Table of Contents

1. BURNING ZONE CONTROL..................................................................................2

Viewing kiln from the kiln-hood....................................................................................3
Appearance of clinker.....................................................................................................3
The feed behind the flame..............................................................................................4
The dark feed under the flame........................................................................................4
Color of the coating........................................................................................................6
2-KILN EXIT GAS ANALYSIS CONTROL....................................................................9
3. FUEL RATE CONTROL.........................................................................................13
Rules in fuel rate control..............................................................................................14
Precalciner kilns...........................................................................................................16
4. KILN SPEED CONTROL........................................................................................17
5. CLINKER COOLER CONTROL............................................................................21
5.1 Variables in cooler control.................................................................................21
5.2 Under-grate pressure and air flow rate...............................................................23
6. SECONDARY AND TERTIARY AIR TEMPERATURE CONTROL...................24
7. KILN HOOD PRESSURE CONTROL....................................................................28
8. KILN EXIT - GAS TEMPERATURE CONTROL..................................................29
8.1 Kiln inlet temperature........................................................................................29
8.2 Kiln inlet draft control.......................................................................................32
9. Feed rate control.......................................................................................................34
 KILN CONTROL VARIABLES

Before explaining the control variables one has to understand first the meaning of a
variable and a controller.
So what is the meaning of a variable?
A variable is a physical quantity that can be measured and /or changed; like weight,
pressure, temperature, speed, level, flow, etc.
What is a process control?
A process control is the regulation of the physical variables to obtain a desired end
result.
Then the following question should also be answered
What are the goals of process control?
Process controls are for Optimizing operation conditions in the kiln
1- to maximize production.
2-to achieve maximum energy efficiency.
 CCR Operators
Kiln Control Variables 2/35

1. BURNING ZONE CONTROL

Burning zone temperature is not only one of the most important kiln control variables
we have in any rotary kiln system, but
but it is also the hardest and difficult to control, understand and monitor. Now, rotary
kilns are equipped with state of the art technology for measuring the different
temperature and pressures etc. needed to control burning zone temperature.
Even with the help of this technology, the operator should be trained to be able to make
use of these instruments to evaluate the data provided to be able to control the situation in
the burning zone.
Apart from this the kiln operator should be trained also to make visual inspection of the
burning zone. The visual inspection does not only helps to relate the conditions aken
from the instruments but to evaluate the clinker, the coating, the flame, and the air
stream. Color is important for the kiln operator assess the clinker, coating, and flame
condition in the kiln. The size of the clinker, the thickness of the coating, the shape of the
flame and the color of that flame can reveal at lot of information that the operator needs.
The pyrometer is recording the temperature in a very limited area at the last end of the
kiln but the overall condition in the burning zone cannot be revealed by the pyrometer,
but by visual inspection. Changes taking place are better observed by visual inspection.
Sometimes the changes indicated by the pyrometer may not be true.
The interference of dust coming from the grate cooler with the secondary air, shifting of
the burning zone caused by change in burnability of the raw mix or change flame
characteristics, may affect the reading of the pyrometer without any real significant
change in the burning zone condition and temperature.
T.V cameras in the kiln hood are there to help the operator to see part of the burning
zone, However kiln interior after the flame area, color of the clinker and its granulation
size, intensity and momentum of the flame, the type of coat in the burning zone etc, are
not revealed by the cameras.
 CCR Operators
Kiln Control Variables 3/35

Viewing kiln from the kiln-hood

It is quite dangerous to look at it without protective glass as this can being a strong light
source would cause partial and temporary blindness. one should always use the blue
filtering glass.
Also looking to the flame for a very long time makes the eyes loose the ability to see the
details. This filter glass enables the operator to see the flame and what is behind better
than without it.
If the operator is away from the kiln fire-hood then it is his duty to try his best to utilize
the instruments he has to judge accurately the condition in the burning zone. In other
words if the instruments indicate an increase in the burning zone temperature and it is
really happening and when the instruments indicates decrease in the burning- zone -
temperature and he finds it true then what he really needs is to judge the burning zone
condition. The most important thing for any operator to learn is to be able to see the
change on time and not after it takes place. After any adjustment, the operator should
check and feed back therefore good operator should never leave the kiln unchecked for
long time.

Appearance of clinker
The visual inspection of the kiln hood can give an indication of the quality of the clinker
by the size and color of the hot clinker. However the laboratory can give better indication
like the liter weight and free lime content.
Correlating the operator observation of in the burning zone with the laboratory data is
quite useful.
If the clinker is overburned, it is burned in a hotter atmosphere, the cascading movement
of the clinker bed in the burning zone becomes higher, and clinker grains become bigger.
In such condition the color of the clinker becomes more to he orange yellow and
sometime white –yellow in color. If we have such condition in the burning zone it
indicates that the clinker will have higher liter weight, bigger size, darker color after
cooling.
 CCR Operators
Kiln Control Variables 4/35

If the color becomes dark red it means the clinker will have less liter weight and may
have higher free lime and will tend to be dusty and brownish in color and sometimes
when breaking it ,brown –yellow color material will be found inside.

The feed behind the flame

It is difficult to see behind the flame, but in spite of this the operator should spare no
effort in trying to see behind the flame because it is the region of the kiln where early
detection of possible kiln upsets can be seen. Special attention should be given to the
physical characteristics of the feed behind the flame. Changes in that raw feed position
give early warning signals that the burning zone condition are about to change. The
operator reaction controlling the position of the raw feed has a significant influence on
the operation of the kiln .Also it is an indication of the operator capability to control the
kiln properly.

The dark feed under the flame

Looking into the burning zone, one will observe a color change of the lower part of the
feed bed under the flame from dark to bright. This point in the burning zone is of great
importance to the operator. The actual position of this dark feed gives the kiln operator
one of the earliest indications that the burning zone tends to warm up or cool down. In
normal operation this dark feed is stationed nearly at the first quarter of the flame length
starting from the flame end. When the burning zone is cooling down the dark feed tend to
move furthers towards the direction of the kiln outlet. When the burning zone is warming
up the dark feed will start to retreat in the direction of the kiln inlet.
When the boundary of the flame is well defined and the quantity of dust is minimum the
dark area can be detected very clearly.
The adjustment of the flame characteristics is one of the main factors that can control the
position of this dark feed.
 Whenever the flame is shortened the dark feed will move in the direction of the
kiln outlet.
 CCR Operators
Kiln Control Variables 5/35

Therefore, the dark feed can change position due to the change in the shape of the flame,
the change in burnability of kiln feed, or the change in the feed charge loading in the
kiln.
 When the kiln feed is harder to burn than usual and the flame is shortened and
when kiln material loading is higher, then the dark bed moves toward the kilns
outlet because the burning zone is cooling down, since there is not enough heat to
raise the temperature of the kiln feed to the degree from the cherry red color to the
bright red whitish color. So it is unmistakable indication on the condition of the
burning zone.
 When the flame is made longer but still strong enough and there is enough heat to
raise the temperature of the feed so the dark feed can move toward the kiln inlet
area.
 When the feed is easier to burn than usual this dark feed will move in the direction
of the inlet area because the feed will need less heat than usual to arrive to the
temperature that give it the bright red whitish color.
 When the feed loading of the kiln charge decreases then the warming up of the
burning zone is under way, so this area of dark feed will move in the direction of
the kiln inlet.

