热耗十大原则

10GoldenRules

forHeatConsumptionMastery

热耗管理十大原则DPCOctober2009–V1DIVISIONORACTIVITY10GoldenRulesforHeatConsumptionMastery

热耗管理十大原则Prepareaconsistentrawmix

稳定入窑生料Controloxygenlevelinkilnandpre-heater

控制窑内及预热器氧含量

Optimizefuelcombustion优化燃烧Masterkilnstability稳定窑况Optimizecoolerefficiency优化冷却机Masterpre-heaterandcalcineroperation控制预热器及分解炉操作Optimizekilnthroughput优化窑产量Maximizereliabilityfactor最大化RFMinimizecementkilndustorkilndustloss最小化窑灰损失Applyoperatingprocedureswithskilledoperators熟练的操作员执行标准操作程序Notesonspecificprocesses

备注:关于特殊生产工艺2RULE1:Prepareaconsistentraw

mixWhatistheKFUIlevelinyourplant?

你们工厂的KFUI如何？Canyouimprovetherawmixburnability?

能否改善生料的易烧性？IstheclinkerC3Stargetoptimized?C3S目标值是否已经优化？准备稳定的入窑生料3Rawmixislinkedtospecificheatconsumption

生料对热耗的影响

RawmixuniformityaffectsprocessstabilitythusSHC(Alsohaspositiveeffectsonproducts)

入窑生料的均匀性影响工艺稳定性，以及热耗，产品（质量）ClinkerLSFaffectsclinkeringtemperature,oversaturationhastobeavoided

熟料的LSF影响烧成温度，应避免过饱和LSFClinkeringtemperaturedegCRule1预均化效果矿山原料变化入窑生料稳定性取样及质控取样误差控制策略及频次分析仪校准;仪器故障时窑灰管理

开停生料磨时数量/质量变化均化库的效率粉磨细度及大小分布配料仓中料的变化卸料均匀性计量精度4RawmixImpactsspecificheatconsumption生料对热耗的影响

TheburnabiltyindexofrawmixhasadirectimpactonSHC.(MeasuredusingLafargeK1450index)生料的易烧性系数对热耗有直接影响（用K1450评估）

Source:ETC2008rawmixannualsurvey

来源：ETC2008生料年度调查ImpactonSHCdependsonK1450level:K1450对热耗的影响Mainsfactorsaffectingburnability:

易烧性的主要影响因素ImpactonK1450

对K1450的影响

Rawmixfineness

生料细度+1%res100mm-1.6Quartz

石英+1%-10Aluminaratio

铝率+0.14MgO+0.1%+2.6Na2O+0.1%-12S+0.1%+3.8NotanegativeimpactifS/A>2.5

如果S/A>2.5

会产生负面影响Rule15Prepareaconsistentrawmix

准备稳定的生料Prerequisite

前提条件Teamwork-Quarry,Lab,ProductionandProcess

团队工作－矿山，化验室，生产，工艺Actions行动Settargetfor设定目标值 Typicalvalue典型值 KFUI <14 ClinkerC3S熟料C3S 60%MonitorK1450evolution

监测K1450

HaveaweeklyreviewofC3SandKFUIduringperformancemeeting;emergencyactionplantobeimplementedifKFUI>30

每周业绩会上回顾审视C3S及KFUI：如果KFUI>30

，需采取紧急措施Implementregularfollowupofburnabilityindex(minimumonceayearduringrawmixandclinkermappingexercise);actionplanifK1450<50.

执行定期检查易烧性系数（最少一年一次），若K1450<50则采取行动Reviewtheselectionofrawmaterialsinthescopeofburnabilityimprovement(slag,puzzolana,quartzreduction)onceayear每年检查回顾一次原料选择对易烧性的影响(矿渣，火山灰，石英减量等）Performarawmixlineauditevery3years,usingrawmixauditgrid采用生料审计表格，每三年进行一次生料系统的审计Measurementmethods

测量方法KFUI:dailymeasurement每天检查K1450:Testofburnabilityforcementplantrawmeal,doneinTClabonly

生料易烧性试验：仅在TC实验室做。Support支持文件Rawmixpreparationtrainingmaterial

生料制备培训资料TechnicaldoctrineRawmix

生料相关技术文件

Rule1K14506RULE2

Controloxygenlevelsinkilnandpre-heater

控制窑及预热器的氧含量Whatistheoptimumoxygenlevelforyourkilnsystem?

