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Clinker Production Line Assessment
Description:
A performance Improvement Audit of the clinker production line
Procedures:
- Heat & Mass balance of operating Line.
- Crushing and grinding Operation Performance review
- Pyro line operation review, preheater, kiln and cooler
- Quality Performance Review, raw mix and clinker quality
- Main Equipment Capacity Assessment
- Main Burner Audit
- Implementation of cost free actions to improve performance
- Control loops review.
- Specific Heat Consumption reduction recommendations
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Operation assessment
Description:
Quick evaluation of operation and quality parameters of the production line targeting to find quick wins to improve production capacity and enhance heat and power consumption rates.
Procedures:
- Raw mix and product sampling
- Mill and kiln operation parameters recording
- Operational activities trending package
- Review operation and quality parameters
- Performance review of each shop
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Volatile Balance & Build up Control
Description:
Close monitoring to the volatile matters cycle in the pyro system and giving the correct measure to control it
Procedures:
- Perform volatile balance
- Review kiln feed and Main volatile components material, Alkali/sulfate ratio
- Thermal profiles of preheater, kiln inlet, riser and cyclones
- Build up tracker
- Assess kiln operation and review operational parameters
- Check gas analyzers and sensors
- Build up control procedures
- Evaluate manual cleaning: techniques, tools and safety precautions
- Preventive cleaning plan and recommendations
- Shutdown cleaning procedures
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Build up automatic cleaning system
Description:
Evaluate and upgrade build up cleaning system at the preheater and cooler shops
Procedures:
- Check current air blasters performance
- Repair defects
- Study build ups locations and behaviour
- Proposal of new air blasters installation
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Coal shop Safety Assessment
Description:
Executing Coal Shop Safety Audit and defining gaps “Coal shop includes: raw coal handling, coal grinding, fine coal handling”
Procedures:
- Check fundamental safety of equipment: explosion vents, access restrictions, earthling straps, motors, safety signage, escape routes….
- Review Interlocks and control loops
- Evaluate coal mill operation, operational targets, expected limits and records
- Review kiln and coal shop start/ stop/ emergency stop procedures
- Evaluate Management and operators awareness and competencies
- Check Coal mill bag filter hazards
- Evaluate Excessive level of oxygen in the shop.
- Check critical Sensors availability and sensors calibration, Gas analyzers
- Assess raw coal storage , different types of coal, first in- first out
- Fire suppression system assessment
- Evaluate General Housekeeping and Housekeeping Advice
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False air mapping
Description:
False air audit to define false air positions throughout the pyro-line
Procedures:
- Measuring and calculating false air at the pyro-line
- False air mapping report with recommendations
Deliverables:
Stop pyro-line leaking leads to increase productivity and reduce thermal and power consumption
Advantages:
Take measures of sealing the pyro-system during running and plan for repairs at upcoming shutdown
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Alternative Fuel Co-processing
Description:
Operating and burning multiple alternative fuel without any disturbances for the entire process
Procedures:
- Alternative fuel performance evaluation
- Fuel mix cost analysis
- Alternatives possibility study
- Storage management
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Alternative Fuel New Projects
Description:
Design and installation new alternative fuel systems
Procedures:
- Resourcing and evaluation new alternative fuel types
- Production line operation and quality assessment
- Providing the engineering and design phase
- Installation and commissioning of the new system
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Raw Mix Audit
Description:
Study, analyze and design raw mix based on available raw materials, quarry and mining plans, produced cement types and international standards in order to provide best achievable raw mix.
Procedures:
- Check Chemistry Variations: Quarry, external suppliers and RM
- Check Sampling Methodology: Equipment, protocol, delays
- Main Equipment: Operation, Reliability
- Dust management: by pass, kiln dust
- Check Feeders: Accuracy, Calibration, control loop
- Check Software (QMC): Use, optimization, communication
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Kiln alignment
Description:
This service aims to restore optimum mechanical condition for rotary kilns by performing Kiln (cold and/or hot) alignment services including shell profile study and mechanical audit for all kiln elements.