The operator should be trained to see the dark feed at any time he looks to the kiln, since
any change in the position of the dark feed must be viewed in the light of all of these
influences mentioned before. The operator must regulate operation of the kiln so as to
achieve this end.
A slow shifting of the dark feed is a strong indication the operator should make use of
during operation to make the flame either longer or shorter according to the situation.
This does not mean that the operator should have a free hand to change the flame at any
indication of change in the position of the dark feed. Shortening the flame has a limit
This limit is defined by no contact between the flame and the feed, the coat and the bricks
at any time or for any period of time. The shorting of the flame may concentrate the heat
where not need.
The condition of the brick should be considered before shortening the flame.
 CCR Operators
Kiln Control Variables 6/35

This is due to the fact that the concentration of the heat may accelerate the deterioration
of the bricks in this area and the radiation rate will increase. On the other hand, if we are
allowed to have bad burned clinker in the cooler, then dust will increase in the cooler to
the degree of visibility deteriorating the burning zone, the temperature will start to
decrease, since the temperature of the secondary air will deteriorate and this will
automatically lead to change in the flame structure. The ignition point of the fuel will go
deeper inside the kiln. This combustion condition will be of poor quality and the burning
zone will be considered as cold.
In such condition the operator should rely on the clinker condition in the burning zone
rather than on the dark feed. This is because the high intensity area may be still working
behind this dusty condition and away from the cold front.
Experience has established the rule that whenever dusty condition prevails in the burning
zone, the clinker condition behind and under the flame, rather than the color of the front
of the burning zone, governs subsequent corrective measures after an upset.

Color of the coating

Color of coating tells a great deal about the condition in the burning zone. The color of
the coating in the intense heat area should be whitish yellow.
When the color changes to red or orange red the burning zone is cooling down.
If it starts to change into white then it is heating up and if the color becomes dazzling
the burning zone is over heated.
Wall of the bricks in the rotary kiln is a major source of heat for the kiln feed charge.
The heat is transferred to the wall by radiation and conduction. In the same manner the
absorbed heat by the wall will be transferred to the kiln feed charge by radiation and
conduction from the kiln wall. Therefore it is well proven that the temperature of the
walls and the coating are of prime importance to the process of heating up of the kiln feed
charge and the burning process as well.
The coating can be considered as heat storage in the burning zone. But the coating with
its temperature stored in, will not be able to do much if material lumps rush into the
 CCR Operators
Kiln Control Variables 7/35

burning zone. The operator then has no alternative but to slow down the kiln speed to
control the situation to prevent producing bad clinker. consequently can help securing
good burning but not a decisive factor in controlling the burning process itself.
The general appearance of the coat is also important to the operator.
The loosing of the coating, the formation of rings and the weak points that the shell
scanner can indicate are very important and should always looked after by the operator.
The duty of the operator is to keep good watch over the condition of the coating in the
burning zone and to notice any change in the structure of the coating. It is his duty to
always try to build good coating to protect the bricks and kiln shell from over heating.
One of the most important conditions the operator should avoid the excessive overheating
of the coating and brick wall in the burning zone. If such condition starts to exist in the
kiln, the bricks will be lost in a matter of days not even weeks. The clinker ball formation
will start and even liquid clinker will exist and frequent snowman will form in the cooler.
This condition will make the operation harder or even impossible. The operator should
start to correct the operation condition in the burning zone since the continuation of such
situation will make great damage to the kiln. This condition of extremely heated burning
zone is very bad to coating since it starts to liquify and to come off the walls. The bricks
may also start to deteriorate and the operator should concentrate on saving them and not
on producing clinker.
The bad conduct or the feeling of irresponsibility of the operator or gross misjudgment
may result in red spot on the kiln shell, a sure indication that there was bad judgment or
gross misconduct of the kiln operator.
So we can say it is the obligation of the kiln operator look after the changes in the
following items since any change in any one of them will surely indicate a change in
burning zone temperature.
1. Clinker color
2. Clinker size
3. Type of cascading movement of the clinker under the flame itself.
4. Feed bed before the directly before the flame area
5. Dark feed position
6. Appearance of secondary air coming from the cooler and the quantity of dust in it
 CCR Operators
Kiln Control Variables 8/35

7. Coating condition
8. Flame shape and color
The control of the burning zone temperature is not as easy as to simply increase fuel
when the zone become cooled and reducing fuel when the burning zone becomes
overheated. But burning zone control should be considered with other kiln variables
before any corrective action can be taken.

Now how an operator can predict changes as early as possible and make counter
adjustment in controlled steps. This mean to control in anticipation He should develop
the habit of predicting the condition of the burning zone (say 15 minutes ahead) not
waiting for the large deviation to happen and appear on the counters which can lead to
unstable operation and is not complying with optimum operation practices. This principal
is not only applied for the burning zone but also to any other variable in the kiln main
control functions.
The good and dedicated operator himself can with time know the proven indicators of the
approaching changes in the burning zone temperature .These indicators are:
 Kiln drive torque and amps
 oxygen content in the kiln exist gas if the I.D. fan speed and fuel rate and set up
parameter of the main burner stay the same.
 NOx in the content of the exit gas and relating it to the oxidation or reduction
condition in the kiln burning zone
 CO2 content in the kiln exit gas
 kiln inlet temperature
 Kiln inlet draft
These are the tools for early warning that alert an operator to upcoming changes in
burning zone temperature.
 CCR Operators
Kiln Control Variables 9/35

