BLUE CIRCLE TECHNICAL CENTRE

KILN AND PRE-HEATER TROUBLE SHOOTING

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

Top stage cyclone gas Partial feed starvation. For partial loss try to increase
exit temperature increases feed to required level if unable
Erratic feed rate too then reduce fan and fuel to
match feed. If the loss is total
then emergency shutdown
If temp rise rapid total loss advisable.
of feed
Top stage cyclone gas Increase of feed Lower feed rate
exit temperature Erratic feed rate. Tune controller or fix feed
decreases system problem.

Large inleak. Patch inleak

Reduction or loss
of Adjust fan and feed to match
calciner fuel. fuel and gradually bring kiln
back up to full feed rate.
Reduction or loss of kiln Bring fuel back to normal
fuel levels or if total loss
emergency shutdown.
Bottom stage cyclone Sudden increase of feed. Adjust feed rate
gas exit temperature
decreases Intermittent blocking of Check upper stage cyclone
upper stage cyclones flap valves moving freely.
causing flush of material
down the tower

Shortage of combustion Adjust fan (tertiary air ) and

air. fuel to increase Oxygen levels
in calciner.
Calciner will not ignite Too low temperature in Reduce feed and kiln speed
the calciner. increase fuel to kiln.
(or secondary coal)
Lack of fuel. Check fuel delivery system for
faults.

Not enough combustion Adjust fan (tertiary air ) and

air. fuel to increase Oxygen levels
in calciner.

Trevor Fenton Page 1 05/02/2024

 BLUE CIRCLE TECHNICAL CENTRE

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

Bottom stage cyclone gas Feed starvation or partial For partial loss try to increase
exit temperature high loss of feed feed to required level if unable
too then reduce fan and fuel to
match feed. If the loss is total
then emergency shutdown
advisable.

Higher stage cyclone Emergency shutdown then

blockage causing feed clear blockage
starvation in lower part of
tower
Any lower stage cyclone Possible blockage in upper Emergency shutdown, clear
gas exit temperatures stage cyclone/s blockage
high
Check all flap valves for free
movement.

Increase in kiln exit Blockage in final stage Emergency shutdown clear

temperature cyclone blockage

Decrease in kiln exit Possible material Check splash plates or splash

temperature bypassing final stage boxes for damage and wear.
cyclone and falling
through into kiln Adjustable splash plates can
be adjusted.

Bottom stage material Upper stage cyclone Emergence shutdown.

temperature decreases blockage check exit gas
for increase Clear blockage and check all
flap valves are moving freely.

Trevor Fenton Page 2 05/02/2024

 BLUE CIRCLE TECHNICAL CENTRE

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

Persistent cyclone Higher than normal Check feed rate consistency.
blockages during normal operating temperatures. Check calciner temperature
operation. Rough or uneven control.
refractory in cyclone Check cyclone refractory for
shelves damage etc

Flap valves sticking. Check flap valves for free

movement..

High pre-heater Flap valves sticking Check flap valves for free
temperatures followed by movement..
drop in kiln power then Intermittent blockage of
kiln flush cyclones

Cyclone blockages on Overheating lower part of Start plant at lower

kiln start up tower on start up temperatures

Briefly increase feed to system

and then reduces as the
temperatures stabilise.

Kiln feed chemistry Check with laboratory for

changes in chemistry and
request corrections.

Trevor Fenton Page 3 05/02/2024

 BLUE CIRCLE TECHNICAL CENTRE

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

Heavy riser duct coating Low kiln exit oxygen Adjust fan and tertiary air to
–causing an increase in increase kiln exit Oxygen.
all tower pressures
Projections on lining or Repair as soon as possible
damaged refractory

Inleaks around kiln seal or Repair kiln seal patch inleaks

riser duct area

High sulphur input Adjust fuel mix to kiln

Overburning (high kiln Reduce kiln fuel to lower

exit NOX levels NOX levels

Inadequate cleaning Increase intensity and

frequency of cleaning

Steep increase in kiln Coating fall or ring break Reduce kiln speed and feed
power followed by away. increase fuel if Oxygen
gradual drop in kiln available. when situation
power. As power drops Fall of coating from kiln stabilises bring kiln back to
kiln exit NOX and riser normal operating conditions.
Burning zone temperature
decrease. Pre-heater cleaning
Sudden drop in kiln Loss of calciner fuel. Reduce feed speed increase
power and kiln flushes kiln fuel. Check calciner fuel
system for faults. Bring kiln
back up to normal production

