Kiln Process-70039029 - A4-P - 1.0 - EN

Rotary kiln plant (ILC)
Maple Leaf 3, Pakistan
Process Instruction
Date: 08-Feb-2018
Created by: JTHO
Pages: 45
Doc. No.: 70039029-1.0

Process Instruction: 70039029-1.0
List of contents:
Page:
1. General information ............................................................................ 3
2. Design and operating principle .............................................................. 4
3. Drying and heating of lining prior to start-up ........................................... 7
4. Start of kiln plant .............................................................................. 19
5. Stop of kiln plant .............................................................................. 23
6. Operation ........................................................................................ 26
7. Interlocking, programming and control circuits ....................................... 30
8. Prevention of fires and explosions ........................................................ 36
9. Barring ........................................................................................... 38
10. Operating parameters and alarm limits ................................................. 40
NOTE!
The present instruction manual is concerned with the situations which,
according to the experience of FLSmidth, are the most likely to occur. An
exhaustive enumeration of all conceivable situations, which may occur
during manufacture, installation, operation and maintenance of the
equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not
foreseen in the instruction manual, and which the operator is/or feels
unable to handle, it is recommended that FLSmidth is contacted without
undue delay for advice on appropriate action.
Separate instruction manuals

The plant under review also comprises several other instruction manuals
containing detailed information about the single machines or
arrangements.
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 2/45
1. General information
This manual is intended as a reference guide for use in connection with
starting the plant, normal operation of the plant, and stopping the plant.
The manual can further be used as a tool to assist in plant optimization and
to support operator judgements on plant operation.
The majority of the directions given in the manual are of a generalized
character. A range of relevant factors of specific or local nature are involved,
and it would be impossible to provide a detailed evaluation of all these factors
in this manual without sacrifice of clarity.
In this manual it is a fundamental condition that the control panel equipment
has been installed, tested and made fully operational.
This manual should be thoroughly studied prior to start-up, so as to permit
detailed planning of this phase.
2. Design and operating principle

2.1. Design main elements
The clinker producing plant is an FLS-ILC (In-Line Calciner) installation
incorporating the following main elements:
Kiln:
Diameter 5.50 meter
Length 66 meter
Number of supports 2
Inclination 3.5 %
Required motor power on rollers 1000 kW
Nominal consumption 688 kW
Maximum speed 5.0 r/min
Preheater:
Cyclone strings 2
Cyclone stages 5
2 HR+ of 6.9 m (top)
2 LP of 6.9 m
Cyclone dimensions 2 LP of 7.2 m
2 LP of 7.2 m
2 LP of 7.2 m (bottom)
Calciner:
In-line calciner vessel 8.5 m × 47.0 m
Reduction zone 3.7 m × 3.0 m
Fuel types:
Kiln Coal/Oil/Petcoke
Calciner Coal/Oil/Petcoke
Other:
Fuel to kiln Coal/Oil/Petcoke
Fuel to calciner Coal/Oil/Petcoke
Clinker cooler type CB 18x58 iHRB
Kiln feed system type Elevator
Inline gas conditioning tower before ID-fan No - future WHR
Kiln bypass system installed No
SNCR injection system No
Designed plant capacity 7300 t/d
2.2. Operating principle

The formation of clinker minerals requires heating of the raw meal to
approximately 1450°C. The arrangement of the preheater, kiln, and
clinker cooler, also called the pyro system, will minimise the energy
consumption for heating the raw meal by using the heat exchanging
principle of the preheater and the heat recuperation done in the clinker
cooler.
The thermal energy required for heating, calcination of the raw meal
and formation of the clinker is introduced to the pyro system in two
places, i.e. by introducing fuel into the calciner and to the kiln main
burner.
During start-up of a cold plant the use of igniters for ignition of the
fuel is required, but during operation the temperatures inside the pyro
system will ensure the ignition of the fuels.
The raw meal feed - the kiln feed - is extracted from the raw meal silo
system and transported to the pre-heater.
The pre-heater is operating as a counter current heat exchanger with
the raw meal passing downwards (downstream) through the pre-heater
stages by gravity, and the gas moving upwards (upstream) drawn by
the preheater fan. This results in heat being exchanged from the gas to
the raw meal.
Material from stage 4 is passed through a meal dividing gate which
allows for material distribution between the lower part of the calciner
and kiln riser. An improved NOx reduction is achieved when dividing
more material to the calciner. However, to reduce coating formation in
the kiln riser area some of the material must still be diverted to here.
The combustion gas used in the calciner is a mixture of hot air from
the clinker cooler drawn through the tertiary air duct and kiln gases
from the rotary kiln. To ensure sufficient air is available for
combustion, the oxygen content in the preheater exit gas is monitored.
The total amount of raw meal is leaving the top of the calciner with the
gas and led to the bottom stage cyclone. From this lower most cyclone
the material slides to the rotary kiln inlet with a calcination degree of
approximately 90-95%.
Due to the inclination and rotation of the kiln, the raw meal is
transported downstream through the kiln. Simultaneously, the raw
meal is gradually heated and fully calcinated by the heat supplied to
the kiln.
Clinkerization - clinker formation - takes place when the raw meal
passes through the burning zone of the kiln.
The clinker formed leaves the kiln and drops into the clinker cooler for
heat recuperation and following cooling.
2.2.1. Clinker cooler
The clinker leave the kiln at round 1450°C and fall down onto the
cooler inlet zone, after which they are transported slowly
downstream through the cooler.
While passing through the cooler the clinker is constantly exposed
to a cooling air stream from below with the purpose of cooling
down the clinker as well as recuperating heat back to the kiln
system.
The cooling air that passes up through the clinker bed is in

consequence heated up. The hot air, from the first part of the
cooler, is drawn back into the kiln system and used as combustion
air. Approximately 45% of the total cooling air is returned back to
the kiln system and recuperates approximately 75% of the clinker
heat back to the kiln system. The remaining air, from the last part
of the cooler, is extracted as excess air from the cooler.
The excess air extracted from the outlet end of the cooler is de-
dusted by the cooler de-dusting equipment and the collected
clinker dust being forwarded to the clinker conveyor.
At the outlet of the cooler a clinker crusher is installed for breaking
the lumps that are larger than ~25-30 mm.
2.2.2. Gas treatment and distribution
Whenever the kiln is in normal operation and no waste heat
recovery system is running, the exhaust gases are supplied to the
raw mill at a temperature of ~310°C. The kiln/raw mill gasses are
subsequently de-dusted in the common main filter installation
before released to the atmosphere.
The dust collected in the main filter is returned to the process via
the transport equipment to either the kiln feed or the CF-silo. The
possibility of dumping the dust into a truck normally also exists.
3. Drying and heating of lining prior to start-up

3.1. Preconditions and criteria for start-up
This section must be compared with enclosure 1, which in graphical
form provides information about heating and start-up procedures. The
procedures mentioned entails use of certain start-up burners
3.1.1. Personnel
Operators and operating personnel must be fully familiarized with
the instruments and functions of the control panel.
Furthermore, the personnel must be well informed about the
layout and operating principle of the motor control system,
especially all interlocking diagrams which indicate protective,
safety and operational interlocking.
3.1.2. Raw materials
Prior to start-up, raw materials must be available in sufficient
quantities and with a well-known quality in order to ensure
continuous, stable kiln operation.
3.1.3. Preparations
The following activities must be carried out prior to the initial start-
up:
1) All kiln plant machinery should be subjected to no-load testing
and where possible testing under load.
The trial run of the kiln should only comprise the kiln drive
without turning the kiln.
Trial run of machines loaded with material should be performed

over a prolonged period, for instance for 24 hours with the kiln
feed in circulation.
Water and/or air must be available where necessary. See

separate instruction manuals and diagrams.
2) The entire electrical and electronic control system must be
tested to ensure that all interlocking, i.e. safety, protective and
operational interlocking are active, and that they function as
intended.
3) Ensure that all process alarm limits have been set. (Refer to
section 10 in this instruction)
4) The raw meal must be recycled to test the operation of the
feed arrangement and for calibration of the load cells.
5) Prior to the production of clinker an appropriate amount of
correct quality raw meal must be available. The consumption of
raw meal for at least one day must be available.
6) Ignition burner and main burner must be prepared for start-up.
7) The plant laboratory should be on standby and prepared to
perform the necessary analyses of the kiln feed and clinker,
particularly to determine the content of free lime, the litre
weight of the clinker, and the kiln feed analysis.
8) In order to optimize the regulation of the primary air volume in

the kiln for optimization of the flame structure, it is advisable
to measure the airflow supplied to the burner by the primary
air fan at different valve openings and pressures. Hence it is
possible to ascertain what valve position should be used during
operation.
NOTE!
Where specific demands for initial drying procedure of the concrete are
stipulated by the supplier of the castables for the grate cooler, account
must be taken of such criteria during the start-up phase or, if this is not
possible, it may be necessary to dry out the grate cooler on a separate
basis.
3.1.4. Preparations prior to heating

