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22 problems in New dry Kiln Operation

 1. the kiln tail and pre-decomposition system temperature is high

 
1) Check whether the KH and n values ​​of raw meal are too high, and the content of molten phase (A1203 and Fe203) is low; whether the raw material fsi02 is relatively high and the raw material fineness is coarse. If several cases are true, the clinker is difficult to sinter due to poor burnability of raw materials, and the above-mentioned high temperature is a normal phenomenon. However, attention should be paid to the control of the extreme temperature and the kiln tail O: content.
 
2) The ventilation in the kiln is not good, the air excess coefficient control at the kiln is low, and the system leaks to produce secondary combustion.
 
3) If the weight of the ash discharge valve is too light or because it is afraid of blockage, the kiln tail post will lift the valve stem of the ash discharge valve, resulting in lower dust collection efficiency, increased material circulation and higher temperature of the pre-decomposition system.
 
4) Insufficient feeding or uneven feeding.
 
5) The clogging of the cyclone causes the temperature of the system to rise.
 
6) The wind outside the burner is too large and the flame is too long, resulting in a high temperature at the kiln tail.
 
7) The firing zone temperature is too low and the pulverized coal is post-combusted.
 
8) The kiln tail negative pressure is too high, the pumping force in the kiln is too high, and the high temperature belt is moved backward.
 

2, the kiln tail and pre-decomposition system temperature is low

 
1) For a certain amount of feed, the amount of coal used is less.
 
2) The ash discharge valve is not flexible, and it is partially stacked or collapsed. Due to poor material dispersion and poor heat exchange, the preheater C, the outlet temperature rises, but the kiln tail temperature drops.
 
3) The preheater system leaks air, increasing the amount of exhaust gas and heat consumption, and the temperature of the exhaust gas is lowered.
 

3, the firing zone temperature is too low

 
1) The wind, coal and materials are not well matched. For a certain amount of feed, the heat consumption control is low or the flame is too long, and the high temperature belt is not concentrated.
 
2) Under certain combustion conditions, the kiln speed is too fast.
 
3) The material of the preheater system is collapsed and the raw material with low temperature and low decomposition rate is in front of the kiln.
 
4) When the kiln tail feeds more or kiln skin, the amount of coal used does not increase in time.
 
5) In the case of poor ventilation in the kiln, the amount of coal used in the kiln head is increased. As a result, the temperature of the kiln tail rises and the temperature of the firing zone decreases.
 
6) The clinker layer on the one-chamber of the cooler is too thin and the secondary air temperature is too low.
 

4, the firing zone temperature is too high

 
1) The amount of coal used is not reduced in time.
 
2) The wind in the burner is too large, causing the flame to be too short and the high temperature belt to be too concentrated.
 
3) The secondary air temperature is too high, the black fire head is short, and the fire point position is moved forward.
 

5, the secondary air temperature is too high

 
1) The flame is too scattered, the coarse coal powder is mixed with human clinker, and the person continues to burn after cooling.
 
2) Clinker clinking is too fine to increase the resistance of the layer, the secondary air volume is reduced, and the air temperature is increased; a large amount of fine clinker is returned to the kiln along with the secondary air.
 
3) The clinker is well granulated, but the one layer of the cooler is too thick.
 
4) The flame is too short, the high temperature belt moves forward, and the temperature of the clinker from the kiln is too high.
 
5) The kiln skin, the front ring or the back ring, so that the amount of clinker in the kiln increases during a certain period of time.
 

6, the cooler exhaust gas temperature is too high

 
1) The cooling machine jaws run too fast, and the clinker does not cool enough to enter the middle or rear of the cooler.
 
2) The clinker cooling air volume is insufficient, the clinker temperature of the cooling machine is high, and the exhaust gas temperature naturally rises.
 
3) The clinker layer resistance is too large (the material layer is too thick or the clinker particles are fine) or the material layer is too easy to penetrate (the material layer is too thin or the clinker particles are too thick), so that the clinker is not well cooled, and the temperature of the outlet gas rises. high.
 

7, the secondary air temperature is too low

 
1) The nozzle extends, the flame is longer, and there is a certain length of cooling belt in the kiln.
 
