation of wear)
• Minimisation of the auxiliary power consumption
• Elimination of health risks for the operating personnel
All these requirements and conditions are fulfilled and complied with by observing
the operating instructions, by a technical system of process interlocks and by the
installed control system.
The best possible heat recuperation on a grate cooler is always achieved with a
clinker bed that is as deep as possible. This maximises both the retention time of
the clinker on the grate and the retention time of the cooling air that flows through
the clinker bed in crosscurrent.
However, in industrial practice you often find phenomena that reduce the validity
of the above-mentioned rule:
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• If the clinker beds are too deep, local eruption-like air blowthroughs occur.
The air escaping through these blowthroughs only has a limited contact with
the clinker particles and is therefore only involved to a limited extent in the
heat transfer. A decisive criterion in this context is the air permeability of the
clinker bed. The air permeability, in turn, depends to a large extent on the
grain size distribution curve of the clinker. Clinker with a large content of
fines has a bad air permeability. A further indicator is the steepness of the
grain size distribution curve. Clinker with a steep distribution curve has a
greater gap volume and therefore better air permeability than clinker with a
flat grain size distribution curve.
• Inhomogeneities in the grain size distribution, e.g. due to segregation when
the material is discharged from the rotary kiln or as a result of coating
collapse (relatively coarse clinker lumps), result in locally better or poorer air
permeability of the clinker bed. As a consequence, the already mentioned
local air blowthroughs may occur.
• The clinker in the kiln discharge zone or on the first cooler grate may frit if
the clinker bed is too deep or the cooling air flow rate is too small. This
strongly reduces the air permeability in such sections, so that the cooling of
the material and the heat transfer are non-optimum.
You can conclude from the above that the cooler has to be operated at the
deepest possible clinker bed but without any air blowthroughs. The optimum bed
depth depends to a large extent on the granulometric distribution of the clinker.
The clinker bed depth is optimal when no or only minor air blowthroughs occur
and the clinker does not frit.
In industrial practice, bed depths between 0.5 m and 0.8 m are normal. When the
clinker fineness changes, it may be necessary to adjust the bed depth. As a rule,
the bed depth required for finer clinker is less than that needed for coarser
clinker.
Air flow rate

The clinker has to be quickly cooled to assure a good clinker quality. This
prevents re-formation of C3S into C2S and free lime. This initial fast cooling-down
takes place on the static pre-grate. The cooling air flow rate must be selected to
ensure that fritting and excessive formation of snowmen are prevented. As
already explained above, the clinker's granulometric distribution plays an
important role in addition to its tendency to stick.
The specific cooling air flow rate on the static pre-grate has to be set between
4000 and 7000 m3/m2/h effective aeration surface. If the clinker has a particularly
strong tendency to form snowmen, the static pre-grate is also kept free by using
the shock blowers. The further cooling air distribution over the length of the cooler
generally has an approximately linear, downward-inclined characteristic curve of
the gas inlet velocity.
The design characteristic curve has a +/- range which is reached in operation. As
a rule, the fans are operated 5 - 15% below the design characteristic curve. This
is dependent on the clinker grain size, the bed depth, the required ultimate clinker
temperature etc. If necessary, certain reserves resulting from pressure and motor
reserves are available in addition to the values of the design characteristic curve.
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For optimum operation of the clinker cooler in combination with the kiln system,
not only the bed depth but also the uniformity of operation are of major
importance. It can be assumed that, as a result of varying coating conditions, the
mass flow discharged from the rotary kiln is not always constant. To minimise the
recoupling effects, e.g. via the temperature of the secondary air, the bed depth on
the grate must be as constant as possible. As there is no available means of
directly measuring the bed depth on a clinker cooler that has been sufficiently
tested in industrial practice, the pressure in one of the aeration compartments is
used as substitute controlled variable. The connection between bed depth and
compartment pressure is mainly influenced by the flow rate and the granulometric
distribution of the clinker. During normal operation and when production is
constant, the set flow rates in the individual compartments remain unchanged.
The effect of variation in the granulometric distribution is not taken into account in
the control loop.
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Figure 28
Rotary kiln plant
Operating manual
Saman Gargh Cement Co., Iran Kühlerbetrieb: Richtlinie zur Einstellung der Kühlluftmengen Bearbeiter: 150-ADL
SAMANFA Anmerkung: Diese Richtlinie muss den tatsächlichen Betriebsbedingungen angepasst werden Datum: 29.01.2009
Rohmehl/Klinker-Faktor 1,65
Schichthöhe 500 - 800 mm Umgebungstemperatur: 20 °C
Schubzahl 5 - 7 1/min bei 3500 t/24 h Baromterstand: 856 mbar
Ofenaufgabe t/h 241 96 112 128 144 160 176 193 209 225 241
Ofenleistung t/24 h 3500 1400 1630 1860 2090 2330 2560 2810 3040 3270 3500
Ofenleistung % 100 40,0% 46,7% 53,3% 60,0% 66,7% 73,3% 80,0% 86,7% 93,3% 100,0%
Air flow rate setting and distribution

Auslegung Ventilatoren
m³/h mbar
Ventilator 1A/1B m³/h 29000 100 19720 20270 20820 21370 21920 22470 23020 23570 24120 24650
Ventilator 2 m³/h 35000 90 22310 23140 23970 24800 25630 26460 27290 28120 28950 29750
Ventilator 3 m³/h 34000 80 20230 21190 22150 23110 24070 25030 25990 26950 27910 28900
Ventilator 4 m³/h 44000 70 24310 25760 27210 28660 30110 31560 33010 34460 35910 37400
Ventilator 5 m³/h 42000 60 21420 23010 24600 26190 27780 29370 30960 32550 34140 35700
Ventilator 6 m³/h 46000 55 21510 23460 25410 27360 29310 31260 33210 35160 37110 39100
Ventilator 7 m³/h 59000 50 25080 27870 30660 33450 36240 39030 41820 44610 47400 50150
Ventilator 8 m³/h 54000 40 20660 23460 26260 29060 31860 34660 37460 40260 43060 45900
Ventilator 9 m³/h 65000 35 22100 25780 29460 33140 36820 40500 44180 47860 51540 55250
Kühlluft, gesamt m³/h 408000 197340 213940 230540 247140 263740 280340 296940 313540 330140 346800
spez. Kühlluftmenge m³/kg cli. 2,80 3,38 3,15 2,97 2,84 2,72 2,63 2,54 2,48 2,42 2,38
spez. Kühlluftmenge Nm³/kg cli. 2,20 2,66 2,48 2,34 2,23 2,14 2,07 2,00 1,95 1,91 1,87
6-7
Operation
Operating reliability
The capacity of the cooling air fans and also the power of the grate drive have
been dimensioned with adequate safety taking into account the a.m. conditions
and a number of other criteria. The same also applies, for example, to the
refractory lining quality or to all other materials used. Nevertheless, the limits of
material loading capacity, e.g. with regard to temperature, may be reached under
certain operating conditions. Therefore make absolutely sure that the material-
related limit values (e.g. maximum temperature of the grate plates) are not
exceeded.
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6.5 Safety interlocks of the kiln plant

