ATC REPORT

Activity:

STUDY

CHINA / QUJIANG Plant

Precalciner study
by ZHANG WEIDONG//HAN ZHENFENG//
WANG XIANGWEI
ATC, 17th-21st July 2006

Distribution:
Region
BU
Plant

Zhou Wei//Zhang JingHong

ATC

Sinan Urhan//Renaud deBelmont

Other
Codification

TSP QJP400GENERAL/ZWD_HZF_WXW
study

0807

Preca

TABLE OF CONTENTS
A.

Executive Summary.......................................................................................................... 3

B.

Main Report....................................................................................................................... 6
1

Introduction..................................................................................................................... 6

Work Done...................................................................................................................... 6

Analysis / Argument / Conclusions..................................................................................6

3.1

Background Information...........................................................................................6

3.2

Safety...................................................................................................................... 8

3.3

Precalciner Survey...................................................................................................9

3.4

False Air Audit........................................................................................................15

3.5

Fan Efficiency........................................................................................................16

Recommendations........................................................................................................17

Acknowledgements.......................................................................................................18

Appendices.................................................................................................................... 18

A.

EXECUTIVE SUMMARY

Objectives:
The objective of the mission was to explain the poor combustion in the precalciner although
residence time is high enough and to advice on possible modification,
Aside from the initial objectives, some QW relative missions will be completed:
Fan efficiency Audit for #3 Kiln ID Fan, ESP Fan; #1 ESP Fan.
Organize a session to follow up QW recommendations tracking.
Results / Findings
Safety:

The accesses are very poor, no proper step or ladder to arrive the measuring points.

Many Preheater concrete beams overhead the accesses are too low to pass through,
and no necessary alarm marks.

QJP Precalciner Evaluation:

Although the kiln feeding variability made hardly possible any reliable investigation, it can be
said that the CO problem does not come from pre-calciner dimension (big enough). O2 level at
C2 exit is in average too low and may be a root cause on top of the huge circuit variation
because of kiln feed variability. Burner design should be further investigated.
Items
Residence time

Target/Normal
~ 2.0s

PC temperature
profile
PC exit gas
temperature
CO kiln exit
O2 kiln exit
CO PC exit gas
O2 PC exit gas
Temperature In
main section
Burn condition by
visual inspection
Stable fuel
splitting PC

Existing status
3.6s

Evaluation
OK

Uniform and
reasonable.

PC upper is higher than middle and bottom;

huge variations--- Max 98 between two
points at same level.

Bad

Stable 5

Max. 24

Bad

<100ppm

Not measured. Later 2006 indicates 0ppm

Not
measured

500ppm

Normal 2014~6250ppm Seldom 500ppm

Bad

2~3%

0.8~3.2%

Poor

Stable

Unstable Max. variations 45

Bad

Many sparkles was found in different section

Bad

Around 60%

OK

3-5%

No sparkle at
outlet
Kiln/PC=40:60

Therefore, the Kiln feed has to be maintained uniform quantity +/-1% before we really
evaluate the Calciner.

Page 3 of 18

 Visual inspection
We tried to evaluate Precalciner combustion condition by visual inspection during the
mission implementation. We found that the brightness of flames between two inspection holes
at same level (measurement point C) are very different; at the same time many sparkles were
found inside the Precalciner. This confirms that the Precalciner combustion condition is poor.
Fan Efficiency:

Under the scope of fan efficiency audit we have covered #3 Kiln ID Fan, ESP Fan; #1
ESP Fan. Because of the lack of power factor of #3 kiln cooler ID Fan, we cant
complete Fan efficiency Audit for it. The Fans efficiency of #3 Kiln ID Fan, ESP Fan and
#1 ESP Fan is 44%, 41% and 51%. Fans Efficiency is less than 65% and the Fans
have obvious scope for the improvement.
The Impact would be 8-9 kW/tck. The analysis of the Fan Efficiency and Mechanical
check on the Fans should be given in order to formulate an action plan to improve the
performance to reduce the overall power consumption of the plant.

