Three different plants, one common problem, three different root-causes.

Common issue: Snowman formation. 

Root cause in Case#1. Static Grate fans RPM were less. 

Why: Because of wrong O/load setting, CCR couldn't increase the speed. 

Action taken: O/load setting reset and problem solved [2018, 1350TPD plant].


Root cause in Case#2. Frequent temperature spike in kiln + preheater due to uneven coal dosing. 

Why: Uncontrolled coal firing due to coal flushing through Feeding screw.

Action taken: Barrel of screw was modified with a simple solution. Temperature controlled and problem solved [2022, 2300TPD plant]. 


Root cause in Case#3. Air Blaster purging pressure was less. They were not being fully charged.  

Why: No header for air blasters. 1/2" line from main pipe line and tapping of the same size for 12 nos. of air-blasters (sounds funny but such things happen). 

Action taken: Supply line upgraded. Header provided.  No snowman after that [June-2024, 5500TPD plant].

Same problem but different root-causes in three different plants.

In case#1 and case#2, the actions have not only resolved the Snowman issue, but they improved the plant operation dramatically. 

Please add your experience in comments.

Thanks.

 


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