Fig. 29 shows the most important safety interlocks of the kiln plant.
T before filter > CO downstream of
maxmax heat exchanger
> MaxMax (0.8%)
Stop Kiln hood pressure

> MaxMax (+2mbar
Filter or +1mbar>3sec)
fan
Pressure
downstream of
Stop
DOPOL fan
System fan Primary air fan
Stop
Temp. downstream
Main burner Stop of heat exchanger
> MaxMax (450°C)
Stop after
Filter dust
1 hour
Stop
Raw meal CO after PHASE II

Stop PC burner Stop
feed system > MaxMax (0.5%)
Clinker crusher
Stop
Stop
Stop after
Main drive 5 min Grate 1 Stop Grate 2
Stop
Clinker conveying
Stop after 5 Stop after 15 Reduced kiln output or stop

minutes minutes
Cooler fans
in recuperation Cooler fans Cooler fans
zone, failure of 2 Recuperation in finish cooling
zone, Cooler exhaust air
or more zone, failure of
failure of fan
Fans one fan
one fan
Figure 29 Safety interlocks
Be sure to comply with the additional safety interlocks for the cooler, as stipulated
in the machine manual.
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6.6 Operation in the case of a power failure

In order to guarantee the safety of the kiln plant in the event of a power failure, it is necessary to
connect various units to an emergency power supply system. The following table gives a basic
overview of the drive units that must be taken into consideration.
List of the emergency power consumers Essen- Recom- Note Item

tial mended
I. General
1. Emergency lighting X Customer
2. Cooling water pumps / cooling water X Customer
supply system
3. Passenger and goods lifts X 4G1.EV01
4G2.EV01
4. Telephone and intercom systems X Customer
5. Workshops X Customer
6. USP unit for computer and process X Customer
automation equipment
II. Raw mill
7. Control voltage for the entire raw grinding X Customer
plant
8. Damper, mill exhaust air fan X 3F1.FN01.
TVJ01
3F2.FN01.
VJ01
9. Drive of mill exhaust air fan X 3F1.FN01.
DRV01
3F2.FN01.
RV01
10. Sealing air fans for roller mill X 3F1.RM01.
CAS01/02
3F2.RM01.CA
S01/02
11. Transformers and control cabinets for X 4E1.EL01.
electrostatic precipitator XCC01
4E2.EL01.
CC01
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tial mended
III. Kiln plant
12. Control voltage for the entire kiln plant X Customer
®
13. Fresh-air flaps in DOPOL exhaust gas X 4G1.FA01
duct 4G2.FA01
14. Dampers in DOPOL® exhaust gas duct X 4G1.TV01
4G2.TV01
15. Protective air fan for clinkering zone X Customer
pyrometer
16. Control panel instrumentation X Customer
17. USP unit for computer and process X Customer
automation equipment
18. Protective air fan for TV-equipment (kiln X Customer
and cooler)
III. Kiln drive
19. Auxiliary hydraulic power unit X Customer
20. Oil pumps for circulation lubrication 4K1.KN01.
system for bearings (supporting rollers) RST01-03
4K2.KN01.
RST01-03
21. Control cabinet for rotary kiln drive X 4K1.KN01.
XTB05/06
4K2.KN01.
XTB05/06
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tial mended
V. Firing system
22. Control cabinet for rotary kiln firing X 4K1.BU01.
system XCC01
4K2.BU01.
XCC01
23. Control cabinet for precalciner firing X 4G1.BU01.
systems XCC01
4G2.BU01.
XCC01
24. Primary air fan (axial air) X 4K1.BU01.
FNP01
4K2.BU01.
FNP01
25. Actuator for flap at primary air fan 4K1.BU01.TV
X J01-M5001
4K2.BU01.TV
J01-M5001
26. Primary air fan PC X 4G1.BU01-
04.FNP01
4G2.BU01-
04.FNP01
27. Actuators for dampers in tertiary air duct 4G1.TD01.FG
X J01/02-
M5001
4G1.TD01.FG
J01/02-
M5001
28. High voltage transformers and control X 4E1.EL01.XC
cabinets for kiln electrostatic precipitator C01
4E2.EL01.XC
C01
29. Heavy oil treatment system, light oil X Customer
burner for oil preheating, combustion air
fan, light oil pump, circulating air pump
30. Fan for kiln outlet cooling X 4K1.KN01.FN
C01/02
4K2.KN01.FN
C01/02
31. Motor for burner carriage adjustment X 4K1.BU01.BU
C01-M5101
4K2.BU01.BU
C01-M5101
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tial mended
32. Only in the case of grate coolers
33. Grease lubrication pump for reciprocating X Customer
grate cooler (if installed)
34. Hydraulic pump for cooler grate drive, X 4R1.CQ01.
grate 1 HYS01
4R2.CQ01.
HYS01
35. Cooling air fan for clinker crusher X 4R1.HR01
FNJ01
4R1.HR01.
FNJ01
36. Cooling air fan(s) for compartment 1, X 4R1.FN01-07
sealing air and direct aeration fans for 4R1.FN01-07
compartment 1 (if installed)
37. Drive for cooler exhaust air fan X 4S1.FN01.
DRV01
4S2.FN01.
DRV01
38. Drive for fresh air damper of clinker X 4S1.SF01.
cooler electrostatic precipitator SFJ01
4S1.SF01.
FJ01
Note:
For the purpose of power saving, the kiln and the cooler, including clinker conveying equipment,
can be switched to intermittent operation.
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6.7 Deviations from normal operation
Operation in the case of a weak kiln