Before the below mentioned start-up sequence is followed and
before any machines are put into operation, then please study
carefully the description in section 7 concerning interlocking,
programming and control.
3.1.5. Check
• that all tools and all foreign objects have been removed from
all kiln plant machines
• that potential coatings have been removed from cyclones, flue
ducts and riser ducts
(see separate instruction manual for safety)
• that all doors and clean-out hatches are closed
• that all sluice flap gates can move freely and thereafter tighten
up (only to be done during first initial drying out of preheater)
• that the motorized dampers function properly
• that the barring device, with brake, is ready to be operated
• that all plant machinery has been lubricated in strict
accordance with directions given in the separate instruction
manuals
• oil must be applied to the journals of the supporting rollers to
ensure that they are covered by oil when barring operation is
started
(see separate instruction manual)
• the water supply to kiln bearings, and gas analyser is
functioning
• that all instruments in the control system are functioning
Start the heating elements at the bottom of the chambers in the
kiln main filter 2-3 hours ahead of the anticipated start time of
heating-up the kiln.
Place the gas analysis equipment in the kiln system in state of
readiness.
Mount the burner for heating-up of the kiln and prepare the
ignition burner. See separate instructions.
If special requirements for the initial drying of the castables are

stipulated by the supplier of the castables for the grate cooler,
these requirements must either be met during the start-up
procedure or, if this is not possible, the grate cooler must be dried
out separately.
Once these checks and activities have been completed, both the
electrical and the mechanical department must ensure that the
installation is reported ready for start-up.
3.2. Drying-out procedure

3.2.1. Kiln, preheater and cooler
The heating and drying-out of the lining must be performed very
slowly in order to avoid the lining to crack and spall. This especially
applies where large zones equipped with castables are to be dried
out.
It may be necessary to modify the outlined drying out procedure in
case the brick supplier recommends a different code of practice.
However, consultations between the plant management and FLS
are needed before introducing any modifications.
For practical reasons the drying-out of the kiln lining should not
take place until the erection of the installation has advanced so far
that the kiln can be started in immediate aftermath of the drying-
out operation.
The initial heating-up/drying-out procedure of the pyro system
should, depending on the amount of available start-up burners,
stretch over three phases (cooler, preheater and kiln).
In connection with subsequent kiln starts, the heating period can
normally be reduced, though it depends on the type of lining
repairs conducted during the intervening periods.
As mentioned previously, it is recommended to extend the heat-up
period if concrete castables have been used for casting operations
inside the kiln system.
For drying-out procedures, start-up burners fired with light fuel oil
(diesel) are preferable compared to firing with heavy fuel oil which
requires proper fuel preparation. It is of great importance in order
to obtain good flame without soot formation and avoid overheating
of the refractory during the heating-up (drying-out) period.
In some cases, the raw mill start up and production of the first raw
meal is performed in continuation to the drying out of the
preheater and before the kiln dry-out. In this case the heating-up
program has to be customized for the actual case with special
focus on phase 2 heating-up program as mentioned below.
Drying-out procedure is started and performed in three (3)
phases:
Phase Burner(s) Duration

Phase 1. Portable start-up burner 72-96 hours.
placed in kiln hood, and in
Cooler Do not use heavy
back of cooler if available.
fuel oil or natural
gas.
Phase 2. Calciner burner and 48 hours
portable burner placed in
Preheater (kiln riser) and
kiln hood and kiln riser
Tertiary Air Duct (TA).
duct.
Phase 3. Main kiln- and calciner 72 hours*)
burner.
Rotary kiln and Preheater.
*): If complete drying-out of the preheater has been achieved
in phase 2, the period of 72 hours can be reduced to 48 hours
for phase 3.
3.2.2. Phase 1: Cooler Drying-Out (CDO)

Note! This is only possible if portable start-up burners are available.
Before this phase is started install a temporary light brick or block
insulation wall in the kiln inlet and/or outlet, this is to avoid hot gasses
to be drawn through the kiln tube. Assure that cold clinker has been
placed on top of the grate plates in the entire cooler (~50-100 mm)
and covering the grate plates/cross bars.
No. Sequence/Action Notes

1.CDO Place the portable start-up burners in the Do not use heavy fuel oil
kiln hood and back end of cooler or natural gas.
respectively. (Refer also to separate
instruction manual for
drying out procedure for
coolers and tertiary air
duct).
2.CDO Check the pressure and temperature of
the fuel (oil viscosity).
3.CDO Open the TA damper to 100% open If necessary open one or

position. more man doors to
supply extra combustion
air.
4.CDO Start the excess air fan at minimum speed
and adjust the speed of the fan.
5.CDO Open the excess air fan damper gradually. MAKE SURE THAT THE
Set the automatic control in kiln hood to a DRAFT IS TOWARDS
set point of –0.5 mbar. THE EXCESS AIR FAN!
6.CDO If subsequent start-up burners are not
already in operation start these and
maintain reasonable stable flames.
7.CDO Control the temperature in the kiln hood, For the first 24 hours the
cooler roof and inlet to the de-dusting temperature must be
equipment. kept ≤ 220°C. The
temporary installed wall

in the kiln, mentioned
above, should be in
place in order to prevent
heat to escape, flowing
via the kiln tube.
8.CDO Make sure to follow the heating-up
program (phase 1) during the whole
period (72-96 hours).
3.2.3. Phase 2: Preheater (kiln riser) and tertiary air duct Drying-Out
(PDO)
Remember to maintain the separation wall in the kiln, in order to avoid
hot gasses going into the kiln tube as well as preventing entrance of
cold air from the cooler.
Make sure that fuel is ready to be supplied to the portable burner now
placed at the bottom of the kiln riser pipe. The start-up burner in the
kiln hood is kept at its location.

1.PDO Check the pressure and temperature of Do not use natural gas.
the fuel (oil viscosity).
2.PDO Start the lubricator for the smoke
chamber seal.
3.PDO Start the filter fan at minimum speed and The interlocking
adjust the speed of the fan. between dust transport
and filter fan can be
temporary cancelled (no
dust in the system).
4.PDO Open the TA damper to ~12% open.
5.PDO Maintain in general minimum draft in the It may be necessary to
kiln inlet. It may be necessary to open gradually adjust the
man doors in the kiln inlet/riser to supply damper(s) at ID-fan
the combustion air. inlet.
6.PDO Start the ignition burner.
7.PDO Start the portable burner in the bottom of Check that the fuel is
the kiln riser and subsequently the ignited. If necessary,
calciner burner at an absolute minimum. adjust the draft
conditions to facilitate
the flame formation.
8.PDO If subsequent start-up burners are not
already in operation start these and
maintain reasonable stable flames.
9.PDO Adjust the draft in the riser and TA duct. Make sure to avoid local
overheating close to the
flame formation.
10.PDO Soon after start of the burner, the gas
analysers at preheater outlet should be
put into operation.
11.PDO Slowly increase the temperature of the The drying of the TA and
kiln riser pipe to 120°C and keep the the first part of the
temperature at this level during the first drying of the riser pipe
24 hours followed by an increase to is finalised after 48

approximately 500°C during the next 24 hours.
hours, see enclosure.
In case that the first raw meal is to be produced using the calciner as a
heat source, the (first) start up of the raw mill can normally be
performed in prolongation of the preheater dry-out.
Special attention to the temperature level after the preheater must be
taken.
3.2.4. Phase 3: Rotary Kiln and Preheater Drying-Out (KDO)

Remove the separation wall(s) in the kiln inlet/outlet. Remove all the
start-up burners (kiln hood and riser).
Maintain the clinker layer inside the cooler as mentioned in phase 1.

