Kiln Operation

[@bhaskaragate6494]

Excellent presentation and very useful for CROs. Congratulations Fred Aubert. Thanks for sharing.

[@FredAubert]

I am glad to hear that you enjoyed the video and that you can use it for training purposes. Next one will be on cooler operation, but for now I need some time to finish it... Cheers Fred

[@ኑኣሚን]

Thank you d/r

[@FredAubert]

You are most welcome, I appreciate the feedback, thank you! Keep well and safe, Fred

[@jashunayak6063]

Nice video and very useful information

[@FredAubert]

I am glad you found it useful, thank you for the feedback!

[@ytecgaming6115]

Good morning sir, This video very useful to us

[@FredAubert]

I am glad to hear that, thank you for the comment!

[@gopalchari6750]

Thanks, I have used the video in my training session.

[@FredAubert]

Hey that's very good indeed! If your operators can use such information then please use all the material I can provide...

[@mulugetahay1286]

thank you for your amazing video lecture , please keep it up for other processes sir.

[@FredAubert]

I am glad you liked it... Sorry but I missed your comment, already one year ago. In case you are interested I suggest you have a look at the new YT Channel I have opened, here is the link: kzbin.info/door/yAYzvQOH7mjguyZQ8hvftAvideos? You will find training material related to cement plants... Have fun and Cheers Fred

[@attahussain9449]

Sir thank you for your time it is a very use full material kindly share further videos,

[@Gamontqmchannel]

Really good vide, simple and quite illustrative at the same time,.. thanks to sharing that quite valuable and unique information

[@FredAubert]

I am very glad you enjoyed it and hope you can use some of the ideas in it. For now I am working on a new video for the clinker cooler, will be posting it whenever I manage to finish it!

[@Gamontqmchannel]

It was really a pleasure to enjoy your video, I will wait for the next one,.. I just sent you a kind request to accept me in your LINKEDIN network and in your Group, I believe we could have interesting and fruitful conversations, That for me will represent an opportunity to learn

[@ANSARKHAN411]

thanks for such an informative video please share more pyro process related videos and also RAw mill videos too

[@FredAubert]

Hello Ansar I am glad you enjoyed the explanations and yes, the plan is to produce more of such videos on cement process... and this includes as well the raw mills, ball mills and VRM! I also hope that you visited my other YT channel dedicated to technology.... Cheers, Fred

[@ameerahmad305]

@@FredAubert Sir waiting for the videos on VRM and ball mills

[@FredAubert]

@@ameerahmad305 I am afraid that you will have to wait a bit longer, extremely busy at the moment ... Sorry about that and if I may suggest, look for some material from your equipment supplier. Don't hesitate to call / contact them, they will provide the information you are looking for. Keep safe, Fred

[@ameerahmad305]

@@FredAubert Sir the video you shared is unique and best described specially for the new comers. We usually operate plant but don't actually know the theory behind every step.

[@FredAubert]

@@ameerahmad305 Thank you for the feedback, much appreciated. Unfortunately, right now I spend my day following up on previous commitments and training activities and I really do not have time to produce new videos :-( I hope that end of the year or new year I will get some time for myself, but I cannot promise you anything ....

[@saleemurrazzaq1980]

excellent

[@FredAubert]

Thank you for the feedback, I hope that you / your peers and subordinates can make good use of the information! Many greetings, Fred

[@jerry4829]

Thanks a lot Fred

[@FredAubert]

You are most welcome Jerry!

[@alfredomas2857]

Very interesting educational information. Overall, for control room operators

[@FredAubert]

Glad to hear you enjoyed it and found it useful!

[@aungzawmyint2863]

Thanks for your explanation.

[@FredAubert]

I am glad you liked the video!

[@jafarhamedi6003]

Thank you for your awesome information.

[@FredAubert]

I am happy to hear that you liked it and hope it can be helpful to you! Cheers Fred

[@عبداللهعباس-ذ7ن8س]

Thank you very much, very useful content

[@FredAubert]

Glad you enjoyed it! 😁

[@عبداللهعباس-ذ7ن8س]

You can give me your own mobile number to communicate with you in Shan

[@mesfinnigate3602]

Thank you for your video and I need additional information kiln chemistry.

[@FredAubert]

I am glad to hear that you enjoyed the video.... Concerning your request about chemistry, please provide more information about your plant, position and needs. This would help to start communicating properly between us, the only way I can help. Best regards Fred

[@aboutceramics2470]

kzbin.info/www/bejne/qmanlHRvatCjY6s

[@ICC2012]

Good Information Sir.

