Kiln evaluation and optimisation

Regular kiln evaluation and optimisation studies are an indispensable tool for plant management and production staff, and provide a key to optimal kiln operation in terms of heat and energy consumption, as well as production rate and quality. A thorough kiln evaluation and optimisation study covers the clinker burning process from raw meal homogenising to transport from the clinker cooler. Together with your plant personnel, a FLSmidth specialist will evaluate the kiln system through measurements of process parameters, analysis of available operational data and a visual inspection of the installation. The specialist will also make suggestions for changes to operational procedures or process parameters in order to optimise kiln operation. The specialist can be contracted to assist in implementing these changes at the plant. When the study is complete, the results are compiled in a written report that contains an overall assessment of kiln performance, recommendations for optimisation of the installations and suggested solutions to specific problems, such as decreased production, increased energy consumption, reduced product quality, etc.

Kiln lining inspection

FLSmidth specialists can be contracted to evaluate the performance of the kiln lining and, if possible, carry out visual inspection of the refractory lining or assist plant personnel in troubleshooting of lining problems. Our specialists will act as independent advisors, based on our extensive experience with the various types of lining materials. This experience includes the effects on the lining of kiln burner performance and the physical and chemical properties of the clinker. The inspection results in a written report with relevant recommendations for improved refractory lining efficiency.

Raw mill evaluation and optimisation

A raw mill evaluation and optimisation program covers examination of the raw material grinding process from the mill feed to raw meal homogenisation. A Customer Services specialist will evaluate the grinding process and installation by analysing mill feed transport, addition of corrective materials, drying, grinding, separation, energy consumption, auxiliary heating systems, dust transport to silo, quality control methods and dust emission control, as applicable in each individual case. These findings are compiled in a report that gives an evaluation of the raw material grinding process at the plant and pinpoints issues of special concern highlighted during the visit.

Cement mill evaluation and optimisation

Cement mill evaluation and optimisation concentrates on the areas which are relevant to optimising the cement grinding process, namely clinker blending, addition of gypsum and additives, grinding aids, clinker grinding, separation, cooling, energy consumption, cement quality, transport arrangements to the silo and dust emission control. The results of a Customer Services specialist’s evaluation are compiled in a report with suggestions for future action.