065_tsp Qjp400generalkiln Audit 20-08-07

8/18/2019 065_tsp Qjp400generalkiln Audit 20-08-07

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ATC REPORT

Activity: AUDIT/PROCESS

CHINA / QUJIANG

3# KILN AUDIT

by Jea L!c J"e $ L""i %a Le"& $ %a& 'ia"(!i

ATC) *+,-. J!0y .12

Distribution

Region

BU

Plant

ATC S. Urhan, JS Lee, RdeBelmontOther

Codifiation TSP!"JP#$$%&'&RAL!(iln Audit !)$*$+*$


2/37

TALE O4 CONTENTS

A5 E'ECUTI6E SU77AR855555555555555555555555555555555555555555555555555555555555555555555555555555555553 A.-. Safet issues............................................................................................................./

A.). 0ain O1erating Parameters....................................................................................../

A./. 2igh 3alse air inlea4age...........................................................................................#

A.#. 2igh flutuation in (iln slurr feed rate.....................................................................5

A.5. 2igh CO formation....................................................................................................5

A.6. Poor ooler 1erformane..........................................................................................6

A.. 2igh 2eat onsum1tion.............................................................................................6

5 7AIN REPORT55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555559

B.-. 7ntrodution...............................................................................................................8

B.). 9or4 Done................................................................................................................8

B./. Analsis ! Argument ! Conlusions.........................................................................-$

B.3.1. Safety issues...................................................................................................10

B.3.2. High fluctuation in Kiln slurry feeding rate.......................................................10

B.3.3. High False air inleakage..................................................................................14

B.3.4. High CO foration...........................................................................................1!

B.3.". #oor cooler $erforances...............................................................................22

B.3.%. High heat consu$tion....................................................................................24

B.#. 9as to 7m1lement.................................................................................................)

B.5. A4no:ledgements................................................................................................./$

B.6. Referenes............................................................................................................../$

B.. A11endies............................................................................................................./-

Page ) of /


3/37

A5 E'ECUTI6E SU77AR8

Obective*2

"JP 4iln /; audit :as onduted from -6eti?es of the 4iln audit are to determine the baffling fators

and to identif the bottlene4s in 4iln sstem.

Re!0t / 4i;i&

There is a lot of room for im1ro?ement. 9e reommend a 9R to be signed for )$$+ to

address all the o11ortunities re1orted belo:.

The main 1roess issues are @ 4iln feeding instabilit, high inlea4age, 1oor ooler

1erformane, o?erburning lo: free lime and high CO in 1realiner.

4"!< =ai


4/37

The 1lant an not inrease 1rodution beause the &P fan o1erates at -$$G beause of

high false air inlea4age more than 55G of the gas at &P outlet. 7D fan alread o1erates at

1ositi?e 1ressure at its outlet. (iln is o1erating :ith high CO gas.

2igh flutuation of 4iln feed :as also a bottlene4 as it affets the margin o1erator shall

ta4e to ontrol o1eration during 1ush of feeding. 2igh CO formation :as a big onern in

the 4iln sstem.

All the bottlene4s!bafflings identified in the 4iln sstem are desribed belo:@

A535 Hi&( 4a0e ai< i0ea>a&e

0ain false air inlea4age are sho:n on the shemati diagram belo:@

Loation@ Outlet 3alse air G, based on

eHui1ment outlet

3alse air 'm/!h, based

on alulation ?alue

Outlet %as flo: 'm/!h,

based on alulation ?alue

P2 C) lone +)5))

P2 C- lone $.5G ##$ +)86)

Dr*rusher inlet .15 ))+5- -$5+-/

Drer rusher outlet /$.G /)5#$ -/+/5/

P2 SO ) outlet -.8G )6)# -#$8

(iln &P inlet )8.6G #-68) -+)668

(iln &P outlet -.8G /#/- -+6-$$

Total 51 -$/5+ -+6-$$

3or e?er - G of false air redution, the sa?ings of &P fan and 7D fan 1o:er onsum1tion

:ere estimated to be a11roimatel /.-6 49h and -+.8 49h. These figures are eHui?alent

to a sa?ing of $.#+ 49h!ton of lin4er. B targeting Ionl /$ G false air based on &P

Page # of /

SO)

--.8 G

O)

/ G O)

+ G O) G O)

--. G

O)

+./G

O)

-.8 G

false

air

).8 G O)

)8.6G

false

air

-.8G false

air

/$.G false

air

).5G

false

air

$.5G

false

air


5/37

outlet, the sa?ings :ould be as high as K+49h!t4. This :ould hel1 redue the ?er

eessi?e 1o:er onsum1tion of the burning line 8K6649h!t4 aording to 00P. 7n )$$6,

7D 3an outlet O) :as Ionl 8.$G to 8.6G ?s. --.6G in )$$. The situation has :orsened.

