Cement KILN Taking High Current

I have no experience specifically in cement kilns, but a few ideas do come to my mind. I would investigate if any of the cabling shows any thermal damage. I would also investigate any of the terminal nodes for the variety of equipment involved for a dust build up that might wick up moisture while cool. Also if electric power is the only energy source for heating any part of this kiln, make sure that the heating elements are properly located, that movement of the elements will not cause a shorting. Now my most likely candidate for your intermittent high current failure is some power supply filtering capacitor is displaying an early breakdown failure accelerated by the higher than normal temperatures from working around a kiln. According to the Arrhenius equation for capacitor failure rates, the lifetime of an electrolytic capacitor halves with every 7° C above the specified failure rate temperature. If this is the case, you will soon have a permanent failure that will easily identify the dieing capacitor. Replacing the capacitor will temporarily solve the problem.

Good Luck

If I were you I would dig into the mechanical system of the kiln and find what is wrong in its mechanics. You have an undiagnosed mechanical problem that comes and goes... you need to find it. Let us know what you find

Dear Ram

Please thoroughly in electrical side and mechanical side too. There is some gone wrong suddenly increase of load on kiln dc motor. May be DC starter MCC which may be soft start that me gone wrong. Only thing you can check standard current load. Good luck good wish

Thanks Regards

Vijay Shinde

The kiln is a high starting torque load, especially with a lot of material in the kiln. The motor must lift the unbalance until it cascades. Starting torques above normal torque is not unusual. Unplanned shutdowns can cause the hot kiln to warp, exacerbating the starting torque by a warped kiln that will straighten out partially when in use. Prudent use of the emergency drive to keep the kiln turning when hot with loss of the main drive, or using the emergency drive to start a bent kiln will help the main drive. The armature current is proportional to torque on a dc drive with a fixed field current. If your motor has a choice of field current, increasing the field will slow the motor speed and will increase the torque per armature ampere. Tony.

I am betting on a short some where in your system. Cement kilns are very humid and and that is why I have voted to support RedFred and his comments. I have some experience with cement kilns and his response was as close to right on as I can imagine.