2-KILN EXIT GAS ANALYSIS CONTROL

Oxygen, Carbon monoxide, Carbon di-oxide and NOx measurements are made round the
clock in any rotary kiln. The instruments used in determining these compounds must
work as long as the kiln is in operation i.e. fuel is fired in the kiln system.
These instruments used in measurements are working in a very harsh condition very high
temperature and high accumulation of dust. Therefore it is very important to frequently
inspect them and repair if necessary.
Now the rotary dry kiln works with very high production that normally not less than
4200t/day and any disturbance can represent considerable loss. Therefore working with
gas analyzer that is not reliable or malfunctioning is quite dangerous and counter
productive. The situation may deteriorate so that the kiln operator will not be in a
position to judge his action regarding how much fuel he should introduce to the main
burner.
Does he work with combusting gas at the inlet? Does he get the correct oxygen content in
the kiln-inlet area? Many wrong decisions can be made with wrong information from the
instruments of gas analyzer either in kiln inlet or after precalciner. Any kiln operator
would automatically reduce the fuel rate in the main burner or in the precalciner burner
when he notices the indication of carbon monoxide in the kiln inlet or after precalciner
then he will asks the question later. The kiln inlet area with the false air, the high
temperature and in the presence of combusting material like carbon monoxides can lead
very quickly to explosion.
Oxygen should be in the range of not less than 0.7 and that represents the border of
insufficient oxygen level in the kiln and not more than 3.5% in the kiln inlet and that
represents the border of high excess air in the kiln. for optimum operation the advisable
oxygen level should be between 1and 1.5% Same values can be applied to precalciner.
It advisable to have two gas analyzers in the precalciner kilns, one after the precalciner
and one at the top of the preheater at the down comer duct.
If the operator has only one at the down comer duct after upper most cyclones then he
would find big difficulty in relating the changes in oxygen and carbon monoxide to either
 CCR Operators
Kiln Control Variables 10/35

one of the two burning locations he has in the total kiln system. Therefore it is
recommended to have two gas analyzers, one at the kiln outlet and the another at the
precalciner out let therefore, each of the two combustion process can be independently
controlled.
Installing an additional gas analyzer in the down comer duct after upper most can help
give more information regarding the overall condition in the kiln and preheater and can
work as safeguard against malfunction of any of the other gas analyzers in the kiln and
preheater.
Now if a kiln works steady at maximum production yet with more than 3% oxygen or the
kiln works with deficiency of oxygen of 0.7% then in such condition the kiln works in a
stable condition, therefore there is no point in introducing any major changes because this
may upset the kiln.
The moves in such condition should be delicate and in a slow but steady way, so the
balance of the kiln would not be disturbed.
The strategy in such condition is to think first what to do, then starts the process of fine-
tuning in a way not disturbing the stability of the kiln in any way. The time between each
small change and another should be not less than one hour.
The whole process of fine-tuning should take from 10 to -16 hrs.
With the other control variables in consideration the, following are the basic steps to
follow as regards exit gas control:
 Secure sufficient oxygen and no carbon monoxide in the kiln atmosphere.
 Stabilize the kiln oxygen and make it level off and stay within a definite narrow
range.
 Optimize by fine-tuning the oxygen in the kiln in small steps to bring the oxygen
level to the range of 1-1.5% for optimum kiln efficiency.
The major and principal equipment that the operator uses in this process is the gas
analyzer. The gas analyzer normally gives indication for the Carbon monoxide and
Oxygen level, but rarely any gas analyzer gives indication for carbon dioxide. Many kiln
manager sees no use in estimating the carbon dioxide in the kiln atmosphere, but this
kind of estimation is very helpful in case of having the un-pre-calcined material in the
kiln. At that time the carbon dioxide percent can go up sharply in the kiln-inlet. The
 CCR Operators
Kiln Control Variables 11/35

operator should expect that the kiln will go to unstable condition. He can be prepared for
this and can slow the kiln and increase? and make any other necessary steps.
In recent years, the utilization of recordings of NO x in the kiln exit gas to determine the
changes in the burning zone temperature, becomes quite necessary
There is a relation between the burning zone temperature and the concentration of NOx in
the kiln atmosphere.
 When the temperature of the flame of the main burner changes in the burning
zone.
 Also when the Oxygen in the main burner increases in the burning zone, the NOx
concentration increases.
We should mention here that cannot relate the NO x directly to the prevailing temperature
of the burning zone but it is a rapid and excellent indicator of the changes that already
have taken place there.
In any rotary cement kiln it is nice to work in an efficient way by making the kiln work
with as short burning zone as possible i.e. short flame and high flame temperature that in
turn means high NOx content. Therefore as a general rule if the kiln work with say
1500ppm of NOx then start to be 2000ppm then the kiln tends to:
 have more draft i.e. excess Oxygen.
 may starts to have higher burning zone temperature.

If a kiln works normally with 1600ppm of NOx concentration in the kiln out let, then the
concentration goes down to 600ppm so that indicates the following:
- there is loss of oxygen in the burning-zone.
- the burning-zone temperature is lowering and starts to cool down.
- the operator should not wait until reduction condition prevails in the burning zone but
when the concentration of the NO x starts to decrease he should stop that trend of cooling
down of the burning zone.
Another feature we should look after in the kiln gas analyzer is the variation of the
readings, whenever this reading exceed ±0.5 % on regular intervals then the accuracy of
the gas analyzer should be checked and a calibration of the apparatus.
 CCR Operators
Kiln Control Variables 12/35

Also when the gas analyzer shows straight line reading for long time this is an indication
of malfunction necessitates checking of it.
In any rotary kiln the register of oxygen recording of this variable is in the range of 0-
5%.It is advisable not work over long period of time at the upper limit of 5%. The
operator does not know if the oxygen is 5.4 or 6 or 8-or15%In short the operator does
not know what are the combustion conditions in his kiln.
It is a good operating practice to always set the fuel and/or I.D. fan speed so that the
oxygen recording at least below the 5% mark whenever the fuel is fired into the kiln.
This is also recommended when the kiln is in state of firing to warm up at the start up
periods.
It is the duty of the kiln operator to stabilize the oxygen percent after lit- up of the kiln at
a level below 5% Oxygen at the kiln inlet gas analyzer.

O2 CO CO2 NOx
Fuel Increases down up down down
Decreases up down up up
I.D. fan Increases up down up up
Decreases down up down down
Flame Decreases - - - up
Temp. Increases - - - down
Feed rate Increases down - up -
Calcine Decreases up - down -
 CCR Operators
Kiln Control Variables 13/35

3. FUEL RATE CONTROL

Before the kiln is fired for any reason i.e. long shutdown or short shutdown the following
requirements should strictly be met:
1. The gas analyzer is calibrated and working properly.
2. Sufficient air is present to achieve complete combustion of fuel
3. strong Source of heat enough to ignite the fuel is available.
4. The primary air fan is running and the draft is properly set.
5. The I.D. fan is running condition and the draft is adjusted in a way that prevent
any sudden, delayed, explosive ignition of the fuel.
After the lit-up the operator should:
1- Inspect the gas analyzer for CO and that the gas analyzer is measuring oxygen below
the limit of less than %5 limit mentioned before.
N.B if the fire is not let up or distinguished for any reason, the kiln should be purged
for 5 minutes before any another attempts is carried out again.
This is to get rid of combustible gases which may be present in the kiln atmosphere.
2- Never attempt to control the burning zone temperature by merely increasing or
decreasing the fuel in the main burner. For example increasing the I.D fan speed to
permit raising the fuel rate because the exit gas is deficient in oxygen. This will make
trouble, because no consideration is given to the temperature at the kiln inlet.
If the operator increases the I.D. then this will definitely fan speed to increase the fuel
rate in order to increase burning zone temperature, increase the kiln inlet temperature.
This practice should not be the case in operation of the kiln because the kiln inlet
temperature is playing a vital role in operation of he kiln, and cannot be allowed to
freely fluctuate up and down.
3- The kiln operator should anticipate the reactions caused by the change in I.D fan speed
or the fuel rate or both.
 CCR Operators
Kiln Control Variables 14/35

He should remember that

 An increase in fuel rate results in higher kiln inlet temperature, low oxygen
percent in exit gas and higher burning zone temperature.
 An increase in I.D. fan speed results in higher kiln inlet temperature, and lower
kiln burning zone temperature and higher oxygen in the kiln inlet.
From this it is very obvious that the fuel rate alone does not govern the burning
zone temperature. Without changing the fuel rate, a change in the burning zone
temperature can be made merely by altering the kiln draft with the I.D. fan
speed. is also clear that the altering of fuel rate adjustment will give the fastest
reaction whenever a change in burning zone temperature is required.