2) The cooling chamber has a thin layer of material (the material layer is thin and recovers less heat and the temperature is low).
 
3) The air volume of the one-chamber high-pressure fan of the cooling machine is too large.
 
4) The clinker on the raft is unevenly distributed, and the cooling wind is short-circuited and does not have a cooling effect.
 

8, burned with material over burned

 
1) Too much coal is used and the firing temperature is too high.
 
2) Clinker KH and n are low, and AI2O3 and Fe203 are high.
 
3) The raw material is not well homogenized, the chemical composition fluctuates too much or the raw material fineness is too fine, so that the material is too easy to be sintered.
 
4) When the kiln ash is directly connected to the kiln, the proportion of instantaneous mixing is too large.
 

9, the preheater negative pressure is too high

 
1) If the gas pipeline, the cyclone population passage and the kiln tail chamber produce crusts or piles, the negative pressure will increase afterwards.
 
2) If the material layer on the raft is too thick or the front ring is high, the air volume of the secondary wind kiln will decrease, but the air volume of the high temperature fan at the kiln end will remain unchanged, and the system negative pressure will rise.
 
3) In the kiln, the knot or the long thick kiln skin will increase the negative pressure afterwards.
 

10, kiln head tempering

 
1) Cooling machine exhaust fan valve opening is too large.
 
2) The clinker cooling fan fails or the material layer is too dense, and the resistance is too large, resulting in a decrease in cooling air volume. In the case that the opening degree of the cooling machine exhaust fan is constant, the wind will be forced from the kiln.
 
3) The ash hole of the kiln tail and the observation hole are suddenly opened, and the pumping force of the system is reduced.
 
4) In the kiln ring, the system resistance increases, the kiln head negative pressure decreases or even positive pressure occurs.
 

11, knot kiln ring

 
1) The secondary air temperature is high for a long time, the pulverized coal burns too fast, and the flame is too concentrated.
 
2) The firing zone is too hot and the material is too hot.
 
3) The clinker particles are too fine and the powder is more. The opening of the high pressure fan of the cooling machine is too large, and a large amount of powder is returned to the kiln.
 

12, after the ring

 
1) The uniformity of raw materials is poor, the chemical composition fluctuates greatly, and the molten phase changes significantly.
 
2) The raw material KH or n value is low, and the calcination flame is too long.
 
3) The coal powder is coarse or the combustion air is insufficient to produce a reducing atmosphere, so that Fe203---FeO, the liquid phase appears in advance.
 
4) Coal and wind are not well mixed, and coal ash is concentrated and settled.
 

13, preheater system collapse

 
1) The kiln output is low and is in the danger zone of collapse.
 
2) The amount of feed is suddenly too small and unstable.
 
3) The design structure of the cyclone is unreasonable. The horizontal section of the inlet of the cyclone is too long, and the inclination angle of the bottom of the volute is too small, which is easy to accumulate.
 
4) The sealing outlet of the cyclone cone, the ash discharge valve and the discharge pipe are not well sealed, and the air leakage is serious.
 

14, running raw materials

 
1) For a certain raw material feeding amount, the amount of coal used is less, the heat consumption control is lower, and the calcination temperature is not enough.
 
2) The ring or a large number of kiln skins fell, the amount of incoming material suddenly increased, and the operator did not know or did not pay attention, the coal consumption and kiln speed were not adjusted or judged incorrectly.
 
3) The amount of coal used in the decomposition furnace is too small, the decomposition rate of the raw material of the human kiln is low, the coal used in the kiln is large, but the ventilation in the kiln is not good, and the temperature of the firing zone cannot be raised.
 
4) Rotary kiln production runs in a low range, causing frequent collapse of the preheater system.
 

15, the kiln head or the cooling machine back to the kiln clinker dust is too large

 
1) The firing zone has a low temperature, the clinker is not well burned, and the fCaO content is high.
 
2) The L/D value of the rotary kiln is too large, and the CaC03 decomposition rate of the human kiln raw material is too high, which makes the new ecological CaO and C2S crystallize in the longer transition zone, and the activity is reduced. It is difficult to form C3S and it is easy to fly. Sand material.
 
3) n is too high, the amount of liquid phase is too small, clinker sintering is difficult, and it is easy to produce flying sand. .
 
