Kiln Audit
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LAFARGE PAKISTAN CEMENT
Kiln Audit Report-2015 Internal Audit Report Process Team 4/8/2015
It is kiln audit report in which system is analyzed for its critical parameters clinker factor SHC & SPC. To improve and optimize the system reliability and productivity.
Contents
Kiln Operation during trial…………………………………………………………………………..03 Specific Heat Consumption………………………………………………………………………….08 Specific Power Consumption…………………………………………………………………………10 Clinker Factor………………………………………………………………………………………………..10 System Gas Balance……………………………………………………………………………………… 11 Clinker Quality……………………………………………………………………………………………..11 Action Plans…………………………………………………………………………………………………..12
Prepared By Process Team
Page 2
Kiln Audit-2015 Kiln drop test trial was started from 08-April-2015 at 09:00 AM to 09-April-2015 at 09:00 AM, during 24 Hrs clinker weighment was done and net clinker weight was 7195 ton. During this trial all the process measurements of entire pyroline system were taken and calculated the system gas balance, heat balance, SHC, & SPC.
1.1 Kiln Operation during Trial Kiln Operation mimics during the trial are as under
Kiln Operation mimic view
Prepared By Process Team
Page 3
Kiln ID Fans & GCT operational mimic view
Grate Cooler Operational mimic
Prepared By Process Team
Page 4
Kiln Feed Operation mimic
Grate Cooler & Cooler ESP mimic view
Prepared By Process Team
Page 5
Kiln shell scam scanner view during trial
Prepared By Process Team
Page 6
C5 A&B Temperatures and set point During trial cyclone-05 A&B side temperatures trend with set point. It can be clearly seen that temperatures peaks variations from its set points and loss of fuel. It needs to be fine control tune for saving the fuel.
Prepared By Process Team
Page 7
1.2 Specific Heat Consumption The fuel used during the trial was South Africa Coal & Carbon powder, the ratio between the being approximately 85:15 in the duration of trial for both Kiln and Calciner firing. The raw coal feeders are running in proportion. Feeders A01 and B01 were utilized respectively for South Africa Coal and Carbon powder. Total consumption of coal and Cp on both sides is Total Coal towards Kiln:
322.2 ton
Total Coal towards Calciner:
601.8 ton
Prepared By Process Team
Page 8
During trial the Pfisters error by LOW method is as below and these are the fuel tonnage by hourly loss of weight method Main (ton) -0.39 -1.02 -0.67
PC (ton) -0.13 -0.12 0.37
Hourly Average (ton) Day Average
-0.69 -16.64
0.04 0.96
Consumption after Error
305.6
602.8
Description
Specific heat consumption by Heat Balance Tool:
Prepared By Process Team
746 Kcal/Kg clinker
Page 9
1.3 Specific Power Consumption SPC up to Clinker:
62.88 Kwh/ton clinker
SPC up to Kiln area:
32.39 Kwh/ton clinker
1.4 Clinker Factor Kiln Feed consumed during trial:
11524 ton
Clinker weighed:
7195 ton
Clinker Factor:
1.602
Clinker Factor by adding Kiln Feed scale error: 1.67 Raw mill dust was fed directly to the kiln through-out the trail. Kiln feed scale error requires LOW calibration during shutdown.
Prepared By Process Team
Page 10
1.5 System Gas Balance Sheet Gas balance around the whole system is as below and false air across the Preheater is 33395 Nm3/hr or 14.8% which is higher than its target value <7%.
1.6 Clinker Quality The free lime average during the trail was well within the plant operations target. The results from the hourly laboratory results is listed as Average Free Lime:
1.39%
Average Clinker Temperature:
158 C
Clinker Ltr Wight:
1210 g/Ltr
Clinker C3S:
58.53 %
Prepared By Process Team
Page 11
1.7 Action Plans Sr #
Description
Who
When
1
Kiln Inlet analyzer remained out of order throughout the trial, need to be improved its reliability for accurate fuel mix control in kiln and Calciner. Kiln ID fans J1T06 & J1T12 sealing work is required specially shafts sealing, expansion joints and casing joints. Preheater dust losses increased due C4-A bended dip tube and missed dispersion plates of C3B, C4A, C2B which Affecting the cyclone efficiencies, clinker factor and productivity, Need to be maintenance work for improving KPI’s.
Ch Asif/Sohail
29-April-2015
Pervaiz Iqbal
28-April-2015
Fahim-Ul-Ehsan
Scheduled
CO observed at the bottom cyclone exit gas up to 0.5%. This not only a safety hazard but also a waste of fuel due to incomplete combustion. 0.1% CO= 4Kcal/Kg clinker, total waste is 20 Kcal/Kg clinker, so need to be optimized the Calciner combustion by low moisture fuel (AF), small particle size, and good distribution of fuel w.r.t retention time. It also needs the C05 gozze neck cleaning in shutdown. Mechanical flaps were missed and stuck at Cyclone 4 & 5 both A and B side, need to be placed modified flaps with good sealing to stop the gases reversible path and good material flow.