Rules in fuel rate control

Always check the oxygen content and CO analyzer in the trends or recorders on the
monitor or the panel after any adjustment of fuel rate. It should be mentioned here that
the burning zone reacts slowly to any fuel rate adjustment.
There is a time delay until a noticeable change in temperature takes place. Since these
time delays can be as much as at least 10 to 15 minutes, especially after an upset
condition, it is quite common among new operators to either over-fuel the kiln or under
fuel the kiln for a prolonged period of time.
This will make the operation condition in the kiln alternates between excessively hot and
cold burning zone.
This is what is known as a cyclic operation condition.
Due to this time delay the operator should be trained to anticipate these fluctuations of
extreme temperatures and make their fuel adjustment before the actual change in
temperature takes place.
The other instruments can give operators positive signs that a turnaround in temperature
conditions in the burning is imminent.
 CCR Operators
Kiln Control Variables 15/35

The early warning signals are:

Oxygen% without fuel increases B.Z. is heating up
Or I.D fan adjustment decreases B.Z. is cooling down

Kiln drive torque increased B.Z. is heating up

Decreases B.Z. is cooling down

NOx increased B.Z is heating up

Decreased B.Z is cooling down

CO2 increased B.Z is cooling down

Decreased B.Z is heating up

Kiln inlet temp*. Higher than normal heating up

Lower than normal cooling down
*The operator should look to the temperature of the kiln inlet that prevails at a time that
is equal to the travel time of the feed through the kiln on the trend chart e.g. if travel time
is 25 minutes, the operator looks at the kiln inlet temperature that prevailed 25 minutes
before and relates it to the feed he has at the moment in the burning zone.
The kiln operator should control the fuel rate on the basis of the following variables:
First: the burning zone temperature
Second: the kiln inlet temperature
Third: the percent of oxygen in the kiln inlet.
Simple control logic of adjusting fuel rate strictly and solely on the basis of condition on
the burning zone alone seldom yields satisfactory stable and efficient kiln operation.
 CCR Operators
Kiln Control Variables 16/35

Precalciner kilns
In case of precalciner kilns the fuel rate to the precalciner is automatically controlled in a
closed loop that uses the lower most cyclones, preheater exit gas temperature as input
variables. When these temperatures are below the set point, more fuel will be given to the
precalciner and. When the temperature is above the set point, less fuel will be injected to
the precalciner. In the precalciner the response of this loop should be fast since the area at
which the temperature change is very small and the speed of gas is high.

What the kiln operator should do during severe kiln upsets in relation to fuel rate in
the kiln?
During kiln severe upsets, the kiln burning zone will be blackened and the unburned fine
clinker will over flow the cooler and the visibility in the kiln hood will be nil. The kiln
operator natural and spontaneous reaction to the situation will be increasing the fuel rate
to the kiln regardless the real situation would be. This is a natural tendency of all
operators because he understands that a lot of heat is needed to bring back the burning
zone to its normal operation condition.
Since the kiln speed in this condition is greatly reduced and since the visibility is greatly
reduced, the operator will think that the burning zone is of very low in temperature and
he will leave the fuel rate very high for a long time in the kiln without alteration, waiting
for the burning zone to clear. In most cases the kiln will be very hot in the burning zone
and the burning zone will be in an overheated condition. The following are to be
considered during such condition:
Operation of rotary cement kilns with no or very little oxygen (even when there is no
combustion are showing) does not produce the desired heating of the burning zone. The
reason for this is that the dust in kiln atmosphere and low oxygen (oxygen deficiency will
make the flame tend to go deeper into the kiln in search of oxygen) combined together
will produce lower flame temperature in the burning zone area, and this flame will be of
lower temperature than clinkering temperature required in the burning zone.
The solution to this situation is to try less fuel to operate at a little higher oxygen
percentage of 0.6 to 0.9% When the unburned material goes in the burning zone and
onrush of this material has passed through the it, the result will be a lighter load in the
 CCR Operators
Kiln Control Variables 17/35

kiln after this onrush leave the burning zone. This lighter load will cause rapid increase in
the burning zone temperature. The detection of the temperature increase in burning zone
cannot be easily done, since there will be dusty clinker or material in the cooler and going
again to the burning zone with secondary air. The solution to such situation is to search
and try to detect and anticipate the definite sign that there is lighter load of material is
reaching the burning zone These signs are
- Oxygen increases
- NOx increases
- Kiln amps up
- And cooler under grate pressure decreases
If the degree of little loading is severe and the material charge in the kiln burning zone is
very little, then the operator should decrease the fuel rate) to prevent the burning zone
form overheating and again he should but into consideration the effect of that on kiln
inlet temperature.

4. KILN SPEED CONTROL

Any kiln cannot run over extended period of time in stable condition at which nothing in
operation parameters is changed. Sooner or later an adjustment is needed in kiln speed if
the kiln has to continue producing good clinker. Kiln speed is one of the main controls in
kiln operation.
There should be an appropriate action the operator must take in case of kiln upset ; this
upset may not be due to operator error but due to
 Change in the physical and chemical characteristics of the kiln feed.
 Change in the mineralogical characteristics of the raw materials.
 Change in the homogeneity of the kiln feed and change in the standard deviation
of say L.S.F. or silica modulus.
 Change in the fuel chemical composition or in its temperature in case of fuel oil.
 Change in calcination degree coming from the precalciner.
 Etc.
 CCR Operators
Kiln Control Variables 18/35

This action is called slow down procedure.

When an upset condition such as heavy onrush of material, the duty of the operator
should be to determine that with just increasing the fuel rate he should be able to control
the situation in the burning zone or he must decrease the speed. To determine this he
should first estimate how much is the onrush (heavy and big or light and small). In some
cases it is quite enough to speed up the kiln by 8 to10% of its speed to really control the
onrush of material but sometimes it is important to slow down the kiln to minimum speed
in order to be able to control the situation in the burning zone. Slowing kiln’s speed
depends on the experience of the operator and no literature can teach him how to do it,
but actual training and accumulation of experience is the key.
But one rule has to be followed at all times during kiln operation:
Never allow raw and unburned kiln feed to go to the grate cooler
Even if this means to stop the kiln and reheat it on quarter turn
Or auxiliary drive.