Procedures:
- Measurement of kiln and rollers 3-D coordinates and axis of rotation.
- Measurements of axial slopes of rollers and base plates
- Measurements of rollers and tires diameters in five points along the width
- Measurement of tires and rollers temperature distribution along their width.
- Measurements of girth gear / pinions temperature distribution along their width.
- Measurement of girth gear and pinion meshing in the hot condition
- Measurement of girth gear and tires axial run-out (wobble) in the hot condition.
- Measurement of foundation levels and settlement values.
- Determining the kiln supporting rollers movements required to correct the kiln centre of rotation in the hot condition
- Measurement of kiln shell profile (deformation – axial and radial deviations)
- Measurement of temperature of tire and kiln shell for its total length
- Detailed kiln mechanical auditing will be performed
- Measurement of tires migration and top hot gap.
- Measurement of thrust rollers positions and slopes.
- Preparation of optimal version of adjustment program and schedule.
- Supervision over adjustment procedure
- Supervision over fine adjustment of kiln mechanical balance and requested kiln thrust (Rollers skewing).
- Carry out On-Job-Training to a group of the plant technical staff showing all the measurements steps and procedures
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Kiln rollers and tires grinding
Description:
Surface grinding for kiln carrying rollers and tires to repair surface and increase surface of contact
Procedures:
- Measurements of the tires/rollers diameters in five points along their width. Obtaining their surface profile before and after grinding process (mechanical wear of running surface).
- Measurements of the tires/rollers temperature distribution along the five points on their width.
- Installing the required scaffolding.
- Delivering and assembling the grinding machines.
- Installing and removing the required measuring platforms.
- Eliminating any timing marks, highs and lows, and chatter in the roller surfaces. After grinding the deviation in taper will be less than 0.5mm along the whole width and the straightness will be less than 0.2mm between the ground surface and straight edge.
- Performing rollers repositioning to compensate new ground diameters.
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Detailed specific mechanical audit - kiln
Description:
Comprehensive study of the mechanical health and running conditions of all kiln mechanical elements
Procedures:
Check the operating environment
- Climatic
- Radiated heat
- Dust and spillage
- Equipment size
Check rollers and bearings
- Roller bearings.
- Roller thrust rings.
- Roller surface lubrication.
- Bearing lubrication.
- Roller shafts.
- Roller diameters measurements.
- Roller slopes.
- Roller skewing.
- Roller surfaces general conditions. (Porosity, edge flanging, cracks, etc.….)
Check tires and pads
- Tire diameters measurements.
- Tire edge flanging.
- Migration measurements.
- Top hot gap measurements.
- Tire pad lubrication.
- Tire cooling systems.
- Tire surface lubrication.
- Tire wobbling measurements.
Check thrust rollers
- Thrust roller location.
- Thrust roller traversing.
- Thrust roller hydraulic pressure.
- Thrust roller surface.
- Thrust roller/thrust face contact area.
Check kiln drive system
- Drive motor sizing.
- Main gear box.
- Girth gear and pinion meshing values measurements.
- Girth gear and pinion teeth general conditions.
- Lubrication of girth gear.
- Barring gear general condition.
Check kiln shell
- Kiln shell profile measurements.
- Kiln shell temperature profile measurements.
- Kiln shell general condition.
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Cooler detailed mechanical inspection
Description:
Performing comprehensive audit for cooler elements
Procedures:
- Detailed mechanical inspection of all elements:
- Visual and specific inspection at all elements of clinker cooler in order to confirm mechanical health of each part and identify bottlenecks.
- Operation parameters assessment:
- Collection, measurement and assessment of cooler operation parameters to identify actual achievable performance limits.
