Volume 3 Burning Workshop

3000t/d Cement Projectof National Cement Share Company,Ethiopia
3000t/d Cement Project of National Cement Share

Company, Ethiopia
Training material
Pyro Processing
Contents
CHAPTER 1
Introduction ............................................................................ 3
CHAPTER 2 PROCESS FLOW AND EQUIPMENTS........................................ .4

2.1 PROCESS
FLOW ....................................................................... ...................... ..4
2.2 DESCRIPTION OF MAJOR
EQUIPMENTS..................................................................7
CHAPTER 3 CONTROL
OPERATION............................................................25
3.1 BURNING
SYSTEM ..........................................................................................25
3.2 PULVERIZED COAL
PREPARATION
CHAPTER 4 ......................................................................33
PREPARATION BEFORE STARTUP ........................................36
4.1 INSPECTION ON FIELD EQUIPMENTS ...................................... ...36
4.2 INSPECTION
ON ELECTRIC EQUIPMENT
..............................................................40
CHAPTER 5 STARTUP AND

STOP ................................................................41
5.1 STARTUP AND STOPS FOR BURNING SYSTEM..................................................... ..41
5.2STARTUP AND STOPS
FOR PULVERIZED COAL PREPARATION SYSTEM ........................59
CHAPTER 6 PRECAUTIONS IN TEST RUN AND PRODUCTION .......................72

6.1 PRECAUTIONS OF BURNING SYSTEM IN TEST RUN AND PRODUCTION ........................72
6.2 PRECAUTIONS IN TEST RUN AND PRODUCTION OF PULVERIZED COAL PREPARATION ..85
Chapter 1 Introduction
Clinker making
ranges from raw meal homogenization silo bottom discharging to
clinker entering clinker silo and pulverized coal preparation system, which includes
process flows like kiln inlet exhaust gas treatment, raw meal homogenization silo
discharging weighing and conveying, kiln inlet pre-heater system, kiln middle, kiln
outlet, clinker cooling and conveying, clinker silo top, pulverization coal preparation. In
order to specify design intent, we write this operating specification based on domestic
and abroad design documents and our experience on precalcining cement plant.
This specification intends to specify the basic operating methods and notices for
commissioning and normal production. For commissioning, operator shall firstly
understand this specification and go deep into the structure, working principle and
performance of equipments combining with equipment instructions and theoretical
training. By such method, comprehend single-machine operation,
interlocking running,
equipment maintenance and repair. If the specification deviates from actual situation,
we can discuss with commissioning operator, and revise relating content based on
practical situation.
Chapter 2 Process Flow and Equipments

2.1 Process flow
Raw meal extracted from silo via pneumatic
air slide discharging system is
discharged to small blending bin 331.FB16 to be fully blended, and then through
side discharging system 331.SQ18 331.SQ19 to be discharged out and weighed

by
conveyed
kiln 331.FM21
inlet elevator
laterairslide
through
electro to
T
impact flow tometer
,331.FM22
,
through
331.AS23
411.BE01
be 411.VV02 ,airslide 411.AS03 ,rotar air locking feeder 411.RF05 ,
chute
,
double
layer gravity air locking valve 411.FV06 comes to air tube at exit of second
y
stage cyclone(C2) and enters kiln inlet preheater 411.PR08 .

Raw meal powder fed into preheater 411.PR08 immediately scatters under
effect of high speed air flow, and suspending in air, and then enters C1 cyclone with
After separating, powder under self gravity shifts to lower gas tube. By going
air flow.
through exchange of the 4 stages, the temperature of powder raises to 780,and
enters calciner from C4 cyclone. Control material calcinating rate by adjusting coal
f eeding quantity(general calcinations rate: 93%), the decomposed powder
enters C5 cyclone to separate the collected powder and feed them into kiln inlet
smoke chamber
about 1050 and burnt in kiln. kiln inlet pre-heater equips annular
cleaner and air cannon, gets compressed air from air compressor.
The waste gas (coal powder burnt at kiln outlet and calciner) through high
temperature fan 321.FN19 partly enters raw mill 321.RM03 working as
drying
source.
The
waste
gas
from
raw
mill
goes
through
cyclone
separator 321.CS10 to be classified and then to be conveyed into air converting

box 321.CS30 via
circulating fan 321.FN11 .After treatment, exhaust gas enters kiln inlet pulse bag
into
mill via cyclone
working
as drying
source offan
coalis
filtercoal
321.BF32
. dust
Forcollector
the other part of321.CS28
waste gas
from high
temperature
fed
mil
l
L21.RM06 . The rest part enters air-converting box 321.CS30 with waste gas
discharged from raw mill circulating fan. The gas separated by air-converting box
321.CS30 enters kiln inlet pulse bag filter 321.BF32 to be purified, and then to
be discharged into atmosphere through kiln inlet exhaust fan 321.FN33 .The
dust
(collected by kiln inlet pulse bag filter 321.BF32 )
the
321.CV34 321.CV37 and
321.CS30
through
chain
dust
through chain conveyer
(collected
conveyer
by
air-converting
321.CV38
enter
box
chain
conveyer 321.CV39 together, and then through bucket elevator 321.BE40
enter kiln dust bin to be stored. The dust collected by cyclone dust collector
321.CS28
enters kiln dust bin to be stored through chain
conveyer 321.CV29 .
Kiln dust bin collects the dust produced by waste gas treatment. The dust goes
through weighing device 321.VM43 321.SL44 under the bin and chain conveyer
321.CV45 and then enters kiln inlet pre-heater or raw meal homogenization
silo.
Dust
either
through
bucket
331.BE01
elevator
enters
raw
meal
enters
kiln
inlet
homogenization
silo
or
through
bucket
elevator
411.BE01
preheater 411.PR08 .
Powder in kiln inlet smoke chamber slowly shifts to kiln outlet by slope
and rotation of rotary kiln 421.KL01 . Kiln outlet coal burner 431.BU02
fires coal
Clinker
is heavy
unloaded
fromsupply
kiln opening
to the grates of third generation aerated grate
powder or
oil and
heat to kiln.
cooler 431.CC06 , which goes through the distributing system at inlet, drops
To prevent high temperature of shell of kiln burning zone, it equips 7 axial
onto
fans
reciprocating
plates
under
gravity
and air
and equips
then to be
(421.FN02 grate
421.FN08
to effect
force of
it self
cooling
down.
Kilnforce,
middle
hydraulic
distributed
fully
along
the
grates,
stack
up
to
material
layer
with
certain
thickness.
thrust roller oil station to limit play range of kiln shell.
Cooling air blows from downside of grate plates up to material layer, penetrating and
dust
bucket
then viaThe
electric
valve
come
to chain
cooling
downand
the clinker.
rapid arc
cooled
small
clinker
and dust via the gap fall into
conveyer 431DB.27 ,
meantime, the rapid cooled mass clinker enters crusher 431.CC06a by push of
grates, the crushed clinker and grain from chain conveyer are transported by chain
bucket conveyer 431DB.27 into clinker silo or reject silo.
Grate cooler has 6 chambers. The first chamber contains 5 fans:4 aerating
fan 431.FN11 431.FN14 the air enters aerating beam and grate plates to
cool
clinker, 1 balance fan 431.FN09 the air prevents reverse flow of air at dead grate
plates and movable plates as well as jam of clinker. The second chamber contains
5 fans: 4 aerating fan 431.FN15 431.FN18 the air enters aerating beam and grate
plates to cool clinker, 1 balance fan 431.FN09 the air prevents reverse
flow
of air at dead grate plates and movable plates as well as jam of clinker.
Third chamber to sixth chamber equip an aerating fan each 431.FN19
431.FN22 , the
air from fan penetrate grate plates and cool the clinker. Each fan equips electric
inlet valve, used to adjust air volume.
After cool clinker, the hot gas is emitted as :high temperature air 900 1100 enters
kiln directly from kiln hood to be secondary air firing coal powder or heavy oil, the high
temperature air 700 900 from kiln hood supplies burning energy to coal
powder
powder is
discharged
through
exhaust
431.FN25
.431.EP24
The collected
clinker
or heavy oil,
the rest
part fan
enters
ESP
at kiln
outlet to be purified
transported
to
chain
bucket
via
chain
conveyer 431DB.27
and
conveyer 431.CV26 .
Dusty
air
on
chain-bucket
conveyer
431DB.27
is
purified
by
bag
filter 431.BF28 and then discharged out via fan 431.FN29 .

Coal powder for kiln burning goes through agravity bin L21.BI22 ,annular balance
coal feeding system L21.RF23 , F-K screw pump L21.SP24 and be

continuously
blowed to kiln outlet coal powder burner 431.BU02 by roots fan L21.BL25 .the
primary air used to burn coal power is supplied from two roots 431.BL03
or
431.BL04
and
fan 431.FN05 .
emergency
The heavy oil for burning clinker goes through pumping and heating, and then comes
to kiln outlet coal burner.
Coal powder for calciner burning goes through a gravity bin L21.BI19 ,annular balance
coal feeding system L21.RF20 , F-K screw pump L21.SP21 and

continuously
beheavy
If
oil is used as fuel, it must go through pumping and heating (heat source
blowed
to
calciner
coal
powder
burner 411.BU10 by
roots
for kiln inlet waste gas )and then comes to calciner coal burner 411.BU10 .
fan L21.BL27 .
Prepare a roots fan L21.BL26 as standby to furnish high pressure blast to low
Each
raw coalinto
bin kiln
equips
weighing system (L21.WF02 L21.WF03 at the bottom. The
coal powder
anda calciner.
through belt
weighed
raw coal is fed into vertical
coal mill L21.RM06
coal
conveyer L21.BC04 tee air locking valve L21.AV05 .After grinding,
under
suction of main
antiexplossion pulse bag
raw
fan L21.FN12 enters
to
be
collected,
and
then
through
screw
filter L21.BF10
conveyer L21.SC14 L21.SC15 and electrohydraulic tee chute L21.VV16 be sent
to coal powder bin L21.VV16 or L21.BI22 .Waste gas, purified, is discharged

into atmosphere.
Coal powder bin equips a weighing system at the bottom, the weighed coal powder
through roots fan L21.BL25 L21.BL27 or L21.BL26 is brought to kiln outlet
and
calciner burner.
Hot air in kiln inlet waste gas serves as drying source for coal mill under control of main
blower L21.FN12 of coal mill. Regulate cold blast valve 321.VM26 to
control the
temperature of gas in/out mill so as to
ensure the fineness and moisture of coal powder.
For the sake of safety and constancy of
pulverized coal preparation, the system equips
CO2 extinguisher to protect pulse bag
filter L21.BF10 L21.BF29 L21.BF31 and
coal powder
bin L21.BI19 L21.BI22 ,which is designed to be total flooding
extinguishing system, that means, eject
carbon dioxide in a certain degree and fully
permeate the whole area in set time, it is
possible to put out a fire at any place in
protected area.
The extinguishing system can be controlled
manually, automatically and handled
mechanically. That means if there is
someone
on duty,
manual
control is adopted. If
rotary
shell inner
diameter
4.3m
there is no body, 62m
the automatic control is
rotary shell length
used. Conversion between manual control
3.5%
rotary shell inclination
and automatic control
may be realized on
3
extinguishing
control
panel
(set
manual
rotary kiln shell
control box outside
the protection district.
Rotary kiln
production capacity
3000t/d
supporting
number
The emergency
halt
and
emergency
start
0.39
Rotary kiln rev
buttons have been3.948r/min
set in the manual control
Auxiliary
drive(slow)
box.)
0.17r/ min
Drive motor
2.2 Description of major equipments
Main Drive
Model
Auxiliary Drive
Power(kW) (r/min)
Speed
(kW)
2.2.1type
Rotary kiln (kW)
Power
2
(r/min)
Rev
.2.1.1 technical performance
ZSN4-355-12
IP44
500
1000
Y-225M-4
45
1480
Reducer
Main Drive
Model
ZSY710-35.5-V
Auxiliary Drive
speed ratio
Nominal drive ratio
35.526
model
ZSY250-35.5-
2.2.1.2 General introduction and working principle
34.288
The raw meal powder out from the pre-heater of kiln inlet goes into kiln from the
upper end for further calcination and clinkerization.Due to the inclination and turning
of the shell, material will take a all-around motion which means that the material will
not only roll along the circumference direction but also move from upper end to lower
end, and continue decomposing and clinker forming. After it turns into cement clinker
and then enters cooler from kiln outlet.
Fuel is sprayed into the kiln by kiln outlet, and after fuel burning, the exhaust gas finish
the hot exchange process with the material, and enters the pre-heater from kiln inlet.
The leftover mix with material and become a composition of clinker.
2.2.2 preheater,calciner
2.2.2.1 working principle
The raw meal enters from the C2 C1 cyclone air duct, after mixed with the hot air
current, it enters C1 cyclone with up draft, and then the material goes into C3
C2cyclone air duct after preheated and separated in C1 cyclone, after that, it
enters C2 cyclone with updraft to be preheated again, and enters the C4 C3
cyclone
air duct through discharging pipe of C2 cyclone, then enters C3 cyclone with updraft to
be preheated once again, and then goes into C5 C4 cyclone air duct via
C3
cyclone
it goes discharging pipe, later it enters C4 cyclone with air current, the material is
into C5 cyclone through calciner C5 air duct. After it is separated by C5
preheated and decomposed in C4 cyclone, and then through C4 discharging pipe
cyclone, itenters rotary kiln through the C5 feeding tube.
comes to calciner,the raw meal is preheated and decomposed quickly in the calciner,
2.2.2.2
technical performance
2.2.2.2.1 type KSF calciner
2.2.2.2.2 kiln type 4.362m design capacity 3000t/d
clinker
2.2.3 Technical parameter in normal production

feeding raw meal size 12% residue on 0.08mm sieve
moisture 1%
consumption 206.60t/h
fuel coal or heavy oil

ratio of raw meal/clinker 1.5398
heat consumption 3135kJ/kg.cl.
(750kcal/Kgcl) C1 outlet
Air
volume 680000m 3/h
temperature 32020
pressure -4700Pa
dust content 100g/Nm 3
tertiary air into calciner
air volume 200000m 3/h
temperature 850
2.2.3 the third generation grate cooler