Page 4 of 18

Table of actions
No.

Action

Priority

Proper step or ladder for the measurement points should be installed; some
handrails must be installed also.

Safety

Alarm marks should be fixed on the Preheater concrete beams overhead the
accesses

Safety

Gangways on the scaffolding optionally must be carried away to keep from

falling down.

Safety

The Kiln Feed Fluctuation has to be reduced to +/-1% from 40%.

Improve vacuum filter performance to reduce the feed material quantity and
quality deviation.

Install thermocouples at Precalciner bottom, middle, upper and kiln inlet.

Cross-check Preheater manometers and thermocouples regularly to achieve
more uniform combustion and decarbonatation

Increase O2 in precalciner by reducing inleakage downstream (adecuate

analyser is required).

Improve drying crusher air sealing and weld or change duct to reduce false air

Control KFUI <14

10

11

Calciner Coal fluctuations to PC to be studied in detail, after stabilisation of Kiln

Combustion (ATC)
Is Coal Transportation Velocity OK
Is the fluctuation because of Calciner Temperature or cooler TA?
Burner design
Increase #3 ID Fan, EP Fans & #1 ID Fan from 45% to 65% in consultation
with the Fan experts to reduce 8-9 Kwh/t kk

Page 5 of 18

B.

MAIN REPORT

1
Introduction
This mission is mainly focus on Precalciner study and gives recommendations for further
optimization. On the other hand, Fan efficiency Audit of #3 Kiln ID Fan, ESP Fan, and #1 ESP
Fan and QW recommendations tracking have been completed.
2

Work Done
Precalciner temperature measurement has been done for three times.
Gas analysis of Pyro-system has been done for three times.
Fan efficiency audit.
QW recommendations follow up.

3
Analysis / Argument / Conclusions
Poor Precalciner operation condition was mentioned in QW mission. This mission is carried out
in order to get temperature profile and give recommendations for further optimization.
3.1

Background Information

QJP #3 kiln is semi-wet process product line with 1000t/d design capacity. Process flowsheet
show below:

Kiln #3 Semi-wet process

Figure 1: Pyroprocessing system in QuJiang plant

Page 6 of 18

The whole product line is running at unstable status, the kiln feed still fluctuate (from 50t/h to
80t/h with kiln feed set 80t/h); raw meal composition is not consistent. These issues are all
impact on Precalciner performance negatively. Kiln only reach 770t/d~950t/d output and
tripped four times during 4 days (17th ~20th July).

Photo 1: QuJiang pyroprocessing system main parameter condition 200607

There are no thermocouples at kiln inlet, Precalciner bottom, middle, upper and outlet, no
manometer and gas analyzer at the outlet of Precalciner. Much important information isnt
showed in CCR screens.
The kiln feed quantity and material moisture content was fluctuated seriously due to the
vacuum filter condition. This resulted in all pyroprocessing system running at unstable
condition. Improving vacuum filter running condition became the first thing for optimizing all
pyroprocessing system!

Page 7 of 18

Photo 2: Kiln feed system and material condition in QuJiang plant 200607

3.2

Safety

Some safety issues were found in the plant although several actions plans are in progress after
QW:

