If you have any knowledge about clinker kilns of 1000 to 1400tpd capacity being in operation today and being part of a system including precalciner. The question would be if you consider to be feasible to upgrade a 600tpd long dry kiln to an approx 1200tpd, modern precalciner kiln. What do you think an investment for such an upgrade would be like, in USD? What would be your closest estimation for such a work?

Your chemistry does not sound abnormal and we have discussed the possibility that the large nodules are caused by MgO variation before. A further remote possibility would be Mn₂O₃ variation where slight increases cause the formation of vary large balls and also take the coating out of the burning zone. However, that is a long shot.

We have a 1000tpd FLS kiln with a five-stage preheater. We are having a lot of clinker dust formation which is causing great wear at the kiln hood. What would you recommend to get rid of the clinker dust.

It is difficult to diagnose the problem over the internet, however these problems are often caused by inefficient combustion of the fuel in the main burner, long flames and poor heat flux in the kiln. I suggest you increase the axial primary to the maximum and see if that helps.