2.2.3.1 Technical Performance
Main technical data of cooler
Technical data
Performance
Main technical data
Capacity t/d
330
0
Tertiary air temperature C
900
Clinker temperature
at kiln outlet C
140
0
Material thickness (mm
400
600
Main parameter of
cooler
Technical data
Performance
Main technical data
Type
KCN 3300
Specifications
3.94x34.488 m
Capacity t/d
3300
Efective area of grate plate m2 88.8 m2

Clinker temperature at cooler inlet 1400
(OC)
Clinker temperature at cooler outlet 65OC+ ambient temperature
Grate plate Section
Air chamber
Grate plate stroke (time/ minute)
4~25
Grate plate stroke (mm
130
Drive
Hydraulic
Crusher
1300x3000mm
Motor
YR280M-6 IP44
Motor power
90 kW
2.2.3.2
working principle and construction features
The grate cooler is the third generation produced by Chengdu Calciner Technology
Co.LTD, which adopts aeration beam. It consists of upper shell, frame, grate bed,
drive
unit, clinker crusher, chain conveyor, automatic lubricating system and air
duct,moreover,14 cooling fans are set, the high pressure fan is used on grate plate of
aeration beam at the hot end, medium pressure fan is used on common grate plate.
The hot clinker is discharged on the grate plate from the kiln opening. The
sudden cooling clinker through the inlet distribution system falls on the to-andfro grate plate under the effect of self gravity and wind power, and
then
distribute along the grate bed length and forms a certain thickness material
layer. The cooling air blows into material layer from the lower part to the
upwards, and then the clinker is cooled by penetration and diffusion. The
cooling
air becomes
hot burning
air, which
kiln heat
and loss
calciner(predecomposition
system)as
air, enters
thereby the
reduce
of the
system. The redundant hot air is discharged into the air after filtered by the
ESP. The cooled small clinker falls onto the chain-bucket conveyor under the
grate cooler through bar screen. The big-size clinker goes to chain-bucket
conveyor after crushed and cooled. The granule clinker and dust fall into the
aggregate bin through the grate gap and grate hole. By a certain time, the
material level reaches a certain height in the aggregate bin, the controlling air
lock valve will open automatically, and then the fines is conveyed by the chain
conveyor below the grate cooler. When the remainder in the aggregate bin just
seal the air lock valve, the valve will close to prevent air leakage.
The grate bed of this grate cooler is a compound one with three parts.(1)high
temperature area(feed distribution system).The system is composed by three-steps
grate plate and a row of fixed aerated grate plate, the incline and plane forms a certain
angle, the system collects the clinker into a narrow box, the plane air-jet produce the
even and upward airflow in the clinker clearance. The fluidization fines then is blown
to the clinker surface so that the clinker distribution is even and air-permeable. In
order to avoid the snowmanand deposit of big size clinker, a set of air cannon is
fixed on the shell end, which will fire on and off to clear the deposited material so as to
ensure the operation is sound and safe.(2)medium temperature
area(to-and-fro
aeration beam), this area includes three rows of

moving grate plate and two rows of fixed grate plate. The aerated grate bed is
composed by box-type grate plate beam (including fixed beam and moving beam) and
aeration grate plate. In order to meet the special demand of cooling air caused by the
different material layer and different temperature of right side and left side, the aeration
beam is divided into two small plenum chambers by a separator, which can respectively
supply air and adjust the air volume and air pressure according to their different
material layer. Because of no clearance, no material leakage and no air leakage in the
high temperature area, there is no separator between the medium temperature area
and high temperature area, these two area consist of the first chamber. Each
chamber
is fixed a set of balance fan to control and adjust the pressure under the grate plate of
the first chamber with aeration grate bed, the air volume is adjusted by the gate.(3)low
temperature area. Cooling area includes the third, fourth and fifth chamber. A cooling
fan is set in each of them. The cooling air makes heat exchange with the material layer
as it is through the material layer after it is via the hole on the grate plate and the
clearance among the grate plate. After cooled by the aeration beam area, the
temperature of the clinker has reduced, so the common grate plate is adopted at this
area.
A hammer crusher is installed on the discharging end. The clinker less than the
preset size is discharged through the grizzly(less than 25mm generally ),the big size
clinker falls into the crusher, and then throw to the grate bed for cooling and then
crushing
again
tillthe
it meets
the over
required
size. caused by the leakage of grate plate, the
In order to
avoid
material
deposited
bottom plate has several feed openings. The leak fines through the feed opening is
conveyed to the
discharged end by the chain conveyor fixed on the lower part of
cooler.
Set manhole and inspection hole at the adequate place of the upper and lower shell.
The cooling air passing the material layer becomes the hot air,which may be used as
residual heat of secondary air(into kiln)and tertiary air(into calciner),the redundant
cooling air will be discharged into air after necessarily dust collected.
The grate cooler adopts centralized lubrication system.

2.2.3.3 Ternary control system of grate cooler
In order to get the best effect and operate stably, the cooler is fixed with ternary control
system and necessary monitoring device.
Keep a stable thickness of material layer (resistance).By inspecting the pressure in
aerated air duct of the first chamber; adjust the speed of grate bed. When the
grate
bed pressure increases, the resistance of the material layer increases accordingly, the
material layer thickens or the size thins, so the grate bed speed should be speeded
up, vice versa, in order to keep a stable thickness of the material layer(resistance).
Maintain the invariableness of air volume. When the resistance of the material layer
increases, the resistance of the cooling fan increases, the air capacity reduces
accordingly. For the sake of keeping an invariable air capacity, the control system
will
speed up the rotation speed of the fan (increase fan inlet damper opening) and vice
versa.
Maintaining a stable sub pressure of the kiln outlet is to ensure necessary

secondary air capacity and stable operation. Adjust the exhaust air volume of the cooler
fan(adjust the fan speed or damper opening) according to the set sub pressure of kiln
outlet (-100 to 25 pa ).
The grate cooler equips following monitoring and protection devices.
1 Each air chamber under the grate plate must set pressure monitoring
device, which is used to comprehend the working situation of the grate plate and
material layer.
2 temperature measurement and alarming devices at grate plate in chamber
one.The alarming temperature is set between230 and 260 for the
operator judging the reason of temperature raising and then taking steps.
3 The TV inspection device for material layer may watch over the material layer
state.
4 Alarm and the control for airlock valve of material leakage in air
chamber.
5 Alarm device for rupture of chain conveyor(for material leakage)
6 Regular
protection on overloaded motor, inspection and alarm on fan.
2.2.4 Vertical
coal mill
2.2.4.1 technical performance
2.2.4.1.1 model: MPF1915
spec of roll dia.1500mm,
W idth:530mm
qty. 3
throughput 25t/h
feeding size 50mm
coal powder fineness 0.080mm 8% 10% square screen sieve

residue moisture the fed18% the discharged 0.5%
rev of table 29rpm
rotating direction of table clockwise seen from up to
down
nominal dia.of roller way 1900 mm medium dia.
air leakage factor <5%
feed size 30-50 mm
grinding pressure of roll single roll318 kN
air speed of jetting ring inside mill 80-90
m/s
lubrication of bearing: oil bath
oil mass for each bearing:25L
power 400kw
volt. 6kv jigger
model
motormotor:15kW
YMPS500-6
power ofofmain
barring
volt:380v
frequency:50Hz rev:1180r/min
model of gear box:NGW T2-D-8
output rev:39.3r/min drive
ratio:30
2.2.4.1.2 separator
model: SLS2250
rotor dia.:2250 mm
rev 14-133
classifying efficiency >90

%
r/min
control three phase asynchronous motor): UP2250M-8

motor
power 30kW
model(frequency
rev 3
50Hz
volt.:380V
2.2.4.1.3 seal fan supply
air volume:5000Nm3/h
frequency :50Hz
air pressure:8000Pa
motor power for seal
fan 37kW
motor rev3570r/min
2.2.4.1.4
volt.:380V oil station
oil station of main reducer:

nominal flow 200
L/min
nominal pressure 0.4 MPa
oil supply temp.:403

consumption of cooling water 18
m3/h
temp.of cooling water 32
water pressure:0.2MPa
hydraulic loading station
flow:18L/min
oil pressure:20MPa
effective cubage of oil tank 450L
tee airlocking valve hydraulic station
flow of cooling water 60 L/Min
temp.of cooling water 33
water pressure:0.2 0.4MPa

2.2.4.2 Construction and working principle of coal
MPF1915 vertical coal mill is composed of table, roll, separator, hydraulic pressing,
drive, casing and hydraulic station. Raw coal through middle feeding down pipe comes
to the center of rotating table. Under centrifugal force of the table, raw coal spreads
out and forms material bed. Raw coal is crushed under press of roll, meantime,
the hot air from vane drys the moistured raw coal and brings the crushed raw coal to
upper coarse-power separator at fast speed with ascending air flow, and then by
separating, the eligible product is discharged out with air flow, and the separated
coarse
powder
returns out
to table
be regrinded.
ungrinded
or and
uncrushed
small-size
raw
coal is thrown
to thetovane
at dead The
pedestal
of mill,
then which
is brought
back to grinding table to be recrushed by hot air at fast speed. The coal powder blew
out with air will be separated and collected by separator outside the mill.
Chapter 3
Operation Control
This chapter includes burning system and pulverized coal preparation in burning
workshop.It introduces controls paramter and auto control loop.Operators of DCS
make use of this chapter to understand the measuring point and range of control
parameter,so as to ensure the normal running
3.1 burning system
3.1.1 controls parameter
Since DCS system is employed, the equipment shall be remote control after on-site
data are processed and sent to the central control room. The process parameters and
analog are processed by the data acquisition system while the switch value is done by
the PC system. Refer the table below for the measuring point of automation
No .
Measuring point
Equipment No.
321.VV46
Location of gate of tee chute
Control
Regulation
Temperature of inlet of high temperature 350

fan
321.FN19
321.FN19a
321.FN19d
Pressure of inlet of
high temperature fan
temperature of
main bearing of high temperature fan
rev of high temperature
fan
vibration of high
temperature fan
opening of inlet
valve of high temperature fan
opening of
hydraulic coupler of high temperature fan
-4 7500Pa
75
9 940r/min
monitoring
0 100
0 100
No .
Equipment No.
321.FN19M01
Measuring point
Control
Monitoring
temperature of oil at outlet of hydraulic
coupler of high temperature fan
motor current of high
monitoring
temperature fan
temperature of
monitoring
motor bearing of high temperature fan
monitoring
of high
Winding temperature of motor
temperature fan
321.FN19b
411.PR08
thin oil station of

main bearing of high temperature fan
temperature of
gas at C1 outlet of preheater
temperature of discharged material from
preheater C1
Negative pressure of gas at C1 outlet of
preheater
analysis of gas at C1 outlet of preheater
monitoring
320 360
400 500
4000 7000Pa
Co 0 0.3%
O2 0
6
5%
N0X:0
temperature of gas at C2 outlet of