Photo 3: Some safety issues in QuJiang plant 200607

Page 8 of 18

3.3

Precalciner Survey

3.3.1 Precalciner and preheater measurement

Precalciner temperature measurement:
According to the recommendation of QW report, QJP has already prepared the measurement
holes on the Precalciner body and ducts, then we measured pricalciner temperature at different
level, and check the O2, CO content of gas at preheater different part through gas analyzer.
However, the kiln running status was unstable and tripped four times during four days (from
Monday 17th to Thursday 20th), It is difficult to evaluate precalciner and all pyroprocessing
system exactly even though we got three sets measurement data.
The temperature profile across the Precalciner was not uniform. The temperature variations
was reach to 98 ( from 838 to 936 ) at same level (20-July measurement point D1 and
D2 with 75~80t/h kiln feed), and 45 variation at the same point(from 801 to 855 during
very short time ,17-July measurement point C3 with 60t/h kiln feed).
Gas analysis
We measured O2, CO content of gas at the PC exit, C2 outlet, the Dry-crusher exit and ID fan
inlet in order to evaluate Precalciner combustion condition and calculate false air of PH and PC.
The details show in main report. O2 % at PC exit is still lower (0~2.0%) and CO% is higher than
Lafarge standard (<500ppm) in a majority of operation time. This implies Precalciner was
running at incomplete combustion with lack of air condition. Burn out rate should be increased.
The Measurement results at Precalciner and preheater:

Figure 2: The measurement point at precalciner in QuJiang plant

Page 9 of 18

Kiln Feed: 60t/h (R/C=1.87) Decarbonation Degree: 91-95%

1

A(PC Inlet)

798-850

815-828

B(PC Cone)

760-800

779-855

792-823

C(PC Middle)

872-885

820-828

801-855

D(PC Upside)

849-852

818-821

854-868

PC exit

881-905

17-July-2006 14:50 - 16:15

O2 (%)

CO ppm

No indication

> 10000

1.4-2.0

3500-6250

C2 Cyclone exit

1.7-2.2

3264-3816

The Dry-crusher exit

7.9-8.1

2824-3004

The ID fan inlet

9.5-9.6

1587-2830

PC exit

C2 Cyclone exit
Kiln Feed: 65-70t/h (R/C=1.87) 18-July-2006 10:40 - 12:00
1

A(PC Inlet)

867-870

918-930

B(PC Cone)

790-806

808-818

813-817

C(PC Middle)

835-846

817-820

878-881

D(PC Upside)

835

875-886

894

PC exit

865-872

C2 Cyclone exit

861-904

O2 (%)

CO ppm

No indication

> 10000

0.8-1.2

275-1270

C2 Cyclone exit

0.5-0.9

2257-5171

The Dry-crusher exit

7.1-7.2

4012-4612

The ID fan inlet

8.4-8.5

4882-5771

PC exit

Kiln Feed: 75-80t/h (R/C=1.87) 20-July-2006 9:30 - 10:40

1

A(PC Inlet)

949

904

B(PC Cone)

891

833

C(PC Middle)

832

D(PC Upside)

838

PC exit

938

C2 Cyclone exit

839

O2 (%)

CO ppm

Kiln inlet

0.3-0.4

5200-7800

797

PC exit

1.5-3.2

2203-2014

843

849

C2 Cyclone exit

2.8-4.2

2623-1892

936

886

The Dry-crusher exit

8.7-9.2

288-292

The ID fan inlet

9.1-9.3

2535-2378

Table 1: Precalciner and preheater measurement data in QuJiang plant 200607

3.3.2 Some interrelated calculations and analysis

Precalciner Volume (m3):
QuJiang precalciner volume is 286m3, and larger Precalciner Volume can provide a sufficient
capacity for kiln, QJP #3 kiln size is 3.5*54m, kiln volume(407m3) is big enough for 1000t/d
output capacity.
Gas velocity in Precalciner (m/s):
The gas velocity inprecalciner is 5m/s, and low velocity in main section (< 4 m/s) can increase
fuel residence time in the Precalciner.
PC type
W (m/s)

KSV
5~8

NSF
4.5~6

MFC
4~5

FLS
5.5~6.5

SC
10

MC
8~12

Table 2: The different design of calciner gas velocity

Residence time(s):
Page 10 of 18

D-D
7~10

KHD
18~20

The gas residence time in calciner is 3.6 s. And each of the precalciner type show a very wide
rang of residence times, but the longer residence times is better for burnout and heat
exchange, and avoid carrying excessive heat to the upper stages of the PH, normally, an
additional one second residence time will reduce heat consumption by 15kcal/kg.
Normal gas residence time > 2.0 sec (needs to be > 4.5 sec to allow for NOx reduction) allow
burnout of CO.
Lafarge Precalciners Residence time(s):

