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Yes, actually both grates were running faster and now with less charge in the cooler we have this condition.

Thank you sir for reply ​@@vbrcement3666 Could you make more content about ProCEM simulation?

Thank you for the positive feedback and if I may suggest have a look at the new videos I have posted in this channel... Kind regards, Fred

Thank you for the feedback Mohan! Yes, in case I can be of some help do not hesitate to contact me again. For your information I am very busy at the moment and may take quite some time to come back with an adequate response. Many greetings, Fred

Great, thank you for the feedback and keep an eye on this channel, I will post a new video about tube mills very soon. Greetings, Fred

I am glad you enjoyed it, and you can have a look at the other videos I have produced... www.youtube.com/@vbrcement3666/videos Cheers, Fred

Thank you for the feedback, very much appreciate it! By the way, I have been working on new training material you might be interested to see... th-cam.com/video/rd0VQDoIOI8/w-d-xo.html&

Yes of course, please send me your coordinates at vbrcement@gmail.com and we will manage it whether by mail or WhatsApp. Greetings, Fred

Hello, Thank you for the email and request. All is fine here but unfortunately I have no time to produce new videos at the moment. I cannot tell you when I will be able to produce them, sorry about that. Keep well and healthy! Fred

Hai

Very good observations, well done!

@@FredAubert sir there are in some plants cooler without Flowmeter of the air just the pressure, how could we control their

That is a situation where you will need a very good operator in the field keeping an eye on the cooler. The risk is that if there is a lot of pressure under some of the compartments it could be that the fan is working at its limit capacity - called "shut off pressure". In this case you will have no flow in the cooler and will certainly damage the plates / bars. The "very good operator" the field should listen to the fans and actually stand next to the fan inlet to feel whether there is draft inwards or not. Make sure to analyze the fan curves and to run the fan below this shut off pressure. Difficult to explain the "how to do it" from the distance, but I hope this helps.

@@FredAubert thanks a lot sir we your notes is so good and your ways is really new for us... what we do is monitoring the pressure and make operator in the field monitor the bed I appreciate your recommendations so much sir 💗

Thank you for the very kind feedback and comments, I appreciate the fact that this material can help you. So far I have been very busy with projects but will produce new videos as soon as I find some time... Keep well and wishing you a lot of success in your professional development!

Thank you for the comment, I am happy to hear that you liked it. Best wishes and lots of success in your daily operation! Greetings, Fred

Hello Kandavel My first comment is that your clinker is underburned. The reasons why you cannot achieve a proper burning / firing of your clinker may be multiple, and without any further details about your system I am not in a position to provide suggestions. For a start, look at the options to get your burning zone hotter. Good continuation, Fred

Sir i am in lab person in our side parameters are slightly change in rawmill residue 45 mic is 0.8% from 1.o%but now clinker not formed properly kiln showing in Dusty conditions and clinker come with brown powder this is reduced to strengthen

Happy new Year to you! Sorry to disappoint you but product fineness is just not sufficient for me to provide a realistic solution to your problems. Increasing the raw meal fineness should have improved the clinker burnability so there is something additional to the issue. The best is if your management invites me to visit your plant, then I can analyze what is happening and provide guidance. All the best, Fred

Great to hear that you find this video useful, thank you for the feedback! Keep safe and Best regards, Fred

Yes, you are absolutely right!

Sorry, I just noticed your comment now... I guess that you mean CO. Before entering the analyzer the gas sample should go through a dehydrator. I know there are many models in the market but I would not be in the position to suggest one or another. Muchos saludos, Fred

I am glad you enjoyed the video and profit from it! Thank you for the positive response.

You are most welcome, glad you liked it!

You are most welcome!

Yes, the cooler got empty because the grates are running faster. You are right, retaining the clinker longer in the hot zone (higher clinker bed) will also improve the secondary air temperature. Thank you for the feedback!

Good to hear you liked it, thank you !

Yes, of course, you can email me directly at vbrcement@gmail.com and we can start from there...

And ... no contacts from your side, is it all right?