A weak kiln describes a condition in the burning process which is characterised,
amongst others, by
• inadequate raw meal temperature,
• poor granulation,
• poor clinker quality,
• dusty kiln atmosphere.
This condition is always caused by insufficient thermal energy made available for
the burning process or by the fact that the energy cannot be transferred quickly
enough from the gas to the material. The inadequate ratio between burning
energy and material quantity either occurs
• slowly (e.g. as a result of increasing and finally excessive heat losses caused
by non-optimum operation),
• or all of a sudden, caused by a so-called raw meal flush.
Operation in the case of a raw meal flush

A raw meal flush means, for example, that raw meal accumulates behind a raw
meal ring in the kiln and then, after complete or partial collapse of this ring,
flushes very quickly through the kiln into the clinkering zone or also into the
cooler. In most cases, a short-term increase in the power consumption of the kiln
drive is a relatively good indication of this operating condition. The situation
shown in the Figure below generally occurs:
Kiln Main Drive
Ampere
Requirement
Time
Figure 30 Power display in the case of a raw meal flush
To stabilise the kiln operation, proceed as follows:
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immediately and drastically reduce the kiln rotation speed, e.g. from 3.5 to
2 rpm.
Increase the fuel supply rate at the main burner.
Reduce the kiln feed rate by approx. 20-25%.
Reduce the fuel quantity for the calciner burner in accordance with the
temperature in meal chute 1 (max. temperature approx. 880°C).
Close the tertiary air damper until an adequate oxygen content is available in
the kiln inlet (2-3 % O2).
Adapt the pressure downstream of the preheater to the new operating
conditions.
Reduce the control pressure for the first grate from approx. 50 - 60 mbar to
approximately 45 mbar in order to protect the grates of the cooler against
overheating in the case of a raw meal flush. If the temperature of the grate
plates increases to more than 400 °C despite this measure, increase the air
flow rates of the first 5-8 cooler fans.
Constantly check the O2 content of the kiln exhaust gases during this operating
mode in order to prevent CO formation. Normally, the kiln operation can be re-
stabilised after a short time.
If the kiln operation is not back to normal within 20 minutes, further reduce the
raw meal feed rate or shut down the plant and heat up again. The power and
current consumption of the motor for the kiln drive is very informative for kiln
operation. If the current and power consumption have a decreasing tendency, the
clinkering zone generally gets colder and if these consumption values increase it
gets hotter.
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6.8 Checks during operation
DANGER
When the preheater is being cleaned, there is mortal danger of being buried
alive and suffocated in the rotary kiln and the cooler.
While the preheater is being cleaned, it must not be possible for persons to
gain access to the rotary kiln or the cooler.
The plant manager is responsible for properly cordoning off the area.
Take care particularly in the start-up phase that the flap valves in the meal
chutes operate perfectly and that the meal flows unhindered. Correspondingly
adjust the counterweights of the flap valves and later correct them at rated
throughput and fix them if necessary.
The temperature and pressure conditions, as well as the gas analyses,
provide information about the operating conditions.
Check the values shown on all indicators. If there are unacceptable
deviations, immediately investigate the cause. Immediately eliminate any
faults.
Check the clearance at the kiln inlet seal and adjust it if necessary.
Check the bearing temperatures.
It is advisable not to alter the settings in the first hours after feeding in meal.
To increase the throughput, first raise the speed of the kiln and a little later
increase the feed rates of fuel and raw meal. Any alteration that is effected too
early may cause flushing of raw meal through the kiln.
Carry out any increase in the raw meal feed rate step by step. Adjust the
negative pressure and the fuel quantity so that no CO forms, the oxygen
content in the gas after the precalciner is not lower than 2 % and overheating
of the preheater is prevented. The oxygen content in the gas at the kiln inlet
must not undershoot 2% either.
NOTE
Before increasing the fuel quantity by metered amounts, wait until the content of
oxygen in the gas after the precalciner has clearly risen (e.g. to 4.5 %) due to the
increase in speed of the exhaust gas fans.
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Firing system
After the start-up, you must check the firing system. Make sure that the burner
nozzle of the clinkering zone burner is horizontal. It must project far enough into
the kiln for the last section of the kiln to be used as a cooling zone, so that the
clinker is not too hot when entering the cooler. Align the nozzle tip with the kiln
axis, so that the flame burns at the centre of the rotary kiln without any danger of
overheating the kiln refractory lining.
You will possibly have to slightly correct the position and inclination of the burner
nozzle later during normal kiln operation at nominal capacity. The burning
conditions that occur as a result of the raw meal properties are decisive. Direct
the flame slightly towards the slope of the kiln charge material. Evaluate the
combustion quality on the basis of the content of CO and O2 in the kiln exhaust
gases.
NOTE
Make sure that combustion takes place with air excess; there must be no CO in
the exhaust gas.
6.9 Limit values of the cooler

If limit values are exceeded, especially for the hydraulic pressure, the following
checks are necessary:
• Check the values for the bed depth and the values for compressed air and
cooling air
• Visually check the interior of the cooler from behind (formation of the clinker
bed, formation of "snowmen")
The following measures can be taken to eliminate problems:
• Increase or lower the bed depth by adapting the stroke frequency

• Increase the cooling air flow rate of the front cooling air fans
• Eliminate any "snowmen"
• Check the shock blowers.
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6.10 Safety interlocks of the cooler

The following process engineering safety interlocks are required for protecting
personnel and machine:
Starting up and permanent condition
The grate movements can only be switched on when the operation signal of all
fans is received.
Exception: When the grate is started without clinker load on the grate, the
interlock must be bridged.
Failure of a cooling air fan
Try to start the fan within a time window of 5 minutes. If this does not succeed,
the main kiln drive etc. fails after 5 minutes.
Failure of the cooler exhaust air fan
The cooling air fans of the finish cooling section are automatically run to minimum
speed. The operator must adjust the pressures.
Failure of the exhaust gas fan

All fans are run to their min. position. The grate stops.
Failure of the exhaust air and exhaust gas fans

All fans are run to their min. position. The grate stops.
Failure of the crusher

The grate stops. After 5 minutes, the main kiln drive fails.
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6.11 Checking the process parameters
Pressures and temperatures in the preheater