Fan &fficiency'

The 3ans effiien of ;/ (iln 7D 3an, &SP 3an is BB) B+5 T(e I=?act "!0; be 9>%/tc> by


6/37

/. The fine oal is alread fine +.+ G at 8$ mirons. N0 is )5G. 7t ma result into

in>etion flutuation. 7t also dangerous from a ris4 fire 1oint of ?ie: in oal mill iruit

trials are reommended :ith oarser oal -$*-)G.

#. Lo: tertiar air tem1erature /$C dro11ed do:n b *-$$C to 6/$C aross the TA

dut

A5,5 P""< c""0e< ?e


7/37

E=eusting aial and radial air dam1ers.

To onsider redesigning the burner if ad>usting aial air and

radial air flo: is unsuessful.

-

)

/ I=?


8/37

6 O?ti=ie c""0e< "?e&c>5

To o1timie seondar air and tertiar air tem1erature to +5$

deg C b inreasing the theoretial lin4er bed thi4ness

from /5$ mm to #5$ mm. This an be done b reduing

ooler grate s1eed from 8 stro4e!min to stro4e!min.

To onsider installing fied ooler 1late.

To reset 4iln hood 1ressure to *$.-mbar and to re*ati?ate

automati ontrol bet:een 4iln hood 1ressure and ooler &P

fan.

To install a lin4er tem1erature monitoring sstem so that 4iln

o1erator an monitor the lin4er tem1erature.

To ad>ust blo:ing 1rofile aording to reommended 1attern

-

)

-

)

-

Re;!ce ate< c"tet

Other similar de:atering sstem 1lant manage to redue

:ater ontent do:n to -$G . To be in?estigated. Refer to

2olim 7ndia 1lant @ 0ADU((ARA7 Plant.

)

Page + of /


9/37

5 7AIN REPORT

5+5 It


10/37

a Carbon dioide gas 1rodued :as $.)$ 'm/ ! -$$$ 4Cal of oal ombustion

b 2)O gas 1rodued :as $.$685 'm/ ! -$$$ 4Cal of oal ombustion

'itrogen gas :as $.8)/5 'm/ ! -$$$ 4Cal of oal ombustion+. 2ot Clin4er tem1erature :as -#6$ deg C.

8. Preheater eit dust load :as $.- 4g ! 4g lin4er

-$. (iln ba4end false air inle4age :as $.$ 'm/!4g lin4er.

--. 9ater s1ra inside drer rusher :as ) t1h.

7n A11endi, Table / sho:s the desri1tion of main eHui1ment and its design data. Table #

sho:s the main 4iln o1erating data during the mission and 3igure - sho:s the 1roess data

of the 4iln sstem.

535 Aa0yi / A


11/37


12/37

At the site, :ere able to identif some of the auses of the flutuation@

-. 7t :as obser?ed that the timing of the t:o ?auum filters :as not snhronied. The t:o

1aratati ?auum filters :ere not onsistentl su11ling 4iln slurr feed. Due to the

inonsistent of the ?auum filters, the amount of material on the belt on?eor :as

sometimes less and sometime more. This :as due to the t:o ?auum filters :ere

sometimes disharging slurr at the same time, and sometimes disharging one at a

time.

Chart 3 Inconsistent slurry feed on belt conveyor

). 7t :as obser?ed that there :as material aumulating on the load ell of the belt

on?eor :eigher.

/. 7t :as obser?ed that there :as a lot of s1illage underneath the belt on?eor before therotar ?al?e. The leaning of the s1illage :as done one a shift b :or4er.