[@rkmvpraktanincrchapter8404]

Sir, please share the link to your other KZbin channel dedicated to technology. You may put its link in the description of this video. Thanks

[@FredAubert]

Hello, You will find hereafter the link to my other channel videos, I hope this is what you need... kzbin.info/door/yAYzvQOH7mjguyZQ8hvftAvideos Thanks for your interest and happy watching! Bests, Fred

[@omarsigoix9927]

could you please make same video for mix crushing i will be very thankfull i apreciate your video

[@FredAubert]

Hello Omar Thank you for the feedback, I am always glad to hear when someone can use or finds this material worthwhile. Concerning your request for a new video, I am not sure if I understand what you mean with "mix crushing". I think that the easiest would be if you send me a few screen shots of your system and I can see what I can do. I understand that you may be concerned about disclosing your company name in case I produce this new video out of the screen shots. Be assured that I will mask all relevant information so no one can see what company it is. You can send the screen shots at my address at [e-mail] Looking forward to your feedback and Best regards, Fred

[@eduardodaquiljr9637]

does the flow of limestone intermittent? or continuous?

[@FredAubert]

Hi Eduardo, The kiln feed or raw meal is a mixture of limestone + silica + alumina + iron oxides. It is a continuous process in this case. The original technology used so called "vertical kilns" and those indeed were typically processing batches of material. Mind you, these vertical kilns produced mainly free lime - in Spanish Cal viva. Hope this helps....

[@eduardodaquiljr9637]

@@FredAubert Thank you,actually based on your theory I already understand it is a continous calcining.I am refering to your lectures in designing a small rotary kiln for quicklime production.Thank you and more power on your channel.

[@anujkumarverma2777]

Respected Sir, very useful information. Kindly add video on coolers and alkali bypass system.

[@FredAubert]

I am glad you found the video useful. Concerning your request, because of Covid I have a lot of work at the moment so please be patient....

[@gopalchari6750]

Excellent explanation.

[@FredAubert]

Thank you, I am glad you liked it! Keep an eye open for the next cooler operation coming up...

[@BlackSpikeD]

Yessir love this video

[@vbrcement3666]

Thank you for the comment, I am glad to hear that you enjoyed this video! Take care and work hard my friend 👍

[@badramrajusitharamarao1288]

Good evening sir, exlent sir, please explain kiln operations in ccr

[@FredAubert]

Good evening to you Badram I am glad you enjoyed the video on kiln operation, but I am not sure to understand your question or what additional information you need. Regards, Fred

[@badramrajusitharamarao1288]

Good information sir

[@FredAubert]

I am glad you like it and hope you can use some of the recommendations!

[@badramrajusitharamarao1288]

Good morning sir, good information, sir please explain about kiln zones

[@FredAubert]

Hello Sitha You have an interesting question but I think that you can find the answer in Internet.... (example here en.wikipedia.org/wiki/Cement_kiln) What you have to keep in mind is that your kiln zones sizes will vary depending on several factors, mainly your flames shape & size, the fuels you fire and the gas speed in your kiln. This means that you cannot say that your "upper transition zone is 18 m long" and trying to change the size of these zones is not your priority. You have to focus on producing a short and strong flame, keep your Oxygen levels as low as possible (no CO) and the zones will be adjusted accordingly. I hope this helps you ... let me know. Regards, Fred

[@sarinyachan561]

Good information. How do you detect the temperature?

[@FredAubert]

Hello Sarinya Those temperatures are taken with thermocouples... But I am not sure about your question. Please be more specific. Cheers Fred

[@damo87araimo]

How do you detect the temperature of the solids just after the flame? During the heat up the solids thermocouple was reading 650 Deg C but shot up to 1400 Deg C when the solids arrived. @@FredAubert

[@FredAubert]

In this case, when looking into the kiln, you use radiation pyrometers to measure the temperature. I believe that in the example you describe (640C then jumping to 1400C) the pyrometer may be pointing very low under the flame. The 1400C reading is from the material. Not sure to have answered your question...

[@ZahidIqbal-ey4hd]

Such a good information

[@FredAubert]

I am glad you enjoyed it.... Keep safe!

