TECHNICAL QUESTIONNAIRE FOR CEMENT PRODUCERS

RHI AG
Process Technology
Wienerbergstrasse 11
A-1100 Vienna / AUSTRIA
Fax: +43 - 50213 6405

REMARKS: This questionnaire is for compiling and storage of technical data on your cement plant. These data will
neither be published, nor be made available to 3rd parties, but will only be used for the preparation of
quotations, being in line with your specific requirements or demands. Thanking you for your friendly co-
operation and for your support.

CONTACT
COMPANY

ADDRESS

NAME

TELEPHONE

FAX

E-MAIL

Page 1 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls

LINING SITUATION AND PREPARATION OF DATA
We are a full range supplier of refractory material for the cement industry. Our aim is it to work in close
cooperation with you. We would like to discuss your actual refractory lining and process conditions to reach the
best possible performance of refractory materials in your kiln.

Please describe briefly the actual problems with refractory material in your kiln? Where are the main
problems?

Regarding refractory material, in which areas do you see potential for improvements?

Please kindly provide us also some important data and standard deviations, like:
1. daily sieve analysis of the main fuel on the 90 micron sieve for the period of 3 months,
further also the corresponding SO 3 content, the volatile matters, HCV and ash content

2. daily raw meal analyses (average & standard deviation) for the period of 3 months and

further also the moisture content & residue of ground raw meal on the 90 micron sieve

3. hot meal analyses (average & standard deviaton) for the period of 3 months

according to above required values

4. daily clinker analyses (average & standard deviaton) for the period of 3 months

according to above required values

5. refractory lining chart of the current and historical installalled lining, if possible a period

of, at least, 3 years

Page 2 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls

1. KILN DATA
kiln supplier:
kiln is producing grey cement [Y/N]:
kiln is producing white cement [Y/N]:
kiln diameter [mm]:
kiln length [mm]:
position of the different tire stations and girth gear
measured from kiln discharge end [m]:
type of process:
1st year of operation (commissioning):
for kiln with pre-heater tower only:
how many strings?
how many stages?
pre-calciner available?
secondary firing at riser duct?
tertiary air duct available?
how many tertiary air ducts?
degree of calcination at kiln inlet?

original clinker capacity [t/d]:

actual daily clinker capacity [t/d]:
availability, or run factor of the kiln [dpy], or [%]:
yearly production of clinker [tpy]:
yearly production of cement [tpy]:

type of cooler:
for grate cooler only:
how many grates ?
cooler designer?
for planetary cooler only:
number of cooler tubes?
diameter / length?
cooler designer?

Page 3 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls

2. REFRACTORY MATERIAL

present lining thickness of magnesite bricks [mm]:

present lining thickness of alumina bricks [mm]:
present brick shapes for magnesite bricks:
present brick shapes for alumina bricks:
present lining method for magnesia bricks
present lining method for alumina bricks:

specific refractory consumption

total [kg/t clinker]
magnesite bricks [kg/t clinker]
alumina bricks [kg/t clinker]
fireclay bricks [kg/t clinker]
refractory concrete [kg/t clinker]
presently or before used grades of magnesite bricks
high-grade magnesia-spinel bricks
standard magnesia-spinel bricks
magnesia-chrome bricks / dolomite bricks

kiln zones - basic refractory material

nose ring section [rm]
lower transition zone [rm]
central burning zone [rm]
upper transition zone [rm]
kiln zones - alumina refractory material
safety zone [rm]
calcining zone [rm]
preheating zone [rm]
inlet zone [rm]

coating area
stable coating area [rm]
unstable coating area (lower transition zone) [rm]
unstable coating area (upper transition zone) [rm]
other stable / unstable coating areas [rm]
coating thickness [mm]
any excessive coating ring formation [rm]

Page 4 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls

3. LINING CHART
Please mark the present lining and the major wear areas.

Page 5 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls

4. RAW MEAL AND HOT MEAL ANALYSIS
average raw meal analysis [%] + standard deviation :
CaO
SiO2
Al2O3
Fe2O3
MgO
K2O
Na2O
SO3
chlorine, CL-
L.S.F.
moisture content [%]
residue on 90 micron sieve [%]

average hot meal analysis [%] + standard deviation :

CaO
SiO2
Al2O3
Fe2O3
MgO
K2O
Na2O
SO3
chlorine, CL-
L.S.F.
moisture content [%]
residue on 90 micron sieve [%]

Page 6 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls

5. CLINKER ANALYSIS
average clinker analysis [%] + standard deviation :
CaO
SiO2
Al2O3
Fe2O3
MgO
K2O
Na2O
SO3
chlorine, CL-
L.S.F.
C3S
C2S
C3A
C4AF
CaO free
types of usually produced clinker :
clinker analysis silica ratio, min
silica ratio, max
alumina ratio, min
alumina ratio, max
clinker liter weight [g/l]
liquid phase, min [%]
liquid phase, max [%]

Page 7 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls

6. FUEL
manufacturer and type of the main burner:
how many channels for air + fuel?
type of fuel: main fuel
secondary type of fuel
fuel consumption of main fuel
at main burner (t/hr)
at calciner or pre-heater side(t/hr)
fuel consumption of 2 nd type of fuel [%]
at main burner side [%]
at calciner or pre-heater side [%]
heat calorific value of main fuel [kcal/kg]
heat calorific value of 2nd type of fuel [kcal/kg]
volatile matters of coal / petrol coke [kcal/kg]
ash content of main fuel [%]
ash content of 2nd type of fuel [%]
sulphur content of main fuel [%]
sulphur content of 2 nd type of fuel [%]
residue on the 90 micron sieve [%]
moisture content of fuel [%]
changes to fuel type ( i.e coal) in previous 12 months

7. MECHANICAL CONDITION
tyre migrations of
tyre 1
tyre 2
gearth gear
tyre 3

[rm] = running meter

Page 8 / 8 RHI AG, Process Technology 2010 RHI Technical Questionnaire.xls