Kiln Operation Basics – Raw Mix Control

Content
• Improve burnability
• Raw Mix Ratios
• LSF
• SR
• AR
• Raw Mix Fineness
• Raw Mix Uniformity
• KFUI
• SPC

EVA Communication kit February 2008 - 1

 Kiln Operation Basics – Raw Mix Control

KFUI: definition

• KFUI = Kiln Feed Uniformity Index

• KFUI is the index to monitor the kiln feed chemistry

uniformity, it is used in all plants and all technical
centres of Lafarge

EVA Communication kit February 2008 - 2

 Kiln Operation Basics – Raw Mix Control

KFUI: formula
• The chemistry uniformity is monitored through C3S (main
clinker phase) and an associated target
• “Average of the squared difference between an
instantaneous kiln feed sample C3S value and the C3S target,
on a daily basis”:

N
1
KFUI 
N
 3 i
(C S
i 1
 C S
3 T ) 2

 Spot sample taken every day, same time, same place:

• Do a C3S analysis
• Apply the formula to calculate KFUI

EVA Communication kit February 2008 - 3

 Kiln Operation Basics – Raw Mix Control

KFUI: Target

• All plants must achieve the KFUI < 14

 If KFUI > 30, an emergency action plan has to be

implemented through a complete audit

EVA Communication kit February 2008 - 4

 Kiln Operation Basics – Raw Mix Control

High KFUI: Possible reasons

• Raw Materials : Quarry

• Change of location
• Size after crusher  Equipment :
• Sampling :  Crusher and Screens
• Sampling protocol  Sampling tower

• Frequency
 Pre-blending pile control:
Software optimisation

 Sampling protocol

EVA Communication kit February 2008 - 5

 Kiln Operation Basics – Raw Mix Control

High KFUI: Possible reasons

• Filling : Constant layering :

• Continuous operation  Speed constant both

• Buffer hopper ways

• If no material stop Minimise segregation :

 Minimise the fall


Stacker has to follow
the pile height

level detector

Pre-blending Pile

EVA Communication kit February 2008 - 6

 Kiln Operation Basics – Raw Mix Control

High KFUI: Possible reasons

• Reclaimer : Check the angle

• check the speed  Close to angle of
• Avoid recirculation repose
• check the maintenance of rakes
Check the stability of the
flow to the mill

Pre-blending Pile

EVA Communication kit February 2008 - 7

 Kiln Operation Basics – Raw Mix Control

High KFUI: Possible reasons

Weigh-Feeders
• Check the operational range (Max, Min=Max/10)
• Avoid to work at low range
• Regular Zero checks and span checks
• Reliability
• Blockages
• Lack of material
• Cleaning
• to avoid off-set

• tuning checks (PID settings), has to be on target

EVA Communication kit February 2008 - 8

 Kiln Operation Basics – Raw Mix Control

High KFUI: Possible reasons

Sampling and Kiln Dust

• Check the operation of the sampler
• Blockage
• Program (frequency and composite)
• Check the sampler representatively
• location
• Dust management
• should go to kiln feed
• part of the sample or not

EVA Communication kit February 2008 - 9

 Kiln Operation Basics – Raw Mix Control

High KFUI: Possible reasons

• Type of silos Settings

• Efficiency

• Variograph

• Operation at high level of content

• Level of Maintenance

Blending silos

EVA Communication kit February 2008 - 10

 Kiln Operation Basics – Raw Mix Control

KFUI : The picture to remember

YOZGAT Kfui EVOLUTION YOZGAT CLINKER PRODUCTION (tpy)
(12 months moving average)
750,000
28
725,000
21
700,000
14 675,000

7 650,000

0 625,000
1996 1997 1998 1999 2000 1996 1997 1998 1999 2000

YOZGAT SP. CALOR. CONS (kCal/kg ck) YOZGAT POWER EVOLUTION

(Cement mill kWh/t)
820
46
818
45
816 44
43
814
42
812
41
810 40
1996 1997 1998 1999 2000 1996 1997 1998 1999 2000

EVA Communication kit February 2008 - 11

 Kiln Operation Basics – Raw Mix Control

KFUI - Conclusion

• The KFUI is a technical pre-requisite to get

operational improvements

• KFUI improvement is a team effort from the quarry

to the kiln operators through lab operators

• The upper limit is 14

EVA Communication kit February 2008 - 12