500 600
preheater
temperature of
500 600
discharged material from preheater C2
Negative
3000 6000Pa
pressure of gas at C2 outlet of preheater
temperature of gas at C3 outlet of
preheater
Negative pressure of gas at C3 outlet of
preheater
negative pressure of
C3 cone of preheater
temperature of
Negative
temperature of
Negative
temperature of
diacharged material from preheater C5
analysis of gas at outlet of KSF calciner
600 700
2000 5000Pa
0 5000Pa
700 800
1000 4000Pa
0 4000Pa
780 880
1000 3000Pa
0 3000Pa
800 900
Co 0 0.3%
O2 0
4
5%
N0X:0
No .
Equipment No.
411.VV02
411.BE01
10
331.VM50
11
331.SQ08
331.SQ13
12
13
14
15
331.VM55
Measuring point
Temperature
of gas at outlet of KSF calciner
Negative
pressure of gas at outlet of KSF calciner
Temperature of gas
in kiln inlet soot chamber
gas in kiln inlet soot chamber
Cleaning
system of kiln inlet preheater
Location of gate
of electrical tee chute
current of elevator to kiln
material level switch of
elevator
control of aeration to
homogenization
location of pneumatic
switch valve
opening of electrical flow

valve
weight of blending
331.FB16
small bin
location of pneumatic
switch valve
331.SQ18/331.SQ19
opening of electrical flow
valve
331.FM21/331.FM22 impact flow meter
rev of rotary kiln
up-down moving
limit of rotary kiln
temperature of shell of
rotary kiln
Bearing
421.KL01
temperature of idler at hot end of
rotary kiln
Bearing
rotary kiln
Bearing
16
17
421.KL01.M01
421.KL01.GB01
rotary kiln
current of main motor
of rotary kiln
temperature of
bearing of main motor of rotary kiln
winding
temperature of main motor of rotary kiln
Temperature
of bearing of main reducer of rotary kiln
Control
parameter
850 900
1000 3000Pa
900 1100
100 800Pa
Control
Regulation
Monitoring
Monitoring
Control
Regulation
0 100
50 150t
Regulation
0 100
30 270t/h
0.39 3.948r/min
monitoring
350
115
115
115
Monitoring
90
115
90
No .
Equipment No.
18
421.KL01b
19
421.KL01c
20
421.TD09
21
421.PG10
22
23
24
431KS.01
431.BL03/431.BL04
431.CC06
Control
parameter
Measuring point
thin oil station of
Monitoring
main reducer of rotary kiln
oil station of Monitoring
hydraulic thrust roller of rotary kiln
temperature of tertiary air
700 900
tertiary negative pressure
100 800Pa
Opening of high
temperature gate valve
negative pressure of kiln
Hood
temperature kiln hood
temperature of secondary
air to kiln
TV for watching fire at kiln
Outlet
kiln outlet burning
Temperature
pressure of outlet of
primary fan
frequency speed
control of roots fan
motor current of
roots fan
frequency control of
first section of grate cooler
current of drive
motor at first section of grate cooler
second section of grate cooler
current of drive
motor at second section of grate cooler
third section of grate cooler
current of drive
motor at third section of grate cooler
Temperature of left side of first section
of grate cooler
temperature of
right side of first section of grate cooler
monitoring TV of grate
Cooler
pressure under
grates of first chamber of grate cooler
pressure under
grates of second
chamber of
grate cooler
pressure under
grates of third chamber of grate cooler
pressure under
grates of fourth chamber of grate cooler
0 100
-100 100Pa
800 1100
900 1100
Monitoring
1600 1700
0 24000Pa
0 100
Monitoring
0 100
Monitoring
0 100
Monitoring
0 100
Monitoring
230
230
Monitoring
0 12000Pa
0 11000Pa
0 7000Pa
0 6000Pa
No .
Equipment No.
25
26
27
28
29
30
31
431.CC06s
431.FN09
431.FN10
431.FN11
431.FN12
431.FN13
431.FN14
Measuring point
pressure under
grates of fifth chamber of grate cooler
pressure under
grates of sixth chamber of grate cooler
high material
level of dust bucket under grates of grate
cooler
motor current of
crusher of grate cooler
Bearing
temperature of crusher of grate cooler
dry oil lubrication
system of grate cooler
inlet flow of
balance fan at first chamber
opening of inlet valve of
Fan
motor current of fan
Fan
inlet flow
of first chamber aerating fan(first at left )
Fan
outlet pressure of fan
inlet flow
of first chamber aerating fan(first at
right )
Fan
inlet flow
of first chamber aerating fan(second at
left )
Fan
inlet flow
right )
Fan
Control
parameter
0 5000Pa
0 4000Pa
Monitoring
Monitoring
70
Monitoring
0 12000m3/h
0 100
Monitoring
0 41000m3/h
0 100
monitoring
0 17000m3/h
0 100
monitoring
0 12000Pa
0 17000m3/h
0 100
monitoring
0 12000Pa
0 16000m3/h
0 100
monitoring
0 11000Pa
0 16000m3/h
0 100
monitoring
0 11000Pa
No .
32
33
34
35
36
37
38
39
Equipment No.
431.FN15
431.FN16
431.FN17
431.FN18
31.FN19
431.FN20
431.FN21
431.FN22
Measuring point
inlet flow
of second chamber aerating fan(first at
left )
Fan
inlet flow
of second chamber aerating fan(first at
right )
Fan
inlet flow
left )
Fan
inlet flow
of second chamber aerating fan(second
at right )
Fan
inlet flow of third
chamber aerating fan
Fan
inlet flow of fourth
Fan
inlet flow of fifth
Fan
frequency control of fan
inlet flow of sixth
Fan
frequency control of fan
Control
parameter
0 17000m3/h
0 100
monitoring
0 12000Pa
0 17000m3/h
0 100
monitoring
0 12000Pa
0 25000m3/h
0 100
monitoring
0 10000Pa
0 25000m3/h
0 100
monitoring
0 10000Pa
0 57000m3/h
0 100
Monitoring
0 71000m3/h
0 100
monitoring
0 63000m3/h
0 100
0 100
monitoring
0 62000m3/h
0 100
0 100
monitoring
No .
Equipment No.
40
41
42
431.BV23
431.EP24
43
431.FN25
44
431.FN25f
45
46
431.FN25M01
431DB.27
47
48
49
L21.RF23
50
L21.RF20
51
L21.SP24
Measuring point
temperature afterwind
of grate cooler
opening of electrical cold
blast valve
inlet temperature
of EP at kiln outlet
inlet pressure of
EP at kiln outlet
voltage of
electric field at kiln outlet EP 1
current of
voltage of
current of
voltage of
current of
voltage of
current of
Outlet
temperature of kiln outlet EP
outlet pressure
of kiln outlet EP
temperature of
main bearing of kiln outlet fan
vibration of kiln
outlet fan
opening of inlet
valve of kiln outlet fan
motor current of
kiln outlet fan
temperature of
motor bearing of kiln outlet fan
Winding
temperature of motor of kiln outlet fan
current of chain bucket
Conveyer
material level of
clinker silo
material level of reject silo
kiln outlet coal feeding
Amount
calciner coal feeding
Amount
pressure of air used to
conveying coal at kiln outlet
Control
0 500
0 100
250
-1600Pa 0
monitoring
monitoring
monitoring
monitoring
monitoring
monitoring
monitoring
monitoring
150
-1800Pa 0
75
monitoring
0 100
monitoring
90
115
monitoring
0 36m
0 13m
0 10t/h
6 15t/h
0 80000Pa
No .
Equipment No.
52
L21.SP21
53
L21.BL25/L21.BL26/
L21.BL27
Measuring point
pressure of air used
to conveying coal at Calciner
current of roots fan
Control
0 70000Pa
monitoring
Note: the operating parameters should be recorded by the operator on duty
3.1.2 auto control loop

For
the
sake
of
enhancement of running
rate and reduction of labour
intensity,the
system
combines
auto
control loop with computer
air inlet valve of exhaust
regulate the opening
1 Automatically
control.
The
important
fan
321.FN33 at kiln inlet according to pressure of gas at outlet of high temperature
of
controls
fan
321.FN19is
parameter
almost
controlled
automatically,
.
hereby, it reduces man
2 mis
AUtomatically regulate the rev of high temperature fan 321.FN19
made
according to pressure of gas at C1 outlet.
operation.
3 Automatically regulate the opening of air inlet valve of exhaust
fan 431.FN25 at kiln outlet according to negative pressure of kiln
outlet
4 Automatically regulate the opening of coal blast alve 431.BV23 according to
temperature
of
air
at
inlet
of
kiln
outlet
EP 431.EP24 .
5 Automatically regulate the opening of valves at air inlet of fan according to the
air volume at inlet of cooling fan at each chamber of grate cooler.
6 Automatically regulate the speed of grates according to the maximum
3.2valve
pulverized
coal preparation
changing
of the 4 measuring
points(air pressure of aerated beam of step grate
plate in first chamber(2 points), air pressure of aerated beam of resistance grate
3.2.1
parameter
plate incontrols
first chamber,
pressure under grates in second chamber).
Since DCS system is employed, the equipment shall be remote control after on-site
data are processed and sent to the central control room. The process parameters
and analog are processed by the data acquisition system while the switch value is
done by the PC system. Refer the table below for the measuring point of automation
No .
1
2
Equipment No.
321.VM27
321.VM26
Measuring point
opening of hot blast valve
opening of coal blast valve
Control
parameters
0 100%
0 100%
321.CS28
inlet gas temp 0 400

outlet gas
0 350
outlet gas
temp
0 -1800Pa
pressure
dosing feeder feeding

L21.WF02/L21.WF03 Amount
negative pressure of gas
at coal mill inlet
temperature of gas at
coal mill inlet
negative pressure of gas
at coal mill outlet
temperature of gas at
L21.RM06
coal mill outlet
pressure difference
of gas at inlet and outlet of coal mill
vibration of mill
L21.RM06a
L21.RM06c
L21.RM06.GB01
10
L21.RM06.M01
11
L21.FN07
12
L21.BF10
0 60t/h
0 -2000Pa
0 320
0 -8000Pa
0 80
5000 Pa
Monitoring
Tension
Regulation
temperature of main
55
bearing of coal mill
temperature of
Monitoring
oil tank at thin oil station of reducer of coal
mill
rev of separator
Regulation
temperature of
55
bearing of main reducer of separator
temperature of
65
bearing of main motor of mill
winding temperature
115
of main motor of mill
current of main motor of mill
Monitoring
Outlet
Monitoring
pressure of seal fan of roll bearing of coal
mill
current of seal
Monitoring
fan of roll bearing of coal mill
negative pressure
0 -9000Pa
of gas at air inlet of bag filter
temperature of
75
gas at air inlet of bag filter
negative pressure
0 -12000Pa
of gas at air outlet of bag filter
temperature of
75
gas at air outlet of bag filter
temperature of
75
pulverized coal of dust bucket1 6 of bag
filter
CO analysis of bag
Filter
temperature of bearing
of main fan
opening of inlet
valve of main fan
0 0.8
55
0 100%
13
14
L21.FN12
L21.BI19/ L21.BI22
temperature of
motor bearing of main fan
Winding
temperature of motor of main fan
motor current of main fan
weight of coal powder in
pulverized coal bin
temperature of coal
powder in pulverized coal bin
65
85
Monitoring
0 100t
75
Note: the operation record shall be written by operator on duty in

this workshop.
3.2.2 auto control loop

For the sake of enhancement of running rate and reduction of labour intensity,the
system combines auto control loop with computer control. The important controls
parameter
mis
is almost
controlled
automatically,
hereby,
it reduces
man-made
operation.
1 According to negative pressure at inlet of coal mill L21.RM06 , control
opening of valve at fan inlet.

cold and hot
2 .Temperaure control ( at coal mill air inlet ): regualte opening of
blast valves 321.VM26 321.VM27 based on temperature of gas at coal mill
outlet.
3 .Pressure difference control(mill outlet and inlet):the pressure
difference reflects material quantity inside mill, so regulation of coal feeding quantity
can stablize the pressure difference.
4 .According
to fineness of coal powder, regualte frequency of separator
L21.RM06c in CCR.
Chapter 4
Preparations before Startup
All equipments in burning system must be well inspected and regulated before startup,
which must be strictly executed in future production.
4.1 inspections on equipments