1.KDO Start the heavy fuel oil conditioning (boiler Prepare the oil burner
unit) and prepare the fuel oil for firing. with the small nozzle for
heating-up.
2.KDO Start the dust transport from the kiln/raw

mill main filter.
3.KDO Start the filter fan at minimum speed and The interlocking between
adjust the speed of the fan. dust transport and filter
fan can be temporary
cancelled (no dust in the
system).
4.KDO Increase the filter fan speed gradually If possible, set the
(alternatively damper position), so that a automatic pressure
slight negative pressure in the kiln hood is control after the ID-fan
obtained. to a set point facilitating
a slight negative
pressure in the kiln
hood.
5.KDO Start the primary air fan and open the
primary air damper to 10%.
6.KDO Start the ignition burner. The ignition burner can
be extinguished after
approximately 8 hours,
or as soon as the lining
is hot enough for the
burner to burn without
support (not valid for
gas firing!).
7.KDO Start the firing in main burner at minimum Make sure that the
oil/gas flow. oil/gas is ignited, if
necessary adjust the
primary air valve to
facilitate the flame
formation.
8.KDO Adjust the draught in the kiln. It may be necessary to
gradually adjust the
damper(s) at ID-fan
inlet.
9.KDO Soon after start of the burner, the gas
analyser in the riser duct should be put
into operation, if not already in operation.
10.KDO Start the barring of the kiln in accordance Check lubrication of
with the barring programme outlined in supporting rollers. The
section 9 Barring. journals must not
become dry. During
barring it may be
required to pour
additional oil directly on
the journals.
11.KDO The hydraulic pump of the thrust device is See also section 3.4
started at a time when the kiln appears
warm at almost full length and positioned
evenly on the rollers. Furthermore, the
kiln should be on continuously barring.
12.KDO Start the clinker transport, clinker dust
transport and clinker crusher, if not
already in operation.
13.KDO Start the excess air fan at minimum speed
and adjust the speed of the fan.
14.KDO Start one/two cooler fans. Open cooler fan

damper(s) to 10%.
15.KDO Open the excess air fan damper gradually.
Set the automatic control in kiln hood to a
set point of –0.5 mbar.
16.KDO Adjust the hoisting damper in the tertiary
air pipe to ~10% open.
17.KDO Regulate the kiln ID-fan damper so an
oxygen content of 8-10% in the kiln inlet
is achieved. When the kiln has become hot
after some hours, this level can be
reduced to 4-5%.
18.KDO Follow the heating curve shown in the If complete drying-out of
enclosure. Kiln feed is expected to be the preheater has been
started after approximately 72 hours of achieved in phase 2, the
drying-out (for first time dry-out). period of 72 hours can
be reduced to 48 hours
for phase 3.
3.3. Initiation of heat-up, preparations and start kiln production

See also the separate instruction manuals related to the individual equipment
mentioned as well as the guidelines mentioned in section 4.
3.3.1. Heating-up, prepare for production and start production
HU: Heating Up the kiln and preheater.
PS: Preparation for Start (of kiln production).
KP: Start Kiln Production.

HU Heating Up the kiln and preheater.
1.HU Start the gas analyser at kiln inlet.
(1.KDO)
2.HU Start the heavy fuel oil conditioning (boiler Prepare the oil burner
(2.KDO) unit) and prepare the fuel oil for firing. with the small nozzle for
heating-up.
3.HU Start the kiln feed in recycling mode with Recirculation rate usually
recycling to the raw meal silo. ~50-60 % of nominal
feed rate.
4.HU Start dust transport from Kiln/Raw mill
(3.KDO) ESP.
5.HU Start the filter fan at minimum speed and
(4.KDO) adjust the speed of the fan.
6.HU Increase the filter fan speed gradually If possible, set the
(5.KDO) (alternatively damper position), so that a automatic pressure
slight negative pressure in the kiln hood is control after the ID-fan
obtained. to a set point facilitating
a slight negative
pressure in the kiln
hood.
7.HU Start the primary air fan and open the
(6.KDO) primary air damper to 10%.
8.HU Start the ignition burner. The ignition burner can
(7.KDO) be extinguished after
approximately 8 hours,
or as soon as the lining
is hot enough for the
burner to burn without
support (not valid for
gas firing!).
9.HU Start the firing in main burner at minimum Make sure that the
(8.KDO) oil flow. oil/gas is ignited, if
necessary adjust the
primary air valve to
facilitate the flame
formation.
10.HU Adjust the primary air to facilitate the Make sure that the oil is
flame formation. ignited, if necessary
adjust the primary air
valve to facilitate the
flame formation.
11.HU Adjust the draught in the kiln. It may also be necessary
(9.KDO) to gradually make
adjustments to the
damper at ID-fan inlet.
12.HU Start the barring of the kiln in accordance Check lubrication of
(11.KDO) with the barring programme outlined in supporting rollers. The
section 9 Barring. journals must not
become dry. During
barring it may be
required to pour
additional oil directly on

the journals.
13.HU The hydraulic pump of the thrust device is See also section 3.4
(12.KDO) started at a time when the kiln appears
warm at almost full length and positioned
evenly on the rollers. Furthermore, the kiln
should be on continuous barring.
14.HU Soon after start of the burner, the gas
(10.KDO) analyser in the riser duct should be put
into operation, if not already in operation.
15.HU Start the clinker transport, clinker dust
(13.KDO) transport and clinker crusher, if not
already in operation.
16.HU Start the excess air fan at minimum speed
(14.KDO) and adjust the speed of the fan.
17.HU Open the excess air fan damper gradually.

(16.KDO) Set the automatic control for the kiln hood
pressure to a set point of -0.5 mBar.
18.HU Start one/two cooler fans. Open cooler fan
(15.KDO) damper(s) to 10%.
19.HU Open ID-fan damper slightly (5-20%) and Regulate the kiln draft so
(18.KDO) control that the air from the cooler is an oxygen content of 8-
drawn upstream to the kiln. 10% in the kiln inlet is
achieved. When the kiln
has become hot after
some hours, this level
can be reduced to 4-5%.
20.HU Follow the heating programme which Refer also to the general
(19.KDO) should be set up in advance to start firing. drying-out schedule as
shown in enclosure 1.
21.HU Coal firing can be started once high When initiating coal
temperatures inside the kiln have been firing it is necessary to
obtained allowing for safe ignition of the make compensations the
coal. other fuel input(s).
PS Preparation for Start (kiln production).
22.PS Change to main (operation) nozzle. The change of oil nozzle
entails stop of kiln firing,
reduce the draft during
change of nozzle and
reintroduce firing.
23.PS Start the ID-fan and adjust the speed of The draught and fuel
the fan. rate must be reset to
levels applicable prior to
the starting of the ID-
fan.
Make sure damper
openings are adjusted to
maintain sufficient
suction in the kiln hood
and after the kiln pre-
heater.
24.PS Re-start the firing in main burner at Re-start of kiln burner
minimum oil flow. with new nozzle. The use
of the ignition burner is
only required if the kiln
has cooled down and

proper ignition cannot be
achieved.
25.PS Assure that the kiln feed is in recycling Recirculation rate usually
mode with recycling to the raw meal silo. ~50-60 % of nominal
feed rate.
26.PS Stop the barring devises and start the kiln Cancel interlock between
at the lowest speed. This can be done kiln and cooler
approximately 2-3 hours before feeding
the kiln.
27.PS Start all cooler fans and adjust the air flow
in cascade mode to an air ratio
approximately 0.6. These adjustments
must be done slowly to avoid overpressure
in kiln hood.
28.PS Open tertiary damper to 20%.
29.PS Start the calciner burner at minimum When the temperature at
output. the top of the calciner,
after the constriction, is
more then 800°C, and
assuming compliance
with the heating
programme as outlined
in enclosure, the kiln is
ready to accept feed
material
30.PS Open the ID-fan dampers to 100 % and (Pay attention to; that
increase the draught by speeding up the the main filter fan
ID-fan to approximately 70% controller can cope with
the extra air. Pressure
after ID-fan must not
become positive).
KP Start Kiln Production.
31.KP Select kiln feed to pre-heater
32.KP Increase the fuel rate to kiln and calciner
accordingly in order to maintain the
temperature in lower most cyclone at
about 860-880°C.
33.KP Set the draught level and fuel rate so the
fuel supply rate is 5-10% in excess of the
normal operational level at the same
production rate. The reason is that the kiln
system is colder, low secondary/tertiary
temperature, at start-up as compared with
normal operation.
34.KP Gradually adjust the kiln speed according
to increase in kiln production and kiln
conditions.
35.KP Start the cooler drives at minimum speed.
3.3.2. Air supply during the heat-up phase

