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Clinker Weighing test result

11 September 1997
Time (hour)
Kiln Feed totalizer (T)
Kiln Coal totalizer (T)
ILC Calciner coal totalizer (T)
SLC Calciner coal totalizer
Clinker weighing total (T)

start

Stop
14.13
813041
11001.9
6312.82
12078

L min
GHV

Total
22.13
817186
11120.5
6355.32
12230.3

Ton/jam
8
4145
118.6
42.5
152.3
2719.5

518.1
14.8
5.3
19.0
339.9

8.542 kg air/kg Coal


5763 kcal/kg Coal

Fuel consumption
Kiln (PW1)
ILC Calciner (PW2)
SLC Calciner (PW3)
Total

Ton
118.6
42.5
152.3
313.4

Fuel Consumption

%
37.8%
13.6%
48.6%
100.0%

664 kcal/kg Clinker

Combustion air

ton/jam
14.8
5.3
19.0
39.2

(note:pfister feeder calibr

334632.9 kg air/jam
5577.2 kg air/min
0.984 kg air/kg clinker

Clinker Faktor

1.52 (note:the dust return is not weighed)

Material Balance
X

Pulvurized
Coal Ash

kcal/kg terak

19.67 %
0.1967 x kg
3.413E-05 x kg

Raw mix to clinker

LOI 35.18
= (1 - 3.413* X*(10^-2))*100
100 - 35.18
= 1.542733724
5.266E-05 x

CO2 From raw mix

total carbonate
= 0.524171552

Free H2O in the raw mix

H2O

77.22 %
1.789E-05 x

0.5 %

=( 1.542733724

5.26559E-005 x) *

= 0.007752431

2.64602E-007 x

1.12 %
5.26559E-005 x) *
5.89746E-007

Combined H2O in raw mix


H2O
=( 1.542733724
= 0.017278618
Carbon from raw mix

C
=( 1.542733724
= 0.001697007

0.11 %
-

5.26559E-005 x) *
5.79214E-008

Excess Air
% Excess Air =

79 * %O2
0.21 * (100 - % CO2) - %O2

Stage 1 ILC

average exit gas analiysis


CO2
=
29
O2
=
3.5
Excess air =
24.2

Stage 1 SLC

average exit gas analiysis


CO2
=
32
O2
=
3.5
Excess air =
25.6

Dust in Exit Gas

10.5%

Dust rate
kiln Feed
Total

56.28 tph
511.1 tph
567.38 tph

508.5445
564.5431

CLK = KF * (efficiency) * (1 - H2O) * (1-LOI) + (Coal Ash)


335 = 567.4 * (efficiency) * (1 - 0.05) * (1-0.3518) + (39
327.6227334711 =
365.9368374 * Efficiency
Efficiency =
89.5%
Dust =

Water from Coal

0.177 kg dust/kg clinker

Fine Coal H2O


LHV Fine Coal
Fine Coal Consumption

2.29 %
5763 kcal/kg Coal
x
5763

0.000174 x

Dry Coal consumption

=
Water from Coal

+ (15763

0.0229 )

0.000169547 x
x

kg coal/kg terak

kg coal Dry/kg terak


0.0229

5763
=

3.97362E-006 x

kg air/kg terak

Combustion Air Rates:


L min
Air required

8.542 kg air/kg Coal


=

x *
5763

8.542
kg Coal

0.001482214 x

kg air

kg air/kg Clk

8.3976694
Kiln Primary air
Flow

150.7 kg air/min

(measurement pitot tube)

0.027 kg air/kg Clk


L min

2110.585833 kg air/min
7.14% kebutuhan udara dari total combustion of kiln fuel.

Kiln Coal Transport air


Flow

81.8 kg air/min
0.015 kg air/kg Clk

L min

2110.585833 kg air/min
3.9% kebutuhan udara dari total combustion of kiln fuel.

ILC Calciner coal transport and primary air


Flow

25.83 kg air/min
0.005 kg air/kg Clk

L min

756.3229167 kg air/min

3.4% kebutuhan udara dari total combustion of ILC Calciner.