Page -) of /

0ore materialLess material


13/37

Chart 4 Slurry feeding rate with time

#. 7t :as obser?ed there :as a sudden 1ea4 inrease in drer rusher differential

1ressure. The inrease of this differential 1ressure affets the outlet 1ressure of lone

SO) and hene, CO formation :as obser?ed immediatel after this 1henomenon. 7t

:as also obser?ed that this 1henomenon ha11ened in a time le of about #$ minutes

or longer. The 1henomenon :as mabe aused@

a B falling oating inside the drer rusher.

b 2igh flutuation of feed in to drer.

Chart 5 ry!crusher difference pressure with time

2o:e?er, :e do not thin4 that the 1re?ious mentioned im1ro?ement :ill definiti?el im1ro?e

the 4iln feed stabilit. Therefore, it is strongl reommended to a11l the 3LS design of this4ind of iruit see 2olim, ACC LTD 0adu44arai 1lant in 7ndia. 7ndeed the design inludes

Page -/ of /

S1illage

3alling

oating

Derease

of feed


14/37

a Isurge bin at lone disharge :ith rotar ?al?e and :eigh feeder. The a1ait of the

bin is small )$min @ /$t in our ase. The main ob>eti?e is to eliminate flutuation oming

from the hammer mill sstem. This is o1tion is strongl reommended.

Chart " C# content variation with pressure at $% outlet

53535 Hi&( 4a0e ai< i0ea>a&e

Based on our ogen gas measurement, :e ha?e alulated the false air inlea4age in the

4iln sstem starting from C) outlet to (iln &P outlet. The amount of false air inlea4ages are

sho:n in Table -. 9e are onfident that our gas measurement :as Huite aurate as the

differene bet:een the alulated and measured air flo: :as :ithin # G.

&able 1 System false air

7tem O)ontent

G, Atual

measure

ment

?alue

3alse air

G,

based oneHui1me

nt inlet

3alse air

'm/!h,

based onalulation

?alue

%as flo:

?olume

'm/!h, basedon alulation

?alue

%as flo:

?olume

'm/!h,atual

measureme

nt ?alue

Differene

G, based

onalulation

?alue

P2 C) outlet ).8 +)5))

P2 C) M C- $.5G ##$

P2 C- outlet / +)86)

P2 C- M Dr*rusher .15 ))+5-

Dr*rusher inlet -$5+-/

Page -# of /


15/37

Dr*rusher /$.G /)5#$

Dr*rusher outlet + -/+/5/ -/#6- *).G

Dr*rusher M P2 7D3

inlet

-.8G )6)#

P2 7D3 inlet +./ -#$8 -/+// *-.6G

P2 7D3 inlet < (iln &P

inlet)8.6G #-68)

(iln &P inlet --. -+)668 -8$-$6 #.-G

(iln &P -.8G /#/-

(iln &P outlet --.8 -+6-$$ -8$/$5 ).)G

Total 51 -$/5+ -+6-$$ -8$/$5 ).)G

3rom our analsis, the most false air inlea4ages :ere found at@

-. Bet:een lone C- outlet gas dut and drer rusher inlet. The G of false air

inlea4age :as /) G. This is far to high.

). Bet:een drer rusher inlet and outlet. The G of false air inlea4age :as 8 G.

/. Bet:een drer rusher outlet and 4iln &P inlet. The false air inlea4age :as -- G.

#. Bet:een 4iln &P inlet and &P outlet. The false air inlea4age :as -$ G.

The amount of false air inlea4age from C) to 4iln &P outlet :as -$/,5+ 'm/!h :hih :as

55. G of the total airflo: at the &P fan starting from C) gas dut eit, eluding

1realiner inlea4age. The amount of false air inlea4age from C) to SO) lone outlet

:as 5+,#55 'm/!hr. This high false air inlea4age has ob?iousl aused high losses in

eletriit and heat onsum1tion and high instabilit in 4iln o1eration.

Using the 3an La: Theor, :e are able to estimate &P fan and 7D fan 1o:er redution for

e?er - G redution in the 1reheater false air. 3or e?er - G of false air redution, the

sa?ings of &P fan and 7D fan 1o:er onsum1tion :ere estimated to be a11roimatel /.-6

49h and -+.8 49h. These figures are eHui?alent to a sa?ing of $.#+- 49h!ton of lin4er. 7f

the 1lant is targeted to redue the false air inlea4age to /$ G, that means a redution of )5. G false air, the sa?ings for &P fan and 7D fan 1o:er onsum1tion :ould be - 49h

and #$ 49h. The sa?ing in s1eifi 1o:er onsum1tion of &P fan and 7D fan for )5.G of

false air redution :ould be +.-6 49h!ton of lin4er. Please refer to Chart for the

determination of fan 1o:er redution and sa?ing against false air redution.

