big ball cement kiln

solutions of ball-forming in cement rotary kiln

solutions of ball-forming in cement rotary kiln

With the development of the construction field,the consumption of cement is increasing greatly.Cement rotary kiln is the main equipment of cement manufacturers,the normal operation of cement rotary kiln is the guarantee of production in cement manufacturers,but no one can guarantee that the cement rotary kiln will not appear any kind of problems.Various types of rotary kiln equipment in the production process all have encountered the phenomenon of the head,especially the cement rotary kiln,the ball-forming is the most serious.

After the ball-forming in the cement rotary,it reduced the contact of the material in the cross-sectional area of the kiln,and have a certain impact on the ventilation in the kiln, thus impeding the movement of materials,and have a certain effect on yield,quality of materials,influence the stability of the equipment, the consumption of coal and electricity is also increasing,thus resulting in the increase of cost,especially in the cement rotary kiln which continuous to form the ball,the ball-forming destroyed the process characteristics of the kiln,increased the loss of heat consumption,and also brought great harm to the body of the operator in the field,thus increasing the cost of equipment.

If the material ball has been formed in the rotary kiln,we should carry out a full range analysis to the forming of ball,select the samples and carry on the chemical examination,and do complete chemical analysis to the nucleus and shell of ball individually,identify the reasons correctly,and apply medicine according to indications,if the material ball is relatively small,it should be appropriate to increase the ventilation of the kiln in operation,so that the flame is smooth,but must pay attention to the temperature of the kiln tail,it should not be too high;it can slightly reduce the coal used in the kiln head,but must ensure the complete combustion of pulverized coal,and appropriate to reduce the feeding amount,slightly reduce the kiln speed,Slightly reduce the kiln speed,let the material ball inside the kiln roll into the firing zone;After the ball enter into the firing zone,and then reduce some of the kiln speed,use the big fire to burn the ball down in a short time.so as to avoid it enter into the cooler to produce the blockage or smashed the grate,but at the same time, we should pay special attention to the situation of the kiln skin.If the ball-forming is large, we can use the method of thermal cycling to treat;When the material ball is not easy to go forward to enter into the firing zone,at this time,the pulverized coal injection pipe can be extended into,appropriate to reduce the feeding amount of coal,after burning 1-2 hours, the coal pipe is pulled out and then burning for another 1-2 hours.doing this repeatedly,until the material ball broken;if it can not be broken, you can stop the kiln,and carrying on the ignition and heating after cooling for 1-2 hours,so that the material ball broke due to excessive temperature differentials.

Reasonable production management in the running process of the cement rotary kiln can effectively reduce the phenomenon of ball-forming,improve the powder of coal and the burning system,thus change the shape and temperature of the flame,and the effective method to remove the cement rotary kiln head by selecting mechanical treatment.

clinker ball formation in pre burning zone of the rotary kiln - page 1 of 3

clinker ball formation in pre burning zone of the rotary kiln - page 1 of 3

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 phaseQuality/ condition of refractoryHigh alkali feedBurner pipe conditionCooler conditionBut 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 GopalYou 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

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