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Pyro Section Process & Energy Audit [kiln and cooler audit]
Pyro Process Audit Training Introduction
Brief Introduction of Audit Training and Training Structure (5:09)
Process Measurement Procedure with Portable Instruments
Thermocouple and RTD for temperature measurements. (8:47)
Portable Radiation scanner (gun) for temperature measurements. (4:54)
Pitot tube for velocity, flow and pressure measurements. (10:32)
Anemometer for velocity and flow measurements. (4:46)
Pressure probe for static pressure measurements (3:34)
Portable gas analyser for flue gas composition analysis. (6:00)
Fuel Properties [New addition for understanding combustion calculations]
Coal properties (8:18)
Oil and gas properties (8:56)
Combustion Equations [New addition for understanding combustion calculations]
Definitions, Mole Concept, and Assumptions involved in calculation. (7:24)
combustion-equations of Carbon, Hydrogen, Sulphur (4:50)
Combustion Calculations for Process Analysis
Calorific Value Calculation (8:47)
Minimum Stochiometric Air Calculation (5:28)
Minimum Combustion Gas Calculation (4:35)
Calculations for Detailed Mass and Heat Balance
10 Step Formula for mass and heat balance (22:54)
Kiln feed to clinker ratio. (11:01)
Gas Density Calculation (7:45)
Gas/Air Flow Calculations (15:05)
Sensible Heat Calculations (10:10)
Calorific Heat Calculation (8:55)
Theoretical Heat of Clinker Formation (5:05)
Drying and Evaporation calculation (4:43)
Non- Carbonatic Heat Calculation (7:07)
Radiation and Convection Heat Loss Calculations (14:15)
Calculations for Preliminary Mass and Heat Balance
Identification of material streams to be calculated for Preliminary Mass and heat balance (8:07)
Calculations of material streams in case you have detailed fuel analysis (16:44)
Calculations of material streams in case you do not have detailed fuel analysis (7:08)
Process KPI Calculations
Energy Performance Calculation (7:52)
Kiln and Cooler Calculations. (11:00)
Cooler Efficiency Calculations (3:22)
Kiln Firing Calculation (5:34)
False Air Calculation. (8:14)
Fan Calculations. (7:41)
Quality KPI Calculations
Section Introduction
Quality KPIs of Clinker and Control Levers of Quality (21:29)
Burnability KPIs as Control Levers (9:07)
Assessment and Audit of Volatile Phenomena in Kiln (19:34)
Supplementary Quality Calculations
Productivity-Reliability-Environment KPIs of Pyro Section
Productivity KPI (5:53)
Reliability KPI (3:28)
Environment KPI (4:45)
Audit Preparation
Audit Team Formation
Project Charter: Main goal of audit, scope, schedule
Calibration Check and Signal Validation
Material Sampling Schedule
Data Recording Schedule
Process Measurements Schedule
Audit Execution
Activities for Day Before Kiln Audit (7:46)
Activities During Kiln Audit/Inspection (5:27)
Audit Evaluation:) Results and Reports
Section Introduction
Generate Preliminary Mass and Heat Balance for Your Pyro Process
Generate Detailed Mass and Heat Balance for Your Pyro Process
Performance Snapshot Report PSR of Critical KPIs
Detailed Process Audit Report Sample for Guidance Purpose
Training Evaluation
Submission of detailed audit report
False Air Calculation.
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