Fahim-Ul-
Preheater Cyclones temperature difference indicating the poor heat transfer b/w material and gases need to be placed all the missing dispersion plates e.g. C3B, C4A, and C4B & C2B.
Muhammad
Scheduled
Ali/M Sajjadullah
Shutdown
Need to be replacing the cyclone-04 A-side bended dip tube because it effecting cyclone dust separating efficiency and pressure drop.
Muhammad
Scheduled
2
3
4
5
6
7
Prepared By Process Team
Shutdown
29-April-2015
Ehsan/Sajjadullah
Muhammad Ali/Fahim-ulEhan
Scheduled
Shutdown
Page 12
Ali/M Sajjadullah
Shutdown
Older generation sluice flaps are source for false air entry in the system at stage 5, 6, 7 and 8. These are to be replaced with new generation flaps for better sealing.
Pervaiz
Scheduled
Iqbal/Sohail
Shutdown
Error in Kiln Feed scale -4.41%, need to be calibrating the LOW kiln feed weigh system in shut down to remove the error.
Ch Asif/Fahim-
Scheduled
ul-Ehsan-Sohail
Shutdown
False air across the Preheater is 67427 Nm3/hr or 14.8% which is higher than its target value <7%. Need to be sealed properly the leakages points of sliding gates, Calciner outlet expansion joint, expansion joints, main doors, pocking holes and eye holes for saving heat & power
Pervaiz
29-April-2015
Pfister online calibration errors are beyond the acceptable limits specially Calciner side, need the Pfisters reliability regarding calibration error Cooler water spray flow meter is out of order, need to be replacing it with reliable meter.
Ch Asif/Sohail
27-April-2015
Ch Asif/Sohail
29-April-2015
13
Required validation of LOW method of fine coal bin to calculate SHC.
Ch Asif/FahimScheduled ulEhsan/Sajjadullah Shutdown
14
Kiln thermal loading is 5.54 MW/m2, standard is < 5.5 MW/m2, its need to be down by optimizing the main side fuel
Fahim-Ul-
8
9
10
11
12
Iqbal/Sohail
29-April-2015
Ehsan/Sajjadullah
15
Needs to be fine control tune of cyclone-05 set point for saving the fuel.
Prepared By Process Team
Imran Haider
29-April-2015
Page 13
Kiln Audit Report-2015 Internal Audit Report Process Team 4/8/2015
It is kiln audit report in which system is analyzed for its critical parameters clinker factor SHC & SPC. To improve and optimize the system reliability and productivity.
Contents
Kiln Operation during trial…………………………………………………………………………..03 Specific Heat Consumption………………………………………………………………………….08 Specific Power Consumption…………………………………………………………………………10 Clinker Factor………………………………………………………………………………………………..10 System Gas Balance……………………………………………………………………………………… 11 Clinker Quality……………………………………………………………………………………………..11 Action Plans…………………………………………………………………………………………………..12
Prepared By Process Team
Page 2
Kiln Audit-2015 Kiln drop test trial was started from 08-April-2015 at 09:00 AM to 09-April-2015 at 09:00 AM, during 24 Hrs clinker weighment was done and net clinker weight was 7195 ton. During this trial all the process measurements of entire pyroline system were taken and calculated the system gas balance, heat balance, SHC, & SPC.
1.1 Kiln Operation during Trial Kiln Operation mimics during the trial are as under
Kiln Operation mimic view
Prepared By Process Team
Page 3
Kiln ID Fans & GCT operational mimic view
Grate Cooler Operational mimic
Prepared By Process Team
Page 4
Kiln Feed Operation mimic
Grate Cooler & Cooler ESP mimic view
Prepared By Process Team
Page 5
Kiln shell scam scanner view during trial
Prepared By Process Team
Page 6
C5 A&B Temperatures and set point During trial cyclone-05 A&B side temperatures trend with set point. It can be clearly seen that temperatures peaks variations from its set points and loss of fuel. It needs to be fine control tune for saving the fuel.