Sudden increase of feed Check feed system reduce

Upper stage cyclone feed stabilise kiln
blocking

Flap valves sticking Adjust counter weights

Trevor Fenton Page 4 05/02/2024

 BLUE CIRCLE TECHNICAL CENTRE

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

Burning zone temperature Fuel delivery erratic Check fuel delivery system
Erratic and kiln power Tune controller.
fluctuating
Fuel quality variable Check fuel blending system

Cooler cycling Tune cooler control or run in

manual to break cycle

Dust from cooler Increase cooler bed depth or

excessive. decrease air on front fans. Try
cooler in manual. Check kiln
feed chemistry for changes.

Feed erratic Tune system or correct fault in

feed delivery

Excessive vibration on Impellers coated Stop kiln and clean impellers

main fans

CO at kiln exit Excessive or erratic fuel Check fuel delivery system

delivery tune controllers.

Incomplete combustion in Adjust fan and /or tertiary air.

calciner. Due to Check residues (if coal or pet
insufficient combustion coke)
air

Fall through of fuel from Check fuel residues consider

calciner. accelerator in kiln riser to
increase velocity.

Trevor Fenton Page 5 05/02/2024

 BLUE CIRCLE TECHNICAL CENTRE

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

Small hot spot on kiln Refractory failure Continue normal operation but
shell direct shell cooling fan at hot
spot, change temperature
profile of kiln by increasing
primary air if possible,
Maintain normal running
conditions, adjust kiln
chemistry to increase coating

Large hot spot on kiln Refractory failure Emergency shutdown cool and
shell repair
Kiln Back end spillage Ring formation at kiln (Short term)
back end Increase kiln speed Reduce
feed

(Long term prevention)

Increase kiln exit Oxygen
level

Reduce feed

Worst-case stop kiln remove

ring.

Falls of build up from Check blaster operation

riser area causing Increase cleaning frequency
temporary damming at
back end of kiln

Trevor Fenton Page 6 05/02/2024

 BLUE CIRCLE TECHNICAL CENTRE

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

High Free Lime Under burning (in kiln) Increase kiln fuel

Poor calcination Increase calciner temperature

to achieve target calcination

Over burning: Calcium Reduce kiln coal and increase

Sulphate Disassociation. kiln exit Oxygen check clinker
SO3.

High kiln volume loading Gradually increase kiln speed

giving poor heat transfer or reduce feed to reduce
and high sensitivity to volume loading. Check
chemistry changes volume loading.

Change in combinability
temperature LSF,SR,AR Increase fuel to kiln if possible
or Residue increases (acid to raise burning zone
insoluble). temperature.
Adjust chemistry high LSF
will give high free lime.
Increases in residue will
increase combinability
temperature.
Clinker sausage or liquid Preheater blockage Reduce fuel rate to minimum
in burning zone leading to feed starvation
in kiln Increase kiln speed if possible
to break up sausage
Loss of feed
Increase air to cooler fans
Over burning
Reduce primary air flow to
Large change in chemistry lengthen flame (cooler flame)

Once situation in burning zone

returns to normal bring kiln
back to normal operating
conditions.

Trevor Fenton Page 7 05/02/2024

 BLUE CIRCLE TECHNICAL CENTRE

FAULT OR INDICATION POSSIBLE CAUSES POSSIBLE ACTIONS

Irregular flame and/or Loss of part of burner pipe Inspect burner pipe for
unusual flame shape damage if the flame is only
slightly distorted adjust
primary air or pipe position to
compensate

Hole in burner pipe Shut down kilnn repair or

replace burner pipe
Bend in burner pipe

REMEMBER THE KILN BURNERS NUMBER ONE RULE

IF IN DOUBT FIRE OUT

Trevor Fenton Page 8 05/02/2024