Chart ' (eduction in I fan and )$ fan $ower Consumption

Page -5 of /


16/37

2igh false air inlea4age su11lies the neessar O) for the 1realiner ombustion see

belo: @ our alulation sho:s that the minimum ombustion air reHuired for aliner

om1lete oal ombustion at 6 t1h :as $.+5 'm/!4g lin4er. 7t :as alulated that the total

neutral air flo: to aliner :as -.$$8 'm/!4g lin4er. The eess neutral air flo: :as -5 G

of the minimum ombustion air flo: :hih is a standard ?alue. 2o:e?er, the ombustion

:ould be im1ro?ed if this O) :as 1ro?ided b hot gas from the ooler instead of old

inlea4age gas that ha?e to be heated reHuiring more fuel.

Beside false air inlea4age in 1reheater to:er, :e also managed to determine other false air

inlea4age in the 4iln sstem.

3alse air in tertiar air dut :as alulated to be -)/+ 'm/!hr or $.$) 'm/!4g l. 3rom our

measurement, it :as found that the tertiar air tem1erature at its outlet :as -$$ deg C

lo:er than its inlet due to the false air inlea4age and also radiation loss. 7t :as obser?ed

that the tertiar air dut tem1erature :as not onsistent. This ould e1lain :h theflutuation of C) outlet gas tem1erature :as also due to high ?ariation of the tertiar air

dut tem1erature.

The G of 1rimar air at 4iln burner 1i1e :as alulated at /6.- G :hih :as )-.- G higher

than the -5 G maimum 1rimar air reommended b Lafarge Proess %uidelines. The

additional )-.- G 1rimar air :as atuall additional false air inlea4age of /66+ 'm/!hr.

At the site, :e :ere able to identif some of the ause of the false air inlea4ages@

Page -6 of /


17/37

-. 7t :as obser?ed that there :as false air inlea4age at the ins1etion door of lone SO)

gas dut. Please refer to Chart +.

Chart 8 False air inleakage at Cyclone SO2 inlet gas duct

). The area bet:een Clone C -and drer rusher inlet, :e :ere not able to obser?e the

false air inlea4ages.

/. At the drer rusher, :e :ere not able to obser?e the false air inlea4age.

#. At the 4iln &P inlet and outlet, :e :ere not able to obser?e false air inlea4ages.

5. 7t :as obser?ed that there :as false air inlea4age at the 4iln main door. Please refer to

Chart 8.

Chart 9 False air inleakage at kiln main door

Page - of /

Air lea4age

Big ga1

around

4iln burner

1i1e


18/37

535B5 Hi&( CO @"


19/37

O2 +uantity

3rom our air measurement and alulation, the tertiar air dut air flo: :as $.6#// 'm/!4g

lin4er, the 4iln eess air flo: :as alulated to be $.-#)# 'm/!4g lin4er, aliner 1rimar

air flo: :as $.-)/ 'm/!4g l and the false air at 4iln ba4end :as $.$ 'm/!4g l. The totalamount of neutral air su11lied to aliner :as -.$$8 'm/!4g l or #6,)++ 'm/!h. The

minimum ombustion air reHuired for aliner :as $.+5 'm/!4g l or #$,-#- 'm/!hr. This

sur1lus air flo: :as -5 G eess of the minimum oal ombustion air flo:. The air flo:

should be suffiient for om1lete ombustion. 2o:e?er, it :ould be better to get the O)

using hot gas from the ooler.

'e?ertheless, the main ause for CO formation is not o?erall la4 of O). 2o:e?er, it is

1ossible that loall, in the s1ae or in the time, there is la4 of O) beause of @

3lutuation in the O) ontent beause of flutuation in the draft ob?ious 4iln feedflutuation of flutuation in amount of oal not obser?ed for la4 of 1ressure

gauge.

Poor loation of the 1realiner burner ma4ing the ontat bet:een a?ailable O)

and fuel diffiult. This 1oint has not bee in?estigated et.

