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Crusher
Stacker/Reclaimer
Dryer
Raw Mill
Final Mixing
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Electrical
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desalination
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2006\11\11

Power plant
2006\11\12

Desalination
2006\11\13

Lime stone Crusher

2006\11\14

Clay Crusher
2006\11\15

Tertiary Crusher
2006\11\18

Raw Mat. Storage

2006\11\19

Raw Mills
2006\11\20

Mat. & Gas Analysis

2006\11\21

Laboratory
2006\11\22

Pre Heater
2006\11\25

By Pass
2006\11\26

Kiln rotary
2006\11\27

Kiln rotary
2006\11\28

Grate Cooler

2006\11\29

Cement Mills
2006\12\2

Packing House
2006\12\3

Oil Station
2006\12\4

Process Measurements
2006\12\5

Calculation
2006\12\6

Training Report
(3 ) :(4-3 ) (CCR .
: :
:
(1 .
(2 .
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(4 .
)(CCR
,

.
): (CCR
) (CCR :

) (Stacker .
) (CCR :

.
) (CCR :

.

. .



.
)(CCR
) (CCR

 .
,
.
) (CCR :
.
.
, .
.
)
. (Scanner
): (CCR




Process Engineering Calculations
in Cement Industry
Calculation of Atmospheric Pressure with Altitude from Sea Level
P (mmwg) = 10133 x e -0.0001255*h
Where h = ht. from sea level in m
Conditions at NTP
Pressure = 1 Atm = 1.013 x 105 N/m2
Temperature = 273 K
Air Density at NTP
Gas law
PxV=nxRxT
V (Volume) = mass/density
n = mass/MW of air
R (Constant) = 8.314
Flow
.Movement of gas particle in a duct when some external force is applied on the gas
Pitot Tube, Pressure meter

Flow Calculations
Calculation of Velocity in a duct
D.P. = Density x (Velocity)2
2
Velocity = C x (2 x 9.8 x D.P.)0.5
Density)0.5)
Where C = Pitot tube constant
D.P. = Difference in Pressure in mmwg
Density = Kg/m3
Velocity = m/sec
Calculation of Density
((.Density = Density at NTP x 273 x (10120-(St. Pr
Kg/m3) (273+T gas) x 10336)
Density at NTP in Kg/Nm3
St. Pr. in mmwg
T gas in degree C
Calculation of Flow
Flow = Velocity x Area of Duct x 3600 m3/hr
Area of duct (m2) = x D2
4
Where
(D = Diameter of duct (m
= 3.14
V = m/sec

Calculation of Flow at Fan inlet for FD Fans

Flow = Velocity x Area of inlet Duct x 3600 m3/hr

Velocity is measured by Anemometer at Fan inlet

Area of duct = x D2
4
Where
D = Diameter of duct
= 3.14
Flow Conversion from m3/hr to Nm3/Hr
Volumetric Flow rate = m3/hr
(Mass Flow rate (Kg/Hr) = m3/hr x density (kg/m3
(Mass Flow rate (Nm3/Hr) = Mass Flow rate (Kg/hr
(Density at NTP (Kg/Nm3
Mass Flow rate = Nm3/hr
(Mass Flow rate = Nm3/hr x density at NTP (kg/Nm3
(Kg/Hr)
(Volumetric Flow rate (m3/Hr) = Mass Flow rate (Kg/hr
(Density of gas (Kg/m3
Velocities in ducts
Preheater gas ducts = 16 18 m/sec
Tertiary air ducts = 24 26 m/sec
Kiln Hood = 6 m/sec
Coal conveying pipes = 35 m/sec
Venting line hood = less than 5 m/sec
Composition of Air By Volume
Oxygen (O2) = 21%
Nitrogen (N2) = 79%
By Weight
Oxygen (O2) = 23.3%
Nitrogen (N2) = 76.7%

Calculation of False air in the system

((False air (%) = 100 x (O2 (outlet) O2 (inlet
((O2 (Outlet - 21)
Calculation of Kiln Feed to Clinker Factor
Kiln Feed/Clinker Factor
(Fuel Cons (%) x Fuel Ash (%))\10000) x( (1 + Dust Loss)\100-1) ) =
(LOI)\100 1))
Fuels
C + O2 = `CO2, Heat Evolved 7829 Kcal/Kg
C + O2 = CO , Heat Evolved 2400 Kcal/Kg
H2 + 0.5 O2 = H2O, Heat Evolved 28641 Kcal/Kg
S + O2 = SO2, Heat Evolved 2213 Kcal/Kg
Calculation of Theoretical Air Requirement for
.Combustion of Fuel
HFO Analysis
%
84.5
C
%
11.9
H
%
0.22
N
%
3.28
S
%
0.1
O
Kcal/Kg HFO
9407
.C.V
Calculation of Theoretical Air Requirement for
.Combustion of Fuel
C + O2 = CO2
44 32 12
CO2 Produced = 44/12*0.854
Kg/Kg Fuel 3.098 =