你们工厂窑系统的优化的氧含量是多少?Isyourfalseairundercontrol?

工厂的漏风量在控制范围内吗？Canyouroperatorsrelyonyourgasanalysissystems?

工厂的操作员是否能依靠气体分析仪系统？7Manageexcessairatkilninletandcalcineroutlet管理窑尾烟室及分解炉出口过剩空气量Prerequisite前提条件Teamwork–Process,MaintenanceandProduction团队协作－工艺，维修和生产Actions行动SettargetO2levels设定目标O2含量Typicalvalue典型值

Kilninlet窑尾烟室2-3%(accordingtokilnandfuels依据窑及燃料)KeepkilnInlettargetoxygenshouldbesetaslowaspossible,whilstmaintainingCO<100ppm(andSO2<3000ppm)

窑尾烟室O2含量尽量低，同时CO<100ppm(SO2<3000ppm)

NotebulkyAF&ARMmaycauseCOhigherthan100ppm(seePost-SevillaCombustionmanual)注意块状替代燃料或原料可能导致CO含量高于100ppm（见Post-SevillaCombustionmanual）Investigatecombustionparametersforvaluessignificantlyhigherorlowerthantarget,tofinditemstoimprove

审视工艺参数是否有明显的高于或低于目标值，找出并改进。Maintainreliableandaccurategasanalyzersandsamplingsystems维护好气体分析仪和取样系统:可靠,准确。Ensurecorrectlocationofprobes-samplethemainprocessgasstreamwithoutcontaminationbyfalseair.

确保探头在正确的位置－对主要气流取样，避免受漏风的影响。Weeklycalibration(minimum)byinstrumentdepartment

由自动化部门每周（至少）进行校准。Frequentprobecleaningasrequired(automaticandmanual)byproduction生产单位按需求频次清理探头（自动或手动）Withairseparatesystems,ensureproperfunctioningoftertiaryairdamper(orcalcinerdiaphragm)

带三次风管的窑型，应保证三次风门（或）缩口阀门功能正常。Measurementmethods测量方法Continuousmonitoringbygasanalyzers气体分析仪连续测量CrosscheckO2accuracyreadingwithportableanalyzers

用便携式分析仪校对O2准确性。Support支持文件SeeprocedurePRPYRP0845:“Measuregascompositionbygasanalyzer”

见程序PRPYRP0845:“用气体分析仪测量气体成分”

Rule28ManageFalseAir管理漏风Prerequisite前提条件Teamwork团队协作–Process,MaintenanceandProduction

工艺，维修及生产Actions行动Settargetfalseairlevels设定漏风目标 TypicalValues典型值Preheater预热器 <5%Coolerexhaust 窑头余风 <10%Developinspectionplan

编制检查计划Conductregularoverallmeasurements,inspectionsandrepairs(minimummonthly)

例行整体测量，检查和维修（每月至少一次）Re-designrepeatedproblemareas重新设计（改进）频繁故障区域Performdetailedmeasurementoversystem(minimumannually)每年至少一次全面测量Measurementmethods

测量方法Byoxygendifferencewherepossible

条件允许时测量O2差异Bytemperaturedifferenceonmillsandfilters

磨机及收尘器测量温度差Directmeasurementbyvolumeflowdifference

直接测量风量变化Support支持文件SeeprocedurePRPYRP0609:“Controlfalseairinthepre-heater”

见程序PRPYRP0609:“控制预热器漏风”SeeprocedurePRPYRP0610:“Measurefalseair”

见程序PRPYRP0610:“测量漏风”