During the heat-up period, the maximum amount of the heat input
should be utilized for heating of the kiln, i.e. only the necessary air
volume should be drawn through the kiln.
However, an adequate air surplus must be present for the

combustion process.
3.4. Inspection during heat-up period

The programme for heat-up period is graphically indicated in the
enclosure.
It is very important that no attempt is made to speed up the
pre-heating programme.
In case of interruptions during the heat-up period compensation is
needed by extending the time period, so that the actual heating period
has the stipulated duration.
The speed of heating-up, as measured at the lower most cyclone gas
temperature and the outlet from the pre-heater tower, should follow
the curves very closely, as indicated in the enclosure.
It is advisable to record operational experience gained during initial
heating-up periods, so that the curves in the enclosure can be adjusted
in accordance with the local conditions.
A regulation of fuel rate, draught level and oxygen level is needed to
ensure strict adherence to the curves for the temperature rise.
Overall, the prime aim is, as previously mentioned, to ensure retention
of the supplied heat inside the kiln.
Any increase in the draught level will rapidly cause the temperature in
the cyclone tower to rise at the expense of the temperature in the kiln,
and this is not desirable.
The following inspection and check-up must be made during the
heating-up period:
Kiln lining
Inspect the kiln lining at regular intervals. The lining in the burning
zone must not be exposed to fast and local overheating.
Kiln shell temperature
Check the kiln shell temperature. Special attention must be focused on
the burning zone where high surface temperatures may occur.
Temperatures of up to 430°C will be acceptable.
If the kiln shell should become too hot in the burning zone, and the
temperature after the pre-heater is relatively low the amount of fuel
supplied to the kiln can be reduced.
Alternatively the flame shape must be adjusted if the flame shape is
the cause of the high shell temperature.
See instruction for main burner.
Barring
Strict observance of the specified barring programme is needed, but in
the event that an alarm is tripped by the thrust device equipment
indicating the position of the kiln, then the kiln must be barred
continuously until the alarm can be cancelled.
Continuous barring is also needed if the kiln is subjected to cooling, for
example due to heavy rainfall.
Clinker transport
If the kiln has been filled with raw materials, it may, from time to
time, be necessary to start the cooler drives in order to transport away
the excess materials.
See interlocking for start of cooler drive.
4. Start of kiln plant

4.1. Getting ready for operation
Operational status must be prepared several hours in advance of the
anticipated time for start-up with feed.
4.2. Preparation for kiln start

Reduce the ID-fan damper to < 25% and reduce the fuel rate to obtain
same oxygen level in the kiln inlet.
Start ID-fan at minimum speed 10%
The draught and fuel rate must be reset to levels applicable prior to
the starting of the ID-fan.
Please make sure damper openings are adjusted to maintain sufficient
suction in the kiln hood and after the kiln pre-heater.
Start all cooler fans and adjust the air flow in cascade mode to an air
ratio approximately 0.6. These adjustments must be done slowly to
avoid overpressure in kiln hood.
4.3. Starting and operation of the grate cooler

See also separate instruction manual.
4.3.1. Cooler operation
The two prime objectives of the grate cooler are as follows:
• To cool the clinker to a temperature that prevents damage
to the subsequent conveying system.
• To recuperate the maximum amount of thermal energy to
ensure efficient operating economy of the kiln system.
Additional to these two prime objectives, a number of physical and
transport related factors are involved, making it very difficult to
give exact guidelines with respect to air volumes etc.
• The clinker granulometry is a factor of great significance
• The clinker should flow evenly over the entire grate area
A visual inspection of the grates is recommended during the
running-in of the cooler.
Gradually as the clinker begins to leave the kiln, the grate cooler
must be put into operation.
To avoid a build-up of clinker on the grates, the transport system
for the clinker in the cooler (cooler drive) is started stepwise with
increasing material flow from the kiln.
Gradually as the production increases, the cooling air is increased.
Also the cooler grates can from early beginning be maintained in
continuous operation. The cooler drives must be in operation
before the kiln drive can be started. This interlock can be overruled
during the heating-up period.
A pressure of around -0.5 mbar in the kiln hood is maintained to
stabilize pressures and flow in the kiln system.
The amount of cooling air should be the maximum possible without

making the clinker bed unstable. If the clinker bed starts to
fluidize, then the cooling efficiency is destroyed.
The kiln speed must be reduced if the temperature rise is due to
“surge of material” from the kiln.
4.4. Starting of kiln main drive

Stop the barring devices and start the kiln at the lowest speed. This
can be done approximately 2-3 hours before feeding the kiln.
Cancel interlock between kiln and cooler.
4.5. Preparations for/and calciner operation

The firing in the calciner can be started at the same time as the feed to
the pre-heater. However, the following interlocking must be fulfilled:
• Kiln main burner in operation with ID-fan in operation.
• Kiln drive in operation.
• The temperature in the top of the calciner, after the constriction
must be higher than minimum 800°C.
• The O2 content in the gases after the pre-heater must be > 5%.
• If the CO or CH4 content in the gases after the pre-heater rises to
MAX I level 0.5%, increase the draft.
If the CO or CH4 concentration still increases to Max II (0.9%) level
for more than 10 seconds, then the fuel rate to the calciner must
automatically be reduced by minimum 20% and the calciner burner
is automatically changed to manual control mode.
If MAX III level has been reached (1.2%), then the interlocking will
force the fuel for calciner and main burner to a preset minimum.
The combustion gas/air to the calciner is controlled both by adjustment
of the speed of the ID-fan and by changing the position of the damper
in the tertiary air duct.
The CO content at the kiln inlet must be maintained lower than 0.1%
and at an oxygen level between 3-4%. At the same time the CH4
concentration must remain at below 0.1%.
NOTE!
Always increase draught before fuel rate is increased, to prevent
formation of explosive gases.
4.6. Starting of kiln feed and establishing normal production rate

When the temperature at the top of the calciner, after the constriction,
is more then 800°C, and assuming compliance with the heating
programme as outlined in enclosure, the kiln is ready to accept feed
material.
Personnel must be stationed in the cyclone tower in order to watch the