When the operator slow down the kiln there are number of changes that can take place.
The operator should be alerted to be able to notice the indication of these changes and
take appropriate actions:-
 Kiln inlet temperature will start to increase, but this is undesirable, since this
temperature should be held within ± 20ºC.
 Reducing the I.D. fan speed will help reducing this increase in temperature of the
kiln inlet.
 Reducing kiln draft resulting from I.D. fan speed decrease, will make the oxygen
content less in the kiln exit gas and there will not be enough oxygen for fuel to
complete combustion. Therefore, the logical action would be to reduce the kiln
fuel rate until the gas analyzer in the kiln inlet reads 0.8% oxygen.

What is the effect of slower kiln speed on the cooler and secondary and tertiary air
temperature?
when the operator decreases kiln speed, less material will enter the cooler. The direct
result will be lower secondary and tertiary air temperatures and the under grates pressure
 CCR Operators
Kiln Control Variables 19/35

will decrease. Therefore the spontaneous reaction of the operator is to reduce the grates
stages speed to maintain the under grate pressure. This will be very difficult to do. It is
almost impossible to have some undergrate pressure in the cooler when the kiln is slowed
down as that when the kiln has full speed. At this instance of upset condition the clinker
will be under-burned and dusty and keeping the cooler fan at relatively high speed will be
counter productive.

When should the operator decide to increase the kiln speed again in the time of
upset periods in the kiln?
 Never increase kiln speed before there is definite sign of burning zone warming
up, due to less feed coming to the kiln burning zone. The behavior of the operator
during this period should be as follows:
 Never hold the kiln on very low speed until the kiln reaches normal clinkering
temperature.
 Start increasing the speed as soon as there is a sign of warming up of the burning
zone.
 The more the kiln speed increases, the smaller should be the increments and the
longer the time intervals between each speed increase.
 The operator should remember that:
The way the kiln speed is increased is the most important
factor in getting the kiln into stable conditions again
 CCR Operators
Kiln Control Variables 20/35

EXAMPLE 1:
An operator started to increase the kiln speed in large steps at a time of 15rph i.e
0.25rpm, until the kiln reached 150rph i.e.2.5rpm, then he extended the time between
each speed increment and also he carried out the increase in smaller steps. The rate was
9rph i.e.0.15rpm from150 to186rph i.e.3.1rpm, 6rph from 186 to 198rph i.e. 3.3rpm and
3i.e.0.055rph from 198 to 210rph.i.e 3.5rpm.
Time interval is irrelevant here because it depends on many factors we can’t put into
consideration during explaining this example.

EXAMPLE 2:
In the last example if the kiln operator started to increases the speed say at 0.5 rpm for a
short period, then he went at 1rpm then quickly jumped to 2 rpm then to 3rpm and finally
to 3.5 rpm then surly he will be obliged to backup on the kiln speed since the burning
zone was not ready for these speeds. Since every time he increases the speed the kiln inlet
temperature will drop, he therefore has to start reheating the kiln-burning zone all over
again.

EXAMPLE 3:
Here in this example the condition is opposite to what the second example showed:
The operator waited too long to increase kiln speed. The result he suddenly found that the
burning zone gained heat very rapidly, forcing him to increase kiln speed in large
increments and in short time intervals. In such case full kiln speed can be maintained but
very soon the kiln would be overloaded and the operator had to slow the kiln speed and
eventually decreased feed.
The important rule in kiln speed increase is that:
Whenever the operator increases kiln speed, kiln inlet temperature will decreases,
requiring increasing fuel rate to the kiln. Any increase in the fuel rate will require an
adjustment in kiln fuel rate and an increase I.D. fan speed. Both should be increase in a
manner equal to that practiced in increasing kiln speed.
 CCR Operators
Kiln Control Variables 21/35

5. CLINKER COOLER CONTROL

It is quite important the operator to aster cooler controls as well as other control functions
of the rotary systems, since the cooler itself performs an integrate part of the clinker
burning process.
Cooler conditions influence the burning process in the kiln and consequently the quality
of the clinker. The cooler upset condition or the bad operation practices of the grate
cooler can lead stable condition to pass through extended periods of upset condition with
the eventual results of losing production and higher fuel consumption and perhaps
damage of the equipment.
The grate coolers now can handle up to 10000ton clinker/day without any problem and it
is a very reliable equipment and if it is well operated can be very stable and reliable.

5.1 Variables in cooler control

The following are the objective that should be worked on and fulfilled during cooler
operation:
 Clinker temperature should be as low as possible to save valuable heat and protect
clinker-conveying system.
 Secondary and tertiary air temperatures should be as stable and as high as possible
especially for secondary air temperature, because this is important for kiln
operation stability and good fuel efficiency.
 Cooler exit gas or excess gas temperature should be as low as possible, and
volume as small as possible to decrease the amount of heat wasted to the
atmosphere.
 Kiln hood pressure should be negative.
 Depth of the clinker-bed is kept at its optimum height to the keep the free passage
of air through clinker bed.
 To keep the cooler controlling parameters in such a way that protect the cooler
components from overheating.
 CCR Operators
Kiln Control Variables 22/35

The basic control variables in the cooler

1. The cooler grate speed determines the clinker bed depth and its residence time in
the cooler.
2. The quantity of air delivered by cooler fans to the different grate compartments
and the way of distributing it on these compartments.
Moreover there still two controllers that are used in case of emergency:
 Decreasing the kiln speed so the amount of clinker to the cooler will be
automatically decreased.
 Changing the main burner conditions so the clinker temperature from the kiln to
the cooler will be changed such as shifting the burning zone further inside the kiln,
consequently the cooling zone in the kiln that exists directly after the flame
increases and gives the clinker more time to be cooled before falling to the cooler.
The different instruments the kiln operator should always follows in order to keep
good control over cooler are:
 Under grate pressure which should be kept as stable as possible because it
determines automatically the speed of the first grate and consequently the speed of
the second and the third grates according to the ratios of the speeds for each grate.
 Secondary and tertiary air temperatures
 Amps of the grate different stages drive motors.
 Temperature of discharged clinker from the cooler last stage.
 Kiln hood draft.
 Cooler exit gas temperature.
 Cooler grate plates temperature
 Cooler airflow rate for each fan.
 CCR Operators
Kiln Control Variables 23/35