O2 Required = 32/12*0.854
Kg/Kg Fuel 2.253 =
Calculation of Theoretical Air Requirement for
.Combustion of Fuel
H2 + 0.5 O2 = H2O
18 16 2
H2O Produced = 18/2*0.119
Kg/Kg Fuel 1.071 =
O2 Required = 16/2*0.119
Kg/Kg Fuel 0.952 =
Calculation of Theoretical Air Requirement for
.Combustion of Fuel
S + O2 = SO2
64 32 32
SO2 Produced = 64/32*0.0328
Kg/Kg Fuel 0.0656 =
O2 Required = 32/32*0.0328
Kg/Kg Fuel 0.0328 =

Calculation of Theoretical Air Requirement for

.Combustion of Fuel
N2 Produced = 0.0022 Kg/Kg Fuel
O2 Available = 0.001 Kg/Kg Fuel
Total O2 Required for burning of Fuel
O2 for C + O2 for H + O2 for S O2 Available
Kg/Kg Fuel 3.237 = 0.001 0.033 + 0.952 + 2.253
Calculation of Theoretical Air Requirement for
.Combustion of Fuel
O2 Required for burning of Fuel = 3.237 Kg/Kg Fuel

Corresponding air = 3.237/ 0.233

Kg/Kg Fuel 13.892 =
13.892/1.293 =
Nm3/Kg Fuel 10.745 =
Calculation of Combustion Gases from Fuel
Total Combustion Gases Produced from Combustion of Fuel
CO2 from C + H2O from H + SO2 from S + N2 + Excess O2
0.0022 + 0.0656 + 1.071 + 3.098 =
.Kg Combustion/Kg Fuel 4.2368 =

Calculation of Specific Heat Consumption

Clinker Production = 9000 TPD
TPH 375 =
Kiln Fuel Consumption = 11200 Kg/Hr
Pyro-1 Fuel Consumption = 10800 Liter/Hr
Kg/Hr 9720 =
Pyro-2 Fuel Consumption = 10600 Liter/Hr
Kg/Hr 9540 =
Total Fuel Consumption = 30460 Kg/Hr
Specific Fuel Consumption = 0.0812 Kg/Kg Clinker
Calorific Value of Fuel = 9407 Kcal/Kg Fuel
Specific Heat Consumption = 9407* 0.0812
Kcal/Kg Clinker 763.8 =
Fan Laws
(Capacity O (Fan Speed
Pressure O (Fan Speed)2
Power O (Fan Speed)3
Capacity O (Impeller Dia.)3
Pressure O (Impeller Dia.)2
Power O (Impeller Dia.)5
Fan Efficiency
Fan Efficiency = Theoretical Power x 100

Shaft Power
(Fan Theoretical Power (KW) = Flow (m3/sec) x Pressure (mmwg
102
Actual Power = 3 x Voltage (Volts) x Current (Amps) x Power Factor
Shaft Power = Actual Power x Motor Efficiency
Kiln & Cooler Loading
________(Kiln Volumetric Loading = Kiln Output (TPD
(Kiln Effective Volume (m3
Kiln Effective Volume = x (Kiln effective Dia.)2 x Kiln Length
4
Norms = 5.5 -6.0 TPD/m3
(Kiln Thermal Loading (Million Kcal/hr/m2
Kiln O/P (TPD) x Kiln Fuel (%) x Heat Consumption x 10 =
x Kiln effective cross sectional area 24
Kiln Effective cross sectional area = x (Kiln effective Dia.)2
4
Norms = 5.5 -6.0 Million Kcal/hr/m2
(Clinker Cooler Loading (TPD/m2)= Kiln Output (TPD
(Cooler grate area (m2
Norms = 60 TPD/m2
Degree of Material Filling in Kiln
-: (Residence time of material in kiln (min
________________(x Kiln Length (m 11.4 =
(Kiln RPM x 60 x (Kiln Effective Dia.) x Kiln Slope (m/m
-: Degree of material filling
Clinker (Kg/Hr) x KF/Clk. Factor x R. Time (min) x 100 =
(BD of KF (Kg/m3) x 60 x Kiln Vol. (m3
% Norms :- 12 14
Flame Momentum

Flame momentum is mixing of fuel with primary air & secondary air for better
.combustion of fuel
(Flame momentum :- % of primary air x Tip velocity (m/sec
Unit of flame momentum :- %. m/sec
or
(N/MW (European standard -:
Norms :- 1400 1450 %.m/sec
N/MW 5.5 5.0

: )( Kiln hood pressure
.
) (
:
) . (to +1.0 mbar 1.0-
,
, )(
.
.
.

.

. :
/ :
:
-1 .
-2 . X-Ray
-3 .
/ :
:
-1 .
-2 X-Ray

 / :
:
Blaine Apparatus
: . : -1 .
-2 .
-3 .
-4 .
-5 .
-6 .
-7 .
:
3.0410 .


,

,
.
) ) seconds 74 3130/ 2
.
:
: . : -1 .
-2 .
:
) ( .
740 , 359
. 2035 .
30 ,
30 , 30 ,
30 ,
. 30 .
.
,
, ,
, 64 ,
23-25 24 .

3 7 28 .