#recalciner residence tie

Chart 11 Precalciner construction and measurement data

3rom our alulations, the oal residene time :as estimated to be ).6s :hih is suffiient

for om1lete ombustion. The reommended residene time is K)s. 2ene, too short

Page -8 of /


20/37

residene time is not a diret ause for bad ombustion. Ob?iousl, less inlea4age :ould

inrease e?en more the residene time.

There are enough time and enough O) for ombustion. 2o:e?er, as alread mentioned,

the flutuating and lo: tertiar air tem1erature E65$C at 1realiner inlet affets the

Hualit and the s1eed of the ignition of the ombustion.

Coal $re$aration and in,ection

Coal finel ground +.+GR+$, finer than the reommended figure for a )5G N0 oal. Too

fine oal ma reate flutuation in the in>etion. 2o:e?er it is not al:as the ase.

The design of the 1realiner burner has not been studied et. The 1rimar air seems to be

O(.

The Hualit of oal shall also be further in?estigated.

)$act of high inleakage

Although false air brings O) for the ombustion, it has an o?erall negati?e im1at on the

ombustion Hualit for the follo:ing reasons @

The O) ma not be loated :here it is reHuired

The false air ha?e to be heated, reHuiring more fuel and as a onseHuene more

O), hene reduing the o?erall residene time in the 1realiner.

Build u1 formation that affets the flo: 1attern

O(erall insta-ility of the syste and )*Fan outlet under$ressure

Obser?ing the trends and ommun understanding indiate that CO generation is ob?iousl

learl affeted b the huge flutuation of the 4iln feeding. 2o:e?er shall be the other

fators, im1ortant ?ariation in the 4iln feeding affets all the dnamis inside the 1realiner

and as a result the ombustion. Addressing these flutuations is the main fator to redue

CO.

A standard :a to smooth those ?ariation is to 4ee1 the 7D3an outlet 1ressure under

ontrol, slightl in suion around *-mbar. This is not the ase in "JP see net to1i.

#ositi(e $ressure at Kiln )* fan outlet

Based on our measurement, the stati 1ressure at the 4iln &P inlet :as at 1ositi?e /.) mbar

e?en though 4iln &P fan dam1er and &P fan s1eed ha?e run u1 to -$$ G. 7t :as obser?ed

that the 4iln 7D fan s1eed :as o1erating at 5+ G. 9e :ere told b the 1lant 1ersonnel that

7D fan s1eed :as normall at #$ to #5 G 5 ears ago. The air flo: at 7D fan :as measured

to be -#$,8+5 'm/!hr. The 7D fan s1eed :as set at 5+ G.

Page )$ of /


21/37

Using 3an La: Theor, 7D fan at s1eed of #5 G :ould be o1erating at -$8,/8# 'm/!hr of

air flo:. The redution of air flo: of /-,58- m/!hr is eHui?alent to /$.5 G redution of total

sstem false air of -$/,)+ 'm/!hr. This ould e1lain that the 4iln might be o1erating at

onl )5. G of sstem false air inlea4age 5 ears ago. Therefore, it is reommended to the1lant to redue the false air inlea4age to /$ G at this moment. The 1ositi?e 1ressure at the

7D fan outlet an then be eliminated.

Other factor

7t :as also alulated that the 4iln hood ross ?eloit :as high at --.m!s. The

reommended figure :as 6 m!s. This high ?eloit air might affet the stabilit of flame and

e?en might ause high refrator :ear rate at 4iln nosering and burner 1i1e.

Hence the ost $ro-a-le causes of high CO foration in the kiln syste ere'

-. 2igh ?ariation of the 4iln feed affeting all the gas flo: of the line

). 2igh false air inlea4age in 1reheater sstem :hih has been disussed earlier.

/. 2igh usage of 1re*aliner oal fuel rate due to lo: tem1erature tertiar air and high

inlea4age.

#. Coal fineness of +.+ G ould be too fine.

5. The design of the installation should be he4ed :ith more details in. burner.

6. La4 of ontrol of 7D fan outlet 1ressure beause of eessi?e inlea4age

/einder of 200% o-ser(ations '

7tems Target!'ormal &isting status &?aluation

Residene time< ).$s（ＮｏｒｍａｌＣｏａｌ）

E/.$s O(

PC tem1erature

1rofile

Uniform and

reasonable.