The important process parameters that must be checked include the temperature
of the raw meal in the hot meal chute of cyclone 1 and the gas temperature
downstream of cyclone 1. All other temperature and pressure measurements in
the individual stages of the preheater are primarily used for monitoring so that
any irregularities are detected.
The temperatures result from the mass flows of fuel at the main and calciner
burner. Nevertheless, the pressures and temperatures must be checked regularly
by the operating personnel. Rising pressures in the preheater are an indication of
possible coatings in the kiln inlet, calciner or the cyclone inlets. Increasing
temperatures in the gas ducts are in most cases an indication of incipient cyclone
clogging and have to be monitored very critically.
Checking the combustion process
Main burner
The energy required for clinker formation and complete decarbonation, sintering
and formation of clinker mineral is supplied via the main burner to the rotary kiln.
The fuel quantity needed is approx. 45% of the total fuel quantity. The parameters
below are available to the operating personnel for checking the required fuel
quantity:
• Scanning pyrometer in the clinkering zone:
Normally, the indicated clinkering zone temperature at rated capacity is
approx. 1250-1400 °C (depending on the scanning pyrometer alignment).
• Power consumption of the main drive:
The power consumption is approximately 2/3 of the maximum drive power of
the motor.
A decrease in the clinkering zone temperature combined with a decrease in the
power consumption of the main drive normally means that the kiln is being
operated with an insufficient fuel quantity, i.e. the kiln is slowly getting cold or
weak. If the stroke frequency of the cooler grates simultaneously increases while
the compartment pressure remains constant, the kiln had dammed up material
that is now discharging at a higher rate. In both cases, you must increase the fuel
supply rate at the main burner in order to prevent the kiln from getting weak.
The gas analyses of O2, CO and NOx in the kiln inlet are used for assessing and
controlling the combustion.
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Content of O2 and CO in the kiln inlet

Operate the kiln so that the O2 content in the kiln inlet is 2 - 3%. CO should not
form in the case of good combustion and adequate oxygen excess. Generally, an
insufficient content of oxygen is also indicated by a decreasing concentration of
NOx. The operating personnel controls the O2 content in the kiln inlet by means
of the tertiary air dampers. If the O2 content in the kiln inlet is too low and the
oxygen excess after stage 2 is sufficient, slightly close the damper to increase the
secondary air flow rate. If the oxygen content in the kiln inlet is too high and after
stage 2 too low, take the opposite action.
If the O2 content at both measuring points is too low, increase the draught in the
plant by means of the kiln exhaust gas fan in order to operate the two firing points
at sufficient air excess.
Preheater
The operator uses the temperature of the raw meal in the hot meal chute for
checking the required fuel quantity. In some cases, the gas temperature after
cyclone 1 has also proved suitable. As long as this temperature is approximately
850 - 870 °C, you can assume that the fuel quantity is adequate.
For ensuring an adequate air excess for the combustion, you must normally
operate the calciner at approximately 2 - 3 % O2 after stage 2. Under these
conditions, CO formation should not be possible. Set the secondary air/tertiary air
ratio (i.e. the ratio of the combustion air volumes for main and calciner burner) via
the tertiary air dampers.
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6.12 Typical operating data
NOTE
The operating data listed in the table are typical operating parameters that may
possibly change during commissioning.
Temperatures
Hot gas temperature at kiln inlet approx. 1150 °C
Temperature downstream of DOPOL® preheater 300 - 340 °C
Pressures
Pressure in the kiln hood -0.2 mbar
Pressure downstream of DOPOL® preheater -50 -55°mbar
6.13 Optimising the plant

If necessary, you can alter the clinkering zone by taking the following measures:
• by axially shifting the burner nozzle;
• by varying the primary air.
• more swirl air than axial air results in a short wide flame
• more axial air than swirl air results in a long narrow flame.
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6.14 Operating the shock blowers
DANGER
There is mortal danger if shock blowers are unintentionally activated.
Automatic shock blowers are still pressurised after the plant has been
electrically disconnected.
Depressurise the shock blowers before you enter the cooler.
To prevent snowmen from forming on the static grate or on the "Horse Shoe", or
to eliminate them, shock blowers have to be used. In order to maintain the bed of
clinker on the static grate, do not switch on these shock blowers until a
continuous stream of material is discharged from the kiln. If the pile of clinker
becomes too high during the startup, manually activate the shock blowers in the
front end of the cooler. This will disperse the clinker.
The time intervals can only be changed directly at the control unit of the shock
blowers. Set the supply pressure of the compressed air to maximum pressure.
You can further optimise these intervals when the clinker and kiln conditions are
favourable and after longer operating experience. Perform the setting at the local
control unit.
Monitor the pressure before the shock blowers in order to ensure their proper
functioning. Under no circumstances may the supply pressure fall below 4 bar.
en-D000091-4C-4V
Operating manual Shutting down the plant
7 Shutting down the plant

For the detailed program for shutting down the plant under normal circumstances,
refer to the process functional diagrams.
7.1 Shutting down the kiln plant under normal circumstances
Previous to a planned plant stoppage, you should continuously reduce the
throughput in 5% steps to empty the kiln. If possible, maintain the maximum kiln
speed in order to reduce the filling ratio. The minimum feed rate is normally
between 40 % and 50 % of the normal feed rate.
If the temperatures in the clinkering zone or downstream of the preheater reach

the critical values, you must switch off the kiln. You can then turn the kiln for a
time until it is empty, using the main drive and continuously adapted fuel quantity
at the main burner. An empty kiln is easier to reheat and to restart.
1. Stop the calciner burner and the raw meal feed system.
2. For brief interruptions:

Reduce the fuel supply rate for the main burner to min.
For longer interruptions:
Stop the fuel supply. You must keep the primary air fan in operation to
cool the burner lance. For longer stoppages, withdraw the burner from
the kiln.
3. Open the fresh-air flaps.
4. Close the shut-off flaps in the exhaust gas duct to approx. 15 - 20 %.
5. Reduce the speed of the fans to 20 - 25%.
6. Reduce the speed of the cooling air fans in the cooler.
7. Reduce the speed of the cooler exhaust air fan in the cooler.
8. Close the tertiary air damper.
9. Reduce the kiln rotation speed to minimum or switch over to auxiliary

drive.
10. Turn the kiln until it is cold

(i.e. turn it until it has cooled down):
10a. If it is raining, turn continuously with the auxiliary drive.
enK01378A
Shutting down the plant Operating manual
10b. Otherwise: turn the kiln by 1/3 of a rotation at different intervals of time
with the auxiliary drive:
1st to 2nd hour: turn the kiln by 1/3 of a rotation every 10 minutes
3rd hour: turn 1/3 of a rotation every 15 minutes
4th hour: turn 1/3 of a rotation every 20 minutes
5th to 8th hour: turn 1/3 of a rotation every 25 minutes
Then turn 1/3 of a rotation every 30 minutes until a shell temperature of

