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KILN AUDITTRAINING

OKKE PLANT – KOREASept. 8 – 12, 2008

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OBJECTIVES

To transfer the knowledge and skillsnecessary for:

Performing a heat & mass balance on the pyrosystem

Interpreting results & drawing conclusions

Benchmarking performance & makingrecommendations

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AGENDA

Day 1

Introduction / Safety Briefing

Kiln Audit Training / Details, Report WritingGuideline Presentations

Plant Walk Through

Checking of Instruments

Review of Operation from CCR

Day 2

Collection of Measurements (2 sets) AM / PM

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AGENDA

Day 3

Performing Calculations

Day 4

Complete Heat & Mass Balance

Identify Areas of Improvement &Recommendations

Day 5

Presentations by participants

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GOALS OF KILN AUDIT

To get a detailed view of the kiln lineperformance

Evaluate exact data for heat consumption,production,...

Basis for comparison

impact of investment or modifications carriedout

comparison to other plants Detect weak points - Action Plan

Detect optimization potential

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WHEN TO DO A KILN AUDIT

Every 3 years, a complete kiln audit is to becompleted with assistance from the TC

Once a year, a simple kiln audit should becompleted by the plant alone

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Silo

Raw Mill

Raw

Material

Bypass

Exhaust

Dust Flow

during compound operation

Feed

   D  u  s   t   f   l  o  w

   d  u  r   i  n  g

   d   i  r  e  c   t   O  p  e  r  a   t   i  o  n

BOUNDARY SELECTION

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Silo

Raw Mill

Raw

Material

Bypass

KF = 204 tph

Exhaust

Dust Flow

during compound operationD = 11.0 tph

Feed

   D  u  s   t

   f   l  o  w

   d  u  r   i  n  g

   d   i  r  e  c   t   O  p  e  r  a   t   i  o  n

Coal Ash = 1.8 tph

Cli = 126 tph

Boundary for

mass balance

BOUNDARY SELECTION

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BOUNDARY SELECTION

Any boundary shape can be chosen Every stream that crosses the envelope must be taken

into account

The boundary line is chosen so that the boundary pointsare:

useful for the balance goals

easily accessible for reliable measurements

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Σ massin = Σ massout

MASS BALANCE

Σ heatin = Σ heatoutHEAT BALANCE

“Energy cannot be created or destroyed butmay be converted from one form to another”

Energy in = Energy out

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Σ massin = Σ massout

Kiln System

Primary air

Clinker

Fuels

coolingair

False airKiln feed

Kiln exit

gases

Waterspray

Exit dust

Return

dust

MASS BALANCE

Cooler exhaust gas

Bypass gas and dust

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Kiln System

Primary air

Clinker

Fuel

coolingair

False airKiln feed

Kiln exit

gases

Waterspray

Exit dust

Return

dust

Σ heatin = Σ heatout

Wall

losses

HEAT BALANCE

Cooler exhaust gas

Bypass gas and dust

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COOLER BALANCE

Tertiary airVent air

Secondary air

Coal mill Raw mill

Clinker

Cooling air Clinker

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1. INPUT from sensible heat

FUEL from combustion

RAW MEAL from sensible heatfrom sensible heat of water

COMBUSTION AIR from sensible heat of all theair supplied (prim. sec.)

Total input

2. OUTPUTHeat of formationEvaporation of water from raw mealExhaust gas sensible heatDust sensible heatIncomplete combustion (CO)Clinker exit temperatureCooler exhaust gasesLosses due to radiation and convectionWater cooling (Recupol inlet chute)Difference

Total output

kJ/kg clk25

5560

2571

67

5750

17502370754

25 —59

100540 —

152

5750

%0.4

96.7

0.40.2

1.2

100

30.441.213.10.4 —1.01.79.4 —2.6

100

Wet Process

kJ/kg clk15

3343

3017

20

3425

1750506314

21 —50

276452

4214

3425

%0.4

97.6

0.90.5

0.6

100

51.114.89.20.6 —1.58.1

13.21.20.4

100

Semi-Dry (Lepol)

kJ/kg clk13

3150

54 —

6

3223

175013

63618 —63

423297 —23

3223

%0.4

97.6

1.7 —

0.2

100

54.30.4

19.70.6 —2.0

13.19.2 —0.7

100

Dry Preheater (4-Stage)

HEAT BALANCE EXAMPLES

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QUESTIONS ???