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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 ???