@@vbrcement3666 i have already mail you sir

@@AlokSharma-qqwwee Then I am not sure what you mean when you ask if you can contact me personally. Please clarify what you need.

@@vbrcement3666 if the free lime in clincker is more than 2% or less than 0.80% then how will it effect grinding efficiency ? I have mail you this question but due to some issue it remains unsent.. I apologize for that ..

To calculate the clinker production you use the so called "clinker factor" or raw meal factor. This factor is based on the LOI or "loss on ignition", which considers mainly how much CO2 is released from you calcium carbonate. The factor also considers the dust "lost" or the dust which is not recovered from the 1st stage of your preheater tower. The LOI can be calculate with the chemical composition of your raw meal. The dust loss, cannot be calculated, unfortunately. In other words if you feed 100 t/h to the kiln and you have a clinker factor of 1.56 then, in theory you will produce 64 t/h of clinker... But not all the kiln feed will go through the kiln, because of the dust loss. The only good and precise way to know your real clinker factor (which will include dust loss) is to measure and weight the actual clinker production during a defined amount of time (ideally 8 or more hours), with the kiln running very stable and with the same feed. A rule of thumb to know your clinker production (very rough estimate) is to multiply the kiln feed t/h x 15 = tons of clinker per day. In you case, your system would produce 8200 tons / day or 340 t/h. This would be a very approximate 1.60 clinker factor. I hope this helps.... let me know please! Regards, Fred

​@@vbrcement3666sir can I get your contact details

Bonjour Benjamin Je suis content de savoir que tu as apprécié la vidéo et qu'elle puisse te servir pour ton stage. Tu peux bien sur me contacter ... vbrcement@gmail.com ... mais je dois te prévenir que je suis passablement occupé en ce moment et il se peut que, si ta / tes questions nécessitent de beaucoup de temps, je ne puisse te répondre sans avoir à te facturer. Par curiosité, dans quel pays tu fais ton stage? Amicalement, Fred

@@vbrcement3666 Merci beaucoup pour votre réponse rapide. Il se déroule au Cambodge pour une durée de 2 mois.

@@benjamincatau8556 Merci pour ce rapide retour, et j'attends donc tes questions...

@@benjamincatau8556 Je n'ai toujours rien reçu sur mon email, est ce tout est en ordre?

Hello Bilal, Here is the link to the video, it is in my channel: th-cam.com/video/i46gGIlaFNY/w-d-xo.html& Have fun, Fred

Glad you liked it!

I am glad you liked it! Yes it is a good idea to work on a specific ETA cooler, I shall work on this!

​@@FredAubert , I got some question about cover of grate: 1. Why use pebble stone filling in the lanes? 2. Can we use clinker(unburn or normal)? if can or can't, why? Also the stroke length of the grate,i.e eta cooler with 6 lanes: lane No.1 & 6(125mm) are shorter than lane No.2,3,4&5(180mm). Can you please explain about that too? Thank before hand.🙏

Hello Viden I presume that your questions relate to a restart after a major overhaul, that is with an empty cooler. The idea of pre-loading the lanes is to protect the plates and offer some initial resistance to air flow, at least till you have clinker dropping down from the cooler. You can use clinker, but it is good material and costly in comparison to pebbles / gravel. Unburnt clinker is not good for that purpose, it will fly away as soon as you start your fans. Concerning the late 1 and 6 (side lanes) lengths being shorter, one of the reasons I can see is to avoid forming so called "rat holes" and / or "red rivers" in the cooler. If 1 and 6 are shorter, this means you will never open gaps in those areas which in turn would ensure air distribution within the other lanes. I hope this clarifies your questions.... Bests Fred

Hello@@FredAubert , You're answering right on point sir. With your good explain like this, I should answer my senior questions now. Thank you very much!! Respect, Viden

Thank you for the feedback!