SLC Calciner coal transport and primary air


Flow

91 kg air/min
0.016 kg air/kg Clk

L min

2710.305417 kg air/min

3.4% kebutuhan udara dari total combustion of SLC Calcine


Remaining air requirement ILC/kiln String
=[( 0.001482214 x

(1

= 0.000946553 x

0.242 ))

-0.046

Remaining air requirement ILC/kiln String


=[( 0.001482214 x

(1

= 0.000905049 x

Combustion products from coal


=

0.256 ))
-0.016

9.349 kg gas/kg coal including water in Coal


X

kcal/kg terak
5763 kcal/kg Coal

= 0.001622245 x kg gas/kg clk

9.349 kg gas/kg coal

Extra air required to burn carbon in the kiln feed


C

Air

Lb

11.53

lb/lb clk

0.0017

0.0195664918

---------- >

Including

24.2 % Excess air in ILC

0.0243081

---------- >

Including

25.6 % Excess air in SLC

0.0245852

Extra Product of Combustion for ILC


CO2
N2

0.006 kg CO2/kg clk


0.0187 Kg N2/kg Clk

Extra Product of Combustion for SLC


CO2

0.006 kg CO2/kg clk

N2

0.0189 Kg N2/kg Clk

= [(

37.8%

Excess Air
ILC/kiln string

= 0.000184636 x

SLC string

=[

13.6% )
5763

0.0047 kg air/kg clk

48.6%

= 0.000184752 x

Sistem surface losses


Radiation losses
Kiln Radiation loss

8.542
5763

0.0050 kg air/kg clk

23

Cooler and firing hood radiation loss


Preheater and tertiary air dust radiation loss

6
28

Cooler
124 C

Average clinker discharge temperature


Heat of Cooler

1 kg/kg clk
=

Radiation Loss

124 *

#NAME? kcal/kg clk

6 kcal/kg clk

Excess Air
Flow

388554 kg/hr @

238 C

1.158726595 kg air/kg clk


CP

#NAME?

Heat Of excess Air

#NAME? kcal/kg clk

Hot air for the raw mill


Flow

122897 kg/hr @
0.366497378 kg air/kg clk

CP

#NAME?

Heat Of excess Air

#NAME? kcal/kg clk

Total Cooler loss

#NAME? kcal/kg clk

407 C

note:pfister feeder calibration not correct)

0.0050251

0.0112

0.0011

LOI) + (Coal Ash)


5) * (1-0.3518) + (39.17*0.1967)

mbustion of kiln fuel.

mbustion of kiln fuel.

mbustion of ILC Calciner.

mbustion of SLC Calciner.

37.8% +

13.6% )]

kg air/kg clk

48.6% )]
kg air/kg clk

ncluding water in Coal

kg gas/kg coal

-0.016

-0.027

-0.015

-0.005

CO2

N2

3.6666667

8.85504

0.0062224

0.0150271

kg air/kg clk
kg air/kg clk

8.542 *

0.2423313 ] * x + ( 0.0243081

kg air/kg clk

0.2564935 ] * x + (

kg air/kg clk

kcal/kg clk

0.0245852

0.0196 )

-0.0196 )

kcal/kg clk
kcal/kg clk

#NAME?

System Heat Input


Fuel : Combustion Heat
Free heat w/ coal
Air : Primary
Kiln Coal transport
ILC Coal transport
SLC Coal transport
Remaining ILC
Remaining SLC
Extra for C - ILC
Extra for C - SLC
Cooler : Excess Air
Hot air for RM
Water from coal
Raw Feed
Returned dust
Sum Of heat inputs

System Heat Input


Combustion Product (Coal)
Combustion Product (Carbon in mix)
CO2 - ILC
N2 - ILC
CO2 - SLC
N2 - SLC
Excess Air In exit gas - ILC
Excess Air In exit gas - ILC
CO2 from Raw Feed
Vapor from free H2O In feed
Vapor from comb H2O In feed
Dust
Radiation : Kiln
Preheater
Cooler loss : Heat in Clinker
Radiation
Hot air for mill
Excess Air
Heat of reaction
Sum Of heat inputs

kg/kg
80 0.000174 x
32
32
32
32
32 0.00094655 x
32 0.00090505 x
32
32
32
32
80 3.974E-006 x
90 -5.266E-05 x
90

kcal/kg C

0.027
0.015
0.005
0.016
-0.04622
-0.01628
0.024308
0.024585
1.158727
0.366497
1.542734
0.177

kg/kg
348 0.00162225 x
348
348
348
348
348 0.00018464 x
348 0.00018475 x
348 -1.789E-05 x
348
348
348

