LEARNING REPORT

Safety Considerations
Mass Flow
Major Systems
Kiln Feed Extraction
Dedusting
Preheating/Pre-Calcining
Pyro-processing
Cooling
Insulation
Fuel
Blowers
Transport
Plant Air
Auxiliaries
Kiln Camera
Gas Analyzers
Air blasters

Interlocks
Routine Activities
Inspections
Housekeeping
De-blocking
Cleaning kiln camera
Emptying pan conveyor dust tray
Poking (kiln backend, burner rhino
horn)



PRESENTATION OUTLINE

Hazards:
Hot surfaces/environment
Fire
Heights
Gas handling
Oil handling
Noise
Others
Mitigation:
PPE: Hard hat, coverall, safety
shoes, hand gloves, eye goggles
are standard PPE in UniCem. Area
specific requirements include
thermal suit, ear muff.
Equipment: Fire extinguishers,
Housekeeping.
Safety Considerations
Safety Procedures:
Risk assessment, hot work permit, work at height & fall hazard risk assessment,
confined space permit, scaffold request

Mass Flow
Material, Gas, Dust
Material Flow
X X X X X X X
2
3
4
5
CF Silo
K K
L.O.W.
Bin
B B
Mixing
Vessel
Kiln
G
C
a
l
c
i
n
e
r

Cooler
X
Clinker
Silo
Gas Flow
X X X X X X X
2
3
4
5
CF Silo
K K
L.O.W.
Bin
B B
Mixing
Vessel
Kiln
G
C
a
l
c
i
n
e
r

Cooler
X
Clinker
Silo
Dust Reclamation Flow
X X X X X X X
2
3
4
5
CF Silo
K K
L.O.W.
Bin
B B
Mixing
Vessel
Kiln
G
C
a
l
c
i
n
e
r

Cooler
X
Clinker
Silo

Major Systems
Kiln Feed Extraction, Preheating/Pre-Calcining, Pyro-processing, Cooling,
Insulation, Fuel, Blowers, Transport, Plant Air & Water
Kiln Feed System
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1. Extraction gates:
- 7 in number
- Operate according to a predetermined sequence to extract material from
the CF-Silo at different rates. This is key to CF-Silo homogenization
- Pneumatically actuated
2. Extraction air-slides
3. Aeration system & patches:
- Responsible for fluidization of material
- 42 aeration patches
- Fed by blowers 341BL300, 305, 310 (for extraction) and 351BL110, 111 (for
LOW)
4. Mixing tank
5. Butterfly valves
6. Loss-of-Weight bin:
- Allows for accurate metering of kiln feed flow
- 3 load cells
- Operates by using control parameters to open/close the Kiln feed flow
control gates to achieve flow set-point
7. Kiln feed control gates
8. Air-slide 300
9. Air-lift 351AL340:
- Powered by 6 blowers 351BL342 to 347
- Operating pressure range (420 480)mbar
Dedusting
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1.
- 7 in number
- Operate according to a predetermined sequence to extract material from
the CF-Silo at different rates. This is key to CF-Silo homogenization
- Pneumatically actuated
2. Extraction air-slides
3. Aeration system & patches:
- Responsible for fluidization of material
- 42 aeration patches
- Fed by blowers 341BL300, 305, 310 (for extraction) and 351BL110, 111 (for
LOW)
4. Mixing tank
5. Butterfly valves
6. Loss-of-Weight bin:
- Allows for accurate metering of kiln feed flow
- 3 load cells
- Operates by using control parameters to open/close the Kiln feed flow
control gates to achieve flow set-point
7. Kiln feed control gates
8. Air-slide 300
9. Air-lift 351AL340:
- Powered by 6 blowers 351BL342 to 347
- Operating pressure range (420 480)mbar
Kiln Feed System
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1. Extraction gates
2. Extraction air-slides
3. Mixing tank
4. Butterfly valves
5. Loss-of-Weight bin
6. Kiln feed control gates
7. Air-slide 300
8. Air-lift

Refractories
X X X X X X X
CF Silo
K K
L.O.W. Bin
B B
Mixing Vessel
1. Extraction gates
2. Extraction air-slides
3. Mixing tank
4. Butterfly valves
5. Loss-of-Weight bin
6. Kiln feed control gates
7. Air-slide 300
8. Air-lift

Refractories
1. Exist as shaped and castable
2. Insulate vessel walls from thermal mechanical and chemical shock
1. Bricks
- Used exclusively in the kiln.
- Kiln process zones determine required properties
Refractories

Auxiliaries
Kiln Camera, Gas Analyzers, Air blasters
Kiln Main Burner System
Operation
Oil lance
Material Transport
Transport Process Diagram

Considerations
Material
Kiln feed; Fine, Sometimes moist (GCT outlet)
Clinker; Coarse lumps, hot.



Kiln Area Transport Equipment
Air Slides
Air Lift
Screw Conveyors
Drag Chains
Pan Conveyor
Bucket elevator