5.2 Under-grate pressure and air flow rate

The under grate pressure and airflow rate are the key to any successful cooler control
objective. The understanding and thorough knowledge of these control is essential to the
operator to enable him to maintain operating stability of the kiln and prevent the cooler
components from overheating and damage.
It should be noted that the operator cannot operate any cooler that is full with under
burned clinker. In order to operate the cooler correctly and keep it in good and stable
operating condition, it should handle good burned clinker with proper liter weight.
The under grate pressure is an indication that the clinker is cooled ideally. By fixing this
under grate pressure in each compartment in the cooler, the operator can hold the cooler
control fairly stable and in balance.
Under-grate pressure is governed by:
1. Depth of the clinker bed over the grate
2. Average particle size of the clinker in the cooler
3. Temperature of the clinker in the cooler
4. Amount of air introduced into the cooler
The thicker the clinker bed over the grate plates in any cooler stage, the higher the
resistance and require more pressure and force from the fan to push the air through this
bed. If the condition is the reverse it will be much easier for the fan to push the air
through the thin clinker bed.
Therefore, if all factors affecting the under-grate pressure are constant then, a thicker bed
will results in higher under- grate pressure.
Control of the clinker bed thickness:
The clinker bed thickness is controlled by the speed of cooler grates. A deeper bed can be
obtained by slowing of the grate speed. Therefore, it is logical to obtain and maintain a
constant clinker bed depth by keeping the under grate pressure constant regulating
cooler’s grate speed. Whenever under- grate pressure deviates from the set point, the
grate will readjust its speed to regain the original set value. This works very well as long
as the kiln is in stable condition. But in upset condition, when the clinker characteristics
 CCR Operators
Kiln Control Variables 24/35

change or the kiln drive trips, etc the operator will find that such practice is not suitable
to cool the clinker properly and has to go to manual operation of the cooler until he get
control over this upset condition in the kiln.

Air low rate:

Sometimes the kiln suddenly starts to discharge high amount of clinker due to the falling
down of a coat in the kiln-burning zone. The reaction of the cooler control is to speed up
the grate to maintain the under-grate pressure constant. This will result in reducing the
residence time of the clinker in the cooler resulting hotter clinker leaving the cooler. In
such cases the operator should start to deliver more air to the cooler to compensate for the
shorter time of the clinker in the cooler, increasing the specific airflow rate in the cooler.

6. SECONDARY AND TERTIARY AIR TEMPERATURE

CONTROL

The source of both of the secondary and tertiary air is the grate cooler first stage.
Both of them are drawn form either the kiln hood or in some cases the tertiary air is
drawn form the middle of the roof of the first stage of the grate cooler. This ensure that
the temperature of the secondary air to be higher than the tertiary air.
The main point that affects the efficiency of recuperating heat from the clinker
discharged to the cooler is the efficient application of the air in the first two
compartments of the grate cooler and the direct result will be higher secondary and
tertiary temperature and lower vent air or excess fan temperature in the cooler.
The importance of the tertiary air is similar to that of the secondary air therefore the
topic to be discussed in this chapter will focus on the secondary air and the tertiary air
whenever necessary.
Secondary air temperature has a direct influence on the shape of the flame and the point
of ignition of the fuel; therefore irregular secondary air temperature can cause irregular
flame characteristics that can cause shifting in the burning zone.
The stable condition in any kiln operation depends on many parameters; one of the most
important of them is the stability of secondary air temperature within the range of ±40ºC.
 CCR Operators
Kiln Control Variables 25/35

This also applies to the tertiary air condition.

Control of the secondary air temperature during normal kiln operation:

Every kiln operator understands that he must maintain the secondary air temperature as
high as possible because it contains the maximum amount of heat that can be recovered
from the clinker. The direct result of this is improving the fuel efficiency since less fuel
will be required to increase the secondary air temperature entering the kiln.
The second advantage of higher secondary air temperature is that it gives the operator the
chance and therefore the advantage of burning the clinker nearer to the nose ring of the
kiln. This maximizes kiln capacity because the clinker inters the cooler very hot and is
sintered very near to the cooler and therefore the kiln will be in the best possible
condition.
However there are practical limits for secondary air temperature. The extreme case of
having very high secondary air temperature will result in over heating the area of nose
ring, kiln hood and the first stage cooler area.
Tertiary air temperature, should not be more than 900ºC since the temperature in the
precalciner should not exceed this limit.

Factors affecting secondary and tertiary air temperature:

1. The speed of the clinker bed on the grate cooler in relation to the volume and
temperature of air introduced into the cooler to cool that bed of clinker.
2. The grain size distribution of the clinker and the temperature of that clinker
discharged from the kiln to the cooler.
The rule of thump in secondary air temperature is that
 The higher the speed of the grate the less bed clinker thickness will be and the
lower the secondary and tertiary air temperatures.
 The lower the speed of the grate the higher bed clinker thickness will be and the
higher the secondary and tertiary air temperature.
 CCR Operators
Kiln Control Variables 26/35

This can simply be explained if all other factors are remained unchanged as follows:
 When the grate cooler speed is reduced the clinker speed is lowered, the direct
result will be higher clinker bed thickness and the air will find more chance to
absorb more heat from the clinker in the cooler and visa versa.
 When the cooler speed is increased the clinker bed is lowered and the chance of
cooling air to absorb heat will decrease resulting in lower secondary and tertiary
air temperature.
We have to remember all the time that, the grate speed is an important factor in
determining the temperature of secondary and tertiary air temperature .There are other
factor that also should put into consideration before any attempt is to be made to control
and adjust the secondary and tertiary air temperatures.
Secondary air temperature as said before is controlled by the speed of the grate cooler
speed and the volume and temperature of the air used in the cooler to cool the clinker as
well as the grain size distribution of the clinker and its temperature.
In the end this directly related to the bed thickness of the grate, then the control of the
secondary temperature goes hand in hand with the under grate pressure control since and
change in this two variables affects the bed thickness and its characteristics and
consequently the under grate pressure control.

Clinker grain size and its effect on secondary and tertiary air temperature:
For example consider a kiln in an upset condition and the clinker produced was either
small nodules, or in worst case condition is dust. The operator in this condition would
reduce kiln speed; so amount of clinker discharged to the kiln is reduced. This would lead
to lower secondary air temperature. To maintain the previous secondary air temperature;
the operator had only one choice to lower grate cooler speed. In such case, the operator
must slow down the grate speed to such an extent that it would choke the free passage of
the cooling air through the bed.
This would make the clinker leave the cooler red-hot and the direct result is less heat in
the secondary and tertiary air and cause damage to clinker transport system. Normally the
proper operating practice is to maintain all the time the normal grate clinker bed
thickness.
 CCR Operators
Kiln Control Variables 27/35

The second most important thing to do in such cases is to increase the quantity of air to
the cooler in order to have higher cooling capacity.
The operator should never attempt to hold the secondary air temperature
At its normal operating level in an upset condition in the kiln
And the clinker is dusty or having lower liter weight

Temperature of clinker discharged from and its effect on secondary and tertiary air
temperatures

By changing the character of the main burner flame, the burning zone can be shifted very
near to kiln nose ring outlet, thus the clinker can be discharged to the cooler very hot, and
so the secondary air temperature will be higher.
Also the operator can make the opposite and shift the burning zone further inside the kiln
so the clinker can leave the kiln more cooled than the previous condition and this can
reduce secondary air temperature and tertiary air temperature.