100 °C has been reached in the clinkering zone.
11. Operate the cooler grates at intervals.
12. After turning the kiln until it is cold, shut down the cooler
13. Switch off the primary air fan.
14. Close the damper in the exhaust gas duct.
15. Stop the fans.
16. Stop the filter fan.
17. Switch off all other plant components.
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7.2 Shutting down the cooler

As long as the kiln is being turned with the main drive, you must keep the cooler
grates operating, as otherwise the main drive of the rotary kiln fails via the
interlock.
If the kiln is only being rotated with the auxiliary drive, the cooler grates must be
operated at intervals. For this purpose, start the grate from the control room in
individual operation.
Never allow the cooler to run until it is empty, except as preparation for the
performance of repair work. You must adjust the stroke frequency to suit the
decreasing quantity of incoming material. Furthermore, you must prevent
excessive dust formation by throttling the cooling air flow correspondingly, but
only to a degree which still ensures that the grate plates are not damaged by
overheating. Be sure to close the throttle devices before the fans are stopped.
Never shut down the fans until the grate plates and the material on the grate have
sufficiently cooled down. The grate could otherwise be damaged.
If the clinker cooler was emptied for repair work, restart the plant as described
previously.
Note that the rotary kiln can also discharge material to be cooled while it is being
turned until cold and inched. If this happens, you must switch the clinker cooler
on again for a short time.
Stop Condition
1 Shock blowers None
2 Bullnose cooling system Clinkering zone burner off
3 Grate 1 Raw meal feed off

Main kiln drive off
4 Cooling air fans of grate 1 Grate 1 off
5 Hammer crusher Grate 2 off
6 Grate 2 Grate 1 off
7 Fans for cooler aeration system of Grate 2 off

grate 2
8 Cooler exhaust air fan Cooling air fans off
9 Dust conveying system of cooler Cooler exhaust air filter off

exhaust air filter
10 Clinker conveying Dust conveyors off

Grate 2 off
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7.3 Shutting down the kiln plant in case of emergency

The control and monitoring devices installed in the system are designed to
ensure continuous plant operation on a permanent basis. Nevertheless,
unforeseen circumstances can lead to operating trouble.
EMERGENCY OFF
If personnel are in danger or damage to the plant threatens, shut down
dangerous sections of the plant or even the complete plant as quickly as possible
to prevent accidents. To shut down in case of emergency, actuate the
EMERGENCY OFF devices on the control panel or on the machines.
If danger threatens, proceed as follows:
Shut down the kiln plant with EMERGENCY OFF.
This also shuts down the conveying equipment.
Subsequently, shut down the plant components upstream of the switched off
plant component via the programmed control system.
Shut down the other sections of the plant in accordance with the normal
shutdown sequence.
Shutting down in the case of malfunctions

Especially if malfunctions occur in the following plant components, you have to
shut down the kiln plant as described above.
• kiln drive,
• filter fan,
• exhaust gas fan,
• clinker conveyor,
• raw meal feed system (if an immediate change over to an emergency route is
impossible).
On the other hand, you may be able to eliminate faults affecting auxiliary units
without interrupting plant operation.
If any damage to the refractory lining occurs, shut down the plant immediately.
If the temperature at the exhaust gas fans increases, the reason for this may be
an insufficient or fluctuating raw meal feed rate. First, reduce the fuel quantity and
make the raw meal feed more uniform. If this has no effect, you must shut down
the kiln plant as described in section Shutting down under normal circumstances.
DANGER
The elimination of blockages in the preheater always involves mortal
danger.
Be sure to observe the safety recommendations in section 8 Trouble
shooting.
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7.4 Shutting down the plant in the case of certain malfunctions
DANGER
The elimination of blockages in the preheater always involves mortal
danger.
Be sure to observe the safety recommendations in section 8.2 Safety
recommendations for the elimination of blockages in the preheater.
NOTE
The following tables list the measures taken either automatically by the
interlocking system of the plant or manually by the operator in the case of certain
malfunctions.
Failure of the main burner
Action Interlock Operator
The meal feed equipment stops. X
The calciner burner fails. X
The kiln rotation speed goes to minimum. X
Continuation of normal cooler operation until the X

conditions for a cooler shutdown are fulfilled.
The gas passage (dampers and fans) must be X

adjusted.
Failure of cooler
Cooler grates 1 and 2 stop. (If the clinker X

transport equipment and the cooler are not
operating again after a set time, the following
plant components will stop.)
The main kiln drive stops. X
The raw meal feed system stops. X
The clinkering zone burner goes to minimum X

capacity.
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The kiln must be operated with auxiliary drive. X

adjusted.
Failure of the raw meal feed system
The clinkering zone burner goes to minimum X

capacity.

adjusted.
Failure of the exhaust gas fan
Cooling air reduction to minimum. X
The clinkering zone burner and calciner burner X

fail.
The gas passage (dampers) must be adjusted. X
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Failure of the kiln drive
The fuel quantity for the main burner is reduced X

to minimum.
The kiln must be operated with auxiliary drive. X

adjusted.
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Operating manual Trouble shooting
8 Trouble shooting
8.1 Kiln and preheater
Blockages in the preheater

If you notice a blockage in the preheater, you must shut down the kiln plant at
once unless you can immediately eliminate the blockage by blasting with
compressed air.
8.2 Safety recommendations for eliminating blockages in the preheater
Personnel Measures Result
Kiln operator Shut down the rotary kiln The rotary kiln has been shut
immediately if blockage of the down.
preheater is detected.
Shift supervisor Ensure that all personnel All personnel have left the
leave the danger area. danger area.
The danger areas are:
• preheater tower and
neighbouring ground area
taking wind direction into
account
• rotary kiln: kiln platforms
and neighbouring area
• Clinker cooler
• clinker conveyor
Inform the following persons Persons with appropriate

in charge: authority have been informed.
• control room personnel
• production manager or his
deputy
• plant manager or his
deputy
Wait until at least one person

with appropriate authority has
arrived.
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Trouble shooting Operating manual
Personnel Measures Result
Plant personnel Elimination of the blockage No unauthorised actions by

must be supervised by a the plant personnel
person with appropriate
authority.
Only assign skilled

employees to this work. Their
number should be as small as
possible.
Cordon off the entire danger Only a few experienced

area to prevent access by technicians are present in the
persons not assigned to carry preheater tower.
out the work. All emergency escape routes
are free.
Make absolutely sure that all

emergency escape routes are
kept free.
DANGER
When poke holes and observation ports are opened, hot raw meal may
spatter out. Hot raw meal has the fluid consistency of water.
You may suffer very severe burns. There is mortal danger. Always put on
the complete protective clothing before opening any covers. Never stand in
front of any openings but always to the side.
Secure the place of work against unauthorised access.
Make absolutely sure that emergency escape routes are available and
unobstructed.
For cleaning a clogged-up cyclone proceed as follows:

Operate the exhaust gas fans at low speed. The slight negative pressure
prevents hot gases from escaping.
Clean the meal chute first, in order to ensure that the raw meal can flow away
unhindered.
Clean the cyclone with compressed air blasting lances either from below
through the lateral cleaning slits or from above through the poke holes.
If the cyclone cannot be cleaned in this way, cautiously open the access door
in the gas inlet to the cyclone and eliminate the blockages using the
compressed air blasting lances.
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DANGER
When the access door in the conical part of the cyclone is opened, loose
material can fall down!
You may suffer very severe burns. There is mortal danger.
Check through the access door in the gas inlet to the cyclone that there is
no loose material above the access door in the conical section.
Make sure that nobody is below the access door.
If there are still incrustations in the cyclone which cannot be reached from the
access door, you must clean them out through the round access hatch in the
conical section of the cyclone.
Open the access door with great caution and eliminate the incrustations.
After cleaning the meal chutes and cyclone, you must check that they are free
of incrustations. There must not be even the slightest incrustation, since this
could easily form the starting point for renewed blockage of the cyclone.
Fault Cause Elimination
Raw meal is flushing through • Fall of coating Drastically reduce the kiln
the kiln speed
• Coating ring has collapsed
Additionally, you can
Indication increase the fuel quantity.
The curve of current and To prevent the production of
power consumption shows an CO, the oxygen content after
abrupt peak, which then falls the calciner must not drop
off rapidly. below 1.5 %.
Increase the kiln rotation
speed step by step.
If the kiln process does not
stabilise within 15 minutes,
reduce the meal quantity.
Temperature fluctuations • Fuel not homogenous Keep power consumption of

in the clinkering zone kiln drive constant by
• Large quantities of dust
Indication changing the speed
Power consumption of the
kiln drive
enK01378A
Temperature rise downstream • Insufficient raw meal feed Reduce the fuel quantity,
of exhaust gas fan rate Ensure uniform raw meal
• Fluctuating raw meal feed feeding,
rate Check the water injection
• Water injection into the system and repair if
cooling towers faulty necessary,
If the above described
measures remain
unsuccessful, shut down
the kiln plant (see section
Shutting down the kiln
plant under normal
circumstances)
Excessive vibration of exhaust Incrustations on impellers Switch off the fan and clean
gas fan the impeller
Excessive temperature after Non-uniform feeding of raw Return the raw meal feed to
the preheater (> 400 °C) meal uniform condition
Inadequate raw meal feed Increase the raw meal feed

rate rate
Excessive fuel quantity Reduce the fuel quantity for

the calciner burner
If the fan protection measures

are unsuccessful, shut down
the kiln plant if necessary and
eliminate the cause (e.g. at
the raw meal dosing system)
en-D000091-4C-4V
Incrustations and coating in The refractory lining has Switch off the plant and repair
preheater (recognisable e.g. projections, or is not smooth. the refractory lining.
by increased pressure drop)
Overheating in the preheater Reduce the fuel quantity or
increase the raw meal feed
rate
Infiltration of false air, Check the kiln inlet seal and

particularly at the kiln inlet repair if necessary
seal
Non-uniform raw meal quality Check and, if necessary,

correct the homogenising
system and raw meal dosing
system
Inadequate cleaning Increase the intensity and

frequency of cleaning
Cyclone clogging Jammed flap valves in the Eliminate clogging by

meal chutes blasting out with
compressed air
If this is not possible, shut
down the plant and
eliminate the clogging.
Restore free movement of
the flap valves
Other causes such as Eliminate clogging by

chemical properties of raw blasting out with
meal, overheating, CO compressed air
production or inadequate
If this is not possible, shut
cleaning
down the plant and
eliminate the clogging.
Blockages, especially during Overheating in the lower Start the plant at a low
starting-up of the plant section of the preheater temperature
Briefly feed in a large
quantity of raw meal,
Subsequently reduce the
feed rate again to normal
enK01378A
Production of CO downstream Excessive or irregular supply Check the fuel supply system
of stage 2, while the CO value of fuel to the calciner burner and repair it if necessary
in the kiln inlet is normal.
Not enough air excess in the Increase the air supply by
precalciner opening the tertiary air
dampers
Increase the speed of the
exhaust gas fan if
necessary.
The kiln shell temperature has The kiln's refractory lining is Shut down the plant
risen strongly faulty
Replace the refractory
lining
The bearings of the rollers are Water cooling system and/or Inspect the water cooling
too hot lubrication system faulty system and the lubrication
system and repair if
necessary.
en-D000091-4C-4V
8.3 Reciprocating grate cooler REPOL®
DANGER
Hot material can shoot out through open inspection ports.
There is mortal danger. You could suffer severe burns.
Wear the proper protective clothing and keep emergency escape routes
free.
Material from If it is found during commissioning that the

the rotary kiln is material to be cooled is not centrally
not centrally discharged onto the grate, you must correct
discharged onto this by adjusting or replacing the air
the static pre- distributors and/or orifice plates or/and by
grate altering the Horse Shoe dimensions.
RED RIVER When the material is The aforementioned problem can be

