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Specialized Tools · Kiln · No. 02

Is your ID fan moving kiln gas, or leaked air?

The ID fan is at its limit and the kiln cannot take more feed. The easy answer is a bigger fan. Very often the fan is already big enough: it is pulling air that leaked into the tower through doors, flaps and expansion joints, cooling the gas and taking the place of kiln gas.

What it savesTurns the air leaking into the tower back into capacity for feed.

US$30One-time · yours to keep
See the sample report (PDF)
  • Excel 2013 or later, Windows and Mac
  • No macros, no internet
  • Updates for life
  • Updates for life
  • Your name on every sheet
Your figures in: every result graded GOOD, WATCH or ACT, Today against What if

How this file helps

Find out if it is happening to you, how much it costs, and what to correct.

1Find outThe excess air at the kiln inlet, the calciner and the preheater exit, and the false air between them.
2MeasureWhat the fan really moves, its efficiency, and what one point of O2 costs a day.
3CorrectWhere to walk the tower, and the stack figures the authority will read.

What it gives you

The gas path, point by point.

Excess air at the kiln inlet, the calciner outlet and the preheater exit
The false air between them, and what one point of O2 costs a day
The ID fan efficiency and its fan law against the gas balance
The stack at 10 % O2 against the EU BAT levels

See it working

Worked on a demonstration plant.

Your figures in: every result graded GOOD, WATCH or ACT, Today against What if
Your figures in: every result graded GOOD, WATCH or ACT, Today against What if
The chart drawn for you, ready for the report
The chart drawn for you, ready for the report
What to do first, and why
What to do first, and why

Worked out for you

6 results from the figures you already measure.

Actual gas flow at the preheater exitExcess air factor at three pointsFalse air in the towerCost of one point of O2ID fan efficiency and energy per tonStack dust, NOx and SO2 at 10 % O2

What is inside the file

Kiln Gas and FansYour figures in, Today and What if side by side, every result graded, two charts, and what to do first.
MethodHow every result is obtained, and the references each grade is read against.
LicenseYour name, your company and your email, in the heading of every sheet.

What you need

  • 1The kiln and its fuels
  • 2O2 at the kiln inlet, the calciner outlet and the preheater exit
  • 3ID fan power and pressures
  • 4The stack readings
Industry methodsThe methods used across the cement industry, worked out step by step.
Graded, not just calculatedEach result is marked GOOD, WATCH or ACT against the usual range, with the reason.
Ready for the reportPrint-ready pages with the charts drawn for you.
Yours to keepOne price, no subscription. Use it again and again.

Questions

Before you buy

Can I see it before I buy?

Yes. The sample report shows the whole first sheet of the file, worked on a demonstration plant: every result, the charts and what to do first.

Does it need the internet or macros?

No. It works on Excel 2013 or later, on Windows or Mac, with no macros and no connection. Nothing to install.

Can I use it for several kilns?

Yes. Save one copy per kiln and per test. The file is yours to use for as long as you like.

What is the What-if column?

Type a new figure beside today's and see every result change, before anything is changed in the plant.

Who may use my copy?

One engineer or one plant. Your name is written on every sheet.

How do I pay?

Press Buy. We reply on WhatsApp and by email with the bank details. When the payment arrives, your copy is ready to download from this page.

Is your ID fan moving kiln gas, or leaked air?

Have the answer with your next figures.

US$30One-time · yours to keep
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More in the Kiln package

The other files of this package

Kiln Heat Balance, a worked example
Kiln · No. 01
Kiln Heat Balance

Where does the heat of your kiln go?

The heat crept up 20 kcal/kg this month and nobody can say where it went. On a 5,000 t kiln that is about 17 t of coal a day, burnt for nothing.

What it savesFinds the kilocalories above target, and puts a daily cost on them.

  • The heat of every fuel, main burner and calciner, per kg of clinker
  • The full balance in and out: preheater gas, cooler exhaust, clinker, radiation
US$30one-time · yours to keepSee the file →
Kiln Loading, Burner and Condition, a worked example
Kiln · No. 03
Kiln Loading, Burner and Condition

Is your kiln working in the band of its type?

Free lime jumps, the coating falls and the burning zone shell runs hot. The flame, the kiln speed and the load decide it, and they are rarely checked together.

What it savesKeeps the burning zone and the flame where the clinker is made, not the shell.

  • Residence time, filling and loads against kilns of the same type
  • The flame of the main burner: primary air, tip velocity, momentum
US$30one-time · yours to keepSee the file →
Raw Mix, Clinker and Volatile Cycles, a worked example
Kiln · No. 04
Raw Mix, Clinker and Volatile Cycles

How much more chlorine will your kiln take before it blocks?

The lowest cyclone blocks again and the kiln stops. Chlorine and sulfur circulate unseen until they condense, and every ton of new alternative fuel adds to them.

What it savesTells how much alternative fuel the chemistry will take, before the cyclones find out.

  • LSF, moduli and the clinker phases from the kiln feed
  • The heat of clinker formation for the heat balance
US$30one-time · yours to keepSee the file →

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