0.2932
0.2377
0.2377
0.2377
0.2377
0.2377
0.2377
0.2377
0.2377
0.2377
0.2377
1.0000
#NAME?
#NAME?

kcal/kg C
0.2579
0.006
0.0187
0.006
0.019
0.0047
0.005019
0.524172
0.007752
0.017279
0.177

0.2319
0.2517
0.2319
0.2517
0.2450
0.2450
0.2319
788
0.4600
0.2367

124

0.1927

407
238

0.366497
1.158727

0.2464
0.2425

1.018474 x
0.175646 x

0.842828 x =
x =

kcal/kg
1x
0.0040701024 x
0.20513465
0.111347142
0.03516011
0.12387029
-0.3516419
-0.12387029
0.18492487
0.18703296
8.81507283
2.78814786

0.0072009509 x
0.0068852076 x

0.00031789 x
x

1.0184741508 x

#NAME?
#NAME?
#NAME?

kcal/kg
0.1455952231 x

0.0157423443 x
0.0157521795 x
-0.001443536 x

0.1756462104 x
#NAME? =
665.39472105

0.50205773
1.63492616
0.50205773
1.65356384
0.40427313
0.42789948
42.2933435
6.10891545
2.76573811
14.5906078
23
28
23.894304
6
36.7482989
66.8687352
410
665.394721

#NAME?
#NAME? Kcal/kg

Summary
System Heat Input
Fuel : Combustion Heat
Free heat w/ coal
Air : Primary
Kiln Coal transport
ILC Coal transport
SLC Coal transport
Remaining ILC
Remaining SLC
Extra for C - ILC
Extra for C - SLC
Cooler : Excess Air
Hot air for RM
Water from coal
Raw Feed
Returned dust
Sum Of heat inputs

System Heat Input


Combustion Product (Coal)
Combustion Product (Carbon in mix)
CO2 - ILC
N2 - ILC
CO2 - SLC
N2 - SLC
Excess Air In exit gas - ILC
Excess Air In exit gas - ILC
CO2 from Raw Feed
Vapor from free H2O In feed
Vapor from comb H2O In feed
Dust
Radiation : Kiln
Preheater
Cooler loss : Heat in Clinker
Radiation
Hot air for mill
Excess Air
Heat of reaction
Sum Of heat inputs

80
32
32
32
32
32
32
32
32
32
32
80
90
90

348

kg/kg kcal/kg C kcal/kg


#NAME?
#NAME?
0.2932 #NAME?
0.027 0.237736 0.2051346
0.015 0.237736 0.1113471
0.005 0.237736 0.0351601
0.016 0.237736 0.1238703
#NAME? 0.237736 #NAME?
0.237736 #VALUE!
0.0243081 0.237736 0.1849249
0.0245852 0.237736 0.187033
1.1587266 0.237736 8.8150728
0.3664974 0.237736 2.7881479
#NAME?
1 #NAME?
#NAME? #NAME? #NAME?
0.177 #NAME? #NAME?
#NAME?

kg/kg kcal/kg C kcal/kg


#NAME?
0.2579 #NAME?

348
0.006 0.2318565 0.5020577
348
0.019 0.251656 1.6349262
348
0.006 0.2318565 0.5020577
348
0.019 0.251656 1.6535638
348 #NAME? 0.245004 #NAME?
348
0.245004 #VALUE!
348
0.2318565 #VALUE!
348 0.0077524
788 6.1089155
348 0.0172786 0.4599629 2.7657381
348 0.1771561 0.2366672 14.590608
23
28
124
1 0.192696 23.894304
6
407 0.3664974 0.246361 36.748299
238 1.1587266 0.242474 66.868735
410
#NAME?