Program KilnOpt, description

(Consists of AnalMix and AuitoMix)

You certainly want to have a constantly operating kiln. Then it is very impotant that you feed the kiln in a very steady way. The raw meal can be premixed in a homogenising silo and adjusted. A bed blending takes care for steadiness ot quality. The suppliers of waste material as fuller earth, fly ashes, waste rubber, waste paper etc. should, if possible, supply a constantly defined material. Then you will get your kiln oparation in a good state.

A cement kiln witout a calcinator is to be fed with raw meal or, for wet process, with slurry. For Lepol Kilns you feed the kiln with granules made out of raw meal.

In the case of rotary kiln without special additionals the task will be to mix the components in a homogenising silo or feed a raw mill so that you get an acceptable kiln operation and a defined and a constant quality of clinker.

With the program “AnalMix“ you can design a definite kind of kiln operation. You can change the components and their quantity and get every second the characteristics of clinker and you can print the result. Besides this you can save the results of mixing and recall it to continue adding or subtracting more components.

If the kiln can be fed with additionals (for instance with a calcinator) and you can feed it equally with raw meal and with other raw materials or waste stuff, the question will be, if you have a definite bunch of compomnents directly fed to the kiln : what must the raw meal looke like? In most cases the lime saturate factor of the raw meal will be much higher then the one for a kiln without additionals. The raw meal is created by tons (in a homogenising silo) or tons per hour in a raw mill. But additional feed of the kiln is brought in by tons per hour in respect of the kiln throughput, where the raw meal still will be the leading quantity.

In this case it is an advantage to use the program “AutoMix“. At first you choose 4 components for raw meal which contain Si2O3, Al2O3, Fe2O3, CaO. Then you choose the materials which besides the raw meal are fed directly to the kiln, mostly waste stuff, or waste fuel and add the intenden quantities. Furthermore you set the 3 moduli (lime saturation, silica ratio, Al/Fe ratio) as intended, and you will get with “calculate“ the composition of raw meal and components directly to the kiln. Now you know how the raw meal must be created and how the lime saturation, silica ration and Al/Fe ratio should be and how the klinker properties are. If you want, you can save the raw meal analysis in the database and use it for further alternation in the program “AnalMix“.

If you only have 3 or 2 components for the raw meal, for instance no clay component, but therefore fly ashes directly to the kiln, you can change the amount of fly ashes until the clay component in the raw meal will be zero. It will take you a little longer if you want to compensate a second component (e.g. ferrumoxyd).

The values for the analyses are administered in the same file for both programs. Its name is “Anal.dat“. You can delete values, undelete them, pack the file to remove deleted values and rename the file and create a new one.

Finally you can change a clinker analysis into a raw meal analysis (you should estimate an ignition loss). So you can vary the analyse by adding or subtracting other raw components.

In modern cement processing increasing more waste stuff is used in the kiln process. So the program KilnOpt will be a good utility for decisions. By serious engagement the whole factory will have the benefit.