4.1.1 Inspection & adjusting on lubrication unit and lubrication quantity
Lubrication plays a key role in securing a long term steady running. The quantity of
lubrication oil must be properly since it directly effects on the running of the
equipment: If it is too much, the equipment will go overheat; on the contrary, the
equipment will be damaged. Each single machine should be periodic checked and
lubrication oil is renewed. The oil type and trade mark should be right, and the quality
should meet the requirements, no water and no foreign matters.
A Keep proper oil quantity and free-flowing of oil for thin oil station of main bearing of high
temperature fan
B Keep proper oil quantity and free-flowing of oil for oil station of
thrust roller.
hydraulic
C Keep proper oil quantity and free-flowing of oil for thin oil station of main reducer of kiln
D Keep proper oil quantity and free-flowing of oil for dry oil station of grate cooler.
E Grease drive units including gear box,motor,coupling etc.,make sure no oil leakage,
guarantee replacing grease regularly and the oil are qualified.
F All the bearings and moving parts should be oiled well. G,
Oil the actuators of electric valves.
H, Check the lubricating units of main bearing of coal mill, of coal mill gear box and
motor of the mill, to make sure the valves of the oil groove network are easy to open
and close; make sure the oil pump is free of noise and strange vibration; fins out the
lubrication quantity, pressure, return quantity and whether there is oil leakage; make
sure the new lubrication added into the equipment can meet the requirements in the
introduction
and refresh
periodically
it. inspection hole and equipment inside
and seal
on manholes,
4.1.2 Inspection
Before startup, inside of the equipment should be checked thoroughly. Clear away all
the odds left behind during the installation or maintenance, in case incur seizure or
damages of the equipment; and close all the manholes, cleaning holes and inspection
gates to prevent leakage of air, material and oil etc. during the production.
4.1.3 Inspect the heat preservation and the flanged joint of expansion joint on each air duct.
4.1.4 Inspect whether thers is water leakage on silo and equipment.
4.1.5 Inspect the masonry state of refractory,and then confirm and clear the test hole
to
ensure it unblocked.
4.1.6 Gate
In order to keep the free-flowing of material,the bottom of raw meal proportioning
silo,the part under raw meal feeding weight-loss silo and the screw valve under coal
powder weight-loss silo should be opened to appropriate degree.
4.1.7 Confirmation on open -close direction and opening of valve
a All the manual valves should be opened to appropriate degree
before startup.
b First of all, check the manual flexibility of all of the electric valves on site,
and the firmness of the valve shaft and linkage, after that, take a remote control
on it, make sure the open-close direction onsite is in accordance with that of
control room, and the accuracy of opening and indication. If there is a upper
limit
or lower limit on the switch, the check of limit signal return with control room is
needed.
4.1.8 Inspection on cooling water and compressed air system
It is very important to examine the cooling-down water and compressed air
system
before the equipment is started up. Make sure the valve on the cooling water
passage
is opened to a full extent, and the connecting parts of water pipes are free of
leakage,
especially the cooling down water for the lubrication unit and main bearing of mill.
Rationally control on the cooling down water, too little water can cause the
machine
heat up, too much water is a matter of waste.
Make sure the valve and passage of compressed air employed for the instruments and
the bag filter of coal mill are free of jamming and leakage.
4.1.9 Inspection on equipment fastening
Looseness of equipment would not occur. The driving parts shall be carefully checked,
such as liner bolt of coal mill, bolts of mill door, foundation bolts.The easyloose
parts, like rod drive, must be strictly inspected.
4.1.10
Inspection
instruments
on
There are many instruments on site, such as thermometer, pressure meter

and
material level
equipment
measurement;
they
will
help
the
inspector
to
grasp
the
running situation. Inspect all these instruments systematically, and make sure
Fire-Fighting & Inspection Manual and the manual provided by the manufacturer for
the inspection and requirements.
The fire extinguishers on this extinguishing system must be free of leakage. When
the
extinguishant loss 10% of itself, refresh and refill it in time to restore its normal
working
condition.
4.2 Inspection on electric equipment

4.2.1 Make sure the supply of electricity
4.2.2 Push the electric switchgear to the working position,the current setting value
should be proper.
4.2.3 PC Local power supply of PC is ready
4.2.4 The switches of all the on-site equipments are placed at the central control
site.
4.2.5 Check the condition of high-pressure equipment, and start power supply.
4.2.6 Preparation of equipment is well done
After finish jobs mentioned above, preparation beforehand then is completed, and
start up all the equipment in the order according to the actual situation.
Chapter 5
Startup and Stop
This chapter introduces the precautions, trouble shooting, key points of safety running
and sequence of startup and stops for burning system and pulverized coal preparation
system during test run and production.
5.1 startup and stops for burning system

5.1.1 Drying of Refractory
Before firing the rotary
kiln, the liner refractory of
calciner,
pre-heater,
rotary kiln and
cooler must be dried, in
case
crack
and shell
Proposal
of drying
shalloffbe based on the type of refractory, constructional thickness,
caused by fast speed up
moisture
if fire andcontent. This system adopts two-end drying(kiln outlet and pre-heater). The
fuel
take diesel
first and later coal power would be the main fuel. The concrete
feedwould
directly.
The atdry
process is
very
importantaccording to actual situations on site.
proposal
can
be adjusted
to new kiln, since it would
For
rotary
kiln, refractory is used from kiln outlet to kiln inlet: special kiln mouth used
straight
affect
filling
compound,
magnesia-chromite bricks ,anti-spalling high alumina
service
life of linersilica
and bricks,
kiln system.
bricks , mullite high strength casting material etc refractory mortar. This type
of
brick liner has swelling stress at the cold end, which would become loosewhen
temperature exceeds 800, hereby temperature must slowly rise in 300 800,
especial the local part, in addition, pay attention not to rotate the kiln as less as
possible in case big stress change of brick liner. Drying method and kiln speed can
refer to following table. Practical operation is changeable based on actual situation.
NEW LINER
NORMAL TEMP.
Temperature rise of rotary kiln
TIME
KILN INLET TEMP.
NORMAL TEMP.
200
200
200 600
600
600 800
ABOVE 800
8H
16H
16H
24H
8H
8H
3H
10H
4H
2H
temperature rise curve for new kiln

Heating up
curve
temp
30
16
Curve for burning zone turns more than 10m.
TEMP
Note: process operator shall control the time and speed of temperature
rise according to replacement of refractory at firing.
temperature rise and kiln running of rotary kiln

KILN INLET TEMP.
INTERVAL(MIN)
200 400
400 600
600 700
700 800
800
DEGREE
60
30
15
10
90
90
90
90
CONTINUOUSLY TURN THE KILN AT SLOW SPEED
Note:The time of slow-turning must be cut down if rain or wind.

The refractory used in kiln inlet pre-heater and calciner are high strength alkali
resisting firebrick, anti-spalling high alumina bricks, high strength alkali resisting
castables, ceramic fiber board etc. Compound liner with different thermal conductivity
is adopted in lining masonry. Due to large area and thickness, heating and drying in
normal temperature is not allowed in 24hours after construction. Temperature rise is
based on the guarantee of getting rid of adhesive water andcombined water.
Dewatering of adhesive water is between 150 200, and that of combined water
is between 400 500, hereby the temperature must be constant for a while
within
above temperature. The drying of pre-heater liner shall be done along with kiln drying.
Rise rotary kiln temperature meanwhile dry pre-heater.
Generally, C1 outlet shall be constant at 150 200 for 12 hours, and C5 outlet
shall be constant at 450 500

hours.
for 12
5.1.1.1 work before drying

5.1.1.1.1 Single-machine commissioning and interlocking commissioning before drying
5.1.1.1.2 Pulverized coal preparation system shall be provided with conditions for
loaded test run, limestone grinding(coal mill) shall be finished.
5.1.1.1.3 Coal powder weighing. Feeding and coal powder conveying system are loaded
and run smoothly.
5.1.1.1.4 Air compressors are finished debugging and run normally, which is qualified to
supply air to kiln inlet ,feeding system and coal feeding system.
5.1.1.1.5 Cooling water pipes of burning system and pulverized coal preparation system are
free with normal hydraulic pressure.
5.1.1.1.6 Make sure that flap valves under cyclones of pre-heater are flexible and well
sealed. Shift heavy punch to proper place, hang it up and fully open it for hot air
passing.
5.1.1.1.7 Kiln outlet coal burning system must keep free of pipelines after
interlocked test run, also shall be flexible. Firing system has done the testing spout.
5.1.1.1.8 Make sure that oil tank and oil pump are ready. Prepare diesel oil
80 100 and cotton yam for firing 30Kg.
5.1.1.1.9 Make sure that bolts in cooler are fixed, crusher and relating conveying
machines are in good condition.
5.1.1.2 firing and temperature rise

5.1.1.2.1 Startup fan 321FN33(fire for the first time shall open 2 3 inspection holes
of
pre-heater, and then get the time to start fan321FN33 according to kiln
burning),regulate the opening of baffle(fan 321FN33 321FN19)and keep
the negative pressure of kiln hood between-20 -50Pa.
5.1.1.2.2 Start up primary fan set 431BF03 or 431BF04 and inform the site to
start
up diesel pump set.
5.1.1.2.3 Fire on site, after that, regulate oil spout quantity and primary air pressure
and opening of baffle of burner(431BU02) based on the shape of flame.
5.1.1.2.4 Rise in temperature according to the curve , notice following items:
5.1.1.2.4.1 Temperature rise shall be based on the temperature of kiln inlet.

5.1.1.2.4.2 Stick to slowly rise in temperature do not turn around in drying
process, strictly rise in temperature as per the curve and prevent over heating up.
5.1.1.2.4.3 regulation on temperaturerise a. regulate oil spouting
c.When kiln inlet temperaure rise up to 300 350 , feed coal power
quantity. amount and burn with coal and oil.

appropriate
5.1.1.3
coal feeding
b. regulate
ventilation in kiln, keep proper negative pressure.
5.1.1.3.1 Inform operator controlling raw material system to start up the conveying
machines(convey raw meal to silo)and dust conveyer
5.1.1.3.2 Inform site operator to make sure kiln outlet coal feeding system is in good
condition. Set minimum coal feeding amount so as to prevent flameout caused by
overfeeding.
5.1.1.3.3 Prevent flameout of burner 431BU02 by sudden feeding, properly regulate
inside/outside flow of burner 431BU02 as well as its opening of central valve,
which is the way to guarantee good burning and air volume.

5.1.1.3.4 Increase coal feeding amount as per temperaturerise curve, gradually reduce oil spouting amount. Try to
avoid black smoke from chimney and control the
5.1.1.3.5 Strictly control negative pressure of kiln outlet, and ensure that coal powder
content of CO at C1 outlet below 0.1%.
can fully burn out, meanwhile, prevent overheat at preheater outlet.
5.1.1.3.6 If air supply insufficiently, central control operator shall start main fan
set 321FN19 and fans in chamber 1 and 2 of grate cooler to supplement the
oxygen when fan 321FN19 slowly runs and draws in air insufficiently.
5.1.1.3.7 If the burner suddenly flame out in kiln, inform site operator to
stop
diesel pump immediately and find out the causes, and then refire it. Temperaure
W hen the first section of grate cooler accumulates too much, CCr or site
5.1.1.3.8
rise
operator start up the first grate bed. If the materials are still too much, then start up
shall be based on the temporal kiln inlet temperaure.
conveying system and second, third grate bed to convey the materials.
5.1.1.3.9 When kiln inlet temperature rises above 950, the air temperature at preheater outlet is about 350, it is allowable to feed as long as thermal storage and other
in
conditions in kiln are eligible.

5.1.1.4 completion mark of drying
a. check if there is vapor on casting hole at the top of preheater.
Method: put glass piece at exhaust hole to see if there is coagulation of vapor.
b. For inspection, the key points shall be at C4 cone, C5 cylinder and top of
calciner.Drill6 8 holes from outside of the three places, which must penetrate
thermal insulation coating into firebricks, insert mercurial thermometer at later
stage of drying, if the temperature reaches above 120, the drying at this place is
eligible,and
then seal the inspection hole.
5.1.2 preparation before feeding
Preparation before first fire and feeding: confirm raw mill and coal mill are ready to
startup, guarantee raw meal and coal powder can be supplied sufficiently. See
following items:
5.1.2.1 1 hour before feeding, cast ball and open the flap valve at each stage of preheater.
5. 1.2.2 When kiln inlet temperature reaches above 800, inform site operator to start
up kiln slow drive device.

5. 1.2.3 According to brick replacement amount in kiln, judge whether it is necessary to
feed raw meal in advance(new kiln need to pre-feed).
5.1.2.4 Start up silo top dust collector, clinker conveying dust collector, clinker conveying
system 431DB27 , crusher, grate cooler conveying and three grate beds.
5.1.2.5 Inform production safety department and maintenance department.
5.1.2.6 Start up rotary valve etc conveying machines under electric dust collector
431EP24
5.1.2.7 Start up kiln outlet fan 431FN25 , ensure kiln hood is in micronegative
pressure. Technically, it is possible to hold the negative pressure of kiln
outlet
higher like -50 -150Pa before feeding. When EP outlet temperature reaches above
90, the site shall be charged 431EP24.
5.1.2.8 20min before feeding, start up first and second grate bed at slowest speed so
as to form material layer and enhance the temperature of gas into kiln.
5.1.2.9 Inform site operator to inspect the accumulation on front dead grate plates at
first section of grate cooler, and any burnt materials drop down in kiln, and then start
up air cannon.
5.1.2.10 Start up silo bottom bag filter 331BF31 , chute conveying system. Inform
site
operator to regulate the opening of baffle of bag filters. Feed standard bin up
to
material level 80%.
5.1.2.11 When kiln inlet temperature reaches above 950 and preheater outlet
5.1.3.1 Start up the balance fans in cooler.