Rule29TypicalSourcesofFalseAir典型漏风点

Missingbolts

法兰FanSeals

轴封Doors

孔，门Doors孔，门FlapSeals

翻板阀轴封KilnInletSeal

窑尾密封ClinkerChute

熟料溜子ExpansionJoints膨胀节ClassifierSeal

轴封FeedingPoint

喂料点FeedingPoint

喂料点Doors

孔，门Doors

孔，门FanSeals

风机轴封PokeHoles

捅料孔FlangesTieRodSeals拉拉杆KilnHoodSeals

窑头密封FanSeals

轴封Seals

锁风，密封Seals

锁风设备Casingcracks

壳体开裂Casingwear&corrosion

壳体腐蚀，摩擦Isolationdampers

隔离阀ExpansionJoints

膨胀节

Lookforgaps/cracks/missing

bolts/missing

packing

etc…查找：裂纹，间隙，螺栓脱落,盘根脱落

Listenforwhistlingair听：风哨的声音Lookfordust

blowingoutduring

startup看(找)：启动时冒灰Rule210RULE3OptimizefuelcombustionWhattypeofburner,whichset-upandwhatmonitoring?何种煤管?设定值?怎样监测？Doyouhaveanoxidisingatmosphereinthekiln?你们窑内是否为氧化气氛？优化燃料燃烧11Setupandmonitorawelldesignedburner

安装和监测-设计良好的喷煤管:Prerequisite前提条件Teamwork:Production,ProcessandMaintenance团队协作：生产，工艺及维修Recommendedhighmomentumburner(1stchoice:Lafargetype/AlternativeUnithermM.A.S/others)

推荐高推力喷煤管（首选：拉法基煤管/或者UnithermM.A.S/其他）Actions

行动Burnerset-ups

喷煤管安装：(swirlanglesuchthatswirlrotationinsamedirectionaskilnrotation内风旋向应与窑旋向相同)

Lafargetype

拉法基煤管

Gas气Oil油Coal烟煤

Petcoke

无烟煤

Alternativefuels

替代燃料recommendation

设计值（建议）Specificimpulse

推力比[Is][Nh/GJ]1,21,21,51,81,82,2Swirl

旋流比[-]0,050,08-0,150,150,150,150,15Alignburnerorflamewithkilnaxis(especiallywhenusingAF)喷煤管(或火焰)方向与窑同轴（尤其使用替代燃料时）UseLafargeburnerspreadsheettomonitormomentumandswirl,tobeadaptedtofuelpropertiesandkilnphysicalandoperatingconditions使用拉法基计算表格来监测推力和旋流比时，要根据燃料性质以及窑况来决定。Avoidexcessiveprimaryairandcontroltransportair,especiallywhenaddingseveralfuels(transportvelocityat25/30m/s,fuel/airratioat4/6kg/Nm3)避免出现过剩一次风（控制送煤风），尤其在使用多种燃料时（送煤风风速25/30m/s，燃料/空气为4/6kg/Nm3）Lookforchangesinpressureforagivenflow,whichcouldindicatemechanicalchangesinburnerandothercomponents(eg:blowerdustfilters)当风量给定时，检查压力变化，其变化可能意味着喷煤管的一些机械问题或其他部分的故障（如：风机滤网等）Support

支持文件SeeTA“Fuelflexibility”

见技术文件“燃料多样性”SeeprocedurePRPYRP0602:“Startup&optimizeaburner”

见技术文件PRPYRP0602:“喷煤管使用与优化”SeetoolPRPYRT09-05:“Lafargeburnerspreadsheet”

见计算工具PRPYRT09-05:“拉法基喷煤管计算表格”Rule312Operatethekilnwithanoxidisingatmosphere

在氧化气氛下操作窑Prerequisite前提条件Teamwork:Production,ProcessandMaintenance,Quality

团队合作：生产，工艺，维修，质控部门Reliablekilnbackendanalyzer,withCO/SO2*/NO,withresultsinppm,andO2可靠的窑尾气体分析仪:CO/NO（单位为ppm）O2/SO2*

Actions行动Setgasanalysislevels设定目标值 TypicalValues典型值CO(inppm) <100SO2(inppm) <3000O2(in%):ifS/A<1,2 1.2–3

ifS/A>1.2 2–3.5Avoidlocallyreducingconditions(e.g.:withcoarsealternativefuelsSSW,animalmeal);forlowVolatileMatterssolidfossilfuels,respectthefollowingrules:避免局部还原气氛（例如：粗的替代燃料SSW，动物骨料等）对于低挥发固体化石燃料，遵循如下原则：rejectsat200µm<0.1%200µm筛余<0.1%

rejectsat90µm<½VolatileMatters90µm筛余<½挥发物Asrequired,measureFeOonclinkertoqualifyqualityofburning

如需要，测量熟料中的FeO含量，以评价燃烧控制的水平Support支持文件SeeprocedurePRPRYP0845:“Measuregascompositionbygasanalyzer”

见程序PRPRYP0845:“如何用气体分析仪测量气体成分”“FeOmeasurement”proceduresetupwithTechnicalCentre

按TC程序“FeO的测量”

*ifS/A>1.2Rule313RULE4:MasterkilnstabilityWhatisthefreelimetargetandvariation?

