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Technical Cement Forum / Re: Brown Core
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fluence sysbacip
fluence sysbacip

Dear sir,

 we are trying our best to get rid of this soft brown core but still no use  we have oxygen at inlet 3 % at preheater top 4.6 % CO is negligible kiln filing degree is about 13.5 % ID fan is running on maximum RPM.

This brown soft core containes high alkalies K2O about 3.33 while Na2O about 0.5 % and Sulfur at 1.35 %.

we are exporting clinker but due to this brown clinker our export has stopped due to some  strict condition we are not able to reduce the feed.

Raw meal modulie we chaged to LSF 95 , SM 2.4 AM 1.55

Plz i want your kind suggestions to get out of this problem.

Ted Krapkat
Ted Krapkat
fluence sysbacip:
We are trying our best to get rid of this soft brown core but still no use  we have oxygen at inlet 3 % at preheater top 4.6 % CO is negligible kiln filing degree is about 13.5 % ID fan is running on maximum RPM.

This brown soft core containes high alkalies K2O about 3.33 while Na2O about 0.5 % and Sulfur at 1.35 %.

Plz i want your kind suggestions to get out of this problem.

 

Hello Sheikh,

Sorry, I missed your request above and did not respond sooner because I only noticed it just now. Are you still having this problem?

From what you have said above, it looks like you solved your CO problem but are still getting buildups in the kiln inlet area which are causing these 'kiln eggs' with soft brown centres.

The analysis you have supplied of these buildups shows SO3 is under control and does not appear to be the problem. K2O, however, is quite high and might be a clue. Did you test for chloride? If chloride is also high the buildups causing these 'kiln eggs' may be forming due to high levels of potassium chloride recirculation.

High K2O+Cl recirculation is normally due to a change in one or more of  four conditions;-

1. An increase in K2O and/or Cl inputs.

2. A decrease in SO3 input, which lowers the tendency for the K2O to be removed from the kiln as K2SO4.

3. An increase in burning zone/kiln inlet temperature which causes excessive KCl evaporation

4. A significant reduction in raw meal particle size, which increases raw meal surface area and enhances K2O/Cl evaporation.

If you haven't changed your raw material/fuel inputs for K2O and Cl, or suddenly reduced your raw meal particle size,  then I would suspect that the kiln temperature might be too high.

 

Hope this helps,

Ted.