discharged from the kiln, fine prevented to a certain extent by adjusting the
and coarse materials are cooling air distribution to the various aeration
separated so that the cooling zones on the cooler grate in accordance with
air cannot flow uniformly the clinker discharge conditions of the rotary
through the material bed on kiln.
the cooler grate due to
Alterations of the operating mode or the raw
differences in flow
material may make it necessary to alter the
resistance. This can lead to
cooling air distribution and adjust the stroke
the situation that sectors of
frequency.
material on the grate are
only insufficiently or not at all Normally, you can eliminate red rivers by
penetrated by the cooling air. increasing the air flow rate in the affected
Such material streaks are zone (observation of the bed of cooling
called "RED RIVERS" and material).
usually occur on one side at
the edge of the grate.
enK01378A
Sudden Overloading of the clinker • Change over the drive from automatic to
increase in cooler due to coating falling manual operation
quantity of down in the kiln. • Reduce the kiln speed to a degree ensuring
material to be
that the compartment air pressure in the
cooled
area of the measuring point for the
conveying speed regulation is not much
higher than during normal operation
• Reduce the kiln feed rate according to the
extent of the disturbance
• Increase the cooling air flow rate if
necessary (increase in exhaust air
temperature)
• Monitor the clinker cooler visually until the
disturbance has ended.
Formation of If the material to be cooled • Avoid fluctuations in the chemical

snowmen in has a tendency to stick composition of the raw meal and fuel.
inlet zone together, there is a danger • Push the burner lance further into the kiln,
that it will build-up to form so that a part of the kiln serves as pre-
so-called snowmen. The cooler and the temperature of the material
tendency to stick together discharged onto the clinker cooler is
results from temporary lowered.
overheating of the material
often caused by high • Change the cooling air distribution to the
fluctuations in the chemical different cooler compartments in the initial
raw meal composition of the cooler section.
fuel. • Improve the initial cooling.
• If necessary, install additional shock
blowers activated at regular intervals, thus
preventing the formation of snowmen.
en-D000091-4C-4V
Drive failure See separate machine • If the first grate fails, the following grate
manual may continue to operate, however only at
minimum stroke frequency so that the grate
will not run empty. Immediately reduce the
speed of the rotary kiln to minimum
(auxiliary drive).
• To prevent damage, keep the fans of the
recuperation section running for at least 5
to 10 minutes with the current setting. You
must throttle the fans of the following cooler
compartments.
• If grate 2 fails, immediately shut down grate
1. You must keep the hammer crusher and
the conveyor for the cooler discharge
material running.
Failure of the See separate machine Grate 1 and grate 2 must be switched off.
hammer manual Keep the aeration of the cooler compartments
crusher running for at least 5 to 10 minutes, in order to
prevent overheating. Immediately reduce the
speed of the rotary kiln to minimum (auxiliary
drive). Keep the conveyor for the cooler
discharge material running.
Failure of single Faulty drive motors or Clinker coolers which are interlocked in
or all cooling air broken V-belts accordance with POLYSIUS AG standards
fans are switched off upon failure of more than one
or all cooling air fans.
The hammer crusher and the conveyor for the
cooler discharge material must continue in
operation.
Reduce the kiln speed to minimum. Make
absolutely sure that the clinker cooler is
intensively aerated. If the exhaust air fan of
the plant is still in operational condition,
increase the negative pressure in the kiln
hood and open the doors under the aeration
floor.
Replace any faulty parts as quickly as
possible.
enK01378A
Failure of If the conveyor for cooler discharge material

finished fails, immediately switch off all the grates.
material Keep the aeration of the cooler compartments
outward running for at least 5 to 10 minutes, in order to
conveying prevent overheating. Immediately reduce the
equipment speed of the rotary kiln to minimum (auxiliary
drive).
If any faults occur which are not described above, please consult the
subsuppliers' documentation for more information about faults, their causes and
their elimination.
en-D000091-4C-4V
Operating manual Cleaning, inspection and maintenance
9 Cleaning, inspection and maintenance

9.1 Work during operation
Cleaning of preheater and calciner

Cyclone clogging may be due to falls of coating or pieces of the refractory lining.
Cyclone clogging may also be caused by the sudden fall of large deposits of meal
in the transitions between the gas ducts and the cyclones. These problems,
however, almost never occur if the preheater is cleaned and checked regularly.
The points in the preheater and calciner which require cleaning and the suitable
cleaning intervals can only be established after a certain period of operation. Until
these locations and intervals are known, you should perform the cleaning in
accordance with the following scheme (see page 9-2).
All other abnormal operating conditions of the kiln plant that affect safety (such as
exceeding of a specified CO content in the exhaust gas) are detected by sensors
and processed in accordance with specified interlocking plans.
You can perform cleaning work during plant operation because the negative
pressure in the plant prevents the hot raw meal from flowing out. Nevertheless,
hot gas and meal may escape due to pressure surges in the system and you
must therefore take extreme care when opening covers.
Clean by blasting out and removing the coatings with the compressed air blasting
lance.
Depressurising the shock blowers
Before opening poke holes, make absolutely sure that the shock blowers in the
neighbouring area are depressurised:
Close the supply valve for compressed air to the shock blowers.
Relieve the pressure in the shock blowers (depressurise)
DANGER
When poke holes and observation ports are opened, hot raw meal may
spatter out. Hot raw meal has the fluid consistency of water. You may
suffer very severe burns. There is mortal danger.
Always put on the complete protective clothing before opening any covers.
Never stand in front of any openings but always to the side.
Secure the place of work against unauthorised access.
Make absolutely sure that emergency escape routes are available and
unobstructed.
Close the openings again when the work is finished.
Open the supply valve for compressed air to the shock blowers.
enK01378A
Cleaning, inspection and maintenance Operating manual
Example: Cleaning scheme for a preheater with 5 stages
Figure 31 Inspect and clean the preheater
A Clean every 4 hours C Inspect every 4 hours

B Blast out every 2 hours D Clean every 24 hours
en-D000091-4C-4V
Regular checks, inspection and maintenance work

False air, particularly at the kiln inlet, speeds up the formation of incrustations in
the preheater, so that good kiln inlet sealing is of very great importance.
Regularly lubricate the kiln inlet seal with graphite grease.

