smooth kiln operation with bypass

dear all

please comment on possoble causes & solutions from the analysis given below .

a white cement kiln with jigh content of alkalies, sulfur & chlorides at bottom cyclone as well as in bypass even than there is normal & smooth kiln operation without any trouble.

hot meal sample: (bottom cyclone)

k20= 3.77, na2o= 0.28 , so3= 3.74 , cl= 3.37

bypass dust sample:

k20= 3.82  , na2o=0.32 , so3= 7.17 , cl= 3.28

clinker sample:

k20 = 0.58 , na20= 0.11 , so3= 0.98

such high concentrations are seen since last 3-4 days in hot meal & bypass but we are not facing any problem of major buildup & cyclone jamming.

fuel is 100% petcoke .

can anyone suggest to overcome the problem so that chloride in hotmeal & bypass can be reduced to counter for enticipated jamming problem in future.

what should be role of operation staff to counter the same when quality deptt. says that the input of volatiles has not increased . but in my openion the hot meal sample should not have such high concentration if input remains the same or low.

pl. reply

 

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re smooth kiln operation with bypass

please send your kiln feed analyses and you should increase by pass to avoid any blockage  and check mixing chamber or inlet slope why material is not going towards  bypass and recirculating into system

THANKS AND TAKE CARE

 

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re smooth kiln operation with bypass

well i also have in mind that we should increase bypass volume .

the kiln feed analysis is written below.

SIO2	AL2O3	FE2O3	CAO	MGO	SO3	K2O	SUM	LSF		SM		RESIDUE				LIQ
14.74	2.50	0.18	43.55	1.67	0.07	0.47	99.23	98.21	5.49				AVG		10.13
14.52	2.35	0.18	43.05	1.20	0.02	0.42	98.5	96.84	5.23				MIN		9.68
14.91	2.63	0.20	43.93	2.70	0.11	0.52	100.07	98.85	5.72				MAX		10.66
0.13	0.11	0.01	0.32	0.54	0.03	0.04	0.64	0.75	0.19				SD		0.39

also , i do not understand why the concentrations of bypass dust volatiles is much higher than hot meal to kiln?I think it is the recirculation from the kiln which is responsible for higher concentration of volatiles in bypass than hot meal.

can i relate the concentrations of volatiles in bypass & hotmeal for better operation of byapss ,  so that i can find out the actual bypass required.

xxxxxxx

 

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