[@ahmadfawziahmad46]

Hello .. Do you have a simulation system for education? Please

[@FredAubert]

Hello Ahmad Yes we have a simulator and we normally use it for training purposes. We normally run these training sessions for cement plants, that is all control room operators (we do several sessions for all shifts). My suggestion is that you mention it to your management and see what they say... Best regards, Fred

[@fabricetshombe1374]

Thanks Sir for your explanation about kiln operation basic, it was really cleared. I need also VRM operation Basic. I'm working at cement factory in Drc ( flsmidth design )

[@FredAubert]

I am glad to hear that you could use it. Concerning the VRM / FLS operation, I have a lot to do at the moment - because of COVID and distance learning - and this particular project will have to be delayed... But, keep an eye open to see what else I can publish in the meantime. Keep safe, Fred

[@林珉-g2h]

Rotary Kiln Specification: Φ2.5×40m-Φ6.0×95(m) www.bestjawcrusher.com/products/rotary_kiln/?rico

[@BilalAhmed-fj7we]

Thank you sir

[@hammadhafeez8594]

Appreciate your effort sir. Currently I am working in a cement industry where Energy consumption is approx 790-800 KCal/kg clinker consumption. I am keen to optimize this energy consumption. I would be grateful if you can guide me how to reduce this energy consumption. And can you refer a software for carryingout energy balance.

[@FredAubert]

Hello Hammad Thank you for the feedback, I am glad that you could watch the video and hope it gave you some ideas about how to optimize your system. Concerning you question, I would say that you have to start with the simplest, more obvious research. These findings will help you identify potential improvements which will bring you substantial reductions in specific thermal consumption. I terms of "software" for an energy balance I suggest to use an Excel sheet. What is important is to take proper measurements, the software and calculations will be done on Excel. I can give you some hints about where to start with your investigations, but will need from you some more information about your kiln system. It would be great if you can send me some screen shots of the preheater / precalciner / kiln / cooler at stable conditions. We can take it from there on. Think about it, no compromise from your part and no charges from my side. Keep well and safe from this Covid19 ... Fred

[@sjpsjp1535]

beautiful...thanks a lotttt

[@FredAubert]

Most welcome!

[@FredAubert]

Most welcome!

[@quezialima3929]

Thank

[@pvprasad8845]

Hi sir..Please upload more videos on kiln Operation tips

[@FredAubert]

Hello... I am glad that you enjoyed the video, and yes I am working on preparing other videos which will be uploaded as soon as I find enough time to finish them! Have a little patience, please! Cheers Fred

[@garciacontracting]

Hi Mr Auber. We are thinking of a similar system, but with more air flow and more heat exchangers. The idea is to maximize heat absorbtion, and to dry a masive ammount of silica sand, not to make klinker nor lime, but over 1000t of sand per hourscan you design it? How much?

[@FredAubert]

Hola Camilo En lo personal no tengo mucha experiencia con secadores del tipo "flash dryer" y si fuese el caso de desarrollar un simulador de este tipo, entonces necesitare dimensionamiento del secador, tipos de refractarios instalados, datos de su operación desde arranque (precalentamiento) hasta producción nominal, rangos de temperaturas que se manejan, combustibles, consumos específicos ... en fin la lista sigue y sigue. En cuanto al costo? Bueno creo que del punto de vista de rentabilidad para tu planta, te debo decir que sería demasiado caro desarrollar solo un modelo y más bien sería vender este simulador a varias plantas. No te puedo dar una cifra definitiva pues necesito conocer más del sistema para poder hacerlo. Sin embargo te puedo adelantar que estamos hablando por ahi de los 60'000 a 80'000 US$ Pero claro que si el sistema es muy sencillo, entonces el precio bajará a solo unos cuantos miles.... Lo mejor es que me envíes algunas pantallas de tu sistema operativo. Saludos, Fred

[@ibrakh7982]

is it in general or for specific company?

[@FredAubert]

This is based on a kiln simulator which was tuned to a specific "real" kiln. I hope this answers your question...

[@ibrakh7982]

@@FredAubert thanks alot great informations

[@raxtor3199]

Hi Sir could you Share the software?

[@FredAubert]

Hi Ismail Yes of course, I can share the software but this will have to be done through a training session. There is no point of just sending you material and then you couldn't know how to use it. I suggest you talk to your management. My proposal is that I go to your plant for one week, see how the plant runs, what the training needs are, and then we plan a delivery session. Let me know what they have to say and we take it from therre. Best regards, Fred

[@raxtor3199]

@@FredAubert sorry i have no kiln. I am working for alignment system. And i know that there are lots of types...

[@FredAubert]

@@raxtor3199 Hi Ismail If you have no kiln, then there is no point in sharing the kiln simulator, I guess. You are probably right, there are many types of software to support / help in aligning equipment, but I do not know of any in particular to recommend. Good luck in your search and Best regards, Fred

[@mohanmadayi1498]

hello sir i happened to watch your intersting video in kiln operation. The problem i am facing is higher tower temp of 430- 440 c. its a 4 stage cyclone with 100 % gas firing. Earlier the top temp was 380-390c Now when i try to increse feed and bring down the temperture the kiln gets upset run. i am getting calciner temp of 900 c . can you explain whatcould have gone wrong. False air leakge arrested max . but still the situation same.