5.1.3.2 Ensure that kiln at zero speed, inform site inspector to switch auxiliary motor to
main motor. After receive the switching signal and notice from inspector, set
kiln
speed at 0.4 0.5r/min, and start up the main motor of kiln.
5.1.3.4 Guarantee the inlet negative pressure through

regulating the rev of high
temperature fan and opening of baffle(regulate air volume
by run at low rev and widen
the opening of baffle till it is fully opened and then speed
up), and then according to kiln
hood negative pressure, regulate the air volume of
each chamber and opening of
431FN25 baffle.
5.1.3.5 First feeding of rotary kiln80t/h.
5.1.3.6 When feed materials, the air, material and coal change greatly, this may
cause
accretions and block at the cyclon pipes and kiln inlet dust chamber.
a.inform site inspector to check the flap valve, whether it is blocked or not
b.inform site inspector to check the conic section of cyclone and material-hole of chute,
observe the draft of material-hole and judge whether it is blocked.
c. Notice the temperature and pressure of preheater, estimate the state of system.
5.1.3.7 Inform operator at raw material system to regulate the opening of baffle of fan at the
tail of bag filter outlet, ensure the negative pressure of high temperature fan
between -300 -600Pa.
5.1.3.8 After clinker fed into cooler, gradually increase grates speed and air volumn of
grate cooler, thereafter:
5.1.3.8.1 rise temperature of secondary air and tertiary air
5.1.3.8.2 stablize the negative pressure at kiln
hood
5.1.3.8.3 Prevent snow man
5.1.3.9 After feed and run stably, oil burnt or stop of oil pump can be selected.if
oil pump stops, it must draw out the oil gun.
5.1.4 full load run
5.1.4.1 Try to stabilize material and coal feeding, decrease unnecessary regulations, at
least the big one so as to keep stablization of thermal regulation of kiln.
In normal
the speed
grates
5.1.4.2 kiln
inlet operation,
negativeregulate
pressure:
about of-300
Pabased on the temperature of grate
plates, pressure in air chamber, accumulation on grate bed.
321FN19 inlet: content of CO 0.1%
5.1.4.3 Notice the negative pressure, temperature of cyclones, and prevent blocking
up. kiln inlet temp. 950 1100
5.1.4.4 Control
process
load running)
content on
of O
outlet3.5%
2 at C1 parameters(full
feeding 198 /h 210

/h kiln speed 3.2
3.9r/min
calcination rate of raw meal into kiln 90%
inlet temp. (321FN19 high temp.fan): 350 kiln current: 400

750A
C1
Outlet negative pressure -5000 Pa
kiln shell temp.: 350
Kiln burning temp.: 1350 1450 kiln hood negative pressure: -20 -50Pa
Tertiary air temp.: 850

431CC06 pressure under grates of first chamber
C5: outlet temp.: 860 880

Negative pressure of conic section-1300 Pa
5500 Pa
temp.of chute: 850
870
431FN25 inlet temp.: 200 250

5.1.5 stop of kiln
5.1.5.1 Stop of kiln due to plan or long time maintenace
5.1.5.1.1 After receive notice of stop, estimate the coal powder amount tfor the two
coal powder bins.
5. 1.5.1.2 Decide the stop time according to storage in coal powder bin.
5.1.5.1.3 If calciner coal powder bin is shown at 5% material level, kiln feeding
amount shall be decreased to 80 100t/h, and prepare to stop kiln.
5.1.5.1.4 Once the calciner weigher is short of coal, set coal feeding amount at
0t/h
close tertiary air baffle, regulate air volume for system and reduce feeding
amount
to 60 80t/h.
The whole process must be slow, fast operation is forbidden. Prevent pre-heater from
block by accretions and accumulations.
5.1.5.1.5 Before stop of kiln and after stop of furnace, properly control the raw meal
amount in standard bin according to the storage of coal power bin.
5.1.5.1.6 Stop calciner coal feeding system, slow down the speed of kiln.
5.1.5.1.7 When there is only a little coal power in bin, stop discharging group.
Gradually reduce kiln outlet coal feeding and air supply for system and
5.1.5.1.9
When empty standard bin, set feeding amount at 0t/h.
slow down kiln.
the material in raw meal conveying group(into kiln) is empty, stop raw
5.1.5.1.8
Stop kiln as long as kiln outlet coal powder bin is empty.
5.1.5.1.10When
meal conveying group and belt elevator.
5.1.5.1.11 Stop primary fan when kiln outlet is short of coal for 4 hours, start
up cooling burner of auxiliary motor 431FN05.
5.1.5.1.12 Stop main motor of high-temperature fan and start up auxiliary drive.
5.1.5.1.13 Stop kiln main drive, inform the site operator to switch it to auxiliary drive.
In case deformation of kiln shell, turn the kiln as per regulations during cooling down.
Regulations of turning kiln
First hour: turn once every 5m at lowest speed or continuously run(driven by auxiliary
motor)
Second hour: turn once every 10minute
Third hour: turn once every 20minute
Fourth hour: turn once every 30minute

Fifth Eighth hour: turn once every 40minute
After Eighth hour: turn once every 60m
Stop the kiln when burning zone shell reaches 100.Auxiliary motor drives kiln at 90
degree every time. In rainy day, hot kiln shall keep running.
5.1.5.1.14 Stop cooling fan for kiln riding ring and kiln outlet cooling fan.
5.1.5.1.15 Before stop of kiln and after stop of furnace, when cut feeding
to
kiln, accordingly reduce air in cooling fan chamber and air of kiln outlet fan.
When there is electric
no redfield
materials
grate bed,
coolingstops.
fan. After
5.1.5.1.16 Stop431EP24
and itsonvibrating
after stop
431FN25
5.1.5.1.17
completion
of
conveying
clinker,
stop
driving
system
of
grate
cooler.
5.1.5.1.18 431EP24 conveying machine stops.
5.1.5.1.19 When inlet of high temperature fan is below 100 , stop
auxiliary drive. According to actual situations, stop kiln inlet bag filter and kiln inlet fan or
not.
5.1.5.1.20 After stop kiln turning, stop thin oil station and hydraulic thrust roller at
kiln middle.
5..1.5.2 temporal stop of kiln
5.1.5.2.1
5.1.5.2.2
5.1.5.2.3
5.1.5.2.4
5.1.5.2.5
Stop feeding, calciner and properly reduce coal feeding to kiln outlet.
Reducer air volume, stop main fan of kiln, switch to auxiliary drive.
Stop main motor, switch in and slowly run as per regulations.
Inspect pre-heater and do ball test
Preserve heat of system, prepare to feed material at any time.
5.1.6 Ordinary failures and disposals

5.1.6.1 operation on trip of high temperature fan
5.1.6.1.1 Regulate baffle of 431FN25 fan and that of fans in cooler chamber, control
the pull at kiln outlet at-50 -100Pa, prevent positive pressure.
5.1.6.1.2 Stop kiln feed, furnace and coal feeding. Reduce coal feed to kiln outlet. If
maintenance time is a little longer, stop main motor of kiln and inform site operator to
turn the kiln as per regulations.
5.1.6.1.3 Inform inspector to check the pre-heater to prevent feeding down pipe from blocked
by drops.
5.1.6.1.4 Keep high temperature fan running slowly as much as possible.
5.1.6.1.5 Make preparation on heat insulation and feeding.

5.1.6.1.6 Inform relevant staff to find out the failure and dispose it.
5.1.6.2 Operation on trip of first section of cooler estimate the
recovery time based on failures.
5.1.6.2.1 Make following treatments in 10m: cut down material, slow down kiln, cut
down coal and air volume for system, properly widen baffle opening of fan in each
chamber at first section of cooler and keep negative pressure of kiln outlet.
5.1.6.2.2 If the time is estimated above 15m, stop the kiln.
5.1.6.3 Operation on stop of clinker conveying and recover estimate the recover time
based on failures
5.1.6.3.1 It is unnecessary to do change if it recovers in 5m.
5.1.6.3.2 If it would recover in 5~15m, consider slow
down kiln, cut down material
and air volume, properly slow down first and second grate
beds, increase air volume
and notice the change of current and pressure, avoid snow
man occur in front of first
section.
5.1.6.3.3 If it would recover more than 15m,current and pressure of first and second section
are too high while failures cant be disposed, stop the kiln immediately.
5.1.6.3.4 operation of recovery
After repair, start up clinker conveying group, notice the speed of third grate
bed, prevent crusher and conveyer from trip and stop.
5.1.6.4
material
unburnt
5.1.6.4.1 Phenomenon: kiln current obviously drops, concentration of Nox, O2

falls,
pressure of first chamber of grate cooler ascends, kiln becomes dark, 431FN25
inlet
temperature rises.
5.1.6.4.2
disposal
5.1.6.4.2.1 Ordinary situation, properly increase coal, slow down kiln and
speed up
grate cooler and properly increase the air exhaust.
5.1.6.5.2 Any fan at second section trips to stop, if it would not recover in short time, cut
5.1.6.4.2.2 Less severe situation: increase coal, slow down kiln and speed up grate
down feeding and coal, slow down kiln, speed up grate bed and increase air volume of
cooler,
narrow tertiary air baffle.
rest fans.
Severe situation: stop material feeding, slow down kiln to the least, inform
5.1.6.4.2.3
Any fan at third section trips to stop, if it would not recover in short time, cut
5.1.6.5.3
site
operator
if there
no flame
in kiln,
gun to fire
till the of
down feeding andwatching
coal, slowfire,
down
kiln, is
speed
up grate
beduse
andoilincrease
air itvolume
current
rest fans.
would not trend to drop and then feed again.
5.1.6.6 blockage in cyclone
5.1.6.5
trip of grate
5.1.6.6.1
cooler fan Phenomenon: the temperature of cyclone bottom falls, but negative
pressure
sharply
thesection
next cyclone
up. time,
5.1.6.5.1
Anyascends,
fan at first
fails to outlet
stop, ifsharply
it wouldget
nottemperature
recover in short
stop the kiln and shoot the trouble.
5.1.6.6.2 Disposal: stop kiln and clear up.strictly do it as per regulations and ensure
personnel safety.
5.1.6.7 power off and back power
5.1.6.7.1 If the power is off, field worker must supply emergency power.
5.1.6.7.1.1 Inform site operator to turn the kiln slowly.
5.1.6.7.1.2 Whether extract the burner on site is based on the time of back power.
5.1.6.7.1.3 Set value for normal stop.
5.1.6.7.1.4 Inform site operator to inspect the relavant equipment(preheater) and solve
the problem timely.
5.1.6.7.2 resume
5.1.6.7.2.1 After power is supplied, site operator would confirm the status of main
and auxiliary equipment, and then resume.
5.1.6.7.2.2 Start up 431BL03 or 431BL04, and then according to the stop time of kiln
and internal temperature, decide the oil applied and temperature-rise.
5.1.6.7.2.3 start up all lubricating devices.
5.1.6.7.2.4 Start up fans in first and second chamber as well as clinker conveyer to
send the accumulated clinker on grate bed.
5.1.6.7.2.5 Other operations must accord to the regulations on kiln failures and stop.
5.2 startup and stops for pulverized coal preparation system

In production, control the coal mill under stable status according to its outlet air
temperature, pressure difference, current of main motor, negative pressure of inlet,
current of separator. Properly regulate the opening of relevant baffles (for temperature),
coal feeding etc parameters based on moisture and fineness of coal powder analyzed in
lab, so as to guarantee the fineness and moisture are eligible.
5.2.1 preparation before running
5.2.1.1 Inspect the system to see if the equipments are ready to be started up.
5.2.1.2 Make interlocking inspection; make sure that all equipments can be controlled
in CCR and ready.
5.2.1.3 Inform relevant workers before startup.
5.2.1.4 If air heater is used, inform site operator to check the storage of diesel oil
and clean the oil gun.
5.2.1.5 Inspect the level of raw coal bin and coal power bin. If raw coal bin is
insufficient, start up raw coal conveying group.
5.2.1.6 Inform lab to do preparation of sampling
5.2.1.7 Make sure CO2 extinguish system can be applied at any time.
5.2.1.8
Inspect the position
and action of baffle and gateInspection
valve. & Revision
No.
Procedures
5.2.2 startup sequence of pulverized coal preparation
1
Do preparation work
Make sure there is

material stored in bin.
Make sure coal powder bin can
receive coal powder
1 Make sure the bin is not
Full
2 Check the
content of CO in coal powder in .

3
Check the temperature of coal powder in.

Make sure the cooling water and
compressed air are supplied.
Make sure anti-explosion bag filter is

in normal condition.
1 outlet
bag filter temp. should not exceed

the limit
2
temperatur
1 material
e of
Check the position of valves
collected in the
Hot blast valves for material fed in mill are

hopper
closed. should not exceed the limit
2
Cold blast valves for material fed in mill are

opened fully.
7
valves are fully closed.