raw meal as it passes through the cyclone pre-heater.
Supervision is performed at the sluice flaps under each cyclone. The
flaps must move freely. This is done to ascertain that the raw meal
passes through. The risk of plugging in the cyclones is particularly high
during start-up.
The control room must have the possibility to contact the supervising
personnel via mobile communication equipment, radio or telephone, so
that early warning can be given from the supervising personnel to the
control room in event that plugging symptoms in cyclones are
observed.
Perform the below operations in RAPID but CORRECT sequence:
1. Open tertiary damper to 20%
2. Start the calciner burner at minimum output
3. Open the ID-fan dampers to 100 % and increase the draught by
speeding up the ID-fan to approximately 70%
(pay attention to; that the main filter fan controller can cope
with the extra air. Pressure after ID-fan must not become
positive)
4. Select kiln feed to pre-heater
5. Increase the fuel rate to kiln and calciner accordingly in order to
maintain the temperature in lower most cyclone at about 860-
880°C
6. Set the draught level and fuel rate so the fuel supply rate is 5-
10% in excess of the normal operational level at the same
production rate. The reason is that the kiln system is colder, low
secondary/tertiary temperature, at start-up as compared with
normal operation
7. Start the cooler drives at minimum speed
When it has been ascertained that the clinker in the burning zone is
well-burned, the kiln speed and the cooler drive speed can gradually be
increased to match the production level.
The draught must always be increased prior to any increase in the fuel
rate in order to avoid CO-formations. Also remember to regulate the
damper in the tertiary air duct for the calciner.
The temperature after the pre-heater must not exceed 450°C.
It is of critical importance that the first material is well burned in
order to avoid circulation of dust between kiln and cooler. Dust
circulation may cause cooling of the burning zone so more time is
needed to stabilise the kiln operation.
Since, as mentioned above, the heat input to the kiln at the beginning
exceeds the amount required for clinker formation, the kiln system will
gradually be heated.
When there is solid evidence of satisfactory clinker formation at low
free lime levels, the kiln output can gradually be increased with
simultaneous increase of draught level, feed rate and fuel rate.
Especially the kiln torque and visual inspection of the clinker are useful
parameters to use in order to judge whether the clinker are well
burned. Further analyses of the clinker litre weight and content of free
lime are useful for judgement of the clinker quality.
4.6.1. Achieving nominal capacity
During the first couple of hours after the production has been
started the feed rate is increased gradually, however, only
concurrently with production of well burnt clinker.
Adapt feed and fuel so the temperature in the lower most cyclone
stage is maintained at approximately 860-880°C., which would
correspond to a degree of calcination of 90-95%. This calcining
temperature should be maintained automatically by the PLC-
control system.
Consequently the kiln production is increased as follows:
• Increase the draught
• Increase the feed
(synchronously with the kiln speed)
• Increase the fuel supply to the calciner
(possibly automatically)
• Check whether a change of the kiln fuel is needed
(depending of free lime, litre weight and torque)
The temperature of the hot air from the cooler to the calciner
through the tertiary air duct will increase progressively as the
clinker volume is increased.
5. Stop of kiln plant

5.1. Normal stoppage of the plant
It is advisable to stop the kiln plant in a controlled manner by following
the sequence outlined below:
• Stop the kiln ID-fan and close the dampers (automatically).
• This automatically triggers the interlocks related to the ID-fan,
such as:
• Kiln burner stop
• Calciner burner stop
• Kiln feed to recirculation
• Kiln drive to min. speed
• Cooler fans to reduced air flow
• (for complete detail please refer to the process interlocking
specifications)
• Reduce the speed of the cooler drives. After few minutes the cooler
drives can be stopped.
• Stop kiln drive and start barring operation as outlined in section 9
Barring.
Where the stoppage period of the kiln extends over a prolonged period
of time, then all machinery not required for barring of the kiln and
cooling of the burner pipe must be stopped i.e.:
• Withdraw the gas analyser from the riser duct.
• Stop the compressors.
• Draw up plans for subsequent clean-up operation in the cyclones,
flue ducts and riser ducts.
• Make sure that the cooling water supply for the kiln bearings is
functioning as long as the kiln is barred.
After the kiln has cooled off:
• Stop the primary air fan and retract the burner.
• Stop the clinker conveying system.
• Inspect the kiln, the cooler, the hot gas ducts and the pre-heater.
• Planning of the maintenance and repair work required prior to
renewed start-up.
NOTE!
The kiln must always be cooled off slowly to prevent too rapid cooling of
the lining in relation to the kiln shell. Otherwise, the lining may work
loose, involving attendant risk of twisting and drop-out of bricks.
5.2. Unscheduled stoppages

In the following a description is given of the most common types of
operational disorders.
5.2.1. Total power failure
All machines and motors are stopped.
The emergency power generator must be started, making it
possible to bar the kiln, to close the fan dampers, to cool down the
burner pipe, to start the nose-ring fan. Cooling water for cooling of
the support roller bearings must be available as long as the kiln is
barred.
5.2.2. The kiln main burner stops functioning
• The calciner burner will stop automatically
Action: Stop ID-fan
5.2.3. The calciner burner stops functioning
Action: Stop ID-fan
5.2.4. Kiln feed failure
If the kiln feed cannot be restarted immediately, it will be
necessary to stop the kiln. Stop the ID-fan and follow the stoppage
procedure outlined in subsection 5.1.
5.2.5. Blockage of cyclones
Blockage symptoms are normally indicated by a drop in the
negative pressure at the bottom of the cyclone or a drop in the
temperature of the material after the cyclone. If blockage is
ascertained in a cyclone, it is essential that the kiln is brought to
an immediate standstill in order to avoid overfilling.
Action: Stop ID-fan
Before the clean-up operation is started, a negative pressure must
be generated by means of the ID-fan and damper.
5.2.6. Hot spots on the kiln shell
A stoppage of the kiln will normally be required if the kiln shell
temperature is higher than 430°C.
An attempt can be made to maintain the kiln in operation to
postpone the stoppage to a more appropriate time, provided the
temperature can be lowered by means of cooling fans with
concentrated cooling at the hot spot(s).
If, however, it is not possible to cool the hot spot, then a kiln
stoppage for repairs of the lining should be made.
It is prudent practice to keep the kiln drive running on minimum
speed until the temperature of the hot spot has been substantially
reduced.
It may be advantageous to make a partial discharge of material
from the kiln by prolonged barring before the repair of the lining is
initiated.
5.2.7. Failure of clinker transport
Interlocking:
• Cooler drives will stop.
• Stop of kiln drive delayed 0-5 minutes.

During this period of time an attempt to restart the clinker
transport must be made, but if operation cannot be resumed, it
will be necessary to stop the kiln in accordance with the procedure
outlined in section 5.1.
5.2.8. Failure of the cooler drives
Interlocking if transport efficiency of cooler is 50% or less.
• Stop of kiln drive delayed 0-5 minutes.
5.2.9. Failure of dust handling system
(Please consult filter instruction from filter supplier)
Normally, kiln operation may continue up to 20 minutes without
dust transport. If it is not possible to restart the dust transport
within 20 minutes the kiln must be stopped in accordance with
procedure outlined in section 5.1.
5.2.10. Failure of ID-fan
Same as stopping the ID-fan (see section 5.1)
5.2.11. Failure cooler excess air fan
Interlocking functions:
• The cooler fans’ air flow will automatically be reduced by 20-
40% (except the cooler fan below the fixed inlet)
• The cooler excess air fan damper open to 100%
• After a delay period (0-5 min) the ID-fan will stop
5.2.12. Failure of cooler fan(s)
Interlocking:
• The cooler drives will stop immediately
6. Operation
6.1. General notes
The kiln performance is optimized by ensuring that operational kiln
adjustments are restricted to an absolute minimum. The necessary
adjustments must be phased in gradually.
Once all control loops are active, these will ensure maintenance of:
• The top temperature of the lower most cyclones, ensuring a
constant degree of calcination.
• The pressure at the kiln outlet. This contributes towards stable
cooler operation, as well as stable secondary and tertiary air
conditions.
• The pressure after the ID-fan for stabilization of draught.
The fuel supply rate to the kiln installation is mainly determined on the
basis of an evaluation of the clinker quality, i.e. the litre weight, free
lime content, and the general appearance of the clinker.
Another determinant is the current status of the kiln, i.e. the trend of
the torque curve, the potential presence of coating formation, or other
operational disorders recently encountered.
The feed rate and the kiln speed are synchronised. However, the
operator can change the synchronising ratio.
6.2. Specific conditions related to kiln operation

In the following a review is made of a range of specific factors affecting
the kiln operation.
6.2.1. Exit gas analysis
The exit gas analysis constitutes the most important source of
information for the evaluation of the combustion process.
Therefore, it is of crucial importance to ensure that the
analysis equipment is functioning properly.
The smoke gases must not contain any unburned substances, i.e.
C (carbon), CO (carbon monoxide) or CH4 (methane).
Presence of such gases may, under adverse circumstances, cause
fires or explosions. Further, the loss incurred by wasting the
latent heat of the unburned part of the gases may be quite
substantial. A CO level of 1% in the smoke gases may entail
additional calorie consumption in the kiln of approximately 40
kcal/kg clinker.
Any presence of unburned substances would indicate inadequacy
of air for the combustion of the fuel. Even with an adequate air
volume, the smoke may contain unburned substances due to the
fact that the mixture of fuel and air is not ideal. Therefore, a
certain air surplus should be applied during the combustion
process.
As previously mentioned, the exit gases from the pre-heater
should contain 4-6% of oxygen. It is possible to set a lower alarm
limit for the oxygen level. A limit of 2% can e.g. be applied. This
alarm will inform the operator about the risk of unburned

substances in the exit gases.
Pre-heater exit gases are continuously monitored for CO & CH4
levels.
The alarm limits should be set as follows:
Alarm CO (%) CH4 (%)

