I want to know about calculation methods of gas and material flow in preheater, pc, kiln, cooler. Further, can you advise why we are getting brown clinker problem in our 2000tpd off-line calciner kiln from which we are recently producing 2500tpd while having 90-91 LSF, 2.26 SM, 1.4 AM and kiln feed residue up to 22 per cent. How we can improve our clinker quality?

The calculation of gas and material flow in the preheater relies on the principles of stoichoimetry (to assess the combustion gas products from the fuel) and the conservation of mass. In principle what goes into the kiln must come out somewhere and will allow you to prepare a mass balance for the kiln. With regard to the brown clinker you are producing this is most probably caused by having reducing burning conditions in the burning zone of the kiln. This is very bad for clinker quality and fuel efficiency of the kiln. Almost certainly the problem is with the kiln burner and might be solved by adjustment. You must be sure that you maintain at least one per cent oxygen at the kiln inlet.

Why does false air infiltration from the bottom stage of a preheater tower increase tower temperature, but in top stage decrease the tower temperature. The preheater system is SLC-S supplied by Fuller. We understand this is a common phenomenon for any other system like ILC, SLC or SLC.

I have not observed this phenomenon, however it is perhaps connected with the additional draft that is required to keep the kiln hood under suction when there is inleak in the bottom stage of the preheater. This would cause the thermal energy from the calciner to be drawn up the preheater. Conversely when the inleak is in the cyclones above the calciner then the inleak makes no difference to the draft on the calciner.