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Technical Cement Forum / Kiln by pass

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Tam Nguyen 23/10/2014 11:51:59

Kiln by pass

Dear All

In our plant, we have some problem with the kiln by pass gas and by pass dust. The by pass gas is extracted and cooled by fresh air go to cyclone ---> by pass fan --> cooler EP. The EP is not working well when the by pass gas goes though caused high dust emission. If we stop the by pass, the EP performance perfect. The other problem with by pass dust is spillage and caused the structure corrosion a lot.

So we are looking for the solution to treat the by pass and dust to eliminate above issue. If you have the best practices in your plant, can you please share us.

Thanks and best regards

Tam

Raj Sahu 25/10/2014 15:24:48

Please inform how much % of kiln gas is by-passed and bypass dust collected in bag house or ESP.Prima facie it seems that there is some design problem in kiln gas bypass system design or it is operated more than its design capacity.However;comprehensive diagnostic study is needed of the present kiln bypass system to suggest any countermeasures to resolve your problem.

Tam Nguyen 27/10/2014 06:14:51

Dear Raj Sahu

The by pass gas is round 5-10% kiln by pass. Normal operating ~ 5%. We got the problem since waste heat recovery in operation.

Regards

Tam

Raj Sahu 27/10/2014 10:53:34

Hi Tam,

Based on limited input information about your plant, I presumed that you don't have any separate bag filter or bag house system for kiln bypass dust collection.You probably sending cooled kiln bypass dust laden gases to your kiln grate cooler ESP to collect the dust.You said that your problem started after installing WHR system to generate electricity from cooler vent gas.In my view after installation of WHR your cooler vent gas temperature and its volume have been increased and with addition of kiln gas bypass dust along with cooler vent gas is exceeded the handling air volume and inlet dust load capacity of cooler ESP.You may check the cooler ESP inlet gas volume to verify the assumption.Probably cooler ESP upgradation to handle high gas volume and dust load to resolve your current problem.

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