- Reliability and capacity enhancement options details:
- Propose possible and recommended capacity enhancement options
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Bypass system optimization
Description:
To optimize bypass system to decrease by-pass rate and eliminate build up problems
Procedures:
- Raw Mix preparation optimization (strategy from quality control point of view)
- Pyro-line Operation review
- Major Cleaning operation
- Process Measurement Management
- Managing Critical sensors
- Preventive build-up elimination campaign
- evaluate cooling tower and filter performance
- Detailed pyro line assessment campaign including Kiln Throughput weight.
- Thermography campaign
- CFD modeling “optional”
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Modernization
Description:
Perform an upgrading and /or amendment to existing equipment targeting increasing capacity, elimination of major and chronic problems, and reduction of power consumption
Upgrade of:
- Burner
- Cooler
- Process filters
- Main fans
- Kiln drive
- Grinding capacity (raw mills and cement mills)
- Alternative fuel projects
- Fuel switch projects (liquid or gas to solid fuel)
- Waste heat recovery units, power cogeneration
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Plant Debottlenecking assessment
Description:
A plant shops assessment aiming to increasing production rate, without sacrificing reliability Performing a bottleneck assessment is to get a systematic picture of the plant limitations. And identify the potential actions to improve production line capacity.
Procedures:
Burning line assessment
- Kiln feeding system
- Preheater / Calciner
- Kiln
- Fuel Dosing System and Main Burner
- Clinker cooler
- Kiln ID fan
- Gas Conditioning
Raw Meal and Fuel Grinding shop assessment
- Mill shop reliability and utilization factors
- Drying capacity
- Mill ventilation and fan performance
- Grinding capacity
Filters and Exhaust Fans
- Kiln Process Filter
- Kiln Filter Fan
- Cooler Exhaust Filter and Fan
Raw mix preparation
- Raw mix uniformity assessment
- Storage Capacity Assessment
- Crusher Assessment
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Mill / Kiln performance tracking
Description:
It is a tool to track and assess production line operation and quality to increase overall performance
Procedures:
- Review data logging
- Review operational and quality targets
- Applying Mill/ Kiln Tracking tools
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Energy management Thermal Management
Description:
Reduction and optimizing thermal energy consumption at pyro-line
Procedures:
- Raw-mix consistency check
- Oxygen levels in pyro-line control
- Fuel combustion optimization
- Kiln stability Mastery
- Cooler efficiency optimization
- Pre-heater and Calciner operation mastery
- Kiln throughput Optimization
- Main equipment down town minimization
- Wasted cement kiln dust or kiln dust losses minimization
- Check applying operating procedures
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Refractory Installation Projects
Description:
To perform refractory work new installation and rehabilitation projects
Procedures:
- Site Visit and collecting Data
- Checking drawing and data sheets
- Risk Assessment
- Analyzing and setting action plan
- Following the Action plant and respecting safety rules
- Handing over and reporting
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Refractory Management Assessment
Description:
Overall assessment of refractory work at the plant to evaluate types, consumptions and installations procedures
Procedures:
- Kiln operation review
- Refractory performance review, KPIs
- Refractory storage assessment
- Refractory Forecasting
- Refractory sourcing & ranking
- Refractory installation procedures
- Kiln Shutdown guidelines
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Refractory supervision and Guidance
Description:
To provide professional supervision and guidance during performing refractory work and shutdowns by refractory experts
Procedures:
- To provide supervision and guidance to:
- Overhauls and shutdowns
- Brick inspection
- Critical Installation like retaining rings and kiln feed shelf
- Special refractory services
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Production Line Boost Campaign
Description:
Full production line operation audit and enhancement campaign performed by a team of experts and targeting complete production line enhancement ( boost) to obtain best achievable production and heat and power consumption rates for all line equipment.
Procedures:
- 1. Full plant Operation assessment
- 2. Action plan and detailed operation management program.
- 3. Action Plan implementation
- 4. Follow up and performance guarantee.
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Housekeeping
- General housekeeping
- Solid fuel shops
- Packing plants
