One year in a cement plant - Technical history, interventions and current status
1. Plant Condition and Major Operational Issues Since Commissioning Since commissioning, the plant has experienced several persistent mechanical, process and operational issues that adversely affected reliability, productivity, energy efficiency and clinker quality. A. Kiln and Cooler Reliability 1. Frequent breakdowns and stoppages associated with kiln supporting roller mechanisms, including high bearing temperatures. 2. Frequent cooler mechanical problems and breakdowns. 3. Frequent kiln coating collapses, resulting in red-hot clinker reaching the DPC and causing clinker quality deterioration. 4. Very low and inconsistent refractory life. 5. Frequent material puffing from the kiln inlet, accompanied by continuous material spillage. 6. Excessively hot kiln hood, with almost zero draft, resulting in unstable kiln operation and frequent hood roof damage. B. Preheater / Calciner Problems 7. Frequent material flushing / build-up at different locations in the preheater. 8. Very high prehea...