clinker ball formation in pre burning zone of the rotary kiln

We have two kilns in our unit.  In  both  the kilns, we are facing very big unshaped clinker coating coming from kiln inlet to pre burning zone and disturb the steady kiln operations. Sometime, this very big coating block the entire cross section of the kiln at the pre burning zone starting. Experts may kindly suggest solutions to solve this problem

Reply

Know the answer to this question? Join the community and register for a free guest account to post a reply.

Re: clinker ball formation in pre burning zone of the rotary kiln

Dear Mr. T.Rajgopal,

Possible reasons for ring  & ball formation,

Raw mix design,

High coal ash %

High liquid phase

Quality/ condition of refractory

High alkali feed

Burner pipe condition

Cooler condition

But to study all above reasons we have to run our kiln for 20 ~ 30 days continuously, we have technique to remove big clinker balls without stopping the kiln.

Reply

Re: clinker ball formation in pre burning zone of the rotary kiln

Hello Gopal 

You mentioned that coating comming from the inlet side...{But Your subject is different} 

so must check the coating status at mixing chamber and  riser duct and if you have inline calciner   must take inspection at venturi area.......

if your both lines facing same problem then lab must take serious action about it, may be your x-ray calibration is out of order  

Reply

Re: clinker ball formation in pre burning zone of the rotary kiln

Thank you very much.  Can you tell us the possible ways to break this coatings without kiln shutdown

Reply