Heat Consumption Mastery Standard: Cement

CEMENT

Heat Consumption Mastery Standard Dec 2011

Heat Consumption Mastery Standard

Systematic Optimisation of Heat Consumption

10 Golden Rules

Action Plans

Basic Level Implementation by December 31st, 2012

Full Implementation by December 31st, 2014*

Tracking Tool *According to plant Priorities

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Basic Level Implementation by December 31st, 2012 

5 Golden Rules



Prepare a consistent raw mix



Control oxygen levels in kiln and pre-heater



Optimize fuel combustion



Master kiln stability



Optimize cooler efficiency

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Full Implementation According to plant Priorities by December 31st, 2014 

10 Golden Rules



Master pre-heater and calciner operation



Optimize kiln throughput



Maximize reliability factor



Minimize wasted cement kiln dust and kiln dust losses



Apply operating procedures with skilled operators

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Basic Level implementation 5 Golden Rules

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Golden Rules 1 – Prepare a Consistent Raw Mix

CONTROL ACTIONS

SUPPORT

Review KFUI results monthly

Training : Raw Mix Optimisation

Review burnability index at least once every 3 years

Technical Doctrine : Raw mix

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Golden Rules 2 – Control Oxygen Levels in Kiln and Pre-heater CONTROL ACTIONS Maintain Process Gas Analysers Availability and Accuracy Develop inspection plan for chasing false air in pyro-line; conduct regular overall measurements & compare with targets; inspections and repairs at least monthly (as per Power Standard)

SUPPORT Procedures & Tools: 1)

How to measure gas composition by gas analyzer

2)

How to control false air in the preheater

3)

How to measure false air

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Golden Rules 3 – Optimize Fuel Combustion CONTROL ACTIONS Align burner or flame with kiln axis

SUPPORT Training : Pyro 1 Training Procedures & Tools :

Process fuel to target fineness (target defined with TC)

Kiln burning zone operating with oxidising atmosphere

1.

How to start up & optimise a burner

2.

How to measure gas composition by gas analyser

3.

Lafarge burner spreadsheet

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Golden Rules 4 – Master Kiln Stability CONTROL ACTIONS

SUPPORT Training : Pyro 1 Training

Free-lime target and control

Keep constant bed depth in the kiln

Procedures & Tools :

1.

Combustion Manual Post Sevilla

2.

TA Fuel Flexibility

3.

LQTS - free lime analysis

4.

Kiln operation guidelines 2006 (TCEA)

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Golden Rules 5 – Optimize Cooler Efficiency CONTROL ACTIONS Stable Cooler Operation

SUPPORT Training : Pyro 1 Training

Optimise Airflow Distribution and Bed Depth

Procedures & Tools :

Maintain Proper Mechanical Condition

1.

How to check the calibration of cooling fan airflows

2.

2) How to adjust the cooling air level and airflows

3.

3) Airflow distribution calculation tool 1

Full implementation 10 Golden Rules

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Golden Rules 6 – Master Pre-heater & Precalciner Operation CONTROL ACTIONS Control calciner temperature

SUPPORT Training : Pyro 1 & Pyro2 Training Procedures & Tools :

Ensure proper condition of preheater components: thimbles (except for lower cyclone), flap valves, splash boxes, refractory, restrictor, etc

Keep build ups under control

1.

How to sample hot meal

2.

How to control hot meal

3.

How to assess and optimise preheater efficiency

4.

Technical Agenda -Fuel Flexibility

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Golden Rules 7 – Optimize Kiln Throughput CONTROL ACTIONS Regularly Challenge Operators on Performance factor

SUPPORT Training : Pyro 1, Lucie, Cecil & KHD Simulator

Documents: Ensure reliability and accuracy of critical kiln system sensors

Analyse all kiln feed reductions of greater than 20% and define corrective actions

1.

Technical agenda - De-bottlenecking

2.

Kiln operation guidelines 2006 (TCEA)

3.

POM P2 - Instrument Quality Assurance

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Golden Rules 8 – Maximize Reliability Factor

CONTROL ACTIONS

Systematically analyze incidents resulting in most significant production losses with the RCA tool (as per POM)

SUPPORT Training : RCA training Documents: POM Toolkit

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Golden Rules 9 – Minimize Wasted CKD and Kiln Dust Losses

CONTROL ACTIONS

SUPPORT

Measure or estimate kiln dust loss

Training : Pyro 1 For long kilns determine effective control levers that can be used to minimise dust wasting. Optimise the kiln chain system by monitoring chain density by zone and replacement at least annually.

Documents Easy+: Cement kiln dust methods for reduction

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Golden Rules 10 – Apply Operating Procedures with Skilled Operators

CONTROL ACTIONS

SUPPORT

Have at least one certified operator per shift, implement POM C1 Have critical SOP Mgt system in place and used.

Training : CRO training

N.B. These 2 actions must be implemented as soon as possible – in any case according to plant POM implementation timeline.

Documents: POM Toolkit

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