你们工厂的游离氧化钙目标?波动情况？Doyouminimizekilnfeedandfueldosingvariability?

你们工厂控制入窑生料秤及煤秤的波动(最小)么？Doyoumanageconsistencyoffuels?你们厂控制燃料的稳定性么?Ifyouhaveaprocesscontrolsystem,doyouoptimizecontrolloopsandmonitorperformanceregularly?如果有过程控制系统，你们厂是否优化了控制回路，是否经常检查回路的效果呢？稳定窑况14Monitorfreelimevariation

监测f-CaO波动Prerequisite前提条件Teamwork–Process,Production,LaboratoryandMaintenance团队协作－工艺，生产，化验室和维修部门KFUIC3S<14Actions行动

SettargetFreeLimelevels设定f-CaO目标TypicalValue典型值Clinkercooleroutlet 冷却机出口熟料1

to1.5%(0.5to1%

长窑)FreeLimeUniformityIndex游离钙均匀指数

<1Minimisekilnfeedvariationbymasteringrawmixuniformity(seerule1)

通过控制生料的均匀性，使窑喂料波动最小（见原则1）Minimizefueldosingvariationsandavoidreducingconditions(seerule3)

减小喂煤波动，避免还原气氛出现（见原则3）Maintaincalcinationontarget(seerule6)

稳定分解率（见原则6）OptimisecooleroperationforgoodandstableSecondaryandTertiaryAirT°C(seerule5)

优化篦冷机操作，获得稳定二次及三次风温（原则5）Adjustkilnfeed/speedratiotooptimisekilnbeddepthandallowshorterburningzone

调整窑喂料/窑速(料速比)，以优化窑填充率，缩短烧成带。Measurementmethods

测量方法RegularFLUIreviews

定期检视FLUISupport

支持文件SeeLQTSonFreeLimeAnalysisbycomplexometrymethod

参见LQTs“滴定法游离钙分析”OnLineFreeLimeAnalysis(OFLA)

在线游离钙分析（OFLA）

Rule415Minimisekilnfeedandfueldosingvariability

煤秤及生料秤波动最小化Prerequisite前提条件Teamwork–Process,ProductionandMaintenance团队合作－工艺，生产和维修KFUIC3S<14Actions行动SettargetKilnFeedandFuelDosinglevels设定目标值TypicalValues典型值Kilnfeedfineness

窑喂料细度dependsonburnability

依据易烧性Kilnfeedflowrate窑喂料量 ±1%Solidfuelflowrate喂煤量 ±1%Maintainequipmenttoensureaccuracyaspertarget

维护设备，以保证计量精度Managereturnofdusttokilnfeedinordertominimizeimpactofrawmillstops控制窑灰循环以使生料磨停机产生的影响减至最低Ensurepropermixingofsolidfuelsbeforegrinding确保固体燃料在粉磨前经过恰当的混合Checkfueltransporttohaveadequatevelocityandfuel/airconcentration

检查燃料输送管线具有合适的速度和固比;UseLuciefuelmanager(ifavailable)whenstartingaprogressiveAFprogram在开始使用AF时，应使用Lucie（若有）中的燃料管理器。Measurementmethods:测量方法：Regularlabanalysis

常规化验室分析Processparameters

工艺参数Support文件支持SeeCombustionmanual(PostSevilla1997)

见燃烧手册（PostSevilla1997）Seetechnicalagenda“FuelFlexibility”

见技术文件“燃料多样性”

Rule416Optimizecontrolloopsofprocesscontrolsystem优化控制回路Prerequisite前提条件Teamwork–Process,ProductionandMaintenance

