Bestway Cement Limited - Chakwal

Production Department
Heat balance of Rotary kiln (Dia 4.8m x 72m)with double string 5 - stage precalciner

Data:o

30

Ambient Temp C

Pre-heater exit gases analysis

Kiln rated output (tpd)

5700

O2 : %

2.6

Actual clinker production (t/hr)

237.5

CO2 : %

28

Raw meal to clinker factor

1.6

Kiln feed (ton/hr)

380

CO : %
Excess air
factor

0.05
1/[1-{(79/21)x(2.6/100-28-2.6-0.05)}]=1.16

Moisture in Kiln feed

0.55%

Dry coal combustion (t/hr)

29.88

clinker & dust

0.186 + (0.00054x100)=1.1914

Dry coal combustion (kg / kg clinker)

0.1258

kiln feed

0.21 + (0.00007 x 70)=0.2149

Air

0.237 + (0.000023 x t)

2.5

water vapour

0.42 + (0.000185 x t)

Temp. of kiln feed C

70

CO2

0.19 + (0.00011 x t)

Temp. of Dry coal fed oC

60

Exit gases

0.23 + (0.00005 x t)

Preheater exit gases temp ( oC)

335

Coal

0.262 + (0.00039 x t)

Temp. of clinker ex-cooler ( oC)

100

Oil

Volume of exhaust air from cooler

(NM3/kg clinker)

1.31

Temp. of Exhaust air from cooler ( oC)

275

Net C.V of dry coal (kcal/kg)

Residual moisture in dry coal fed (%)
o

6000

Specific heat (kcal/kg)

0.42

Density
Air
Page 1 of 4

1.293 kg/m 3

Latent heat of water

Chemical analysis of clinker

at 100 oC
Site above sea
level

SiO2 %

22

Al2O3 %

5.26

Fe2O3 %

3.4

CaO %

65.18

MgO %

2.54

539 kcal/kg
752 m

Barometric
pressure

936 mbar

Maximum
wind velocity
Average
relative
humidity
Grate Cooler
TC-12108

40 m/sec

50%
128.6 m2 (44.32 tpd/m 2)

First 09 fans of first grate capacity

(G10 ~ 18)

270600m 3 cooler EP fan

/hr
capacity
740,000m 3/hr at 250oC, 2119pa and 740rpm

05 fans of 2nd grate capacity (G19 ~

23)

205200m 3 ID fan
/hr
capacity

03 fans of 3rd grate capacity

132600m R.M. E.P fan

/hr
capacity

930,000m 3/hr at 325oC, 7157pa and 990rpm

900,000m 3/hr at 12592pa speed=990rpm

Calculations

Kcal/kg Clinker

%age

754.8

98.07

1.08

0.14

Sensible heat of kiln feed

0.1258 x 6000
0.1258x[0.262+(0.0009 x
60]x(60-30)
1.6x[0.21+(0.00007x70)]x
(70-30)

13.75

1.79

Total Heat In

769.63

100

Heat of Clinker Formation

Heat OUTPUT
(489x5.26)/100 +
(714x65.18)/100 +
(539x2.54)/100 - 73

431.79

56.1

Description

Calculation
Heat INPUT

Heat of Coal combustion

Sensible heat of Coal

Page 2 of 4

Heat required for moisture

evaporation in kiln feed
Heat required for superheating of
water vapour in kiln feed
Heat required for coal moisture
evaporation
Heat required for super heating of
water vapour in coal

Amount of CO2 produced

Heat lost in CO2
Combustion air required for coal fired
/ 1000 kcal
Amount of gases produced from
coal/1000 kcal
Combustion gases produced
Excess air

Total combustion gases

Heat lost in Combustion gases
Heat lost in dust
Heat lost in clinker ex-cooler

Heat lost in excess air from cooler

Heat lost due to presence of CO in PH
exit gases
Difference estimated due to radiation
and convection losses (cooler, kiln, preheater, Calciner and TAD)
Total Heat Out

0.0055 x 1.6 x 539

0.0055 x 1.6 x
[0.42+(0.000185 x 335)] x
(335-30)

4.74

0.61

1.29

0.17

0.1258 x 0.015 x 539

0.1258 x 0.015 x
[0.42+(0.000185 x 335)] x
(335-30)

1.02

0.13

0.28

0.04

38.36

4.98

100.85

13.1

6.22

0.81

1.0 x [0.186 + (0.000054

x 100)] x (100 - 30)

13.4

1.74

1.31 x 1.293 x [0.237 +

(0.000023 x 275] x
(275 - 30)

100.98

13.12

40 x 0.05

0.26

68.7

8.94

769.63

100

((44/56 x 65.18/100)) +
44 x 2.54/40x100) = 0.54
kg/kg clinker
0.54 x [0.19+(0.00011 x
335] x (335-30)
1.41 kg air / 1000 kcal
coal
1.55 kg gases / 1000 kcal
coal
1.55 x 754.8 / 1000 =
1.17 kg/kg clinker
(1.16 - 1) x 1.41 x
754.8/1000 = 0.17 kg/kg
clinker
1.17 + 0.17 = 1.34kg/kg
clinker
1.34 x [0.23 + (0.00005 x
335)] x (335 - 30)
0.1 x [0.186 + (0.000054
x 335)] x (335 - 30)

Page 3 of 4

Before Waste Heat Recovery Power Plant

S.#
A
B
C

Description
Pre-heater:- Volume of Exit gases from
single kiln.
Pre-heater:- Volume of Exit gases from
both kilns.
Volume of pre-heater exit gases at
o
335 C and 6000pa from single kiln

Volume of pre-heater exit gases at

o
335 C and 6000pa from both kilns.

Cooler Exit air from one AQC

Cooler Exit air from both AQCs

G
H

Cooler waste air at 275 oC and 350pa

from one AQC
Cooler waste air at 275 oC and 350pa
from both AQCs

Calculation

Results

1.29 x 237.5 x 1000

306375Nm /hr

2x306375

612750Nm /hr

(306375 x (1013/273) x (608/996)

693976 m /hr

2 x 693976

1387952 m 3/hr

(1.31 x 237.5 x 1000)

311125 Nm 3/hr

2 x 311125

622250 Nm 3/hr

(1013 x 311125) / 273 x (548/939.5)

673388 m 3/hr

2 x 673388

1346776 m 3/hr

(B+F) Total volume of exit gases from both preheaters and both AQCs.

1235000 Nm3/hr.

With Waste Heat Recovery Power Plant

Description

Calculation

Results

Pre-heater: - 693976m 3/hr gases at 335 oC and 6000pa after pre-heater pass through PH 1.34 kg flue gases/kg clinker
waste heat exchanger and comes out from it with 223 oC and 7000pa. Volume of gases
after PH waste heat exchanger = (693976 x 996)/608 x (496/1006) = 560511 m 3/hr

Cooler waste air:- Air 189100Nm 3/hr passes

through preduster at 360oC and AQC heat
exchanger and leaves at 101 oC with volume

189100/237500

2x237500 x [(1.34 x {0.23 + (0.00005 x

Total waste heat recovery through pre-heater 335)} x (335 - 223)) + (0.796x 1.293 x {
and cooler (AQC) from both kilns.
0.237 + (0.000023 x 360)} x (360 - 101))] =
17590314+ 31057544
Overall thermal efficiency of WHR power
plant
Power generation at generator terminal

0.796Nm3/kg clinker

48647858 kcal/hr
= 48.65 million kcal/hr
= 48.65x1000x4.2/3600
= 56.76 MW
26.50%

26.5/100 x 56.76

Page 4 of 4

15.04 MW