Fan1 inlet
start up coal
powder conveying system
Regulate fan inlet valve L21.FN12a .
Shift
hydra electro
tee
chute 2
Notice current of fan
L21.VV16 according to coal powder
in bin
2 start up screw conveyer
L21.SC14 L21.SC15
anti-explosion bag
(3)
filter L21.BF10
Start
up
high
concentration
4
Start
fan L21.FN12
startupup
8
9
10
11
12
heater at main reducer lubrication

station
start up clutch
start up seal
fan at grinding roller bearing.
start up Lv pump of main
check heater
check the mesh of
clutch.
check fan
check motor
main
reducer.
reducer,
and then the Hv pump of
start up heater at main
motor oil station, start up oil pump at
main motor oil station
check heater and

Motor
13
preheating of mill
1 Notice the
temperature of hot air into mill
Control the valves

slowly, let mill outlet
air and bag filter
inside
reaches
normal
working
temperature.
2 Let gas out mill rise to 65 75
3 Control negative pressure of air leaving

mill in
-5500~-7000Pa.
1 Open hot blast valve fully

L21.BT38 321.VM27
2 Gradually open main fan

inlet valve
L21.FN12a
14
15
After
Pre-heating,
be ready
start up
mill
Slowly narrow
cold toblast
valve
start up main motor
321.VM26
of coal
mill
16
17
Recheck the
oil system
check motor current, vibration,
thin oil station and cooling system.
stop
Hv oil
L21.BC04
pumo of main reducer
Start
conveyer L21.BC04
start up
upbelt
coal
mill conveying system
start
up
feeding
(1)
conveyer L21.WF02 or
L21.WF03
(2) Set feeding amount
Timely regulate feeding according to material

inside mill
belt
(3) start up fan L21.FN32
18
19
bag
(4) start up high
filter
L21.BF31anti
explosion
concentration
improve
output
pulse
Stabilize
feeding
meanwhile
regulate the
opening
of
stabilize production
fan
inlet
Input
valve,automatic
openingcontrol loop after
stabilization
of mill inlet
cold
blast
valve
reach required output

1 Air left from mill rises to 65 75
mill
Control the negative pressure of air left
2 at
-8000Pa
quality
conforms
design.
3temperature
Product of
Set
mill outlet
air atto70
5.2.3 control scope of parameters

5.2.3.1 260/300 Normal / highest temperature of hot air mill inlet
5.2.3.2 70/80 Normal / highest temperature of gas mill inlet
5.2.3.3 6000Pa Pressure difference of mill
5.2.3.4 75 Bag filter inlet temperature
5.2.3.5 65 75 Bag filter outlet temperature

5.2.3.6 65 Coal mill main fan inlet air temperature
5.2.3.7 Coal mill main fan inlet negative pressure 8000Pa
5.2.4 Inspection and revision in pulverized coal preparation system running

Regularly inspect the change of all measuring points and notice the running status.
Take proper and effective measures to deal problems.
Inspection and Revision
No.
Description
1
over feeding to
mill
Inspection & Judge
Treatment
1 The inlet and outlet sub
1 reduce the feeding quantity,
pressure of mill is overpressure
and small feeding should be

running for a period of time
2 Mill is over current

3 Main gear
box is overheat
2
feeding
quantity is
insufficient
4 High vibration
Pressure d i f f e r e n c e
b e t w e e n inlet and outlet mill
is less.
2 Stabilize each
parameter values about

feeding quantity after normal
running
Slowly increase the
feeding quantity till the parameter
value is normal.
2 Mill is over current.

3
Temperature
of gas out of
mill is over
high.
Temperature
of gas out of
mill is too low.
Air volume out

of mill is too
high
3 High vibration
feeding amount
lessens
Material
moisture
lessens
Mill inlet
temperature
1
over
Over feeding
increase feeding
Narrow inlet hot blast valve and
widen cold blast valve
Narrow inlet hot blast valve and
widen cold blast valve
1 lessen feeding
2 widen inlet hot blast

2 Material moisture increases valve and narrow cold blast valve
widen inlet hot blast
3 Mill inlet temperature is low 3
valve
and narrow cold blast valve or
reduce feeding
1 L21.FN12
L21.FN12a
L21.BF10
Decrease inlet valve
opening
2
Exhaust gas amount is high
Check condition of the bag

6
Pressure gauge displays

Insufficient
pressure of
thin oil station
Negative
pressure of
bag
filter L21.B
F10
is over high
filter
Check oil pipeline, oil level of oil
tank, oil pump
Accumulation at pipes
1 Narrow fan inlet valve
Inform site operator to dispose it
Dust bucket
of bag filter
L21.BF10
1 Dust
1 Inform site
accumulated at dust bucket
operator to dispose it.
2 dust bucket gets fire
2 Stop and extinguish fire.
10
Gets high
fineness of coal Fineness analysis in lab
temperature
powder
little high of
coal mill
moisture
water analysis in lab
Hand control
separator rev or opening of main
fan
Properly reduce feeding or rise
feeding temperature.
5.2.4.1 safety inspection in running

5.2.4.1.1coal mill
A. Coal mill outlet air temperature shall keep at 70 75, not exceed
80.
B. Notice fineness of coal power, reduce over grinding.
C. When coal feeding is over high or over low, closely monitor
the operating parameters in case of accidents.
D. Inspect at intervals and pay attention to the free of chute.
5.2.4.1.2 Other equipments, bag filter dust bucket and conveying machines shall be free
of block.
5.2.4.1.3 Pipes: process pipes and dust collecting pipes shall be free of block.
5.2.5 Refer to the normal operation procedures of shutting down the coal
pulverization system.
No.
Procedures
Well prepare for the

system shut-down
Switch the loop regulation of gas temperature out of

the mill to manual regulation
3
4
Lower the feeding

Lower the hot air and add up the cold air to make
the gas temperature at the mill outlet drop to 65
.
operation of valves as following

1 Gradually turn
down the inlet valve of blower

2 Gradually
turn up the coal air valve of mill
Inspection & Revision
shut down the feeding system

Set the feeding at 0 L21.WF02
L21.WF03 shut down coal constant

feeder(L21.WF02
L21.WF03)
3 shut down belt
6
7
8
9
10
Inform
theraw
coal
conveyer
L21.BC04
agravic silo of stopping feeding
stop the mill when material inside lessens
gradually narrow the
damper of main fan
L21.FN12 stop fan L21.FN12
L21.BF10
stop high concentration ant explosion pulse bag

filter
11
12
13
Notice the vibration of mill when it

stops
close all electrical valves.

check and make sure there is
no accumulated coal powder in
dust collector.
Stop coal powder conveying system 10m later.

L21.SC14 L21.SC15 Stop screw
conveyer L21.SC14 L21.SC15
.
stop the thin oil station of coal
mill
Make thorough inspection.
5.2.5.1 Inspection of safety before and after the shut-down.

5.2.5.1.1 normal shut-down
a After coal mill stops, discharge the coal powder in bag filter and
conveyer
and then stop fan and conveyer.
b If it would stop over 3 days, the coal powder bin must be emptied. If it would
stop over 15 days, the raw coal bin must be emptied too.
c When coal feeding lessens, the waste gas at outlet shall not exceed 80.
d After coal mill stops, timely regulate the baffle of main fan or stop it.
5.2.5.1.2 Emergency stop

a The constant feeder comes in an emergency shut-down, the
temperature
at the coal mill outlet should not exceed 80. When the shut-down lasts
more than 10mins, then stop the system following the shut-down sequences
as it is under normal condition.
b The coal mill comes to an emergency shut-down, the temperature at the
coal
mill outlet should no exceed 80.
c When the blower of the coal mill comes to the emergency shut down,
temperature at the mill outlet, each conduit and bag filters, etc. should be closely
watched up, and should not exceed the alarm values. If the temperatures keep
shut-down, mill and blower should stop too.

5.2.6 malfunction andtreatments to emergency shut down of pulverized coal
preparation
When there are emergencies like motor tripping, sudden cut-off raw coal
supply,
jamming, over-heated pulverized coal silo or dust bucket of coal mill explosion proof
bag filter come up, then see following table.
Table of treatments to malfunction and emergent shutdown
Failure
Phenomenon &
Causes
No.
belt
conveyer
L21.BC04 L21.
L21.WF03
motor tripping
or belt off-tracking
Disposals
1
Equipment on the system keep

running except the mill.
Belt
conveyer L21.BC04
or
constant feeder
L21.WF02/L21.WF03
3 If it is not be restored
in a shirt time, shut down other
equipment in the normal sequences
L21.RM06a thin
oil station
(L21.RM06) coal mill
Lower
airair
and
add upthe
thehot
cold
to make the gas
temperature
at the mill outlet drop to
65.
and
constant
Coal mill
general malfunction
feeder shall immediately
and breakdown
interlocked stop.
motor trip
1 Due to interlock in
workshop, immediately shut down

the constant feeder
Quick
3
ly
open
up
the
cold
air
valve
into
the
mill,
keep
the
temp
eratur
e of
gas out of the coal mill under 65.
Shut down other equipment in the

normal sequences after stop the coal
mill.
coal
feeding cut off
head
is jammed.
1
Mill
bin
2
Slid
e into the mill
fire in
becomes jammed
1 quickly open up the cold
blast
valve at head of the mill, keep the
temperature of gas out of the coal
mill under 65
2 inform
site
vibrate operator
greatly, stop the mill.
to
dispose
it.CCR shall
be
immediately
1 Find out the
regulated. If it
is empty in
mill and
3 If the chute is blocked, clear it
up.
No.
Failure
Phenomenon &
Causes
Mill
fire source.
1 The gas at
2 L21.BT38 L21.VM08
mill
outlet is over 80.

2 CO content
Rises
(L21.FN12 blower
Disposals
motor trip
Stop the mill immediately, close inlet

valve
L21.BT38,and
valve L21.VM08
at coal mill outlet.
pneumatic
3 Extinguish CO2 to mill.
1 L21.RM06
L21.BC04
L21.WF02 L21.WF03
Due
to
interlock,
(L21.RM06),
belt
coal
mill
conveyer
L21.BC04 and constant feeder
(L21.WF02 or L21.WF03) shut down.

valve
2 into the valve, and open cold
Immediately close up the hot air
motor trip
L21.SC14 L21.SC15
screw conveyor
for
pulverized coal
7
L21.BF10
Anti explosion bag filter
Alarm for climbing

gas temperature out
of
the
mill:
pulverized coal pile
self-ignite
air valve in the mill, to know down the

gas temperature entering the mill
Stop
other equipments in
1 The up part rotary down
stop sequence of fan.
feeder
interlocked stops,
inform
site
operator to dispose it. If it could not
start up in 5m, stop the mill.
operating parameters
regulate the
(2) Timely
1 According to the alarm, turn
up
the cold air valve into the mill, to cool
down the temperature
(2)Put the coal mill system to an
emergency shut-down when a fire is
CO2 into close
the bagup
filter
spotted,
the inlet valve
L21.VM08 of bag filter, and let
Failure
No.
L21.BF10
Anti explosion bag filter
Phenomenon &
Causes
Alarm
when
content rises
CO
1 According to the alarm,
check
2 C content keeps climbing,
out the fire source.
O
shut down the coal mill system
filter after spot the fire source.
immediately, let CO2 into the bag
L21.BF10
anti explosion bag filter

10
agravic silo of
pulverized coal
11
agravic silo of
pulverized coal
Alarm when
the
temperature
of
pulverized
coal in the
dust bucket
rises
Alarm for climbing
temperature in the
pulverized coal mill:
pulverized coal pile
self-ignite
Anti explosion
valves
1 Coal mill comes
to an emergency shut-down
2 timely close up the baffle at
inlet and outlet of bag filter

3 Extinguish the fire with CO2.
1 Coal mill
comes to an emergency shut-down

2 Close up the screw valve gate
at
the silo base.
3
Leaking
pulverized coal from
its silo
pulverized
coal silo is fed under
positive pressure
12
13
Disposals
Extinguish
firewhether
with CO2the
when
upper
1 Findthe
out
a fire is spotted.
dust
collecting pipe is blocked,
hammering can be applied to verify.
Chec
k the
coal
anti feeding and sensor.
explo
2 som
sion
valve
e
at the
coal
silo
explode to
top,
Explosion
deform theproof
and
1) Coal mill
valve
flanges andplate
wheth
system comes to an emergency
breaks,
so on and gas
er
the
shut-down
and pulverized
valve
3leakage
Coal
coal
or
2 Cleaning away the

plate
powder
explosive
sounds are detected escaped
is
fills the bin.
broke
pulverized
coal
by the visitatorial n
3 inspect the actual situation of
No.
Failure
Phenomenon &
Causes
inspector
Disposals
3 Make sure
onsite
whether
there is fire in the equipment, timely
gh
temperature
on use CO2
discharged
coal extinguisher
discharge
mill and bag and
filtering
system,the
findfiring
out
powder or product is pulverized coal and then inspect the
excessive fine.
Repair the broken antiexplosion
the causes.
1 Hi
2 Temperature
of
Replace the flange if it is damaged.

valve, and replace the valve plate.
gas into the mill is

too high
ignite
happens
coa
powder.
4 Hi
necessary
emergency shut-down
14
Selfto
1 The system
All
equipment comes to an emergency shut-down
gh
comes
an
temperatureto
or
2 Close up all
emergency
sparks caused
shut-down
3electric valves
by equipment friction the
Monitor the pulverized coal silo

and the temperature of the bag filter
closely
Chapter 6 Precautions in test run and normal production