PC u11er is higher than middle and bottomQ huge

?ariations*** 0a 8+℃ bet:een t:o 1oints at

same le?el.

Bad

PC eit gas

tem1eratureStable 5℃ 0a. )#℃ Bad

CO 4iln eit -$$11m Un4no:n in )$$6, 7n )$$, seems to be $ O(

O) 4iln eit /*5G Un4no:n in )$$6 and )$$ Un4no:n

CO PC eit gas ＜5$$11m 'ormal )$-#


22/37


23/37


24/37

:e an see that the most 1robable reason for high ooler outlet lin4er tem1erature :as

due to ooling air flo: at hamber / and # :ere lo:er than reommended air flo:.

7n the mission, the grate s1eed :as measured at 8 stro4e!min. Theoretiall the lin4er bed

thi4ness is alulated to be /5$ mm. 7n order to im1ro?e heat reu1eration, the grate

s1eed should be redued to stro4e!min. Theoretiall, :ith this s1eed, the lin4er bed

thi4ness :ould be at #5$ mm.

7t :as also obser?ed that the 4iln hood 1ressure :as al:as ontrolled at $.$ mbar. 3rom

the ontrol room, it :as understood that the o1erator :as atuall using the ooling air fan

?olume flo: rate to regulate the 4iln hood 1ressure. This o1erating 1roedure is totall

against the Lafarge (iln O1erating %uidelines.

3urthermore the bottlene4s identified b the e?aluation tool :ere inluded ooler &P and

&P fan :hih ha?e defiient margin :hen u1set.

535,5 Hi&( (eat c"!=?ti"

Due to high false air, CO formation in the 4iln sstem, 1oor ooler 1erformane, high

1rimar air, high flutuation of the feed rate and lo: free lime o?e*rburning, 4iln is urrentl

o1erating at high heat onsum1tion.

3rom our alulation, the heat loss due to@

3alse air from C) to 7D fan inlet at 5+,#55 'm/!hr :as ),6$),+)5 4Cal!hr or 56.4Cal!4g lin4er. The heat loss :as eHui?alent to #5) 4g Coal !hr of energ from

ombustion. 7f the false air from C) to 7D fan inlet, is redued to /$ G false air, b

-5,$)) 'm/!hr :hih is )5. G redution, then the heat loss :ould be 66+,+## 4Cal !

hr or -#.6 4Cal!4g lin4er.

The redution in 1rimar air flo: :ould inrease the inta4e of seondar air flo:. B

reduing the )-.- G 1rimar air :ould allo: /,6/ 'm/!hr of seondar air inta4e. The

inrease of /,6/ 'm/!hr of seondar air :ould su11l +$6,-)+ 4Cal!hr or -.6

4Cal!4g l of energ to the 4iln. This is eHui?alent to redution of -#$ 4g oal!hr from the

4iln oal feed.

7m1ro?ement in SAT and TAT :ould redue the S2C b /8.84al!4g4.

Stabiliation of the feeding rate should hel1 smooth the sstem outlet tem1erature

?ariation getting the a?eraged figure do:n b E)$C, affeting the S2C b

Beause of the huge ?ariation of the sstem, la4 of 1ro1er instrumentation and

1roess master, the 1lant 1rodues lin4er :ith ?er lo: free lime. 7n order to a?oid

flushes, the o1erator has to o?erburn to be able to ontrol the ?ariation in the le?el of

1re1aration of the material entering the 4iln. There are no other o1tion at the time being.

Page )# of /


25/37

2ene, 4iln feeding ?ariation is reall ause for o?erburning and in this as1et o?er

S2C.

7n addition, the 1lant should in?estigate o11ortunit to redue the a4e :ater ontent.

3or :et dr 1roess, it has been re1orted redution do:n to -$G of the moisture

ontent see 2olim, ACC LTD 0adu44arai 1lant in 7ndia.

Tab0e "@ acti" a;


26/37

o1eration and inrease 1rodution and redue S2C

To ma4e the t:o slurr feeders ?auum filters to disharge slurr

se1aratel aording to timing.

To allo: the :eighting belt s1eed hangeable.

To re?i?e the automati ontrol of the 4iln feeding sstem.

To regularl lean u1 the aumulation of materials on the belt

:eigher.