Figure 3: Gas residence time in precalciner in Lafarge area

From the Precalciner Study Technical Agenda:

Page 11 of 18

 Precalciner heat loading (kcal/m3.h):

QuJiang precalciner heat loading is 83kcal/m3h.
Normally, the higher the clinker production the higher the quantity of fuel, and the higher
Precalciner heat loading. Presently the trend is towards heat loading of 50~70Mcal/m3h.
Lafarge plant Precalciner heat loading:

Figure 4: Precalciner heat loading data in Lafarge area

Precalciner Loading (t/m3d):

Page 12 of 18

QuJiang precalciner material loading is 3t/m3d. There is still room in QJP precalciner to
increase production by around 30% (to bring to 4t/m3d) :
Supplier

PC type

Polysius

Prepol

PC Loading
(t/m3d)
46

Inline

4 4.5

Separate Line

7 7.3

FLS
Fuller
IHI
KHD
ALL Kilns

Comments

PC combustion in TA only

4.5 6
NSF

6.0 7.5

Pyroclon

3.5 4

PyroTop

2.5

Able to operate < 600 mg/Nm3 NOx

5.5
Table 3: Different type precalciner loading

Lafarge plant Precalciner loading (t/m3d):

Figure 5: Different precalciner loading in Lafarge area

And we got QuJiang precalciner measurement and calculation like this:

Page 13 of 18

Table 4: QuJiang PC measurement and calculation 200607

3.3.3 Visual inspection of precalciner:

We inspected the interior of Precalciner on the same level (measurement point C) through
inspection holes, point C1 was very dark at the same time point C2 flame was very bright. Many
sparkles were found inside the Precalciner even though at the outlet point D, This implies the
Precalciner combustion condition is poor, burnout rate is low.

Photo 4: Precalciner internal combustion condition in QuJiang 200607

3.3.4 Precalciner Evaluation

According to the Precalciner measurement and gas analysis, we can get some conclusion like
this:
Items
Gas velocity in PC

Target/Normal
4.5~10m/s
Page 14 of 18

Existing status
5m/s

Evaluation
OK

Residence time
PC heat loading
PC loading
Decarbonation degree

5.5~6.5m/s FLS
>3.5s
3

83 Mcal/m h

A bit high

2.5~7.5t/m3d

3t/m3d

OK

92~95%

OK

No sparkle at
outlet
>50%

91~95%
PC upper is higher than
middle and bottom;Max.
variations 98 between
two points at same level.
24 Max.
Normal 2014~6250ppm
Seldom 500ppm
0.8~3.2%
Unstable Max. variations
45
Many sparkles was found
in different section
Around 60%

0.2%

No testing

Uniform and
reasonable.

CO PC exit gas
O2 PC exit gas
Temperature In main section
Burn out rate by visual
inspection
Stable fuel splitting PC
Unburned carbon hot meal

OK
3

50~70Mcal/m h

PC temperature profile

PC exit gas temperature

3.6s

Stable 5
500ppm
2~3%without CO
Stable

Bad
Bad
Very bad
Bad
Bad
Bad
OK

Table 5: The comparison between QuJiang precalciner and target 200607

After the measurements, it was found that the combustion is not proper in the total pyro
system.
The real Calciner performance could not be evaluated mainly because of the Kiln Feed
Fluctuations upto 40%. It is very difficult to determine the Calciner performance with
these fluctuations.
Therefore, the Kiln feed has to be maintained uniform quantity +/-1% before we really
evaluate the Calciner.
The Calciner performance will be studied in detail and the Calciner modification
recommendations will be done once the Process is stable with Kiln feed at reasonably
within the acceptable limits.
3.4

False Air Audit

False air ratio was 61.1% between Precalciner exit and ID fan inlet, that resulted in high power
consumption in clinker production (increase at least 2kwh/tck more). And Drying Crusher was
the main leakage point where false air is 47.1%. Another main leakage point is dedust cyclone,
we heard strong air leakage sound from there.