This chapter introduces the failures and disposals of burning system and
pulverized
coal preparation system in test run and production.
6.1 Precautions of burning system in test run and production
6.1.1 Schedule and purpose

6.1.1.1 Schedule
After all the equipment are installed as well as single machine trial running and linkage
trial running are finished, check all the equipment thoroughly, then carry out the trial
production after confirmation.
6.1.1.2 purpose
Unload running
is very important
for running-in of
the
bearing,
gear and the
associated
The cooling system of host equipment
B
Abnormal touch between moving parts and fixed parts
running
parts
C
installation accuracy
with gear. Equipment
In
order D
to avoid
6.1.2
the preparation
following
failures
during
After a complete and detailed check, the following preparation work must be carried
feed and trial
out.
process,
a
thorough
6.1.2.1 In pouring lubricating oil
examination
Before
pouring lubricant to kiln and lubricate device of ID fan, acid washing and
must bein carried
out:
water washing are used to clean the lubricate duct inside,as well as inspect inside
carefully.
In pour
proper
to the oil box according to the demand of
oil amount
supply tolubricant
each equipment
A
Lubrication
themselves.
As to the lubricating
lubricant according to
sites of other equipment, they also need in pouring

demand of themselves.
6.1.2.2 Inspecting on the system seal

The air leak into system should
be strictly controlled, which is in
order to
assure the normal work of kiln
therefore the easy leak part should
be checked
carefully.
6.1.2.3 Gist for test run
6.1.2.3.1 single equipment
Test run on single equipment means examination on each equipment by PCcontrol
(without equipment is permitted).Firstly, shift the switch from local control to room
control, and then PC drive the equipment compulsively and stop machine onsite.
During the process, check the following points:
A. signal ready
B. drive devices whether correct or not
C. response signal
D. fault alarm
E. correspondence to motor indication
6.1.2.3.2 interlocking test run
After test run on single
equipment, interlocking test
would take a remote control on
run shall be carried out then.
CCR
equipments
or not.
it, necessary tests as well. Test run may contain
A.Take simulated failure-test on each equipment. Check whether the

programmed interlock is correct or not.
B. Carry out the interlocking test on protection joints of simulated stress and
temperature equipment and so on.
C. Check the expansion setting about the open and close. D.
Check whether the emergent stop works or not.
6.1.2.4 Notices in production
6.1.2.4.1 Quantity of clinker
6.1.2.4.1.1 Ingredients of raw meal
The raw meal component influences the clinker quality; stabilize the raw meal
component according to the demand of cement quantity.
6.1.2.4.1.2 current of kiln drive motor
The current of kiln drive motor may provide the most definite information so as to
comprehend the calcining state whether or not normal. See the following items from
current.
a Under normal running state, a certain feeding amount will let the current keep a
certain range and stabilize, so its better to control the best current and
fluctuation range.
b current falls, calcination is bad.(turn out un burnt or overheat, in

liquefaction)
c When the current rises, over calcine (the time of material calcining is too
long).
If the b and c items occur during the stable running, commonly it is aroused by
the change of material component and coal grade.
d Current goes up suddenly and fluctuation range is rather large,which
shows
the kiln crust.
6.1.2.4.2. Continuous
operation
and
stable
6.1.2.4.2.1 Failure prevention

As the kiln stops, thoroughly check will prevent mechanical failure. Inspect and record
running state of mechanism during operation.
6.1.2.4.2.2 stable operation
There are many factors to influence the stable running, but the stabilization of raw
meal component and quantity is most important factor. If the raw meal component and
quantity are stable, the kiln running is just a transportation equipment at some degree.
The next is proficient operation, correct judge and calcining state process.
6.1.2.4.2.3 Accretions prevention
As to kiln, proper amount accretions may protect kiln liner and cut down radiation. As
to pre-heater, bad ventilation and cyclone blocked up caused by skinning should be
prevented. In order to prevent excess accretions, pay attention to the following items:
a. raw meal component The stable supply of raw meal is very important(raw meal
component and raw meal amount).
b. Kiln inlet CO: due to the bad calcination, CO at kiln inlet increases, which is the
cause of accretions in cyclone and calciner. Therefore, in order to keep a good
calcining, target value maintaining about 4 6 of O2 concentration at C1 outlet
during the operation and CO and O2 concentration regular measuring are a must.
c. kiln inlet temperature Sudden rise of temperature will result in accretions at slop
of the kiln inlet.

d. calciner outlet temperature The temperature is too high and cause excessive
accretions.a. The coal powder calcining is inadequate.

Raw
material
component
and feeding
quantity
6.1.2.4.2.4b.The
following
situations
will block
the cyclone
andchange.
calciner.
c. Pre-heater rises in temperature abnormally.
d. Flap valve is not flexible.
e. The accretions on inner pipe or down pipe
f. of cyclone falls off. The accretions inserted
to calciner
laryngeal
fallblocking
off.
6.1.2.4.2.5 method
of finding
out the
at cyclone and calciner.
a. Pressure of cyclone cone is a little low (find out quickly).
b. Down pipe of cyclone is a little low in temperature (lag)
c. accretions inserted to calciner laryngeal or smoke chamber at kiln inlet
fall off, the subpressure at kiln inlet reduces,the kiln outlet presents plus
pressure and spits back.
d. One of the cyclone is blocked, the gas temperature of the next
connected
cyclone at outlet will rise.
6.1.2.4.2.6 the disposal to block at cyclone and calciner
a) Check the material flow from the inspection hole of cyclone material
chute, judge the blocking equipment(cyclone or calciner),and then cut off

the raw meal and fuel supply, while the kiln
rotation speed drops to the
b)
lowest point. Prepare clearing tool and
c) measures at site.
clear up from down to up, or set water
cannon or compressed air.
d)
it must assign special person to command
and operate, forbid personnel
working at kiln inlet and kiln outlet where the
6.1.2.4.2.7 safety precaution
material leaks. Guarantee
a) Check the accretions. When personnel
carry out accretions
clearing, dont stand in
safety.
front of the clearing hole so as
to
prevent
the
hot
gas
After clearing up, do ballblowing.
test to pre-heater
the
sake
of
safety,
when
clear
the
clearing
hole,
close
other clearing
b) For
and then fire it to rise
hole and forbid the simultaneous
work of the above and lower clearing
temperature.
hole.
c) The number of clearing person must be the minimum, forbid any person
stand at the following stages in case of danger.
d) When clear the pre-heater, forbid any body stand at kiln outlet and the
manhole of grate cooler in case of danger.
6.1.2.4.3 clinker output
6.1.2.4.3.1 raw meal supply quantity
Clinker output is proportion to feeding amount. Adjust the clinker output by feeding
amount control, but it is hard to operate when the producing capability is under
70%,the continuous and stable running is hard to ensure. Is diseconomy for loaddropping run.
6.1.2.4.3.2 Fuel supply amount is proportion to feeding quantity.
6.1.2.4.3.3 The raw meal components directly influence the continuous running and
throughput, therefore, it is necessary to analyze regularly and change the proportion.
6.1.2.4.4 heat consumption
If raw materials and fuel have stable components, kiln system works normally and
raw meal is highly fed, clinker output would be high, unit consumption of coal and
power would be low and unit production costs would be low.
6.1.2.4.4.1 amount of raw meal and fuel
In production, guarantee the proper proportion of air, coal and materials.
Firstly,
ensure the proper calcinating rate of material into kiln, and combine with components
of raw meal and coal powder, f-CaO and liter weight of clinker to judge the burning
inside kiln and estimate the coal dosage and guarantee the clinker would be burnt
properly.
6.1.2.4.4.2 ingredients of raw meal
It influences the heat consumption directly. Regulate it according to the clinker target
value.
The O2 at C1 exit,calciner exit and kiln inlet
According to gas analysis meter to analyze O2 C1 outlet, also regularly analyze O 2

at calciner outlet and kiln inlet, which help to find out the best density of O2. Set the
best density as target value in running, and regulate the fuel quantity and air
volume to maintain the best state. The bad calcining reasons as follows:
a) For a certain fuel, air capacity is insufficient.
b) Pulverized coal nozzle injury
Low temperature of secondary air into kiln
c)
Low grade of coal, supply quantity fluctuates.
d)
Large-size of fine coal power, high moisture.
e)
6.1.2.4.4.4 The gas temperature at pre-heater outlet and calciner outlet.
The gas temperature at C1 outlet is lower, the heat exchange of pre-heater is
better.
In
order
to maintain
pay attention
a.
b.
c.
d.
e.
f.
the
exchange
of pre-heater
and
collecting efficiency,
to the following items:Bad preheat by the bad action of flap valve

Distribution plate is bad to raw meal disperse
Gas flow changes
Abnormal airflow caused by accretions
Distortion of cyclone
Prevent from air leakage.
The air leakage of cyclone and calciner will cut down the gas temperature, and is bad
for the heat exchange, which affects the hourly output and increases the heat
consumption.
6.1.2.5
Management on running equipment
The calcining system is affected by many factors, therefore, the operation parameters
must be known by the operator at any time.
6.1.2.5.1 Estimate the following situation by each point temperature. a,
material flow in the pre-heater and calciner
B burning of fuel and calcining of clinker
C Calcining rate of the raw meal into kiln
6.1.2.5.2 Comprehend the following situation from the pressure at each point.
A Accretions at kiln, preheater and Calciner
B Judge the block in cyclone and feed down pipe
C Judge the using of air, to be the basis for optimizing system.
6.1.2.5.3 the main motorent current of the kiln Comprehend the following situation
from motor current
A Calcination of materials in kiln
B, Accretions and filling rate in kiln

6.1.2.5.4 The measurement of O2 and CO is helpful in charge of the calcination
state in the kiln and calciner as well as the air and fuel used to calcine.
6.1.2.5.5 Chemical analysis value, liter weight, f-CaO of clinker
The above values may help to comprehend the running status, and then judge,
regulate.
6.1.2.6 operational gist in operation
Good command of the controls parameter is helpful to stabilize the kiln. The
following operation is available.
6.1.2.6.1 Regulation on raw meal feeding supply: adjust the feeding supply to go right
state.
a Calcinations aggravation: raw meal components change, kiln crust fall off
greatly.
b Aeration volume is insufficient: it is hard to recover in short time when the fuel
cant be added.
6.1.2.6.2 regulate the fuel quantity
a When the calcinations worsen little, adjust the fuel quantity properly.
b When the calcinations worsen greatly, adjust the fuel quantity according
to
raw meal supply.
6.1.2.6.3
Regulation on aeration
Control air volume when fuel quantity changes.
6.1.2.6.4 regulation on rev of rotary kiln
a W hen the calcinations worsen, lower the rotation speed of rotary kiln,by
this time, the raw meal layer go thick and ties, so it is necessary to cut down
the material feeding amount.
b If calcinations is bad, adjust the feeding amount and fuel amount basically.
Sometimes adjust the rotation speed of rotary kiln is permitted, which will
change the material layer thickness accordingly, therefore, pay attention to
practical operation.
6.1.2.6.5 The pulverized coal duct site and regulation on air inside and outside
a If the black plume head of burning is long, the calcination is bad.

