We have two kilns in our unit.  In  both  the kilns, we are facing very big unshaped clinker coating coming from kiln inlet to pre burning zone and disturb the steady kiln operations. Sometime, this very big coating block the entire cross section of the kiln at the pre burning zone starting. Experts may kindly suggest solutions to solve this problem

Dear Mr. T.Rajgopal,

Possible reasons for ring  & ball formation,

Raw mix design,

High coal ash %

High liquid phase

Quality/ condition of refractory

High alkali feed

Burner pipe condition

Cooler condition

But to study all above reasons we have to run our kiln for 20 ~ 30 days continuously, we have technique to remove big clinker balls without stopping the kiln.

  Vikpro

Hello Gopal 

You mentioned that coating comming from the inlet side...{But Your subject is different} 

so must check the coating status at mixing chamber and  riser duct and if you have inline calciner   must take inspection at venturi area.......

if your both lines facing same problem then lab must take serious action about it, may be your x-ray calibration is out of order  

Thank you very much.  Can you tell us the possible ways to break this coatings without kiln shutdown

Thank you very much.  Can you tell us the possible ways to break this coatings without kiln shutdown

if it is affecting on your production means due to to blockage, so use the man power at the approachable points, if it is not helping then you must take a small stoppage  

Hi:

Does liquid phase refer to (excessive) melting of low T components/intermediates? If yes, is it more reasonable to control the T-profile along the (critical) kiln zones? Having said that, how do you that? Does anyone have experience with thermo-couples in the lining?

Rgds,

Rudy 

Put air blasters at appropriate locations with sequential timers and use them regularly.

Bhaskar Agate

Dear,

        Please check your Raw Material compostion, the ball formation starts from the kiln inlet. One thing which is most important is the percentage of Alumina.

Regards,