Controls of secondary air and tertiary air tempera

To raise secondary air temp to reduce secondary air temp
Decrease cooler grate speed increase cooler grate speed
Increase clinker bed depth in cooler decrease clinker bed depth in cooler
Increase size of clinker particles decrease size of clinker particles
Increase amount of clinker decrease amount of clinker
Burn closer to the nose ring of the kiln burn further back in the kiln
 CCR Operators
Kiln Control Variables 28/35

7. KILN HOOD PRESSURE CONTROL

The kiln I.D. fan draws certain amount of air through the kiln and another amount of air
is forced into the cooler by the cooler fans. In any modern kiln the excess air volume
resulting from the fact that the amount of air from the cooler and used as secondary and
tertiary air is smaller than the amount of the air forced into the cooler for cooling of
clinker. In any modern kiln system will have excess air in the cooler. This may lead to
difficulty in controlling kiln hood pressure. Kiln hood draft is simply a regulation of the
amount of excess air that escapes through the cooler chimney, so that when the hood
pressure is too high, the cooler fan damper opening should be increased, and when the
negative pressure in the kiln hood become too much i.e. hood pressure is too low, the fan
damper should be closed. This requires fine tuning by the kiln operator, therefore this
damper should not be fully open, yet small adjustments in the damper position can be
made to get the desired results.
Factor affecting kiln hood drafts
 The I.D. fan speed
 The volume of air intruded by the cooler fans

This means that if all the operating parameters in the kiln are constant, then any increase
in the kiln I.D. fan speed will result in lower kiln hood pressure. Any reduction in I .D.
fan speed will result in higher kiln hood pressure. When the hood has negative pressure,
it physically means that the kiln hood is under vacuum while if it is having positive
pressure it means it is pressurized.
Basic rule in hood pressure control is that:
Never to operate with positive pressure in the kiln hood

This will result in very troublesome operation condition. Clinker fine particles will be
blown into the kiln hood area and causing the following problems:
The kiln outlet seal will be damaged
Flying red-hot dust will cover the kiln platform
 CCR Operators
Kiln Control Variables 29/35

Dust emission will make viewing the burning zone very poor.
Working in the area of kiln platform hard and troublesome.
Instrumentation in the area of kiln hood will be greatly damaged.
Kiln pyrometer reading will be invalid.
TV camera in the kiln hood will be useless.
Castables in kiln hood and cooler bull nose on the long run will be damaged.
The kiln hood pressure is usually automatically controlled. The controller receives an
input signal from the hood pressure-measuring instrument and sends an output signal to
the damper at the cooler chimney. The operator decides the set point. Any time the hood
pressure deviates from this set point, the controller automatically adjust the damper of the
cooler fan.

8. KILN EXIT - GAS TEMPERATURE CONTROL

Many kiln operators should pay all attention to the burning zone conditions not giving
much considerations and thoughts to the kiln inlet area conditions although this area
stability will lead to stable burning zone condition. The kiln inlet area conditions are:
 Kiln inlet’ temperature.
 The percent of oxygen in the gases in the kiln inlet.
 The pressure and draft condition in the kiln inlet area

8.1 Kiln inlet temperature

The kiln inlet temperature means the temperature of the exit gas from the kiln exit that
leaves the kiln tube to go to :
1- By pass system
2- Kiln riser duct
3- The precalciner if the system has inline-precalciner
4- The lower most cyclones if the system has off line-precalciner
 CCR Operators
Kiln Control Variables 30/35

A tight kiln inlet temperature control is the key to any good, stable, successful kiln
operation. Some experts say about this “the technique of burning clinker from the rear
part of the kiln.” The reason behind having a properly controlled kiln inlet temperature is
that it is the starting point of preparing the material for the change that will take place
before reaching the burning zone ready for partially melting and change into sound
clinker. If this start is not controlled well then eventually the material will not be properly
prepared such as it is not fully calcined or still not having the proper temperature for the
clinkerization so the burning zone will just cool when this material arrives to it. It means
certain heat gradient has to exist throughout the kiln length in order that the clinkerization
process proceeds in the desired manner.
Kiln inlet temperature is the tool by which the kiln operator keeps control over
preparation of kiln material charge before it reaches the burning-zone. The material
temperature control and calcination degree of material in a precalciner kiln is an
important tool the operator should take care of, in order to have more tight control over
kiln inlet condition. This is because in principal it is better to control the feed temperature
than to control kiln inlet gas temperature. The operator should pay full attention to gas
temperature in this area since it is easier to control. The operator should also relate the
temperature in the kiln inlet to the temperature in the lower most preheater cyclones
either in inline precalciner kilns or off line precalciner kilns.
What are the ideal conditions in the kiln-inlet?
There is an ideal kiln inlet temperature for each kiln speed and feed rate that ensure
proper preparation of the feed.
If the temperature is unnecessarily high, the feed will undergo early clinker formation in
back of the kiln, and this will shift the burning zone further back.
This too much heat sent to the back of the kiln represents waste of heat and poor
operating efficiency and results in waste of fuel. In most cases that technique weakens the
heat concentration in the high intensity heat zone of the burning zone. The direct result of
this is less clinker liter weight and less tricalcium silicate.
The opposite will case undesirable condition in which the kiln feed is not completely
calcined at the early part of the kiln and when it enters the burning zone it is ready for
 CCR Operators
Kiln Control Variables 31/35

clinkerization process making the burnability extremely difficult and may lead to upset
condition in the kiln.
Factors affecting kiln inlet temperature:
 I.D. fan speed increase or decrease
 Fuel rate increase or decrease
 Kiln feed rate
 Kiln speed
1. If all other factors remain stable without change and the operator increases the
I.D. fan speed then the kiln inlet temperature increases.
2. If all other factors remain stable without change and the operator increases the
fuel rate to the kiln main burner then the kiln inlet temperature increases.
3. If feed rate decreases then the kiln inlet temperature increases.

If the operator decreases I.D. fan speed, decreases fuel rate or increase feed rate, the kiln
inlet temperature increases.