团队合作－工艺，生产和维修ProcesscontrolsystemorPIDControlLoops（withoperatingrequiredsensors)过程控制系统或PID控制回路（需要的传感器）Actions行动SettargetProcessControlLevels设定目标值 TypicalValues典型值Calcination(kilnwithcalciner)分解率90.0to92.0%KilnHoodPressure 窑头罩压力 -2/-5mmH2OOperatecalcinerfuelrateinterlockedwithbottomstagecyclonegasexitT°C

分解炉喂燃料量与末级筒出口温度形成控制。MaintainconstantO2inexcessatkilnbackendwithpreheaterfan,avoidCOformationandminimizeSO3volatilisation(seerule3)

用ID风机控制窑尾稳定氧气，避免CO形成，最小化SO3挥发。（原则3）Maintainconstantslightlynegativekilnhoodpressure,withcoolerexhaustfan(seerule5)用头排风机控制窑头罩微负压（原则5）Maintainrestoftheprocessvariablesasconstantaspossibletomasterkilnoperationatrequiredproduction(seerules2and6)稳定其他工艺参数，控制好窑稳产。（原则2和3）Support支持文件SeeKilnOperationGuidelinesSeptember2006(TCEA)

见“窑操作指南”2006.09（TCEA)

Rule417RULE5:

Optimizecoolerefficiency优化篦冷机效率Doyouoptimizeairflowdistribution?

你们工厂优化风量分布么？Doyouhaveagoodclinkerdistributionandsize?你们厂熟料颗粒分布好么?熟料料床分布好么？Doyoumaximizeclinkerbeddepth?

你们厂是否最大化熟料料床厚度？Howdoyoucontrolthecooleroperation?

你们厂如何控制冷却机的操作？18Adjustblownairflowdistribution调整风量分布

Prerequisites前提条件Requiredsensorstomeasurefanairflowsandvalvestoadjustvolumes

风量测量所需的传感器和调节风量的阀门Actions行动Intherecuperationzone,maximizeheatrecoveredincombustionair(AS,AT);coolerfanvolumeflowdensitymustbeconstantaccordingto:

在热回收段，应最大化回收热气（二次风，三次风）；鼓风密度应恒定（依据下表）：Specificvaluesdependoncoolerdesignandare“startingpoints”foroptimization(seeairdistributioncalculation)

具体数值要根据冷却机设计型式而定，且仅仅为优化的初始点（参见计算表格）Inthecoolingzone,coolerfanvolumesareproportionaltoclinkerproductionrate;makespecificairflow(Nm3/kgclinker)adjustmentsandminimizeair/clinkerratioaccordingtomaximumacceptableoutletclinkertemperature

在冷却段，风量与产量成比例关系；进行风量(Nm3/kg熟料)调整，依据熟料允许的最高温度来最小化空气用量。Atnominalkilnproduction,keeptotalair/clinkerratioconstant:1.8to2.2Nm3/kgclinker(formostcoolertypes):

正常产量情况下，对多数篦冷机类型，保持空气/熟料比例稳定：1.8to2.2Nm3/kg熟料。Measurementmethods测量方法Continuousmonitoringbypiezometricflowmetersandregularairflowchecksbyfieldmeasurements

用环形流量计来连续监控空气流量，并定期用现场测量来标定。Visualinsidecoolerchecks(throughwindow)toensurethatnovolcanoescreatedduetoexcessiveairblowingdensity

现场肉眼观察（透过观察窗）篦冷机内部，确保不会出现通风过量引起的喷泉。Support支持文件SeeprocedurePRPYRP0607:“Checkthecalibrationofcoolingfanairflows”

见标准程序PRPYRP0607：“校对冷却风量”SeeprocedurePRPYRP0608:“Adjustthecoolingairlevelanddistribution”

见标准程序PRPYRP0608；“调整冷却风量分布”SeetoolPRPYRT0702:“Airdistributioncalculation”

见标准计算工具PRPYRT0702:“风量分布计算表“Chamber#风室123Airflowdensity鼓风密度(Nm3/m2/.s)1,5to1,71,2to1,51,0

Rule519Adjustclinkerdistribution

andsize

调整料床分布和熟料颗粒Prerequisite前提条件Goodclinkerchemistrycontrol(sampling,frequency,labaccuracy)

