Instructional Manual For Clarification Of Startup In Source Categories Affected By New Source Performance Standards - U.s. Environmental Protection Agency - 1979 Page 144
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146 typically used to season the refractory.
At first the kiln is not rotated, then
as the temperature builds up, operators rotate the kiln so that the refractory
is heated evenly.
This process normally takes 3 to
5
days.
Due to equipment
faf.lures, however, f.t may take two or three attempts to season the kiln pro-
perly.
Limestone is not usually introduced to the kiln during the drying out
period.
Water vapor and products of combustion generated during refractory season-
ing are vented either through the air pollution control equipment or a temporary
exhaust opening in the ductwork leading to the air pollution control equipment.
The latter case occurs most often when the control device is a baghouse, con-
sisting of fabric filters which can be affected by the relatively high moisture
content of the gas stream.
Once the refractory lining of the kiln has
bee~
dried out, the kiln can 1) be shut down while ancillary process equipment are
being installed or checked out, or 2) can be brought up to its normal operating
temperature of IIOOoe (2000 0 F) and begin to receive limestone, provided that
all ancillary equipment have been checked out and readied to commence production.
Pre-startup of the hydrator and ancillary equipment follows the same
sequence of shakedowns as the rotary kiln and its associated process operations.
Simf.larly, electrical systems and'mechanical equipment are initially tested
individually and then as a total unit prior to processing of
mat~rial.
The only
major difference between pre-startup of the rotary kiln and the hydrator, is
that the latter does not require seasoning because it is not .lined with refrac-
tory.
The hydrator pre-startup shakedown can last from 2 to 4 weeks.
Startup Operations
Startup for lime manufacturing operations is generally considered to be the
first day limestone is fed into the stone preheater or the rotary kiln, depend-
ing on the plant configuration.
It is at this time that particulate matter is
first generated and emitted as an air pollutant from the limestone calcining
operation.
Typically, the kiln is preheated to 315 to 37l o e (600 to 700
0
F)
before the limestone is introduced.
As more material is fed into the kiln, it
is brought up to its normal operating temperature of 11000e (2000 0 F).
Most of·'
the sources contacted indicated that coal was the principal fuel used to fire
rotary lime kiln furnaces.
Startup begins an intensive period of equipment shakedown.
Process opera-
tions must be synchronized, conveyor and feed systems have to be adjusted,
instrumentation has to be rechecked under actual operating conditions, and air
pollution control equipment must he monitored.
One source stated that once
startup has occurred, the kiln could produce at 50 to 70 percent of its. rated
capacity within two days, but that it could take two to three months of
dehug~
ging and fine tuning before the kiln would he operating close to design capacity.
FLne tuning would include adjustment of burner positions and primary air feed
rates.
Other delays would result from the malfunction or failure of auxilIary
equ:l,pment such as conveying systems, material and fuel feeding systems, and .
instrumentation.
Extended time delays could result if major pieces of process
. lipment had to be reordered.
The sources contacted stated that the 180 day
p'.iodallowed for equipment shakedown prior to required performance tests pro-
vided enough time to reach maximum production rates, unless major process equip-
ment pieces had to be replaced.
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