Free lime is commn issue. I think there are many reasons. It may be operational problem or may be Raw Mix problem. Let start one by one. What is the chemical analysis of your mines different benches? What are the additives? what are the analysis of additive analysis? What is coal proximate & ultimate analysis? What is Coal ash analysis? As your Raw mix is having sulfur. I suggest you to use Raw material which have some MgO. It will definitely improve the burnability of Raw Mix. The major precaution require is there should be close eye on the day to day basis coal as well as additive receipt analysis. I think you do not have any diverter on second last cyclone all kiln feed come through calciner only. Is it? Insure that there is no material falling directly in feed hood. Check the Dispersion plate. More over I would like to suggest to run Kiln speed to maintain filling ratio 13% only. Run kiln with slightly more swirl air. I hope if you go through step by step I hope this issue may be solved.

Well I am running kiln with 17% filling degree . If I reduce it I shall be loosing production which I do not want to.

We have a feed pipe from III cyclone to calcinator to reduce build ups which is also working . Also I am getting an evapoartion factor for SO3 upto 0.75  based on clinker SO3 & LOI & hot meal sample .

We do not find much build ups at kiln inlet.

Even than we are getting high free lime in clinker

please do comment.

Sidhant