To install a hain sra1er under the belt on?eor to lean u1 the

s1illage before the rotar feeder.

To onsider installing an intermediate bin to better ontrol the 4iln

slurr feed@ tetion and the design of aliner.

-

5 Redue o?erburning

To train O1erator in 4iln o1erations.

To redue 4iln feed flutuation

To get 1ro1er instrumentation

-

6 O1timie ooler o1eration b inreasing reo?er I4@ fator from

$.8 to -.-5 as to redue S2C /8.8 4Cal!4g l.

To o1timie seondar air and tertiar air tem1erature to +5$ deg

C b inreasing the theoretial lin4er bed thi4ness from /5$

mm to #5$ mm. This an be done b reduing ooler grate s1eed

from 8 stro4e!min to stro4e!min.

To onsider installing fied ooler 1late.

Plant has to tr to obtain an o1timum undergrate 1ressure

)

Page )6 of /


27/37

To reset 4iln hood 1ressure to *$.)mbar.

To re*ati?ate automati ontrol bet:een 4iln hood 1ressure and

ooler &P fan.

To install a lin4er tem1erature monitoring sstem so that 4iln

o1erator an monitor the lin4er tem1erature.

To re1air or he4 the a?ailabilit of the 4iln hood 1ressure gauge.

To ad>ust blo:ing 1rofile aording to reommended 1attern

To train O1erator in 4iln o1erations.

5B5 %ay t" I=?0e=et

'o. - Ation

Pre?ent safet aident

9a to im1lement @ 3ollo:ed u1 b Safet 0anager and ATC engineers

'o. ) Ation

To redue false air from 55.G to /$G at &P outlet.

9a to im1lement@ Proess ins1etion oordinated :ith maintenane. 9ee4l follo: u1 of

ogen measurement after o1timiation. Thorough ins1etion of drer rusher, gas dute1ansion >oints, and gas duts from C- lone to 4iln &P inlet during shutdo:n. To install

saffolding on 1reheater to:er to ins1et gas duts onditions. To regulate aial and radial

air dam1er to redue 1rimar air flo:. To onsider redesigning the burner if ad>usting

1rimar air flo: is unsuessful :ith ATC su11orts.

'o. / Ation

To 7m1ro?e 4iln slurr feeding as to stabilie o1eration

9a to im1lement@ A11l the 1riorit*- ations. 7nstall instrumentation to better

understand the auses of the la4 of stabilit. To arr out :eighing of 4iln slurr feed

after o1timiation. To onsider installing an intermediate bin to better ontrol the 4iln

slurr feed. To install sam1ling 1oints at the SO ) disharge 1oint. ATC engineers :ill

refer to other installation for detail information from Lafarge 1lants. And also to refer to

other installation or su11lier of the drer rusher for detail information 9ee4l follo: u1 of

tem1erature and gas measurement after o1timiation.

'o. # of ationTo eliminate CO formation

Page ) of /


28/37

9a to im1lement@ 9ee4l follo:ed u1 of gas measurement after o1timiation. To further

in?estigate the design of aliner oal burner, onduting a 1reise ma11ing of O) and CO

in the 1realiner. To be onfirmed b trial@ fine oal too fine of +.+ G at +$ miron resulting

into in>etion flutuation. ATC an hel1 to define the trial 1rotoole. After installation of the1ressure gauge and onnetion to CCR, further in?estigation ould be arried out on the

in>etion sstem. Plant to 1ro?ide dra:ing of the 1realiner burner to ATC for further stud.

'o. 5 of ation

To redue o?erburning.

9a to im1lement@ reduing 4iln feed flutuation is the first ste1. 7n addition, install 1ro1er

instrumentation, train o1erator using -$ golden rules of 4iln o1eration and 1ost se?illa

ombustion one1ts. An attem1t :it higher C/S ould e also an o1tion to ?alidate the

im1at of lin4er Hualit. The o1timum 4iln s1eed to feed ratio should be furtherin?estigated and a re1resentati?e lin4er miroso1 should be om1leted to see the sie

of the remaining free lime as :ell as of belite and alite.

