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16 Cards in this Set
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Specfication, Dimension ,KW , TPH,Kiln feed ,kiln RPM max & min , coal consumption, coal calorific value ,Seal design For line 1? For line 2 ? |
51 mtr,dia 3.4 mtr,3.5% inclination.Main kiln drive - 220 kw , auxiliary drive -11 kw TPH-91,2200 TPD, kiln feed consumption-3454 TPD.coal consumption-5.1TPH in kiln and 7.2 TPH in pyroklone ,
64mtr , dia -4.2 mtr ,3.5 % inclination. Main drive kw - , TPH -180 , 4000TPD ,Kiln feed consumption - 6400 TPD, Coal consumption in kiln - and in pyroklone -
coal calorific value - 5435k cal/kg
Air cooled Outlet ring.- Air cooled outlet ring - Welded to the kiln tube,with supporting arms of the fire end ,taking the different protecting segments.
Outlet seal - Double lamella type is provided at kiln outlet. This design seal plate wafer type is seated on wearing down shell.
A)Cooling air fan of tyre section,1150m3/min, static pr- 2mbar,7.5kw,
B)Nose ring Cooling fan,150m3/min, pressure diff 16mbar,7.5kw
C)Shell Cooling fan , 100m3/min ,pressure 2mbar,3.7kw
D)Pyrojet coal burner, type - HPJ 185 KO, Capacity - 185Gj/h , pressure shock resistant 10 bar, total length- 8mtr ,length refractory enclosing- 5mtr ,Coal throughput- 10tph, net Coal calorific value -4400 Kcal/kg , Residue 90 micron - 15% ,
E)Primary air portion consisting of Primary air for swirl air 2.8%, Rotary compressor for jet Air 3.2%
F)Primary air fan 451FN1 Flow rate - 1250m3/hrs Differential pressure 160mbar ,15kw ,0-3000 rpm
G)Rotary piston Blower for jet air 1500m3/hr,pressure 900 mbar,55kw ,0-3000 rpm |
1234 567891011 1213 |
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What are kiln problems you have seen? Explain kiln floating why it is required. |
Less migration,bearing temperature increase,seal inlet and outlet problem,shell cracking problem thrust Roller problem ,floating problem,Replaced bearing ,adjustment of Roller for upward and downward movement. Kiln shell replacement Because of the kiln slope ,the kiln during running has a tendency to slide towards the kiln hood due to gravitational force. So to avoid it and to keep it into its position thruster is used ,which pushes it upward after a set downward position is reached as indicated by the sensor. When a set upward position reached the thruster releases its push and then kiln again starts slowly sliding downward. |
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3)What is creep and how much is required value. why it happen. If creep is not under controlled value what will happen? |
Ans 3)Creep is relative movement in between shell and tyre.This happen due to diameter diffrence of tyre ID and shell OD. It should be 12 - 22 mm per revolution. More upto 30-40 is required to be corrected. More creep Caused due to wear of chair plate. The sudden temperature change can increase and decrease the creep. Tyre 2 is more critical and rapid heating can result in constriction of the kiln shell which will cause permanent deformation if the yield strength of kiln shell material exceeded beyond the limit. This in turn will increase the tyre creep after regaining the normal working temperature, as well as increased ovality of kiln shell, a factor that may contribute to excessive refractory lining wear.
When chair pads worn exceeds their tolerance range it will cause bigger shell ovality.Higher value of gap and shell ovality means faster wear of components like tire side surface,chair pads, stop block etc. Too much value of creep can lead to crack on shell. More wear can increase the loads at the contact area of tires and rollers, girth gear and pinion ,increases Hertz pressure which leads surface spalling.
When the wear of tire will appear it will be very difficult to do the tire adjustment and it will cause drive failure.
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Calculation of sim for chair pad |
Calculated air gap=creep per revolution/3.14 Shim thickness =(Calculated air gap-allowable gap in hot)/2 Creep=31, Calculated air gap=31/3.14 Shim thickness=(9.87-3)/2=3.5 |
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What are the brick which is used in kiln at different place |
Dalmia 3k-320,Dalburn Dalmia 3k-620,Dalburn |
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What are the brick used in kiln hood |
1)HB-1 ,HG-45-20 ,Al2O3 Fe2O3,45 and 2 % |
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What is kiln retention time and filling percent.Kiln inlet and outlet pressure. |
35.36 sec, filling percent is 25% ,-17.7mmwc,-3.8mmwc |
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What should be kiln burning zone temperature and bearing temperature. |
BZ =1300 Bearing temperature =40-47 |
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What is pressure and temp in preheater fan and cyclone. |
Pre heater fan , temp in 273 Pr in -515 ,Out -23 mmwc first cyclone at inlet 290 c ,-476 mmwc At dis 284 ,-444 mmwc 2nd cyclone 437 c ,-373 mmwc At dis 453 , -453mmwc |
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What is new kiln size. How will be calculated longitudinal expansion of kiln. |
It is 4.2x65 mtr. Longitudinal expansion of kiln will be calculated by formula T ×☆×L Where T =zone temperature ☆ = expansion factor L= length of zone If T =290 ,☆=0.0125,L=26mtr So longitudinal expansion=87mm |
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What is coal mill specification and production TPH.What is F.K Pump and problem. |
It is ball type mill.TPH -17 MT,F.K. Pump send the material from kiln bin to firing point. |
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What is raw mill dimension and its TPH. What material used in raw mill and their % , KW |
Dia- 4.8, length 13.18 mtr,KW -1200 lime stone -96% Sand stone/clay-1% Bauxite -2% Clay-1%
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What is cooler dimension,type ,kw,gearbox size. Specify cooler plate and their nos. IS 4522 stands for? |
Cooler is 2.2 wide and 20 mtr long. Its grade is 9. Previously grade 7 was being used. Cooler plate are following type 1)steeped grate plate 2)Grate plate 3)Omega plate chamber aeriated 4)Omega plate row aeriated Total no. Of chamber are 5. IS 4522 stands for indian standard for heat resistant alloy steel and nickel base castings. This standard published in 1968 and revised in 1979. It was adopted in 1986 by indian standard.
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Properties of Nickel and chromium in austenitic steel. |
Nickel atomic no 28 , it added more than 8% in high chromium steel. Nickel increase strength, impact strength and toughness. boiling point -2730 deg centigrade. Melting point-1455 deg centigrade BHN-667 to1600 MPA
Chromium melting point - 1907 deg C Boiling point -2671 deg C BHN - 687 to 6500 MPA Chromium is extremely hard and it is third hardest element in world. Its atomic no 24. It is hard and brittle. |
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What are the composition of gun metal. |
Copper-88%,Tin-8 -10%,Zinc 2-4%.it has tensile strength 210-310 MPA, BHN- 65 to 74. Property- It can bear high load with low speed. BHN of steel is 130 which shows double hardness to gun metal.It means gun metal may wear fater than mild steel. So it will not harm to shaft of supporting Roller. |
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Girth gear material of raw mill |
Gr34CrMo4 , Chromium 1.06% , Molebedinum 0.217% , OD - 6826 , PCD - 6780,root dia - 6691.34, tooth face width - 700+_ 0.3 ,total height -840, pressure angel- 25 degree , Module - 30 , no.of teeth - 226, tooth depth- 67.5 , hardness on 1K19 - 252 and 262 , Hardness on 2K19 - 283 |
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