MAX I 0.5% 0.5%
MAX II 0.9% 0.9%
MAX III 1.2% 1.2%
MAX I will signal alarm. Then the operator must make the
necessary adjustments to the combustion process.
MAX II when this alarm signals, the fuel rate to the calciner will
be reduced by 20%. The fuel control is forced into manual mode.
The operator must make further adjustments to the combustion
process in order to restore the oxygen level. CH4 MAX II
concentration will signal alarm and the interlock is as described for
CO MAX II alarm.
MAX III if the CO or CH4 concentration reaches or exceeds 1.2%
in the smoke gases, then this alarm is activated and total fuel rate
will be reduced to a preset minimum.
6.2.2. Primary air volume
The primary air is supplied through the burner pipe, ensuring an
effective mixture of air and fuel. Normally the primary air volume
supplied by the fan constitutes 8-10% of the air volume needed for
combustion.
6.2.3. Temperatures after cyclone pre-heater
The ID-fan is designed to withstand operating temperatures up to
400°C. However, short term temperature rises up to 450°C can be
tolerated.
The following alarm limits should be set:
MAX I: Giving alarm which is 25°C above the highest normal exit
temperature.
MAX II: Causing alarm tripping and stoppage of the ID-fan at
450°C delayed 0-5 min.
6.2.4. Bearing temperatures
An excessive temperature in any fan bearing will cause alarm
tripping and automatic switch the fan off. This applies to the ID-
fan and cooler excess air fan.
An excessive temperature in any supporting roller bearing will only
cause alarm indication. The operator must ensure that immediate
action is taken to remedy the situation, if kiln operation is
continued.
6.2.5. Blockage in cyclones

Changes in the temperatures of the material at the discharge point
from the cyclones may be signs of the beginning stages of a
blockage in the cyclones.
Pressure monitoring instruments are installed at the bottom of all
the cyclones. If the pressures approach zero (“0”) during
normal operation this is, combined with a possible change
in temperature, a sure sign of a blockage. The pressure
gauges will cause alarm indication, if the pressure changes below a
set minimum value. It is then up to the operator to assess, on a
case by case basis, whether a kiln stoppage is required.
A drilled hole, with a diameter of about 2 mm, must be present in
the connecting bushings for the pressure instrument, and it is very
important to keep this hole clean.
Once a blockage in a cyclone has been ascertained, the operator
must ensure that the kiln is stopped and the blockage removed by
manual cleaning.
Normally, air lances in appropriate lengths are effective tools.
Extreme caution must be exercised during the clean-out
operation.
NOTE!
The temperature of the material caking may be as high as 900°C, with
attendant risk of sudden outflow of hot raw meal, flowing as if it were a
liquid.
Therefore, it is essential that extreme caution and care are being

exercised during the operation, and it is advisable that the operators
involved are equipped with heat-insulated protective suits during the
clean-out operation.
A number of precautionary measures must to be taken in the

cement plant which is outlined in a separate instruction manual.
6.2.6. Caking in riser duct and kiln inlet
It is possible to detect major caking in the riser duct and kiln inlet
by checking the difference between the pressures at the kiln outlet
and at the lower most cyclone(s).
The safety precautions, which must be taken during the clean-up
operation, are similar to those stipulated for the cyclones.
Operational experience will show whether the extent and locations
of potential caking would make it appropriate to equip the
installation with additional clean-out hatches.
It may also be practical to install air chock blasters at appropriate
locations.
6.2.7. Kiln position
The axial position of the kiln is monitored on the cylinder
movement of the kiln thrust device. The alarm limits must be set
as directed in the instruction manual for the thrust device.
The MAX I alarm is a signal instructing the operator to undertake

inspection of the position of the supporting rollers.
The MAX II alarm automatically stops the kiln drive for prevention
of damage to the smoke chamber seal or kiln hood seal.
In a critical situation, it may be necessary to apply oil directly to
the supporting rollers, if the rollers tend to thrust the kiln upwards.
However, it is very important to ensure that the oil is removed as
soon as possible following the re-alignment of the supporting
rollers.
6.2.8. Kiln lining
The temperatures in the kiln system are so high that most of the
system is protected by means of a lining consisting of bricks and
concrete.
It is a prerequisite for smooth kiln operation that the kiln lining is
intact. Consequently, proper maintenance of the lining is of
paramount importance.
Normally, the lining in the pre-heater, hot-air duct and in most
parts of the cooler will have a lifetime of several years with no
need for replacements.
However, especially the lining installed in the burning zone of the
kiln will require more frequent replacement of bricks.
The exact frequency depends on a range of factors. Generally,
replacement is recommended in case the thickness of bricks -
owing to wear - has been reduced to half the original size.
Any damage to the lining involves the risk that the kiln shell will be
overheated. Particularly the kiln burning zone should be kept
under continuous supervision.
If the kiln shell temperature should rise to 430-450°C, the affected
area must be cooled by means of fans.
In the event of a further rise in temperature, the kiln must be
stopped for repair of the lining.
During operation the condition of the kiln lining can be checked by
installing a radiation pyrometer (scanner) for monitoring of the kiln
shell temperature. This alarm level should not exceed 430°C.
Whenever access to the kiln is possible during a stoppage period,
the opportunity should be taken to inspect the lining. Then
appropriate time schedules for replacement or repair can be
worked out.
7. Interlocking, programming and control circuits

The various motors, machines, dampers and other equipment are operated
and controlled by the central control system. In the following the proposed
structure of the control system is described seen from the operational and
process point of view. A proposal for grouping of the motors is given below.
The general and special rules of interlocking are listed. A survey of all process
related measurements and their treatment is given in section 10.
Finally the list of control loops is presented.
7.1. Interlocking
The detailed interlocking, as programmed, is described in the
interlocking diagrams. However, the main philosophy is given below.
The general rule of operational interlocking is that no machine can
be started before the subsequent machine has been started. Inversely,
stop of any machine will cause the stop of the machine ahead. This
follows the process order.
Protection interlocking like
• bearing temperature
• vibrations
• winding temperature
• minimum oil level
• speed monitors
• maximum material level, etc.
will stop the machine in question immediately
7.1.1. Examples:
• If the speed monitor of an air sluice does not indicate any
rotations, then the motor for this air sluice will stop.
• If the vibration level of the kiln ID-fan is high, then the motor
of this fan will stop.
• If the bearing temperature of the clinker roller breaker is above
the maximum temperature allowed, then this breaker will stop.
7.2. Process interlocking

The special interlocking will be described in the section of programming
as well as in the diagrams giving the process instrumentation.
(DIAGRAMS as described in section 10.)
7.3. Programming
From the central control room the kiln department can be operated by
selection of a number of programs and a number of direct functions.
The programs, installed in the control system, will perform the start
and stop procedures for the machines divided into groups. Further, the
operation is automatically supervised, checking constantly all

interlocking for operation, protection and safety.
The direct functions consist of opening and closing the dampers and
speed control of the motors.
In the control system the various motors and machines will be
arranged in a number of groups for common start and stop.
The following groups are proposed:
(The groupings of machines may be carried out differently to the
proposal, but the main ideas should be kept).
1) Kiln feed
2) Dust transport
3) Mill/kiln filter fan
4) Kiln ID-fan
5) Gas analysers
6) Kiln burner fans
7) Kiln burner
8) Kiln auxiliaries
9) Device for barring
10) Clinker transport system
11) Cooler de-dusting system
12) Clinker breaker
13) Cooler excess air fan
14) Cooler fans
15) Cooler drives
16) Kiln drive
17) Calciner burner
The following equipment can be operated individually:

