ATC_November 2005 - 1

Build-up control
(in Preheater Kilns)
Mastering Riser and Tower Build-ups
Build
Build
-
-
up control
up control
(in
(in
Preheater
Preheater
Kilns)
Kilns)
Mastering Riser and Tower Build Mastering Riser and Tower Build- -ups ups
Technic
Technica
l
l
g
e
n
d
a
Build-up Control (in preheater kilns)
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General information
Objective
Consolidate know-how on build up control in PH Towers
Identify practical ways & means to master build-up
Deliverables
Produce a complete reference book and a shorter practical quick
reference guide for plant users
Division wide team
C. Venkateswarlu (ATC, leader) J . Desseix (RR)C. Landais (CTEO)
H. Schoffmann (CTEC) P. Muithya (CTI)S. Fujimoto (CTS)
Present Status
Document completed in September05
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Target Group
Plants
Optimization Managers ,Process & Production Engineers
CCR operators
Key Messages
Preheater buildups can be mastered under any circumstances as long
as the appropriate levers(Specific to each plant) are applied.
Implementation of this TA will lead to significant improvement in kiln
performance and reliability even with high usage of alternative fuels.
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Content of study
Reference
Main document, Quick Reference Guide & Other
references in annex
TA Agenda covers:
Chemistry
Operations
Refractory
Geometry (design)
Build-up Removal equipment sections
Quick Reference Guide
Key recommendations
Check-lists
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Preventive measures
Control Chemistry of kiln inputs
Kiln operation by Managing
Burning zone
Combustion
Kiln control loops
Refractory
Geometry of preheated
Curative measures
Build up detection & cleaning
Content of study
Build-up Control (in preheater kilns)
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1 - Chemistry
Determine balance (SO3, Cl & Alkalis)
Reduce inputs to regain balance where possible
Track bottom stage meal Cl vs. SO3
Track tendency to determine thresholds
Control levers
Maintaining Chart
Unique to each plant
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CTEC Region Plants- Hot meal monitoring
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2 - Operations
Check-List of Kiln Mastery items
Calciner
Kiln
Burner
Cooler
Special techniques for older & smaller calciner
designs
Meal curtains are more effect techniques
Creating dirty backend
Alternatives are ESWchains to lifters
Appendix includes a more complete meal curtain report (design&optimization)
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Figure A1: Meal
Meal Curtain
Recommended:
Best variable control
Plants with no bypass
Likely a standard feature
on new kilns
Cost depends on layout
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3 - Refractory
CKHC Reference
Use of SiC refractory
Better refractory life
Coating Repellent
SiC percentage in refractory
Buildup Severity
Check with Suppliers / Technical Centers
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4 Geometry (Design)
Designs to avoid build-up by eliminating dead zones
Topics include
Cyclones
ducts
Meal pipes
Flaps
Splash boxes
Key notes
Simple changes
Correct Design mistakes
Corrective Case Studies
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5 Removal Equipment
Preventive equipments.
Safety
Optimize Blasters
Placement maintenance
CO2 cartridges
High pressure water gun
When build-ups are minimized cleaning is effective in
managing the problem
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Conclusions
Build-up can be mastered
ARM / AF is not a good excuse for poor performance
Solution can be complex often a mixture of techniques
Bigger challenge on older designs
TA document is a tool to help plants to self audit & use to determine
plant unique final solutions.