Instructional Manual For Clarification Of Startup In Source Categories Affected By New Source Performance Standards - U.s. Environmental Protection Agency - 1979 Page 29
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146 Pre-startup Operations
Prior to the passage of any raw material through the various processing
steps of the facility, all mechanical and electrical systems in each production
phase are independently operated.
These checks serve to insure that all motors,
fans. screw conveyors, electrically controlled valves, material handling opera-
tions and air pollution control devices are ready for production.
In wet
process operations, all pumps and slurry feed systems are also checked at this
time.
While the real test of these systems comes once the entire facility is
run under full load conditions, these pre-start up checks screen out inoperable
or poorly installed equipment and therefore minimize down time when the entire
facility goes on line.
Once all raw material feed systems are checked "dry" (without feed), raw
materials are fed into the primary crusher and follow the processing steps up
to the kiln feed.
The quantity of material throughput at this time is limited
to the size of the raw material storage bins, typically one
wee~
supply.
The kiln undergoes pre-startup inspection and equipment checks of all
motors, bearings, and instrumentation.
In addition, the refractory of the
kiln is conditioned by running the unit at low fire for several days.
This
conditioning step is typically the last pre-startup check and
ra~
feed into
the kiln follows shortly to avoid a second conditioning cycle.
Finished
product handling, milling and storage systems are checked dry during this
pre-startup period, ss well.
Cement industry personnel indicated that approx-
imately 2 months are needed to perform all pre-startup checks, for both dry
and wet process plants.
Startup Operations
Startup for Portland Cement operations is generally considered to be the
first day raw material is fed into the preheater or the kiln, depending on
facility configuration.
This date is obtainable from plant personnel, as it
is often marked by on-site ceremonies attended by plant, corporate and contractor
officials.
This start-up, however,. also begins an intensive shakedown period
for the facility.
As the production of portland cement is a chemical process
involving many variables, (fuel and feed composition, flow rates, temperatures,
air flow rates, etc.) various adjustments to operating parameters must be made
to produce a final product meeting desired clinker specifications.
This process
is a trial and error procedure that may take several months.
In addition, once
the entire facility begins to operate with feed material, mechanical and elec-
trical breakdowns occur, delaying the time required to reach full capacity.
While several cement industry contractors "felt that startup might better
be~
defined as the first day the plant is run for 24 continuous hours, or the
first day following 1 month's continuous operation, most agreed that for
conventional
plant~,
180 days after initial kiln firing is sufficient time to
allow all but the rare cases an opportunity to debug the system, set up the
process operating parameters and produce at or near rated capacity.
With
modified plants, much of this debugging has already been accomplished, and
they are online before the 180 days.
For the newer suspension preheater units,
17
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