We are one of the leading manufacturer of gas plant in India. We would like to know the following: How oxygen enrichment is beneficial in cememt industries? Do you have any information that any cement industries has opted for oxygen enrichment ?

Unfortunately these problems are regularly reported on kilns burning petroleum coke. The problem is caused by the sulphur content in the petroleum coke. This has the effect of reducing the viscosity of the flux and this leads to the increased fines generation in the clinker. You must ensure that you have good oxidising conditions in the burning zone to minimise the recirculation of sulphates. After that you need to change the chemistry to adjust the viscosity of the flux. Increasing the Al₂O₃ content may help, but perhaps the best solution would be to add some calcium fluoride to the kiln feed.

We are having Polysius design ILC six-stage kiln have dimension of 3.8m ID and 64m length. We are firing 100 petcoke in both main firing and calciner firing. We are facing problem of reduction in output and percentage of fines generation in clinker increased.The kiln feed and petcoke chemical analysis are as under: SiO₂ 13.80 - 14.10 Al2O₃ 3.6 - 3.75 Fe₂O₃ 3.4 -3.6 CaO 42.7 - 42.9 MgO 0.7 - 0.9 SO₃ 0.1 -0.16 K₂0 0.28 - 0.35 Na₂O 0.10 - 0.12 Cl 0.06- 0.09 Petcoke Analysis C 88.5 - 89.5 H₂ 3.8 - 4.2 S 6.0 - 6.5 Violatile Content 9.8 -10.4 Calorific Value 7960 - 8020 Kcal/Kg Coal Ash Content 0.30 - 0.70 Please suggest suitable counter measures to increase throughput rate and stable running of kiln.

It is not clear what problem you are suffering from. With petcoke clinker I expect there is a higher sulphate content in the clinker. Therefore you have to reduce the amount of gypsum addition and that will adversely affect the performance of the cement mill. I'm afrain there is no ready solution to that problem. The clinker might also be denser resulting in loss of milling efficiency. In that case addition of calcium fluoride to the kiln feed will probably help.