Kiln speed and its relation to kiln inlet temperature:

Back end temperature is also affected by the kiln speed change. Since sometimes the kiln
material charge is changed say due to ring in the kiln or mechanical default or electrical
failure in the feed dozing equipment, this will require change in the kiln speed.
Whenever kiln speed is increased, the kiln inlet temperature decreases. In kiln operation,
any change in kiln speed, kiln fuel rate, and /or I.D. fan speed cause changes at both the
kiln inlet and the kiln out let i.e. burning zone.
This means when an operator changes one of the last mentioned variables, changes
definitely do occur throughout the entire kiln. Therefore, if the back end temperature is
lower than necessary, it is not acceptable from the operator to simply just increase the
I.D. fan speed and think the problem is solved without considering the effect of this
adjustment on the burning zone temperature and oxygen content in the kiln exit gas.
 CCR Operators
Kiln Control Variables 32/35

8.2 Kiln inlet draft control

The draft in the kiln inlet area is created by the action of the kiln I.D. fan. This local static
pressure is negative and the suction is measured and indicated by the instrument. This
explains why the negative pressure is changed by either decreasing or increasing under
certain kiln condition.
If there is restriction downstream, even if it is located further inside the kiln far away
from measuring point, the negative pressure increases because suction increases.
If the restriction is in an area located between the I.D. fan itself and the kiln inlet area of
pressure measurement i.e. the obstruction is upstream this suction decreases and the
indication of the negative pressure decreases.
The physical meaning of changing of draft in the kiln inlet area is, the speed of the air in
side the kiln either becomes higher or lower depend on the change in the draft.
The main cause of changing the draft in kiln inlet is changing the speed of the I.D. fan or
the speed of the by-pass fan.
If any alteration in the negativity at the kiln inlet took place, the first thing the operator
should do is the I.D. fan speed is changed before this change in the pressure took place, if
the answer is in the negative, then he has to look for the following the answer for this
change in pressure in the kiln inlet.
And inspection door opened in the area of the kiln inlet or kiln riser duct
Door in by pass fan opened e.g. for cleaning purposes.
Malfunction of I.D. fan damper, i.e. it closes or opens by itself due to any error in the
equipment or due to a human mistake. This situation leads directly to the presence of
combustibles (carbon monoxide).
Anyone opens a door in the kiln inlet area or the by- pass should report first to the kiln
operator before he does so.
If the kiln inlet pressure has drastic drop without changing fan speed i.e. its speed is
constant or because of opened doors in the kiln inlet or by –pass system, the origin of
such change is found in the kiln.
 CCR Operators
Kiln Control Variables 33/35

If a big ring falls down inside the kiln, there will be an immediate drop in the kiln inlet
draft. On the other hand, if a ring is in the process of formation, then the operator will
find that the kiln inlet draft will increase progressively as long as the ring builds up.
This is why an experienced kiln operator should always keep good watch on the draft in
the kiln inlet; he will be able to see by this information inside the kiln with his mental
eye.
It is the eye that can see facts without looking to it physically! The deep experience
through years will create it inside his mind.
This information given by the increasing or decreasing of draft in the kiln inlet will give
the operator the chance to adapt the situation in the kiln for the expected heavier load
or the opposite condition of lighter load.
The draft in the tertiary air will be important if the kiln has an off-line precalciner
because the draft is the main point in controlling of the operation condition in the
precalciner vessel. The operator should keep enough draft in the precalciner that can
permit the gases to lift off the load of the material feed to the precalciner and in the same
time to provide enough oxygen for fuel in it. That means he has to make a compromise
between the draft in the kiln inlet and the draft in the tertiary air duct. In such system
there will be a restricting damper on the kiln riser duct to work with the action of the
tertiary air duct damper to giving the kiln operator the tool to achieve this target.
In case of inline precalciner the gas leaving the kiln goes directly to the precalciner and
the job of the tertiary air duct is to provide the precalciner with the oxygen required for
the ignition of fuel.
The pressure in the preheater should also be taken into considerations because the
pressure drop in the preheater cyclones is an important indication of the condition
prevailing in the cyclones. Like the problems of built up or discharge cones of the
cyclones and feed pipes transfer the material from one cyclone to another. This is very
important since any built up due to the problem of alkali chloride and alkali sulfate will
progress very rapidly and, consequently produces large changes in a short period of time.
 CCR Operators
Kiln Control Variables 34/35

9. FEED RATE CONTROL

One of the most important factor in the control of the feed into the kiln is the accuracy of
the kiln raw meal feed weigh-feeder i.e the dosing system is reliable and working
properly.
The importance of the kiln feed dosing system is that it gives the operator the capacity to
change the feed rate by increasing or decreasing the kiln system according the conditions
in the kiln.
The factors which are determine the kiln feed rate are
 Kiln speed
 Kiln cross-sectional feed loading or volumetric load
 Kiln cross sectional thermal loading
The speed of the kiln is always synchronized with the kiln feed. When the operator is
able to keep this relation in the correct way, most probably he will be able to keep the
kiln in good operation condition.
 What is the relation between kiln speed and the kiln feed rate?
1. If the feed rate changed but kiln speed is kept constant, the burning zone
conditions is remains unchanged from 25 to30 minutes until the different feed rate
arrives to this zone. After a short time, the kiln inlet temperature will start to
change making it necessary to readjust the I.D. fan speed and fuel rate
2. If the feed rate held constant and kiln speed is changed, there will be an immediate
reaction in the burning zone and the kiln inlet temperature and this will demand an
adjustment in I.D. fan speed and fuel rate in the same time with the changing in
the kiln speed
It is important that the operator should keep his attention on the instruments that
registering feed loading or feed rate advancement to the kiln. Any abnormalities will be
noticed as early as possible since this of prime importance in controlling the variations
that may take place in the kiln.
This attitude will give the chance to the kiln operator to detect, counteract these
conditions, and save the kiln from serious upset.
 CCR Operators
Kiln Control Variables 35/35

The chance of overfeeding or the opposite of under feeding the kiln can be very
damaging to the kiln condition and to the refractory in the second case ( feed storage ).
The negligence from the kiln operator side in this critical matter is unforgivable.
Uniform feeding to the kiln is the first step toward stable kiln condition.

But when the operator after achieving stable condition in the kiln try again to add more
feed and what are the criteria to be questioned before he takes such act?
The operator or kiln manager can try to add extra tons to the kiln production when :
 He has additional grinding capacity in the raw grinding department to cover the
additional kiln feed and/or enough raw meal in kiln feed storage silos.
 The kiln operates in stable condition over reasonably extended period of time with
stable burning zone temperature and kiln inlet temperature prior to the intend feed
increase.
 The oxygen reading in the kiln inlet is above 1.5 for at least one shift.
 The black feed in the burning zone, during the last shift is consistently located
behind or directly under the end of the flame inside the kiln.
 In the addition to the excess oxygen the kiln has, it is preferably to have some
reserve rpms in the I.D. fan speed to be utilized if needed.

If these conditions are met, the possibility of increasing the kiln feed few tons is there,
but it should be done in small steps and in a manner that would not upset the delicate
stability of operation. The operator should wait from 2 to 4hrs before trying another
increase in the kiln feed rate. He should look for the same condition as before then he
starts another increase.
It is very important to make this increase in the feed at the end of any operation shift so if
he starts something in the kiln he should complete it and not create difficult conditions
for the next kiln operator.
It is necessary that the kiln department manager evaluate what effect the proposed change
will have on the overall prospects of kiln condition, fuel efficiency, clinker size,
burnability and adjustments that may have to be made to fuel rate, I.D. fan speed, kiln
speed, and other variables.