良好的熟料化学控制（取样，频次，化验准确性）Backandsidewindowstobeabletolookinside

尾部或侧面观察窗：观察篦冷机内部Actions行动Masterclinkerchemistry(minimizingvariationsinrawmixandfuels)andanalyzechemistryvs.events(snowmen,lumps,redrivers,fineclinker)掌控熟料化学（生料和燃料稳定），对异常问题（雪人，大块，红河，飞砂）进行化学分析Operateburningzoneascoolaspossible(seerule4)

尽量降低烧成带温度（原则4）Usedeadgratestostopredrivers(Clinkerfinestendtofluidizemoreeasily)使用固定蓖板制止红河（尤其细料易流化）Install,optimizeandmaintainaircanonsatcoolerinlettoremovesnowmen篦冷机入口安装/维护/优化空气炮并，以清除雪人。Adjustblowingdensitylaterally(ifdesignallowsandspreadairaccordingtolateralgradientofparticlesizeandclinkerdropout

若有侧部调风装置，应优先边侧充气（根据边侧粒度及漏料）Usedirectaeratedplates(ifdesignallows)toadjustairbeamdistribution

使用局部充气蓖板（如设计允许）优化空气梁配风Forfixedinletcoolers(clinkerhastobegranulatedandnotsticky):

对于进口固定篦床（熟料颗粒状，不发粘）：Implementhorseshoedesignandinstallairbeampressuresensorinordertodetectsnowmen

安装马蹄型浇注料，空气梁上安装压力传感器以监测雪人。Firstfansmayneedsignificantlymorepressurecapacitytomovelumps

第一台风机的风压应足以以移动大块料。Measurementmethods测量方法Clinkersizedistribution

熟料粒度分布Dailyclinkerbedvisualchecks

每日熟料料床目视检查Pressureinfixedinletchecks

固定进口处的压力检查。Support

支持文件See“PriorityStudyCoolerTechnologies”参见“篦冷机技术”

Rule520Maximizeclinkerbeddepth

最大化料床厚度Prerequisite前提条件Teamwork–Process,ProductionandMaintenance

团队协作－工艺，生产，维修Adequatestaticpressuresensors

合适的静压传感器Actions行动Usepressureindicationinmonitoredcompartmentasacontrolloopsetpoint

使用压力作为控制回路参数来监控相关风室Adjustgratespeedtocontroltheundergratepressure调整篦速来控制蓖下压力Controlspeedof1stsectioninmultiplegratesections;remainingsectionsfollowbyfixedratio(preferred)

对于多段篦床，控制第一段的篦速，其余篦床篦速按固定比例调节（推荐）Ifairflowchangesarerequiredduetoseasonalreasons,changesetpointaccordingly如果因为季节原因需调整风量，相应的需调整设定值（压力）Measureclinkerbeddepth(closetocoolerinlet,whereclinkerbedisstable):测量篦床厚度（在篦冷机入口附近，料面稳定后）Maximizingclinkerdepthmeansmaximizingfansoutletstaticpressure,butkeepingamarginfornormaloperation最大化料床厚度意味着最大化风机出口静压，但是需留有一定操作余量Measurementmethods测量方法Visualchecksthroughwindowwithheightreferencemarkedoncoolerwallorbyweightedchain

料床厚度：通过观察窗观察篦冷机壁上的高度参照标记或通过重锤链条;Continuousmonitoringbypressuresensorinunder-gratecompartment,orinfanoutletduct用传感器连续监测蓖下压力或者风机出口风管压力Regularpressurechecks,withamanometer

定期用便携式压力表校对压力显示Support支持文件SeeprocedurePRPYRP0620:“Howtooptimizeaclinkercooler”见程序“如何优化篦冷机”

OldGrateCooler旧式篦冷机NewerCoolers

新型篦冷机clinkerbeddepth料床厚度200mm500–700mm(*

特例达1000MM)Rule521Controlcooleroperation

篦冷机操作控制Prerequisite前提条件Teamwork–Process,ProductionandMaintenance团队工作－工艺，生产和维修Goodclinkerchemistrycontrol(sampling,frequency,labaccuracy)好的熟料化学控制（取样，频次，化验准确性）Sensorsingoodoperativecondition

传感器状态良好Actions行动Settargetlevels设定目标值Stabilityofsecondary(&tertiary)airtemperature

稳定二次、三次风温Stabilityofcoolerexitclinkertemperature(alsoventairtemperature)稳定出篦冷机熟料温度（以及排气温度）Control