Adjust the air inside and outside with attention to the kiln crust.
b The installation place of pulverized coal duct should be set well because of the
coal powder tube hardly has any degree of freedom.
c Adjust the raw meal componentsBy chemical analysis of clinker, finally decide the
raw meal component calcined easily which is good for improving the
system running rate and output, as well as stabilize the
ratio.
6.1.2.7 Guidance for operation
6.1.2.7.1 general rule
Material feeding amount meets the requirement. If the material feeding amount
and coal feeding amount change a little and steady at this time, the calcining system
may
reach the best running state.

a Adjust each part slowly to meet the best.
b Good preparation is used to deal with failure at each part rapidly.
c Write down the operation record earnestly, which provides reference

and enhance the efficiency.
6.1.2.7.2 Guidance for operation
The tenets are that keep stabilization and balance of Heat-producing capability and
heat-transfer capability as well as sinter capability and preheating capability. Carry
out the following points in running:
a considers the former and the latter
b calciner corresponds with kiln

c steady sinter point and decomposition temperature
d steady thermal condition of kiln and calciner
In order to keep a proper thermal condition, at first, stabilize the temperature at the
two ends of kiln and calciner inside. Kiln in correspondence with calciner depends on
aeration, coal feeding and material feeding.
The normal operation includes stabilization of the kiln temperature, the former and
the latter consideration, proper use of air and coal, flame lengthening and regulation
on flame shape and position. Not to destroy the kiln crust. Achieve high production,
high quality and low consumption.
The normal operation of calciner needs to regulate coal quantity and air volume in
time, and keep stabilization of the gas temperature at outlet and inside the
kiln.
Strictly control the variety of the temperature and pressure, keep aeration free and
prevent the over high or over low temperature in order to ensure the sound
operation.
6.1.2.7.3 conclusion
The normal operation should conclude: fastness, stabilization and consideration.
6.1.2.7.3.1 fastness
a )fix the kiln rotation speed
b) fix the feeding amount
c
fix the thickness of material layer of clinker on the grate plate
6.1.2.7.3.2 stabilization
a )stabilize the gas temperature at claciner outlet(feed coal)
b )stabilize the exhaust at the primary cylinder outlet(rev of high temperature
fan)
c )stabilize the temperature at firing zone(coal fed amount)

d)stabilize the kiln outlet pressure(opening of inlet valve of kiln outlet fan)
6.1.2.7.3.3 Considerations
a)Consider O2 content at kiln outlet and gas temperature
b ) consider the gas temperature and pressure at primary cylinder
outlet
c()Consider the gas temperature and pressure in
calciner
d()onside the shell surface temperature
e )Consider the exhaust gas quantity of grate cooler
f )Consider exhaust gas process and dust collecting system

6.2 Precautions in Test Run andProduction of Pulverized coal
preparation
Conduct the following is a must after careful and thorough inspection on all
equipments.
6.2.1
filling of lubrication
Clean the lubrication unit

and carefully examine
the inside of machine,
and pour
proper lubrication into
the tank according to
the mill introduction,
until reach the
directory of the level
gauge. Too, clean and oil
up the lubrication unit of
gear box of
mill as required.
Clean and oil up all the lubricated parts of other equipment.
6.2.2 inspection on seal part
Strictly, control the cold air leaked into the system so as to keep the coal mill system
working in good condition. Therefore special examination to the parts where is
air leaky is a must.
6.2.3 Gist of Test Run
Test run is an important stage for future production, so treat it
seriously.
6.2.3.1 single commissioning
Test run on single equipment means examination on each set of equipment by PC
controlling. (without equipment is permitted). Firstly, shift the switch from local control
to room control, and then PC drive the equipment compulsively and stop machine
onsite. During the process, check the following points:
d failure alarm
e motor corresponding to the

direction
6.2.3.2 interlocking test run
After the single commissioning, the interlocking commissioning can start, which
is controlled and put into essential tests by the CCR.
a Put each set of equipment into mockup malfunction test, to check out
whether the sequence interlock is correct.
b Put the protected connectors of equipment of pressure and temperature etc.
into mockup interlock test.
c Check the time-lapse setting for normal startup and shut-down.
d Find out the emergency shut-down can work or not.
6.2.3.3 load commissioning
a After debugging and associated confirming during the
combined
commissioning, the mill can go into load working.
b In order to prevent pulverized coal from accumulating at the
air duct, fill the
coal mill with 6 8t dry limestone, and keep the system running for around
30mins before stop it, and then empty the pulverized coal silo of the
limestone
powder. Feed in raw coal and put the system into normal load commissioning
after a brief cleaning of the inside.
After thec
commissioning
each
is finished,beput
theofinside
of bolts,
mill into
During each of
stage
of stage
commissioning,
ware
the liner
milloverall
gate
bolts, Check
whenever
stopthere
the mill
and fasten
them,
examination.
andthey
find go
outloose,
whether
is heavy
damage
at or
thethere
grinding disc
is
and roller, and whether the fastening bolts inside go loose, break and fall off and
possibility of liners falling off.
whether the welded parts beak off or not.
d At the beginning of mill running, add up the feeding capacity by 12t/h until reach
the required value, and meanwhile pay attention to the mill current.
e Possibly shorten the storage period of pulverized
coal.
6.2.4 precautions in production
6.2.4.1 material supply
a Keep on the raw
coal feeding when the
mill
is running,
and
periodically look
into the bin levels and
feed in timely to
prevent the raw coal
supply from turning
off.
The product fineness can be adjusted by the regulation of the separator rev and
system fan input.
6.2.5 safety precautions
6.2.5.1 safety precautions of system
a To prevent coal powder from escaping, all the equipment runs under zero
pressure or negative pressure as designed. And the machine should be
immediately shut down if the pulverized coal escapes accidently or is
taken
out during the sampling. No pulverized coal accumulated in the equipment.
b Possibly avoid mechanical impact and friction, so as to prevent from fire
and explosion.
c CO2 fire extinguisher is designed to prevent fire and explosion in the
pulverized coal silo and bag filter. Use CO2 to dilute the O2 in the pulverized
coal silo or bag filter down under 12%. Generally, when the pulverized coal
in
the silo or bag filter is more than 80 or the machine comes to an
emergency shutdown, if the pulverized coal remains in the equipment for more
than 3 days, let in CO2.
d There is explosion proof valve set on the bag filter and pulverized coal
silo. When the pressure in the equipment climbs (generally speaking, around
10000Pa), the valve plate of explosion proof valve go broken automatically, to
release pressure and prevent the equipment form damaging.
e The process ducts or dust collecting pipes are inclined with high air speed to
avoid dust settlement at some degree. We set heat preservation coating at
external wall of pipe which avoids condensation of moisture and prevents
from
dust adhesion inside pipes.
6.2.5.2 fsafety
precautions
equipments
connectingofslides
between each set of equipment should be set in a
The
acertain
Coal
mill:
as
for
the
varying
feeding
fortothe
calciningare
system,
slope, and at the slides
where coal
material
is easy
accumulate
set
with
poking
holes
and
inspection
gates
etc..
And
clean
them
often
to
prevent
the
coal or pulverized
coal
accumulating
in the
slides.
constant
feeder can
be from
regulated
and control
the
feeding capacity of the coal
mill,
thereby it can prevent instability and danger in the operation caused by
sufficient or
insufficient pulverized coal. The drying source for the mill is from the outlet of
preheater high-temperature fan. At the air inlet of the mill is set with cold-air
valve
as designed, which can control the air temperature at mill inlet. Under
any
circumstances, temperature of air into the mill should be under 350, and the
temperature at the mill outlet should be between 70 75, and under 80.
b Bag filter: explosion-proof contributes the safety of the bag filter. W hen
the dust buckets temperature exceeds the alarm value during the running, it
c Pulverized coal silo: the pressure sensor set in the pulverized coal silo can directly
indicate the weight. The pulverized coal should be kept at a certain
extent during the normal operation, thereby to prevent mistakes in operation
caused by sufficient or in sufficient pulverize coal storage.
6.2.5.3 precautions
6.2.5.3.1 inspection precautions
Inspect every 2 hours and stick to inspection even if the equipment stops, pay
attention to following items:
a) whether there is leaking coal or pulverized coal
b whether there is fire in the shop
c Clean the shop and whether the pulverized coal accumulates
d whether the equipment becomes heat due to the collision of the helix of
the screw conveyor and the housing and abrasion of bearings or other causes
e prepare enough lubrication to prevent equipment from heating up
f whether the valve plate of explosion-proof valve is broken
g whether the chute is jammed.

6.2.5.3.2 cleaning
Cleaning and keeping a clean system job should be carried out always no matter the
machine is shut-down or at work. Cautions for the cleaning are: (a) clean it after
watering, make sure the pulverized coal is not stirred up again, (b) do not use
compressed air cleaning the floor, (c) cleaning inside of the equipment should be
conducted after it stops. Pulverized coal powder in the equipment should be cleaned
away thoroughly.
6.2.5.3.3 No fire
No fire in the shop, no smoking in the shop, and no gas-welding, gas cutting and using
grinding wheel that can produce sparks in the shop. Thoroughly clear away the
surrounding coal and pulverized coal, when using tools mentioned above become
inevitable.
6.2.6 Safety inspection before operation
a Safety inspection after a
long-term
shut-down:
make
sure
there is no
pulverized coal or odds in the
pulverized coal silo, bag filter and
transportation
equipment,
and check
out
whether there is piling of coal or
pulverized coal.
b Safety inspection after a short-term shut-down: make sure there is no
pulverized coal in the transportation equipment.
c Blow-down: in order to prevent explosion during the start-up,
When any fire spark is spotted in the pulverized coal silo or bag filter, and
temperature constantly and strangely soars, the following measures must be
conducted to prevent heavier casualty.
6.2.7.1 fire in pulverized coal
silo
a Stop coal feeding to the pulverized coal silo.
b Stop the transportation equipment at the silo outlet, and close up the
screw
valve gate at the silo base.
c Jet CO 2
d Make sure the temperature of the pulverized coal silo has dropped below
80.
e Inspect inside the pulverized coal silo.

6.2.7.2: fire in bag filter
a Stop the blower
b Quickly close bag filter inlet valves.
c Jet CO2 inside.
d Make sure the temperature of the dust bucket has
dropped
below 80.
e Inspect inside of the bag filter.
6.2.7.3
equipment
Safety
measures
before
inspection
in
In order to eliminate the potential causes of fire or explosion and possible fire spark,
piled-up pulverized
conducted
coal
in
the
equipment,
internal
inspection
should
be
after the equipment stops.

a Wear safety devices
b Use explosion-proof portable lamp or flash light and fire

is
forbidden, when lighting-up is needed.
C,Examine carefully the pulverized coal silo and in the equipment to make sure
there is no piled-up coal powder or any attachment and especial no any
fire spark.
d
Due
to COof
volatile gas
of the
coal,
the and be
the
designs
fire-fighting
should
base
onoxygen
safety inside
regulations,
6.2.8.2 All of
2 and
examined
and maintained
regularly,
soitas
dodangerous
well when needed.
equipment
shall decrease,
and
willtobe
to enter and maintain in the
equipment for lack of oxygen. Therefore, it should be aerated beforehand,
having the oxygen more than 18%.
6.2.8 Preparation and maintenance of fire
facility.
6.2.8.1 There must be equipped with enough fire-extinguishers and other fire

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3000t/d Cement Projectof National Cement Share Company,Ethiopia

3000t/d Cement Project of National Cement Share

3000t/d Cement Projectof National Cement Share Company,Ethiopia

CHAPTER 2 PROCESS FLOW AND EQUIPMENTS........................................ .4

CHAPTER 5 STARTUP AND

FOR PULVERIZED COAL PREPARATION SYSTEM ........................59

CHAPTER 6 PRECAUTIONS IN TEST RUN AND PRODUCTION .......................72

3000t/d Cement Projectof National Cement Share Company,Ethiopia

ranges from raw meal homogenization silo bottom discharging to

3000t/d Cement Projectof National Cement Share Company,Ethiopia

Chapter 2 Process Flow and Equipments

air slide discharging system is

side discharging system 331.SQ18 331.SQ19 to be discharged out and weighed

stage cyclone(C2) and enters kiln inlet preheater 411.PR08 .

separator 321.CS10 to be classified and then to be conveyed into air converting

3000t/d Cement Projectof National Cement Share Company,Ethiopia

321.CV34 321.CV37 and

through chain conveyer

conveyer 321.CV39 together, and then through bucket elevator 321.BE40

3000t/d Cement Projectof National Cement Share Company,Ethiopia

filter 431.BF28 and then discharged out via fan 431.FN29 .

coal feeding system L21.RF23 , F-K screw pump L21.SP24 and be

coal feeding system L21.RF20 , F-K screw pump L21.SP21 and

to coal powder bin L21.VV16 or L21.BI22 .Waste gas, purified, is discharged

3000t/d Cement Projectof National Cement Share Company,Ethiopia

.2.1.1 technical performance

2.2.1.2 General introduction and working principle

3000t/d Cement Projectof National Cement Share Company,Ethiopia

2.2.3 Technical parameter in normal production

fuel coal or heavy oil

3000t/d Cement Projectof National Cement Share Company,Ethiopia

air volume 200000m 3/h

2.2.3 the third generation grate cooler

Main technical data

Tertiary air temperature C

Material thickness (mm

Main technical data

Efective area of grate plate m2 88.8 m2

Grate plate stroke (time/ minute)

Grate plate stroke (mm

3000t/d Cement Projectof National Cement Share Company,Ethiopia

working principle and construction features

3000t/d Cement Projectof National Cement Share Company,Ethiopia

aeration beam), this area includes three rows of

discharged end by the chain conveyor fixed on the lower part of

3000t/d Cement Projectof National Cement Share Company,Ethiopia

The grate cooler adopts centralized lubrication system.

Maintaining a stable sub pressure of the kiln outlet is to ensure necessary

3000t/d Cement Projectof National Cement Share Company,Ethiopia

feeding size 50mm

coal powder fineness 0.080mm 8% 10% square screen sieve

volt. 6kv jigger

classifying efficiency >90

control three phase asynchronous motor): UP2250M-8

oil station of main reducer:

3000t/d Cement Projectof National Cement Share Company,Ethiopia

nominal pressure 0.4 MPa

oil supply temp.:403

water pressure:0.2 0.4MPa

3000t/d Cement Projectof National Cement Share Company,Ethiopia

Location of gate of tee chute

Temperature of inlet of high temperature 350

3000t/d Cement Projectof National Cement Share Company,Ethiopia

thin oil station of