It


29/37

tem1erature indiator the reliabilit of the thermoou1le M

1ro1er alibration shedule

(iln shell tem1erature

sanner

O4 To maintain the reliabilit of the sanner

M 1ro1er maintenane and alibration

shedule

(iln main motor urrent

indiator

O4 To maintain the reliabilit of the

ammeter M 1ro1er maintenane and


(iln s1eed indiator O4 To maintain the reliabilit M 1ro1er

maintenane and alibration shedule

(iln inlet tem1erature

indiator


thermoou1le M 1ro1er alibration

shedule

(iln inlet 1ressure meter O4 To maintain the reliabilit of the

1ressure meter M 1ro1er alibration

shedule

(iln inlet gas analer O4 To maintain the reliabilit of the

analer M 1ro1er maintenane and

alibration shedule

C) lone bottom

tem1erature indiator



shedule

C) lone outlet gas

tem1erature indiator



shedule

C- lone outlet gas

analer

'o To re1air ogen gas analer

(iln Pfister oal feeder

oal trans1ort 1ressure

meter

'o To install a digital 1ressure meter and

lin4 to PLC

(iln Pfister motor

urrent indiator




(iln Pfister :eighting

sstem


:eighting sstem M 1ro1ermaintenane and 1ro1er alibration

shedule

Caliner Pfister oal

feeder oal trans1ort

1ressure

'o To install a digital 1ressure meter and

lin4 to PLC

Caliner Pfister motor

urrent indiator




Caliner Pfister

:eighting sstem


:eighting sstem M 1ro1ermaintenane and 1ro1er alibration

Page )8 of /


30/37

shedule

Caliner automati

ontrol

'o To re1air ontrol sstem

(iln 1rimar air blo:er1ressure indiator

'o To install digital 1ressure meter and lin4to PLC

(iln 1rimar air blo:er

motor urrent indiator

'o To re1air ammeter

'o. 6 of ation

To o1timie ooler o1eration to redue S2C.

9a to im1lement@ To o1timie ooler undergrate 1ressure b regulating the ooler s1eed.

A ste1 b ste1 a11roah is reommended. 9ee4l follo:ed u1 of air flo: and tem1erature

measurement of ooler sstem after o1timiationF obser?ation of red ri?er. 7n ase of redri?er, ATC should ma4e reommendations aordingl

55 Ac>"0e;&e=et

The /; 4iln audit mission at "UJ7A'% had been suessfull im1lemented :ith the hel1

and su11orts from the 1lant management es1eiall 0r. Vhang Jinghong, 0r. Li Da Bing

and 0r. Vhang Vhe Ping.

5,5 Re@e


31/37

The ooler bed de1th of /; 4ilnWWWWWWWWWWWWWWWWW..

Cooler bed de#t&

of Q!

515 A??e;ice

&able 3 -.$ 3/ 0iln main e*uipments basic data

7tem Unit Designed o1erating Remar4

(iln out1ut t!d 886 --$$ X/.5Y5#m

(iln s1eed r1m /.) /.#

(iln main motor 4: -6$ 8

0ain burner oal rate t!h -.5


32/37

/; hamber fan dam1er G 8$

#; hamber fan ?olume rate 0/!h 6)#$$ #/)5+

#; hamber fan 1ressure Pa --5

#; hamber fan dam1er G 5

7nlet lin4er tem1erature ℃ -/-

Outlet lin4er tem1erature ℃ 65Fambient --$


33/37

Cooler outlet gas tem1erature

℃

)$ Clin4er tem1erature in ooler

outlet ℃

)-$

Page // of /


34/37


35/37

Chart 14 easurement flat without safety railing

Chart 15 o safety protection screen on bleed air damper of cooler ehaust gas duct

Page /5 of /


36/37

Chart 1" o safety protection screen on bleed damper of hot gas to coal mill gas duct

Chart 1' &he cables on floor

Page /6 of /


37/37

ction ta-le fro 200% audit

Tab0e "@ acti"

'o. Ation Priorit

-Pro1er ste1 or ladder for the measurement 1oints should be installedQ

some handrails must be installed also.Safet

) Alarm mar4s should be fied on the Preheater onrete beams

o?erhead the aessesSafet

/%ang:as on the saffolding o1tionall must be arried a:a to 4ee1

from falling do:n.Safet

B

T(e Ki0 4ee; 40!ct!ati" (a t" be

Documents

065_tsp Qjp400generalkiln Audit 20-08-07