Think about the other way around... the coarser the clinker the easier the air could find its way through it, thus the pressure would drop. Think also about how we determine cement Blaine. The finer the cement (higher Blaine) the longer it would take for the column of air to go through it. Lower air flow would mean higher undergrate pressure in our case of the clinker cooler. The example I have given relates to a higher grate speed. This would produce a thinner clinker bed = higher air flow = lower undergrate pressure. In this case the clinker temperature is lower because we kept the same amount of air blown through the undergrate fans. Look at the excess air fan: it is sucking more than on the previous settings to keep the hood pressure constant. Thank you for trying it out and if you have other questions let me know. Cheers Fred

@@vbrcement3666 Sir, very nicely explained... my question is how to judge the clinker bed? We are facing problem in getting the chamber pressure high although on checking through inspection window it is less.. what should be the bed height with fine and course clinkers?

@@anubhavsingh1889 Interesting to see you back here, I hope all is fine on your side! I believe that you have answered your own question, somehow. The cm of clinker bed can be "seen" very approximately through inspection doors. You need to have on the opposite wall of the cooler some marks / references which will give you an indication how much clinker you have on the cooler. The actual cm of clinker are not really important, but rather the pressure you can build up in the chamber. I suggest you follow what your manufacturer tells you and try to achieve the recommended pressure. You mention that it is difficult to get the pressure high enough. There are a few possible reasons for that, but the most common are leakages / deformations on the cooler beams or damaged seals. If this is the case, you will have to find new setpoints for operating the "damaged" cooler, having the main goal of achieving the best secondary (and tertiary) air temperatures. I don't have sufficient information about your kiln and cooler to give a formal appraisal. In case you need further advise, let me know, but to start with send me some screen shots of your kiln + cooler operating at nominal capacity. Cheers, Fred

@@FredAubert Thanks for replying Sir. Had we met somewhere as you wrote interesting to see me here!! Please take my apologies for not able to frame question properly. Actually my point was to make run cooler slower so as to enable clinker cooling and recuperation also. The cooler we have is Fons delta cooler replaced in dec 2020. So it's very new and in good shape. The speed is decided based on 2nd compartment chamber pressure which should be around 60mbar. But we are getting it around 68 to 70 mbar depending upon fan speed and clinkerisation. On checking from site inspection window we get the bed height as 400 - 500 mm.. I am not finding any option to share screenshot here. If you could suggest any other way where I can share screenshots for your reference.. Hope this time I framed my concern rightly. Looking forward to see your reply soon.. take care Sir.. Have a nice day

@@anubhavsingh1889 Hello Anubhav Yes, evidently I got it wrong, you seem to have too much pressure under compartment 2... Some plants would love to have such problems, usually they cannot manage to build up enough clinker bed and I would say that your 400 to 500 mm are very respectable! What I mean about a screenshot is from the monitors in the control room, it would help me to understand what is happening in your kiln and cooler. There is, normally, a possibility to create a "Print Screen" on the operator's panel, this would be ideal to have. Just from your comments I think that you may have a problem with the cooler control loops (PID controls) for the cooler speed and possibly for the cooler fan flows. On the other hand remember that the first purpose of the cooler is to recover thermal energy. Focus on achieving this, while making sure that you are protecting your equipment. Hard to help from the distance, but I guess that eventually we will find a solution. Best regards, Fred

I think that the easiest would be to approach directly the plant and apply for a job there. It may not be "the dream job" at first, but if you become a good mechanical engineer, I am sure that the supervisors / managers will identify your potential and promote you! The key is, work hard and focus on your achievements. The rest will come by itself... Good luck! Fred

Hello Tri I am glad you had a bit of fun looking into the cooler video and I just gave you feedback on your reply, yes you are right, the grates are running faster, this makes a thinner clinker bed with the consequences you can see. Have you seen this other video on kiln operation? th-cam.com/video/i46gGIlaFNY/w-d-xo.html&

yes i would like to see it, hopely you make more videolessons, thank you for your fast respon too, it is my honour if you like to discuss more anytime 😊

At the moment I am quite busy with a project in Sudan, but as soon as I find some time my intention is to prepare more videos such as these.... Keep the good work!