Page 15 of 18

Figure 6: The false air profile in pyroprocessing system

3.5

Fan Efficiency

This mission fan efficiency audit has covered #3 Kiln ID Fan, ESP Fan; #1 ESP Fan. We didnt
complete the #3 kiln cooler ID Fan audit because of the lack of power factor. The details of the
Fans efficiency audit are placed in appendices.
The total Power savings are calculated to be 8 9 Kwh/t of clinker. (Assumed that Kiln ID Fan
Efficiency is taken as 40% and not 17%)
Plant to contact with fan experts to increase fan efficiency.

Page 16 of 18

Recommendations

Action 1: Proper step or ladder for the measurement points should be installed; some
handrails must be installed also.
2: Alarm marks should be fixed on the Preheater concrete beams overhead the
accesses.
3: Gangways on the scaffolding optionally must be carried away to keep from
falling down.
Objective: Safety
Way to implement: Install handrails, step and ladder. Carry away gangways and scaffolding.
Reference documents: Safety guideline.
Plant or BU responsible: Plant.
Expected result: Decrease LTI.

Action 4: Install thermocouples at Precalciner bottom, middle, upper and kiln inlet.
Cross-check Preheater manometers and thermocouples regular to achieve
more uniform combustion and decarbonatation.
Objective: Optimize preheater and precalciner combustion
Way to implement: To buy and install thermocouples at proper position. ATC can advice.
Reference documents: Combustion optimization.
Plant or BU responsible: Plant.
Expected result: Increase output and decrease heat consumption.

Action 5: Improve vacuum filter performance to reduce the feed material quantity and
quality deviation.
Objective: Stabilize all pyroprocessing system.
Way to implement: Try to find high quality filter cloth and improve vacuum equipment.
Reference documents: Combustion optimization.
Plant or BU responsible: Plant, BU and ATC.
Expected result: Improve pyroprocessing system stability and increase capacity.

Action 6: Modify coal transport pipe to decrease the possibility of coal feed fluctuation
Objective: Decrease the fluctuation of coal feed to calciner
Way to implement: Modify incline coal transport pipe to horizontal or vertical pipe..
Page 17 of 18

Reference documents: Combustion optimization.

Plant or BU responsible: Plant.
Expected result: Improve pyroprocessing system stability.
Action 8: Improve drying crusher air sealing and weld or change duct to reduce false
air
Objective: Decrease false air
Way to implement: Weld and change worn out duct. Improve air sealing at drying crusher.
Reference documents: QW.
Plant or BU responsible: Plant.
Expected result: Decrease power consumption 2KWh/kgcli.
Action 9: Try to control KFUI <14
Objective: Stabilize combustion condition
Way to implement: Ask quarry and quality team to reach the aim.
Reference documents: Raw Mix optimization.
Plant or BU responsible: Plant.
Expected result: Improve pyroprocessing system stability and decrease heat consumption.

5
Acknowledgements
The ATC Process Team sincerely thank the management of QuJiang Plant for their excellent
co-operation and positive attitude towards the mission. Thanks to all the plant team especially
to Mr. Zhang jinghong , the process Manager, Mr. Zhang zeping, the process engineer, Mr.
Fang xiongzi, the electrical engineer, Mrs., Zhou xiaorong, the quality Manager for their efforts
to make this mission a Successful.
6

Appendices

Pitot data of
QuJiang 200607

Fan efficiency
QuJiang PC
caiculation QuJiang 200607
calculation

Page 18 of 18