c. Reduction in Clinker Productivity
Moisture content of AFRs converts in additional gas volume and also excess percentage of oxygen require for hard to burn AFRs and hence increases
additional preheater gas volume and increase PH fan power consumption
for same output and if the preheater fan is running on full capacity then the it is
required to reduce the kiln output.
d. Impact on Refractory Life
Since the most of AFR`s contains some additional alkalis, Sulphur or even
chloride which ultimately creates problem in cycle and coating formations in
high temperature zone like smoke chamber and calciner bottom portion which is
so hard sometimes and react with refractories and hampering the refractoriness
and worn out faster.
e. Increase in Maintenance Cost
Also alkali and sulphur gasification during AF burning process may lead to
erosion and corrosion of equipment’s this may increase maintenance cost
accordingly.
f. Impact on Kiln Operation Stability
With the use of various AFR`s it changes the way how the kiln has to be operated.
The impacts on kiln operation are:
- Slower reaction inside kiln
- Variable fuel properties and heat input
- Difficult burning zone temperature signals
- Opposed optimization targets of oxygen and back end temperatureand
expert system may not be useful up to a considerable extent hence losses
of cost of expert control system - Chlorine cycle
- Increase in ash content at kiln inlet.