• Fan dampers.
• Changeover gates and dividing gates.
• Position of valves – gas valves and feed valves.
• Motors with speed regulation, such as kiln drive and cooler fans.
7.4. Comments to programs

For details of the programming reference is made to the separate
documentation for the PLC system. However, in the following some
important notes are pointed out in relation to each group. In general
all bag filters should stop with a minimum delay of 15 minutes to
empty the system.
7.5. Start-up interlocking
Group Conditions to be fulfilled Other

before start
• Air compressors in operation If the feed stops
7.5.1. Kiln feed
or ready for operation. (group 1) during
operation, then the
• ID-fan in operation or kiln
ID-fan must be
feed directed to recirculation.
stopped to prevent
over-heating of the
pre-heater and the
ID-fan.
• The dust transport system The dust from the

7.5.2. Dust transport
must have no alarms. filter can be directed
to the kiln pre-heater
• The dust transport must have
or to the raw meal silo
an approximate 15 minutes
system via the dust
delayed stop sequence in
hopper.
order to empty itself.
• Damper to be closed, and

7.5.3. Mill/kiln filter
filter inlet temperatures lower
fan
than the maximum allowed.
• Dust transport (group 2) in
operation.
• ID-Damper(s) to be closed <

7.5.4. Kiln ID-fan
25%.
• Pre-heater outlet temperature
lower than MAX II.
• Kiln/Raw Mill filter fan (group
3) in operation.
• Availability of compressed air

7.5.5. Gas analysers
and cooling water.

before start
• Primary air damper closed. During start of
7.5.6. Kiln burner
primary air fan, the
fans
emergency cooling fan
must stop
automatically.
(The emergency
cooling fan must start
automatically when
the primary air fan
stops).
• Kiln ID-fan (group 4) in Manual selection:

7.5.7. Kiln burner
operation.
The interlocking
• Primary air fan (group 6) in between the burner
operation. and ID-fan in
operation can be
• CO and/or CH4 < MAX I.
bypassed by selection.
• Analysers for CO and CH4
However, once the ID-
must be in operation and not
fan has been started
in test mode.
the standard
interlocking is
automatically
activated.
• None
7.5.8. Kiln auxiliaries
• Main kiln drive stopped and
7.5.9. Device for
disengaged.
barring
• Barring drive engaged.
• Clinker storage area must not

7.5.10. Clinker
be full.
transport
• Transportation route defined.
• Clinker transport (group 10)

7.5.11. Cooler de-
in operation.
dusting system
• None
7.5.12. Clinker breaker

before start
• Damper of excess fan is The cooler excess air
7.5.13. Cooler excess
closed. fan will automatically
air fan
stop if exit
• Clinker dust transport (group
temperature at cooler
11) in operation.
outlet is above MAX 2.
NOTE that the ID-fan
will stop when the
excess air fan stops.
Delayed 0-5 minutes.
• Cooler excess air fan (group Manual selection:

7.5.14. Cooler fans
13) in operation.
Operation of the fans
• All fan dampers closed. individually during
start-up can be
selected.
• The clinker transport (group

7.5.15. Cooler drives
10) in operation.
• Clinker crusher (group 12) in
operation.
• Cooler fans (group 12) for the
grate cooler in operation and
air flow for all cooler fans >
Min 1.
• Kiln auxiliaries (group 8) in Manual selection:

7.5.16. Kiln drive
operation or in “no alarm”
The interlocking
status.
between kiln drive
• Barring device (group 9) is and cooler drive can
stopped and disengaged. be bypassed by
selection.
• Kiln drive ready for start and
engaged.
• No alarm for kiln position.
• Cooler drives (group 15) in
operation or not stopped for
more than 0-5 minutes.

before start
• Kiln burner (group 7) in
7.5.17. Calciner burner
operation.
• Kiln ID-fan (group 4) in
operation.
• Tertiary air damper open >
20%.
• Calciner outlet temperature
must be above minimum level
and below MAX II level.
• CO and/or CH4 < MAX I.
• O2 ≥ 5%.
• Gas analyser must be in
operation, not in test mode,
and no alarms active.
7.6. Control circuits

The following control circuits are foreseen.
1) The kiln feed is synchronized with the kiln speed.
2) Temperature of gas leaving the conditioning tower is controlled by
regulating the flow of water to the conditioning tower.
3) The temperature in the top of the lower most cyclone controls the
fuel supply to the calciner burner.
4) The pressure after the kiln ID-fan is controlled to a steady pressure
by regulating the speed of the mill/filter fan (Automatic).
5) The pressure in the kiln hood is maintained by the speed of the
cooler excess air fan.
6) The speed of the cooler drive is controlled by the average pressure
in the first cross bar compartment of the cooler. (See instruction
manual for cooler).
7) For all cooler fans air flow will be controlled by the speed of the
cooler fans.
8. Prevention of fires and explosions

8.1. General precautions
On no account must soot nor combustible, unburned exit gases be
allowed to accumulate in the kiln, the cyclones, the flue ducts etc. This
would involve a serious risk of explosion or fire.
Therefore strict adherence to the following rules is needed:
1) In connection with renewed light-up of the kiln, following a
temporary stoppage, the kiln must be lit in according to standard
safety procedure for gas stations.
2) Always ensure that the burner is not operating with an air
deficiency.
3) Inject the fuel at sufficient primary air velocity.
4) Burners must always be started at minimum fuel rate.
5) Never increase the fuel supply rate too suddenly or excessively at
the same time. In any case, the draught must always be increased
first and the upward adjustment of the fuel supply must take place
evenly and slowly.
8.2. Precautionary measures relating to the burners

In the following, the interlocking for the burners and the gas analysers
is summarised. The main purpose of the interlocking is to reduce the
risk of any fire or explosion. These risks are always present when
working with fuels. Although measures are taken to prevent the
dangers, the operator should always observe and act carefully when
working with fuels and firing equipment.
It is therefore an important interlocking that a burner can only
operate, if the gas analysers after the pre-heater are in operation
without any unit alarms or analyser fault on the CO and the CH4
channels.
Further it is conditional for the calciner burner operation that the CO
and/or CH 4 levels have not been over MAX II level.
If the CO and/or CH4 levels are above MAX I, the operator must take
actions to reduce this immediately. Depending on the circumstances
these actions could be either to reduce fuel rate or increase draught.
8.2.1. Procedure for gas analyser test mode
The analyser has a digital input for permission to test mode. This
input must be set before any local test can be performed.
The test permission is selected by the operator in the central
control room. It is automatically de-selected whenever the
analyser is put in test mode or if not, de-selected after 10 minutes
by a timer.
The test permission for analysers must be separated in test
permissions, one for each analyser. The test mode must always be
clearly indicated to the operator.
For further safety, test permission should only be possible for one
analyser at a time.
8.3. Fuels
For precautionary measures to be taken when using fuel, see separate
instruction manuals.
Reference is also made to the regulations of the local authorities.
9. Barring
9.1. General instructions
If the kiln is stopped while hot, barring of the kiln is required to avoid
kiln shell deformation. Normally, barring should always be restricted to
an absolute minimum to prevent damage to the lining.
The following guidelines apply to a situation where the kiln is stopped
in a hot condition and has to be barred:
1. As long as the kiln is hot, the barring operation must be
continuous the first half hour after stoppage.
2. If the axial position of the kiln should cause the alarm to be
tripped, then barring must be continued until the correct
position has been re-established.
3. If the kiln shell is exposed to strong external cooling, for
example due to heavy rainfall, then continuous barring is
required.
4. If during heavy rainfall the kiln stopped, keep barring on main
drive with minimum speed, until barring device is confirm ready
for use.
5. Cooling water supply to the kiln roller
bearings must be uninterrupted during the
entire barring period.
NOTE!
If accidentally for some reason the kiln has not been barred for 2 hours
after the kiln has stopped - though this should never take place
• First priority is to bar the kiln as soon as possible
• A mechanical inspection of the installation is required, before the
kiln is restarted on the main drive
9.2. Barring programs