[@FredAubert]

Hello Mohammed (not sure if this is your name, sorry if it is not) You are describing a typical problem of high exit temperatures, with the consequence of high thermal energy consumption and potential excessive wear + damages to your ID fan. Difficult for me to give you a solution without knowing the "full picture", basically to see what happens in the different parts of the system. It would help if you send me a screen capture of your kiln system, with details of the preheater / precalciner and the cooler. Then may be I can help. Have a good day, Fred

[@siltanbelay1679]

sir thanks for good video and I need to know about the air fuel ration

[@FredAubert]

I am glad you enjoyed the video. Concerning your question, are you talking about primary air or total air?

[@raviyajneswar5474]

Please upload limestone kiln process operation

[@FredAubert]

Sorry to tell you, but I do not have a lime kiln operation video....

[@teedydharmawan1111]

Hi Fred, could you inform what software used for your simulation? I am very interesting to discuss regarding rotary kiln control with you.

[@FredAubert]

Hi Teedy, We use two software / programs, first "acslXtreme" for modelling the cement manufacturing process, then "LABView" to prepare the user interface. It took a couple of years to get a "running simulated kiln" and we were sponsored by a large cement producer. Concerning your other question about rotary kiln control, I am not sure what you want to discuss, that is how to model a kiln or how to control / run a real kiln. Whichever is your need please be aware that this will take considerable time and I may have to charge you for my services. Let me know what your thoughts are and keep safe! Cheers, Fred

[@pvprasad8845]

Thank you sir.. make more videos on KZbin

[@phamvanhien9433]

Hi fred, I am working at a cement factory in Vietnam. Your simulation software is very interesting. can you guide me to make that software? thanks a lot.

[@FredAubert]

Hi Pham I am glad you like the simulator and understand your wish to develop your own. I certainly do not doubt your knowledge about programming and modeling but for your information it took us around two Man / Years of work to reach the stage we are in. We were sponsored by a company you may know, Holderbank - now Holcim. You need to get a license for a so called ACSL program (info: swmath.org/software/4216 ) plus some program to develop graphics - the interface. This is the very easy part, the rest is pure Hell! We use the simulator for training purposes and even at this stage we do not sell it, just use it during training. It is very well secured, no pirated copied on the market LOL. There are simulators out there on the market, some are "Mickey Mouse" stuff, others - e.g. from the company VDZ - are actually not bad at all. An advise from my side: forget it, life is too short. I have been a few times to Vietnam CatLai and Honchong, very interesting to work with the plant people over there, beautiful country, I loved the food. ... Take care and Cheers, Fred

[@yakobdoca2423]

what is that softwarev

[@FredAubert]

The software is a kiln simulator. In case you ask, it is not for sale, I use it for training control room operators.

[@hamidrezar1040]

Hello.Is pre-heating necessary for CSA(calciumsulfoaluminate) cement? and can you explain about CSA cement production process? Thank you

[@FredAubert]

Hello I have no experience in manufacturing CSA cement, sorry about that! When you say pre-heating, do you mean using a preheater tower? As far as I have seen and read, one can fire such clinkers in traditional Portland clinker kilns, but in the case of CSA temperatures needed are lower (lower temperatures= less fuel = less CO2 emissions) Good luck in your search!

[@rudygunarso3176]

What's software you use on this video?

[@FredAubert]

This is a kiln / mill simulator, made some time back using XL Extreme platform and LabView for the user interface. I usually use the simulator for training CCROs and in case you ask, no, it cannot be sold ...

[@elguty2008]

Hi, we work in a cement plant in Mexico anr recently we have some ¨avalanchas¨ in the preheater of raw material, do you think it can be caused by a high conentrate of sulfur on the raw material, we actually use coke as a fuel in burners and a 20% of sustitution of fuel with waste materials in preheather

[@FredAubert]

Hola Alejandro Es temprano para tí, sospecho que estas de turno en la sala de control... No lo mencionas específicamente pero el 20% de AFR en el precalentador se introduce como precalcinación (con aire terciario), o es solo algún quemador secundario? Queman llantas? Me es difícil asegurarte si las avalanchas son causadas por un alto contenido de azufre, sin tener mayores información sobre el tipo de horno y la química del crudo, y del AFR... Sería ideal si me pudieses enviar un screen-shot de tus pantallas en la sala de control. A proposito, yo trabaje algunos años en Mexico, para Cementos Apasco.... Saludos Fred

[@BilalAhmed-fj7we]

Sir next complete operation vedio and Vrm operation vedio

[@FredAubert]

I am working on it, be patient please. I am working on a project in a plant now but as soon as I have some time I will produce the VRM and the clinker cooler videos

[@rajeshbakki1657]

Gud mrng sir iam working in chemical plant so present shutdown our employs are small trail but kiln not working condition perfect rotation is there but some vibration so to extend shutdown so any solution can u expln sir

[@FredAubert]

Good morning to you Rajesh If you want some help, you need to provide me with additional information. You mention chemical plant + kiln + vibration, all very confusing...

