One The tasks of the kiln operator (central control operator):

The kiln operator is one of the key positions in a cement plant. With the cooperation of all relevant departments, the kiln operator bears certain responsibilities for the quality, output, consumption, costs, and safe operation of equipment related to cement clinker production. Through careful monitoring and control of the kiln firing process, the kiln operator must optimize the interplay among air, coal, raw materials, kiln rotation speed, and kiln skin, aiming to produce high-quality cement clinker with minimal fuel and electricity consumption.

To operate firework devices, one must also have a thorough understanding of the performance, maintenance, and operational safety procedures and requirements for each piece of equipment in the system. It is essential to be thoroughly familiar with the operating methods and procedures, as well as the normal ranges and alarm thresholds for each instrument's measurement points, and to know the appropriate actions to take when alarms are triggered. During operation, any potential issues that may arise should be addressed promptly.

Two The kiln operator (fire control operator) should observe the following aspects:

Incoming material size

Observe the size of the feed material entering the kiln by monitoring the flowmeter on the kiln inlet chute. Additionally, you can monitor the current draw of the kiln lift motor to gauge the amount of raw material being fed into the kiln. As the material size increases from small to large, the material layer thickens, becoming narrower at the front and wider at the back; the shadow’s position continuously shifts forward. With the inner and outer airflows remaining constant, the shadow’s position keeps moving forward, causing the flame to retract. Conversely, as the material size decreases from large to small, the material layer thins, the shadow recedes, the flame lengthens, and the flame becomes brighter.

Flue gas temperature variation

The temperature of the flue gas chamber at the kiln outlet is commonly referred to as the "tail temperature." Depending on the kiln type, production method, and operating conditions specific to each plant, the tail temperature can vary in terms of its control level. However, the narrower the fluctuation range, the better. The primary methods for controlling the kiln outlet temperature involve increasing or decreasing the exhaust air volume or adjusting the feed rate accordingly. The kiln outlet temperature serves as a key indicator of whether the thermal process is stable and whether the material feed is uniform and normal. By monitoring changes in the kiln outlet temperature, one can predict incoming material conditions. Maintaining a stable kiln outlet temperature ensures consistent kiln performance. Burn The firing is stable, and the calcination process is normal. Therefore, the kiln operator must carefully monitor the kiln fire—of course, including factors such as negative pressure—and observe the flue gas temperature at all times. If any fluctuations occur, the operator should increase the frequency of monitoring, pay close attention to any changes, and make timely adjustments to ensure that the flue gas temperature remains within the specified range. ±5~10℃ Fluctuating within the range.

Material granulation and lifting height

The clinker particles are uniformly fine and small. 5~20mm Occupation 80% Above, some eggs—about the size of walnuts—are mixed among the small particles, allowing them to roll around freely. The clinker exiting the kiln has a grayish-white color. When the clinker composition remains unchanged, the higher the clinker is lifted by the kiln's rotation, the higher the firing zone temperature; otherwise, the opposite is true.

In addition, many factors influence the size of clinker granules, such as the fineness of coal powder, the level of volatile matter, and the amount of flux minerals. KH 、 n High and low, MgO High and low.

Flame shape, color, and coal feed rate

Coal powder burner During normal calcination, the flame is smooth, lively, and vigorous; the front part is bright white, the middle part is pinkish-white, and the rear part turns black. The flame’s shape closely resembles a brush tip, with an appropriate length that does not scrape off the kiln lining.

Normal firing zone cylinder temperature 200~330℃ , no knot loop.

Coal feeding is stable, and the proportion of coal fed to the kiln head versus that fed to the decomposition furnace is appropriate. Generally, coal injection at the kiln head accounts for approximately the total coal consumption. 40% Coal feeding in the decomposition furnace accounts for approximately... 60% Right. Properly control the fineness of coal powder; the fineness of coal powder should be adjusted according to the volatile matter content of the coal. For bituminous coal with high volatile matter, the coal powder should be coarser; conversely, for bituminous coal with low volatile matter, the coal powder should be finer to accelerate the combustion rate.

Whether the fineness of coal powder is appropriate can be judged based on the following points:

① The temperature of the decomposition furnace body is generally... 850~900℃ The outlet temperature of the decomposition furnace is lower than the temperature of the furnace body itself. 20℃ By the way, if the temperature at the outlet of the decomposition furnace exceeds the temperature inside the furnace body—that is, if there’s a temperature inversion—it indicates that the coal has a low volatile matter content and burns slowly. In this case, you should reduce the fineness of the pulverized coal.

② Are there many buildup rings, clinkers, and scale deposits in the kiln tail flue and the calciner’s throat and nozzle? Has the fineness of the coal powder been properly assessed? If any of the above conditions occur, eliminate any harmful elements. ( such as S 、R2O、 Cl-) In addition to the influences of the three output factors, it can be determined that when the coal powder fineness is coarse, the combustion rate is slow, and the flame is long, appropriate adjustments can be made by reducing the external air flow and lowering the coal powder fineness.

Coal powder burner Wind coal Proportion Cooperate

Wind coal Proportion Appropriately coordinated, Coal powder burner combustion The flame is complete, smooth, lively, and powerful, without scorching the kiln lining, and the interior of the kiln remains bright and clear. When more coal is added with a single blast of air, the flame turns reddish, the black flame tip becomes long, soft, and weak, resulting in incomplete combustion. Examining the gas composition at the kiln tail, we can see that... O2 Low content, CO High content. ( Normal O2 1.5-2.5% ； CO 0-0.3%) If the flame is long but weak and keeps retracting, it indicates that the exhaust volume is too high; therefore, you should reduce the exhaust volume of the high-temperature fan.

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