Prepared By Process Team
Page 7
1.2 Specific Heat Consumption The fuel used during the trial was South Africa Coal & Carbon powder, the ratio between the being approximately 85:15 in the duration of trial for both Kiln and Calciner firing. The raw coal feeders are running in proportion. Feeders A01 and B01 were utilized respectively for South Africa Coal and Carbon powder. Total consumption of coal and Cp on both sides is Total Coal towards Kiln:
322.2 ton
Total Coal towards Calciner:
601.8 ton
Prepared By Process Team
Page 8
During trial the Pfisters error by LOW method is as below and these are the fuel tonnage by hourly loss of weight method Main (ton) -0.39 -1.02 -0.67
PC (ton) -0.13 -0.12 0.37
Hourly Average (ton) Day Average
-0.69 -16.64
0.04 0.96
Consumption after Error
305.6
602.8
Description
Specific heat consumption by Heat Balance Tool:
Prepared By Process Team
746 Kcal/Kg clinker
Page 9
1.3 Specific Power Consumption SPC up to Clinker:
62.88 Kwh/ton clinker
SPC up to Kiln area:
32.39 Kwh/ton clinker
1.4 Clinker Factor Kiln Feed consumed during trial:
11524 ton
Clinker weighed:
7195 ton
Clinker Factor:
1.602
Clinker Factor by adding Kiln Feed scale error: 1.67 Raw mill dust was fed directly to the kiln through-out the trail. Kiln feed scale error requires LOW calibration during shutdown.
Prepared By Process Team
Page 10
1.5 System Gas Balance Sheet Gas balance around the whole system is as below and false air across the Preheater is 33395 Nm3/hr or 14.8% which is higher than its target value <7%.
1.6 Clinker Quality The free lime average during the trail was well within the plant operations target. The results from the hourly laboratory results is listed as Average Free Lime:
1.39%
Average Clinker Temperature:
158 C
Clinker Ltr Wight:
1210 g/Ltr
Clinker C3S:
58.53 %
Prepared By Process Team
Page 11
1.7 Action Plans Sr #
Description
Who
When
1
Kiln Inlet analyzer remained out of order throughout the trial, need to be improved its reliability for accurate fuel mix control in kiln and Calciner. Kiln ID fans J1T06 & J1T12 sealing work is required specially shafts sealing, expansion joints and casing joints. Preheater dust losses increased due C4-A bended dip tube and missed dispersion plates of C3B, C4A, C2B which Affecting the cyclone efficiencies, clinker factor and productivity, Need to be maintenance work for improving KPI’s.
Ch Asif/Sohail
29-April-2015
Pervaiz Iqbal
28-April-2015
Fahim-Ul-Ehsan
Scheduled
CO observed at the bottom cyclone exit gas up to 0.5%. This not only a safety hazard but also a waste of fuel due to incomplete combustion. 0.1% CO= 4Kcal/Kg clinker, total waste is 20 Kcal/Kg clinker, so need to be optimized the Calciner combustion by low moisture fuel (AF), small particle size, and good distribution of fuel w.r.t retention time. It also needs the C05 gozze neck cleaning in shutdown. Mechanical flaps were missed and stuck at Cyclone 4 & 5 both A and B side, need to be placed modified flaps with good sealing to stop the gases reversible path and good material flow.
Fahim-Ul-
Preheater Cyclones temperature difference indicating the poor heat transfer b/w material and gases need to be placed all the missing dispersion plates e.g. C3B, C4A, and C4B & C2B.
Muhammad
Scheduled
Ali/M Sajjadullah
Shutdown
Need to be replacing the cyclone-04 A-side bended dip tube because it effecting cyclone dust separating efficiency and pressure drop.
Muhammad
Scheduled
2
3
4
5
6
7
Prepared By Process Team
Shutdown
29-April-2015
Ehsan/Sajjadullah
Muhammad Ali/Fahim-ulEhan
Scheduled
Shutdown
Page 12
Ali/M Sajjadullah
Shutdown
Older generation sluice flaps are source for false air entry in the system at stage 5, 6, 7 and 8. These are to be replaced with new generation flaps for better sealing.
Pervaiz
Scheduled
Iqbal/Sohail
Shutdown
Error in Kiln Feed scale -4.41%, need to be calibrating the LOW kiln feed weigh system in shut down to remove the error.
Ch Asif/Fahim-
Scheduled
ul-Ehsan-Sohail
Shutdown
False air across the Preheater is 67427 Nm3/hr or 14.8% which is higher than its target value <7%. Need to be sealed properly the leakages points of sliding gates, Calciner outlet expansion joint, expansion joints, main doors, pocking holes and eye holes for saving heat & power
Pervaiz
29-April-2015
Pfister online calibration errors are beyond the acceptable limits specially Calciner side, need the Pfisters reliability regarding calibration error Cooler water spray flow meter is out of order, need to be replacing it with reliable meter.
Ch Asif/Sohail
27-April-2015
Ch Asif/Sohail
29-April-2015
13
Required validation of LOW method of fine coal bin to calculate SHC.
Ch Asif/FahimScheduled ulEhsan/Sajjadullah Shutdown
14
Kiln thermal loading is 5.54 MW/m2, standard is < 5.5 MW/m2, its need to be down by optimizing the main side fuel
Fahim-Ul-
8
9
10
11
12
Iqbal/Sohail
29-April-2015
Ehsan/Sajjadullah
15
Needs to be fine control tune of cyclone-05 set point for saving the fuel.
Prepared By Process Team
Imran Haider
29-April-2015
Page 13
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