[@rajeshbakki1657]

@@FredAubert yeah ok sir

[@rafaelv.4451]

Thank you mr. Fred, do you know about a operation simulator for free i can download?

[@FredAubert]

Hello Rafael, Unfortunately I do not know if such simulators exist to be downloaded for free. Even when they are sold, there is just a limited number of such software. I am using one which was produced many years ago and still have the license to use it. The only thing that I can do nowadays is to run training sessions using this simulator. By the way, Rafael, are you located in Latin America? De ser así podemos conversar en Español, avisame por favor. Cheers Fred

[@rafaelv.4451]

@@FredAubert muchas gracias, efectivamente soy Mexicano, actualmente me encuentro en un curso de capacitación pero no tenemos una herramienta tan útil como esta, es increíble para aprender y no arriesgar la integridad de los equipos.

[@FredAubert]

@@rafaelv.4451 En efecto Rafael, el tener un simulador es primordial para asegurar la capacitación de operadores sin riesgo para el sistema del horno. En su tiempo yo labore para Cementos Apasco, en Apaxco Edo de Mex. y en ese tiempo también usamos un simulador... No se para que planta estas trabajando pero en caso de que pienses les pueda ayudar en capacitación técnica, te sugiero hables con tu gerencia y les propongas lo siguiente: yo ofrezco realizar una visita sin costo alguno (solo me cubren viáticos) y me quedo una semana a evaluar a la gente, ver como esta la planta y hacerles una propuesta de formación. Por supuesto que durante esta semana estaré aconsejando a los operarios, dando Coaching donde pueda. Si aceptan mi propuesta, bien y si no, pues no hay problema. A ver que les parece, me avisas por favor.... Saludos, Fred Aubert (ex gerente de capacitación técnica en las oficinas generales de Holcim / Suiza).

[@butharajumahesh2301]

Sir I have 8 years experience as CCR operator in cement industry . I want to work abroad plz try to send recruiting companies.

[@fredaubert8531]

Hello Butharaju You should know that there are many, MANY operators out there with 8 and more years experience and would like to work abroad... If you want to succeed my recommendation is that you start with doing the following: 1.- Prepare your CV, short and to the point - one page maximum, nobody is going to read a "book of your life" 2.- Write a letter, so called a Motivation Letter, where you explain your capabilities, strengths and experiences as CCRO, and what would a company would benefit from hiring you. This is certainly the key to your success, more important than the CV itself, you have to spend a lot of time on it. With these two items in hand you will have a better chance to approach an international company online (look for the big cement manufacturers, go to their pages, they always have a hiring section). Good luck! Fred

[@butharajumahesh2301]

@@fredaubert8531 I have good resume sir but I want companies names And websites to send CV and take interview to work sir

[@fredaubert8531]

​Just google "large cement manufacturers" or go to globalcement.com/directory and you will get those many of such big cement manufacturers. Concerning your Resume, yes good to have but remember to prepare the motivation letter, otherwise - if I were a cement plant - I could ask myself "why would I run the risk of getting Butharaju here?" The only reason I would get you is to pay you low wages, much lower than locals so be careful with that....

[@siltanbelay1679]

dear sir I want to communicate with you to help me for my gap in energy optimization since I am working in thermal energy optimization in cement factory

[@FredAubert]

Dear Siltan Yes of course I can give you some advises, but before I need to know more about your kiln and how it is operated. Can you send me some screenshots of the system, preheater / precalciner, kiln and cooler? Without this information I cannot do anything. Please use my email address, it would be easier to do that: [e-mail] Kind regards Fred

[@FredAubert]

Hi Siltan I need more information about your kiln system to identify the potential energy conservation points. Can you please email me more details at [e-mail] Thank you!

[@FredAubert]

Hello Siltan, yes I can help you but can you please use my email address: [e-mail] Send me an email and we can start from that point, basically to know what you know best and what you need most. Regards, Fred

[@BilalAhmed-fj7we]

Sir send all vedio cement equipment. Org packages price

[@FredAubert]

So far I did not make other videos, but keep an eye open for any new post!

[@santoshpatra8251]

👍