Sawan Jasoliya

Kiln Back-End Temperature: The Heartbeat of Clinker Quality and Kiln Efficiency Having visited several cement plants across India and abroad, I’ve consistently observed that precise control of kiln back-end temperature, ideally at 1050°C, is the heartbeat of clinker quality and stable kiln operation. A fluctuation of just ±30°C can disrupt the entire pyroprocessing line. When this temperature drops below 1020°C, calcination falls under 90%, leading to unburnt raw meal, high free lime (>1.5%), reduced C₃S (<60%), and a 5–10 MPa drop in cement strength.  It also causes sticky deposits, chokes cyclones, and leads to unscheduled stoppages. On the other hand, temperatures above 1080°C promote alkali volatilization, ring formation, unstable O₂ levels, and higher CO emissions. Refractory linings suffer micro-cracking, shortening their life by up to 20%. Recent technological advances offer solutions. In 2025, leading plants are using hybrid AI systems with physics-informed neural net...

Problem Statement: The  belt bucket elevator (BBE)  feeding the kiln is  getting swayed during operation , leading to operational instability, potential mechanical damage, and interlock tripping. Objective: To achieve  stable, variation-free kiln feed , ensuring the  belt bucket elevator runs smoothly without sway , and preventing unnecessary shutdowns and mechanical failures. Action Plan: Step 1: Immediate Running Condition -> Controlled Operation Bypass the tripping interlocks  temporarily, but keep the elevator under  strict manual supervision. Continuously monitor  the elevator's operation during this period. Manually adjust  the elevator through tensioning device until relative stability is achieved. Restore interlocks  once the system behavior is stable and predictable. Step 2: Inspection of Material Discharge to Elevator Check material discharge ...

For cement plants that do not have advanced coal dosing systems such as Pfister, Coriolis, or Multicore, traditional coal feeding systems still dominate operations.  These include: Venturi-Based Coal Transfer and Firing System,   V1 – A successful project. FK Pump-Based Coal Transfer and Firing System, F1. FK Pump-Based Direct Coal Firing System, FD1 –  Two successful projects. Challenges in Traditional Coal Feeding Systems In these setups, coal transport starts when the coal firing bin reaches its lower limit and stops when it reaches the higher limit. However, this method introduces several challenges: SFM Draft Variation: Sudden coal transport starts and stops create fluctuations in the SFM (Solid Flow Meter) draft, leading to inconsistent feeding. Bin Pressurization & Flushing: During transport, the coal firing bin gets pressurized, causing erratic coal flushing, which disrupts stable firing. Continuous monitoring and regulating is a headache for operators. ...