To download the below  and all other Useful Books and calculations Excel sheets please click here 

To download the below  and all other Useful Books and calculations Excel sheets please click here 

7 Most Common Problem in PyroProcessing for Kiln and Cooler

Ø Cyclone Blockage

Ø Kiln inlet Blockage

Ø Big clinker ball formation

Ø kiln Coating

Ø Feed rushes and dusty kiln

Ø Cooler Snow Man

Ø Red river in clinker cooler

Main Reasons for Cycolne Blockage 

• Insufficient suction due to low rpm in PH fan.
• Flap valve failure & blockage in material pipe.
• Refractory failure.
• High Iron % in Raw mix.
• High Sulfur % in fuel(i.e- coal)

Main Reasons for Kiln Inlet Blockage 

• High Iron % in Raw mix.
• High Sulfur % in fuel(i.e- coal)

Main Reasons for big size clinker ball formation 

• High Iron % in Raw mix.
• High Sulfur (S)% in fuel(i.e- coal).
• Kiln running with slow rpm & % filling is more.
• High BZ temperature.
• % liquid is more.
• Higher % of Magnesia (MgO).

Main Reason for heavy coating  formation in kiln

• High Iron % in Raw m
• High Sulfur (S)% in fuel(i.e- coal).
• Kiln running with slow rpm & % filling is m
• % liquid is m
• Higher % of Magnesia (MgO).

Main Reason for Feed rushes and dust kiln

• High lime in Raw mix or high LSF.
• Very less % of liqui
• High A
• Less iron% in raw m
• Blockage of hot meal due to clinker ball occasion

SNOWMAN FORMATION IN COOLER

• Higher % of liquid, may be iron % is more in raw mix so hot meal will be sticky and viscous.
• Shorter cooling zone; so may be shortage of adequate quenching .
• Higher BZ temperature, may be due to short flame.
• Failure of air blaster in cooler 1st grate if any.

RED RIVER IN COOLER

• Uneven distribution of cooling ai
• Misalignment of kiln & cooler

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