PH temp. profile
We are hving six stage pre-heater with a capacity of 5000 TPD. Four months back bottom (6th) cyclone immersion tube was damaged so, we are operated the kiln without immersion tube and not faced any operational problem. But 10 days back we lost our 4th cyclone immersion tube, to procure the same we need atleast 30 days so mean while we are operating the kiln without immersion tube in 4th and 6th cyclone.
We are facing lot of operational problems, basically PC temperature is suiting up to plus 1060 deg. C and 6th cyclone (bottom most) meal temperature not yet comming more than 840 deg. C some times it is droppin to 820 deg.C also. same time we observed that kiln inlet temperature increasing drastically, but kiln inlet nox is not crossing 400 ppm instead of 600 to 800 ppm. with this PH temp profile we are operating the kiln with 240 to 250 feedrate instead of 340 to 350 tph.
My querry is what could be the technical reason for improper temperature profile arcoss PH. Is it because of not having immersion tubes are any other reason.
Reply in this regard is highly helpfull for me.
Thaks in advance.
re PH temp. profile
You noted that your fourth cyclone dip tube also damaged. Whether the damage is full? All dip tubes removed? Have you checked inside the cyclone?
Before starting check all the cyclones. Cyclone cone may be partially blocked with parts of damaged dip tube. That may be the reason for sudden change in temperature profile and operation with less production. Check all cyclone cone meal chutes for proper flow of material.
Do u have CO analyser at calciner outlet and preheater outlet? If the CO levels are in higher side stop the plant and check the fourth cyclone thoroughly.
Best of luck.