Perform manual gas analyses at the inlet and outlet of the preheater. These
analyses show whether and how much false air infiltrates into the system.
These analyses also provide information on the combustion conditions.
Manual analysis is no replacement for continuous CO and O2 measurements,
however.
The combustion in the main burner is monitored by the measuring probe in the
lower section of gas duct 1. Be sure to check the measurement result of the
probe from time to time by means of a manual analysis of the gas in the kiln inlet,
in order to make sure that the measurement is not being falsified by air inleaking
through the kiln inlet seal, so that good burning conditions are indicated although
these are really not present. You can then correct the probe's measurement
result by taking into consideration the false air entering the system via the kiln
inlet seal. This analysis also provides you with a means of assessing the
tightness of the kiln inlet seal, so that you can recognise leaks and eliminate them
at an early stage.
Greatly fluctuating coating conditions rapidly lead to damage in the kiln refractory
lining, as does an inadequate coating buildup. This is another reason why you
must ensure uniform and good raw meal quality. Meticulous monitoring of the mill
feed material components and the raw meal by the chemical laboratory is
therefore of the utmost importance for troublefree kiln operation.
To ensure safe operation, make absolutely sure that the monitoring devices are
always carefully maintained, even when other check measurements such as the
O2 measurement in the lower section of gas duct 1 indicate normal kiln and firing
system conditions.
The routine maintenance work also includes daily checking and cleaning of the
thermocouples, the pressure measuring points and the gas sampling and
analysing devices, as well as daily inspection of all lubricating points and oil-level
indicators. Proper functioning of all parts is the indispensable prerequisite for
troublefree kiln operation.
At the kiln tyres, which move relative to the rotating kiln shell, you must carefully
lubricate the contact surfaces of the kiln tyre and the bridge plates once or, if
necessary, several times a day. For this purpose, we recommend that you use a
portable sprayer to squirt a high-graphite, sprayable grease or oil between the
bridge plates into the kiln tyre bore. Lubricants with carrier substances which
volatilise due to the kiln shell temperature, leaving only the residual graphite, are
particularly suitable.
Check the kiln movement daily. The kiln must perform a uniform movement
upwards and downwards.
Regularly monitor the unbalance of the exhaust gas fans. Incrustations on
the impellers may lead to unbalances. Switch off any fan affected by
incrustations and thoroughly clean it.
enK01378A
Cleaning, inspection and maintenance Operating manual
Check the flap valves for ease of movement.
9.2 Work during stoppage
Cleaning the preheater
DANGER
When cleaning the preheater.
Mortal danger through being buried alive and suffocating in the rotary kiln
and cooler.
While the preheater is being cleaned, it must not be possible for persons to
gain access to the rotary kiln or the cooler. The plant manager is
responsible for properly cordoning off the area.
In order to avoid future operating problems, make absolutely sure that the
maintenance and repair work is always carried out with the greatest care. During
lengthy stoppages, be sure to perform the following measures in addition to other
work:
Check the raw meal conveying equipment for proper functioning.

Adjust the dosing devices.
Clean the transitions from the gas ducts to the cyclones.
Check the insides of the cyclones for
• roughness
• cracks
• protruding edges, etc.
Check the flap valves in the meal chutes for proper functioning.
Check the CO and O2 measuring and analysis devices.
Check the exhaust gas fan for incrustations and clean if necessary.
Check the kiln refractory lining for damage, including inlet trough and kiln
end sections.
Check the kiln inlet and outlet seal.
Inspect the main burner and calciner burner, and replace any defective parts.
Check cooler grate plates and replace faulty parts.
Check the grate bearings. Replace the bearings when the wear limit has been
reached.
Check the hammer crusher. Replace any defective hammers.
Check the cooling air fans and cooler exhaust air fan for proper functioning.
en-D000091-4C-4V
Check the clinker dust conveyor and clinker conveyor for proper functioning.
Check the filter.
enK01378A
Operating manual Appendix
10 Appendix
10.1 Flowsheets
Designation Drawing No. Register
Flowsheet 65000414
pages 4C1 - 4V2
enK01378A

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Operating manual

Rotary kiln plant

POLYSIUS Order Code (POC)

7.2 Shutting down the cooler .......................................................................... 7-3

1.1 Technical data of the plant

Year of manufacture.............................................................................. 2007 / 2009

1.2 List of machines

Figure 1 Kiln feed control system

Raw meal conveying equipment and kiln feed

1 AEROPOL vertical conveyor 4C1.AC01

1 Bucket elevator 4C1.BE01

4 Bag filter 4C1.BF01 - BF04

1 Continuous feeder 4C1.CD01

1 Diverter gate 4C1.CF01

2 Discharge devices 4C1.DD01 - DD02

1 Monorail trolley 4C1.MC01

1 Sampling system 4C1.QS01

4 Rotary blower 4C1.RB01 - RB04

1 Pneumatic screw pump 4C1.SP01

Raw meal conveying equipment and kiln feed

1 AEROPOL vertical conveyor 4C2.AC01

1 Bucket elevator 4C2.BE01

4 Bag filter 4C2.BF01 - BF04

1 Continuous feeder 4C2.CD01

1 Diverter gate 4C2.CF01

2 Discharge devices 4C2.DD01 - DD02

1 Monorail trolley 4C2.MC01

1 Sampling system 4C2.QS01

4 Rotary blower 4C2.RB01 - RB04

1 Screw pump 4C2.SP01

Figure 2 Raw mill dedusting system

1 Dedusting and interconnected system 4E

1 Electrostatic precipitator 4E1.EL01

1 Evaporation cooling tower 4E1.ET01

1 Electrostatic precipitator 4E2.EL01

1 Evaporation cooling tower 4E2.ET01

Figure 3 Interconnected system dust conveyance

1 Interconnected system dust conveyance 4F1

1 Bucket elevator 4F1.BE01

1 Bag filter 4F1.BF01

1 Bin weighing device 4F1.BN01

1 Continuous feeder 4F1.CD01

1 Dust hopper 4F1.DH01

2 Flat slide valves 4F1.FG01 - FG02

1 Rotary blower 4F1.RB01

1 Rotary airlock 4F1.RF01

3 Trough screw conveyors 4F1.SC01 - SC03

1 Interconnected system dust conveyance 4F2

1 Bucket elevator 4F2.BE01

1 Bag filter 4F2.BF01

1 Bin weighing device 4F2.BN01

1 Continuous feeder 4F2.CD01

1 Dust hopper 4F2.DH01

2 Flat slide valves 4F2.FG01-02

1 Rotary blower 4F2.RB01

1 Rotary airlock 4F2.RF01

3 Trough screw conveyors 4F2.SC01 - SC03

Figure 4 DOPOL preheater

1 Preheater system 4G1

2 Firing systems in calciner (oil) 4G1.BU01 -BU02

2 Firing systems in calciner (gas) 4G1.BU03 -BU04

1 Compressed air cleaning system 4G1.CG01

1 Fresh-air flap 4G1.FA01