KilnHoodPressurebycoolerexhaustfan:通过头排风机控制窑头罩负压Setpoint:–2/–5mmWG(dependingonitsstability)设定值：:–2/–5mmWG

（依其稳定性）Controlclinkerbeddepthandcoolerfanairflowdistribution

控制熟料料床厚度及篦冷机风量分布Ensurekilnoutletsealingoodconditions

保证窑头密封良好Ensuretightnessofcoolercomponents(betweenplates,betweenplatesandsidecastings,betweenchambers,atleveloffinesevacuation)保证篦冷机组件密封良好（蓖板之间，侧封板密封，仓间密封，漏料粒度）Measurementmethods测量方法Coolerinspectionduringkilnshutdowns

停窑时检查篦冷机Othermethodsasseenpreviously

其他方法参见前面Support支持文件SeeprocedurePRPYRP0620:“Howtooptimizeaclinkercooler”

参见标准程序PRPYRP0620:“如何优化篦冷机”。

Rule522RULE6:

Masterpre-heaterandcalcineroperation掌控预热器和分解炉操作Doyouminimizegasby-pass(flapvalves)andoptimizemealdistribution(splashboxes)?

你们工厂是否最小化气体短路（翻板阀）？撒料箱撒料效果是否已优化？Doyouhaveagoodmaterial/gasdistribution(diptubeincyclones)?

你们工厂是否有好的料气分布？内筒效果如何？Doyoumanagebuild-ups(mealcurtain,airblasters,pokingaccesses

你们是否管理好结皮？（料幕，空气炮，捅料作业）23Controlpreheatercalcineroperation控制预热塔操作Prerequisite前提条件Teamwork–Process,MaintenanceProductionandQuality

团队工作－工艺，维修，生产和质控Actions行动Settargetlevels

设定目标值TypicalValues典型值PreheatercalcinationrateSP窑分解率 55–70%PrecalcinercalcinationratePC窑分解率 90–92%O2/COpreheaterexit

预热器出口O2/CO

O2:3–5%;CO<100ppFuelpreparation燃料准备Refertotechnicalagenda”Fuelflexibility参见技术文件“燃料多样性”

Adjustfuelaccordingtocalcinationtarget(throughatemperaturesetpoint)根据分解率目标（参考设定温度）调整燃料用量Adjustpreheaterdraughtaccordingly相应调整预热器通风PerformregularcontrolsofaboveKPIsandimplementcorrectiveactions

定期检查以上KPIs，同时进行必要的行动Measurementmethods:测量方法：Regularcalcinationmeasurements

定期分解率测量Stabilityofgasanalysisandtemperatures

稳定性（气体分析和温度）Support支持文件SeeprocedurePRPYRP0845:“Measuregascompositionbygasanalyzer”

参见程序PRPYRP0845：“用气体分析仪测量气体成分”SeeprocedurePRPYRP0603:“Howtosamplehotmeal”

参见程序PRPYRP0603：“怎样进行热生料取样”SeeprocedurePRPYRP0611:“Howtocontrolhotmeal”

参见程序PRPYRP0611：“怎样控制热生料”Seetechnicalagenda“fuelflexibility”参见技术文件“燃料多样性”

Rule624Reducegasbypassandcontrolmealdistribution

减小气体短路，控制生料撒料Prerequisite前提条件Teamwork–Process,MaintenanceProductionandQuality

团队合作－工艺，维修，生产和质控Actions行动Settargetlevels(aspersupplierdesign)

设定目标值（按照厂商设计）Gascycloneinletandoutletandmaterialcycloneoutlettemperatures

旋风筒进口/出口气体温度和旋风筒出口料温Optimizemealdistributionbyinstallingsplashboxesinplaceofsplashplates

优化生料撒料效果（用撒料箱而不是撒料板）Checkmealpipesdesign(splashboxtypically1mabovecycloneroof,mealpipeangle>60°,flapvalvemin.2mabovesplashbox)检查下料管设计（撒料箱一般高于旋风筒顶部1m，下料管倾斜角度>60°,

