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Preheater Tower Best Safety Practices
Tom Spaits Josh FredlakeVice President Production Manager
ATD Pressure Gas System Giant Cement7634 Southrail Road, Unit 601 654 Judge StreetNorth Charleston, SC 29420 Harleyville, SC [email protected] [email protected]
Preheater Tower
• Prepares feed for the kiln
• Meal can be heated to 1500 F in 30 seconds
• Tons of material can be present at one time
• Material can be sticky and buildup or can suddenly plug
Monitoring The Process
• Kiln operation can effect build up
• Chemical composition can effect build up
• Monitoring or the process is critical
Detection of Buildup
• Pressure and temperature sensors can help determine a problem
• Nuclear density gauges work very well
• Tipping valves• Thermal Imaging
Accountibility
• Know who is on the preheater tower and where they are
• Control room log• Radio communication
Checking The Tower
• Regular inspections and follow up plans to address issues
• Identify Cleaning ports
Preheater Tower Inspection
• Notify control room• Proper PPE required• Exit Strategy• Situational awareness• Hazard recognition
Air Cannons
• Can be located almost anywhere
• Remotely activated• Low Energy (in
comparison)• Stationary
Cardox
• Very Powerful• Can be installed/used
online• Must be used by trained
personnel• Risk of refractory
damage
High Pressure Water
• Powerful spray can be directed as needed
• Can be used on line• Low operating cost• Versatility• Exposure hazards• Specially designed ports• Risk of refractory
damage
Air Lancing
• Low cost• High potential of blow
back• Low energy • Fugitive dust
Preheater Tower Plugs
• How do you know?– Nuclear density monitor– Pressure spike– Temperature spike– Tipping valve
• What next?– Shutdown– Secure the area
• Entire pyro processing line
Preheater Tower Plug
• Barricades warning signs, lights, signs
• Put on proper PPE• Locate the plug
– Small doors– Start at the bottom– Cardox is the best tool
Before A Kilns Start
• New cleanout ports needed?
• Check cyclones before preheat
• Check again before feed• Check again when feed
starts
Thank You!
Questions?