process problems & trouble shooting

RNB CEMENTS (P) LIMITED DEPARTMENT- PROCESS Presented By- Akshay Kumar Si DGM (Process)05/03/23 1

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WHAT ARE THE MAIN PROCESS PROBLEMS IN CEMENT PLANT?In Pyroprocessing- Cyclone Jamming Kiln inlet jamming Big clinker ball formation Coating formation in kiln Feed rushes and dusty kiln Snow man formation in cooler Red river in clinker cooler

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PROCESS PROBLEMS IN GRINDING Mill jamming Residue problems Blaine problems

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Cyclone JammingWhy cyclone jamming happens in Preheater?

Main Reasons-Insufficient suction due to low rpm in PH fan.Flap valve failure & blockage in material pipe.Refractory failure.High Iron % in Raw mix.High Sulfur % in fuel(i.e- coal)

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KILN INLET JAMMINGWhy kiln inlet jamming happens?

Main Reasons- High Iron % in Raw mix. High Sulfur % in fuel(i.e- coal)

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BIG CLINKER BALL FORMATION

Why big size clinker ball formation happens?

Main Reasons-High Iron % in Raw mix.High Sulfur (S)% in fuel(i.e- coal).Kiln running with slow rpm & % filling is more.High BZ temperature.% liquid is more.Higher % of Magnesia (MgO).

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HEAVY COATING FORMATION IN KILNWhy heavy coating formation in kiln?

Main Reasons- High Iron % in Raw mix. High Sulfur (S)% in fuel(i.e- coal). Kiln running with slow rpm & % filling is more. % liquid is more. Higher % of Magnesia (MgO).

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FEED RUSHES & DUST KILN

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Why Feed rushes and dust kiln happens?Main Reasons- High lime in Raw mix or high LSF.Very less % of liquid.High AR.Less iron% in raw mix.Blockage of hot meal due to clinker ball

occasionally.

SNOWMAN FORMATION IN COOLER

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Why snowman is formed in cooler?Main reasons-Higher % of liquid, may be iron % is more in

raw mix so hot meal will be sticky and viscous.Shorter cooling zone; so may be shortage of

adequate quenching .Higher BZ temperature, may be due to short

flame.Failure of air blaster in cooler 1st grate if any.

RED RIVER IN COOLER

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Why red river is shown in cooler?Main reasons-Uneven distribution of cooling air.Mis alignment of kiln & cooler.

RED RIVER

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THANK YOU

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