Pyro Process – Operations and Process

Dilihat 1714

OBJECTIVES The purpose of the course is to give operators, production supervisors, and process engineers the skills and knowledge to Optimize the Pyro Processing System. OUTLINE 1. Kiln Operation 2. Process and Kiln System Design Considerations

Kiln Zones
Raw Material Characteristics
Chemical Reactions in the Kiln
Liquid Phase and Importance of Iron and Aluminum content

3. Calciner Operation

Fuel Types and their Characteristics
Alternative Fuels use in the Calciner and Impact in System Operation

4. Combustion Theory

Heat Transfer
Flame Formation
Main Burner, changes that affect flame formation and lead to better burning conditions

5. Clinker Coolers

Clinker Cooler types
Cooler Operating Philosophy and Optimization of Clinker Coolers

6. Heat Balances

Heat and Material flows
Measurements in the Pyro Process System (Temperature, Pressure, O2 Profile)
Measurements in the Cooler, Airflows, Temperatures and Pressures
Heat Balance Calculations

7. Optimization of Heat Consumption

Kiln Feed Burnability
Distribution of Air and Losses in the Cooler
Clinker Formation
Behavior of Volatile Matter
Volatile Matter Work Session

8. Emissions of NOx, SOx, Particulates, Mercury, etc from Cement Kilns

New Emission Standards
Bag House, Operation and Maintenance
Refractory Considerations
Practical Sessions with the Use of Pyroprocess Simulation/ECS Cemulator Software
Starting and Stopping the Kiln using the ECS Cemulator Software
Interaction of Control Loops between the Kiln and Cooler areas
Various Disturbances
System Cooling Down
Loss of Fuel in the Calciner or Kiln Burner
High Bed Depth in the Cooler
Kiln Push
Change in Pressure Profiles in the Preheater
Main Bag House issues
Kiln Ring formation/Kiln Ring fall
Cyclone Plug
High CO

9. Kiln System Shut Down

Considerations during a Short Shut Down
Considerations during a Maintenance Shut Down
Evaluation running the Kiln System to Full Production

TRAINING METHOD Presentation Discussion Case Study Evaluation FACILITY Training Kit Handout Certificate Lunch + 2x Coffee Break Souvenir Pick Up Participant (Yogyakarta)