翻板阀在撒料箱以上最少2m）Minimisegasbypassbyensuringproperfunctioningofflapvalvesincyclonemealpipes(checkflapdesignwithyourTC)尽量减小气体短路，保证下料管上翻板阀的功能（与TC一起检查翻板阀设计）Checkcycloneefficiency(vortexfinderandgasinletdesignsneedtobeanalyzed)andinspectthemfordamagesandbuild-upsduringkilnstops检查旋风筒效率（分析内筒及进风口设计）停窑时检查是否损坏，有积料等。Measurementmethods:测量方法：Temperatureprofilesinriserductorcyclonegasducts,aboveandbelowmealfeed测量上升烟道或旋风筒换热管道的温度分布（喂料点上下）Temperatureprofilesincyclonemealducts

料管内温度分布Support支持文件SeewithyourTChowtomeasuregasprofileinariserduct连续你的TC如何测量气体分布（烟道内）SeewithyourTChowtomeasurecycloneefficiency

联系你的TC如何测旋风筒效率

Rule625Managebuildups

控制结皮Prerequisite

前提条件Teamwork–Process,MaintenanceProductionandQuality

团队工作－工艺，维修，生产和质控Pressureandtemperaturesensorsingoodoperationalconditions良好的压力和温度传感器Actions行动Frequentlycheckpreheatertoensurenoairin-leakages(patroller)

岗位工经常检查预热器确保无漏风Ensureproperworkingofblockagedetectorsandflapvalves

确保堵料探测仪及翻板阀工作正常Closelymonitorpreheateroutletpressureandcyclonepressuresandtemperatures

密切关注预热器出口压力，旋风筒压力及温度ManagehotmealSO3+Clconcentrationinbottomcyclonemeal

控制末级旋风筒热料中的SO3＋Cl。Usethermo-camera(ifavailable)tolocateareasofthickbuild-ups

用热像仪（如果可能）探测厚结皮的区域Reviewinstallationofairblastersaccordingtobuild-upslocationandensurecorrectoperationofairblasters

根据结皮积料位置，评估空气炮位置，保证空气炮的正确使用Irrequired,implementmealcurtainanduse“non-stick”refractory

如果需要，安装料幕，使用抗结皮浇注料。Ensureregularcleaningoperationsofkilnhearthandriserduct,byqualifiedoperators,instrictcompliancewithsafetyprocedures

由合格人员在严格安全程序下，定期清理烟室，烟道。Support支持文件SeeprocedurePRPYRP0603“Howtosamplehotmeal”

参见标准程序PRPYRP0603：“如何取热生料”SeeprocedurePRPYRP0611:“Howtocontrolhotmeal”“参见标准程序PRPYRP0611：”如何控制热生料“SeeprocedurePRPYRP0614:“Howtocleanapluggedcyclone”

参见标准程序PRPYRP0614：”如何处理旋风筒堵料“SeeprocedurePRPYRP0625:“Howtomeasurewalllossesbyinfraredpyrometer

参见标准程序PRPYRP0625：”如何用红外高温仪测量墙体热损失“Setupsafetyproceduresforcleaningbuild-upsinpreheaterwithTCandOH&Sorganisation与TC和OH&S组织一起建立预热器结皮清理的安全程序。

Rule626RULE7:

Optimizekilnthroughput优化窑产量Doyouoperatekilnatmaximumstablethroughput?你们工厂是否运转在最大稳定产量吗？Doyouknowwhatisyourcurrentbottlenecktoincreaseoutput?

你知道你们工厂的影响提产的生产瓶颈吗？Doyouhaveamarginforcontrol?

你们工厂有操作的富余吗？*Inanonsoldoutplant,optimumcostobjectivesmightleadtoanoperationbelowmaximumstablethroughput

在非售罄的工厂，优化成本的目标也许会使窑在低于最大稳定产量下运行27Permanentlyreviewkilnthroughput

坚持关注窑产量Prerequisite前提条件Teamwork:Production,ProcessandMaintenance,Kilncoach团队合作：生产，工艺，维修和窑教练Propersensors/actuators+ReliabilityFactorandMTBFhighenoughtoenterinto“optimization”approach合适的传感器/执行器＋RF＋高的MTBF

FLPoperatorperformancedailytracking窑况评估看板Rule7ActionsRegularlychallengethekilnoperatoronwhatpreventshimfromincreasingfeedrate:经常挑战窑操作员什么阻止他不能提高喂料Trackshiftperformanceandid