The barring programs are divided into stages of 200 degrees rotation.
This is done to ensure variations in the position of the kiln during
standstill.
9.2.1. Barring during drying of lining before initial start-up
0 - 24 hours: About 200 degrees every 30 minutes
68 - 72 hours: Continuous barring
Keep a close check on the longitudinal expansion of the kiln and its
position on the supporting rollers during the entire period.
See separate instruction manual for thrust device.
9.2.2. Barring during normal start of cold kiln
20 - 24 hours: Continuous barring

Keep a close check on the longitudinal expansion of the kiln and its
position on the supporting rollers during the entire period.
See separate instruction manual for thrust device.
9.2.3. Barring during stoppage of the kiln
0 - ½ hours: Continuous barring
½ - 12 hours: About 200 degrees every 10 minutes
48 - hours: Bar as required, if some of the conditions
mentioned in subsection 9.1 above makes it
necessary.
During the final period the kiln must be barred for a few minutes,
if the axial migration of the kiln exceeds the maximum value for
normal kiln operation.
This barring operation is required to prevent damaging or possible
rupturing of the thrust roller shaft during the kiln tube contraction,
which still may take place up to the 72nd hour.
9.2.4. Braking
If the barring operation is stopped, the kiln is automatically braked
and maintained in an arbitrary position and may therefore be side
heavy. This fact must be taken into account when the brake is
slackened.
Reference is also made to the instruction manual for the barring
device.
10. Operating parameters and alarm limits

The following tables are a survey of the expected normal operating
parameters and the normal alarm limits.
The operating parameters stated are for guidance only and apply to the
normal, stable operating situation. The operating limits stated are meant as
guidance for start-up. It will be possible to adjust many of these with
advantage later on in order to make them more suitable for the actual
operation. Concerning many of the alarm limits they will also have to be
adjusted according to local conditions as factors like the lubrication oil
selected, the ambient temperature, etc. will affect the values. The mechanical
and/or the electrical departments must, in every single case, approve the
change and fixing of the alarm limits for protection of the machines.
Normally, the alarm limits for the operating parameters will be the
responsibility of the production management.
The following notes refer to the tables listed below:

To be fixed in accordance with the specifications in
a)
separate machine instruction
b) To be fixed in accordance with the electrical documentation
To be fixed empirically so the alarm is not activated under

c)
normal operating conditions
The normal value is either given in above text or has to be

x)
evaluated during commissioning
+) Indication given according to the range of instrument
Manual control
Expected value
Max. 3 alarm
Max. 1 alarm
Max. 2 alarm
Operating and
Min. 1 alarm
Min. 2 alarm
control loop
alarm limits
Alarm
Unit
Kiln feed t/h 495
Filter inlet T °C 115 a) a)
ID-fan (No WHR) kW 2x1040
r/min -
Pre-heater out mbar 53
5 stage
°C 310 200 370 450
% O2 3 2.0
% CO 0.0 0.5 0.9 1.2
1) 2)
% CH4 0.0 0.5 0.9 1.2
1) 2)
% NOx x
1) MAX II Automatic reduce fuel to the calciner by 20%
2) MAX III Automatic reduce fuel to preset minimum
Manual control
Expected value
Max. 3 alarm
Max. 1 alarm
Max. 2 alarm
Operating and
Min. 1 alarm
Min. 2 alarm
control loop
alarm limits
Alarm
Unit
Cyclone 1 T1 311
Cyclone 2 T1 502
T2 497
P1 40 15
Cyclone 3 T1 671
T2 666
P1 36 12
Cyclone 4 T1 814 3)
T2 804
P1 29 10
P2 27
Cyclone 5 T1 890 920 960 990 3)
T2 870
P1 21 8
P2 20
3) Temperature controlled by calciner fuel feed rate
T1 = Top temperature [°C] in cyclone
T2 = Bottom temperature [°C] in cyclone
P1 = Pressure [mbar] in cyclone roof
P2 = Pressure [mbar] in cyclone bottom
Manual control
Expected value
Max. 3 alarm
Max. 1 alarm
Max. 2 alarm
Operating and
Min. 1 alarm
Min. 2 alarm
control loop
alarm limits
Alarm
Unit
Tertiary air °C 940
mbar 10
Tert. damper % x +
Kiln inlet mbar 2
% O2 4 1
% CO 0
% CH4 0
% NOx 1200 x
Kiln drive rpm 3.6 + 4)
Kiln position mm ±5 a) a) a) a)
Kiln hood mbar -1 x 5)
°C 1050
Primary air mbar a) c) 6)
kW a)
Coal Kiln t/h 11.3 +
Coal Calciner t/h 19.0 + 3)
4) Manually controlled, but synchronized with kiln feed
5) Cooler excess air fan speed control.
6) Pressure could be controlled by inlet damper.
Amps. = Current
Other: Below measurements are used for protection of the individual equipment.
• Speed monitor
• Motor bearing temperature
• Motor winding temperature
• Bearing temperature
• Pressostate (air pressure control)
• Oil flow control
• Oil level control
• Oil temperature
• Hydraulic oil pressure
• Hydraulic oil temperature
• Hydraulic oil level
Alarm settings to be in accordance with separate instructions.
Cooler operation and settings are described in separate instruction
10.1. Drying out & Preheating, Kiln system with ILC calciner
10.1.1. Legends for translation

(A) Preheating
(B) Drying out
(C) Barring according to
program
(D) Kiln on main drive
(H) Hours
(CT) Cyclone temperature
(KS) Kiln speed
(SF) Start feeding
(BS) Bottom stage
(TS) Top stage
(KF) Kiln feed
(FC) Fuel to calciner
(FK) Fuel to kiln
(TAD) Tertiary air damper

Kiln Process-70039029 - A4-P - 1.0 - EN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Kiln Process-70039029 - A4-P - 1.0 - EN

Uploaded by

Copyright:

Available Formats

Rotary kiln plant (ILC)

Maple Leaf 3, Pakistan

Doc. No.: 70039029-1.0

Separate instruction manuals

2. Design and operating principle

2.2. Operating principle

The cooling air that passes up through the clinker bed is in

3. Drying and heating of lining prior to start-up

Trial run of machines loaded with material should be performed

Water and/or air must be available where necessary. See

8) In order to optimize the regulation of the primary air volume in

3.1.4. Preparations prior to heating

If special requirements for the initial drying of the castables are

3.2. Drying-out procedure

Phase Burner(s) Duration

3.2.2. Phase 1: Cooler Drying-Out (CDO)

No. Sequence/Action Notes

3.CDO Open the TA damper to 100% open If necessary open one or

temporary installed wall

No. Sequence/Action Notes

24 hours followed by an increase to is finalised after 48

3.2.4. Phase 3: Rotary Kiln and Preheater Drying-Out (KDO)

No. Sequence/Action Notes

2.KDO Start the dust transport from the kiln/raw

14.KDO Start one/two cooler fans. Open cooler fan

3.3. Initiation of heat-up, preparations and start kiln production

No. Sequence/Action Notes

additional oil directly on

17.HU Open the excess air fan damper gradually.

has cooled down and

3.3.2. Air supply during the heat-up phase

However, an adequate air surplus must be present for the

3.4. Inspection during heat-up period

4. Start of kiln plant

4.2. Preparation for kiln start

4.3. Starting and operation of the grate cooler

The amount of cooling air should be the maximum possible without

4.4. Starting of kiln main drive

4.5. Preparations for/and calciner operation

4.6. Starting of kiln feed and establishing normal production rate

Personnel must be stationed in the cyclone tower in order to watch the

5. Stop of kiln plant

5.2. Unscheduled stoppages

• Stop of kiln drive delayed 0-5 minutes.

6.2. Specific conditions related to kiln operation

alarm will inform the operator about the risk of unburned

Alarm CO (%) CH4 (%)

6.2.5. Blockage in cyclones

Therefore, it is essential that extreme caution and care are being

A number of precautionary measures must to be taken in the

The MAX I alarm is a signal instructing the operator to undertake

7. Interlocking, programming and control circuits

7.2. Process interlocking

operation is automatically supervised, checking constantly all

The following equipment can be operated individually:

7.4. Comments to programs

7.5. Start-up interlocking

Group Conditions to be fulfilled Other

• The dust transport system The dust from the

• Damper to be closed, and

• ID-Damper(s) to be closed <

• Availability of compressed air

Group Conditions to be fulfilled Other