.
:
:

 : ". " Lime Ston :

0.5 25
HCL ) ( Heater 4-5
.
3-4 ) . ( Phenol Phthalien
NaOH
, .
:
( (reading\2) -25 )5 = %
: X-Ray
:
.
:
:
-1 .
-2 .
-3 .
-4 .
-5 .
-6 20 50 .
-7 . X-Ray
-8 . X-Ray
-9 .
/ :
,
X-Ray
). ( X-ray
)( X-ray
: ) :( Lime stone
K2O
SO3
MgO
CaO
Fe2O3
Al2O3
SiO2
0.20
0.02
0.74
54.15
0.48
1.60
4.03
LSF
AM

SM
P2O5
Cl
Na2O
94.00
3.35
1.95
0.02
0.06
0.04
:
) ( CaO .
) ( K2O & Na2O
, .
) ( AM
.
.
)(X-ray
)( X-ray

:Manufacturing process
Limestone is mined at the captive mine located at a distance of about 3-km from YCC
site. Quarried limestone boulders are crushed to below 25 mm size in a primary
crusher located at the mine. Crushed limestone is then conveyed to the plant site by
,belt conveyor

Main Equipment in Yanbu Cement Plant

The following tables will give a general information about major equipment for new
.line4

Equipment
No
.Cap
Size
Type
L.S Crusher
1
TPH 1200
*********
Double Rotor Hammer
Raw Mills
2
TPH 325
each
x 8.75m LG 5.4
Single Chamber Air Swept Tube Mill
Kilns
1
TPD 7000
x 82m LG 5.6
Dry Process With Preheater and Alkali By Pass System
Cement Mills
2
TPH 190

 x 18.4m LG 5.4
Chamber Close Circuit Mill 2
Packers
4
TPH 120
Spouts 9
Rotary Packers

.Limestone Mining
The limestone deposits present in the mining lease area of YCC are essentially coral
reef formations comprising extensive skeletal coral limestone especially at the
.surface, generally underlain by broken and sometimes powdery coral debris and marl
The current method used by YCC for limestone quarrying is ripping and dozing at a
.slope of 20o to 30o
.The run of the mine is stockpiled in the lease area
.Blasting is not at all carried out
The stockpiled limestone is loaded by wheeled loaders into large dumpers, which
deliver the material to the primary crusher, located currently at a distance of 800 to
.1500 m from the quarry face
Overburden removed from the existing quarry is stocked separately in the mining
.lease area
The primary crusher is a semi-mobile consisting of a hammer crusher mounted on a
.separate crawler transporters. With capacity 1200 t/h and running 12 h/day
The crushed limestone from the quarry is transported to the cement plant by 3 km
long belt conveyor. An approach road of 3 km along the conveyor belt is present for
.movement of plant vehicles
In L4 limestone quarry we have more quality variations so we have to do more
controlling of the materials in the mine before supplying it and we can do that by
. blinding the high quality materials with the low quality materials

Line-4 limestone mine

In Line-4 mine, we have around 314 million tons of reserve is available, But we have
more chloride variations in our materials which causes problems in burning. For that
we have to do more control for quality in the mine before supplying the materials and
we can do that by in pit blinding for example mix the high quality materials with the
.low quality materials
The quality of Lime stone deposit is assessed through drilling and by analyzing the
.drill core samples
In the last three months in my extended period I learned many things like how I can
handle complete shift independently also in this period I saw many problem in the
mine about quality, quantity and heavy equipments and how I can solve it in line-4
mine also I did small study about gypsum mine area 2 and I did time cycle study
:about by pass dust bulker, I will list down all of this activities.Quarrie Description
-:Limestone Quarry
:The limestone quantities indicated to be available in each block are as follows
Block A : extends to 122500 m2 and has average thickness of 11.17 m which,
allowing for an average of 0.5 m of overburden comprising sand and contaminated
limestone, will result in 10.67 m of workable limestone. After allowing a further 2%
.for cavitation,etc. the indicated gross reserve is 104 Mt. low grade
Block B : extends to 60,000 m2 and has average thickness of 10.2 m which, allowing
for an average of 0.5 m of overburden comprising sand and contaminated limestone
which reduced the average working thickness to 9.7m and 2% for cavitations, the
.indicated gross reserve is 119Mt. low grade
Block C : extends to 875000 m2 and has average thickness of 14 m which, allowing
for an average of 0.5 m of overburden comprising sand and contaminated limestone
which reduced the average working thickness to 13.5 m and 2% for cavitations, the
.indicated gross reserve is 91Mt
(high grade.(Total exposed limestone 4.56 Mt
B
C
A

-: Mine Equipments L-4

Equipment
Capacity
Type of Engine
Engine Rate
Loader
992D
10m3 3100 t/shift
V-12 3412
*******
Dumper
777C
75t 2500-3000 t/shift
EUI 3508
V-8
flywheel horsepower at 1800 rpm 770
Dozer
D11N
t/shift 1500-2000
DITA 3508
V-8
flywheel horsepower at 1800 rpm 770

-: Vehicles in line 4
Dozer
4
t/shift 1000-2000
Loader
2

m3 10
Dumper
4
t 75
Rock breakers
1
t/r 60

.
,
20/12/2006 .