4) The kiln head runs raw material.
 
5) The air volume of the one-chamber high-pressure fan of the cooling machine is too large.
 
6) A large number of kiln skins are fallen, and this kiln skin is relatively loose.
 

16, the flame is too long

 
1) The wind outside the burner is too large, the internal wind is too small, and the wind coal is not well mixed.
 
2) The secondary air temperature is low.
 
3) The system exhaust is too large and the flame is stretched.
 
4) The pulverized coal has low volatile content, high ash content and low calorific value; or the pulverized coal fineness is too thick and the water is high, the pulverized coal is not easy to catch fire, and the black fire head is long.
 

17. The flame is too short

 
1) The kiln head negative pressure is too small, and even positive pressure appears.
 
2) The secondary air temperature is high and the pulverized coal burns at a high speed.
 
3) The kiln inner ring, the thick kiln skin, or the crust blockage of the preheater system.
 
4) The wind in the burner is too large, and the outflow wind is too small.
 
5) The quality of coal powder is good, the ignition point is low, and the burning speed is fast. In this case, the fineness can be appropriately relaxed.
 

18, the kiln tail or C5 export CO content is high

 
1) The system exhausts insufficiently and the excess air coefficient is controlled to be small.
 
2) The fineness of coal powder is high, the water is high, and the burning speed is slow.
 
3) The wind in the burner is too small, and the coal wind is not well mixed.
 
4) The secondary air temperature or the firing zone temperature is low, and the pulverized coal is not well burned.
 
5) The ash hole and the observation hole opening time of the preheater system are too long, or the shutdown is not strict, resulting in insufficient system pumping force.
 
6) The system has a serious air leak. At this time, if the high-temperature fan capacity is originally small, the impact on the firing system is even greater.
 

19, clinker is easy to form a large block, the vertical rise is too high

 
1) The clinker KH and n values ​​are low, and the molten phase, especially the Fe203 content, is too high.
 
2) The flame is too short, the firing temperature is too high, and the material is burned.
 
3) For the actual calcination situation at that time, the control kiln speed is too slow.
 
4) The amount of coal used is large, and the control heat consumption is high.
 

20, clinker eat fire, poor granulation

 
1) Clinker KH and n values ​​are too high and the melt phase is too small.
 
2) The raw material fineness is too coarse, the pre-burning is poor, and the chemical reaction is slow.
 
3) The flame is too long, the high temperature zone is not concentrated, and the firing temperature is low.
 
4) The kiln speed is too fast and the residence time of the material in the kiln is too short.
 

21, kiln drive motor current is too large

 
1) The kiln speed is too low and the material filling rate in the kiln is high.
 
2) The proportion of pulverized coal used in the kiln is too large or the control heat consumption is too high. The temperature of the firing zone is too high, which increases the rotational torque of the kiln.
 
3) The burned belt material is over-fired or the raw material KH, n value is low, the flux mineral content is high, the raw material is easy to be sticky, the material in the kiln is high, and the energy consumption is large.
 
4) The ring in the kiln increases the amount of material in the kiln. mainly:
 
1 ring body itself increases the transmission load;
 
2 After the ring is closed, the amount of material accumulated in the kiln increases. The higher the circle, the more material is accumulated in the kiln.
 
5) A large amount of kiln skin in the kiln can cause the kiln drive current to rise sharply, with large fluctuations, and then fall faster.
 
6) The lubrication between the kiln drive gear and the pinion is not good, so the transmission resistance is increased.
 
7) The contact between the wheel and the roller is not good.
 
8) The end of the kiln is too close to the cutting slope to generate friction during operation.
 
9) The movable parts of the kiln head and the kiln tail sealing device are not in good contact with the inactive parts, which increases the resistance.
 

22, kiln drive motor current is too small

 
1) The firing zone has a low temperature.
 
2) The kiln output is low, but the kiln speed is faster and the kiln load is lighter.
 
3) The kiln skin is thinner and more flat.
 

23 cooler zipper overload stop

 
1) The clinker particles are too fine, and a large amount of fine-grain clinker enters the zipper through the quilting.
 
2) The cooling plate is damaged, and the clinker leaks into the zipper.

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