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Arasmeta cement plant - Kiln Audti traning 11.11.

2008
Ref Temp.
Basis
Input
KF
Coal sinsible heat
Cooling Air
Coal moisture
Primary Air
Transport Air
GCT Water
Heat Consumption
Kiln
Calciner
False Air
KF Moisture
Total

Output
KS exit gas
O2
CO2
N2
H2O
CO
CS exit gas
O2
CO2
N2
H2O
CO
Cooler Vent Gas
coal hot gas takeoff
clinker
ph dust
Kiln String
calciner string
Radiation Loss
Kiln +Ph+Cal
Cooelr
Theoretical heat of reaction

0 c
1 kg/hr of clinker
Mass Flow (kg/h) Temp
328680
30468.75
520970
781.25
5146
9462
28050
10
21.25
95125
1320
923589

Mass Flow (kg/h)

Cp(kCal/Kg)
70
70
32.5
70
60
60
25

Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511

32.5
70

5321
4600
Err:511
Err:511

Temp

Cp(kCal/Kg)

Heat(kCal/hr)

Err:511
Err:511
Err:511
Err:511
Err:511 kiln axial, swirl and cooling air
Err:511 both the kiln and calciner coal
Err:511 on the basis of design data
53210000
97750000
Err:511
Err:511
Err:511

Heat(kCal/hr)

138446

7973
39705
85905
4849
14

Err:511

362
362
362
362
362

Err:511
Err:511
Err:511
Err:511
Err:511

Err:511
Err:511
Err:511
Err:511
Err:511

20437
162361
136734
46835
364

173
173
173
173
173

Err:511
Err:511
Err:511
Err:511
Err:511

Err:511
Err:511
Err:511
Err:511
Err:511

218306
7836
200000
28253
9323
18929

250
365
140

Err:511
Err:511
Err:511

Err:511 accuracy of measurement in d
Err:511
Err:511

362
173

Err:511
Err:511

Err:511
Err:511

366732

Err:511

62.3
7
84000000 For clinker formation
Err:511

output - input

Err:511

Err:511 .

2 N2 41.0% 18 108 3.7% 28 1913.8 1156.5% 28 0.6% .8 220 110 67% 33% Calciner Gas Composition Vol Mol wt O2 5. swirl and cooling air both the kiln and calciner coal blower on the basis of design data 425 LPM 25.75 754.65 8.339 H2O 6 CO 0.3% 37.GCT WATER SPRAY kiln axial.6 5.29 H2O 22 CO 0.08 5.4 CO2 31.3% 12.6% 44.0% wt wt% 172.8% 0.05 Calciner coal cons Coal Cv 21.11 32 44 28 18 28 Kiln Gas Composition Vol Mol wt O2 5.55 CO2 20. Kiln coal cons 10 tph Coal Cv 5321 kCal/kg 53210000 kCal/hr 266.8 1372.1 N2 68.1% accuracy of measurement in doubt.492 62.5 m3/hr 25500 kg/hr Heat Consumption on basis of coal cons.011 wt wt% 32 177.4 28. For clinker formation Clinkerization Factor Ph dust% 1.12 396 3.6% 8.25 tph 4600 kCal/kg 97750000 kCal/hr KF distribution Calciner string Kiln String 488.308 0.8% 44 884.

Cross Checking the PH ID fan Data with ideal GCT false air the power consumption of ID fan PC string Outlet flow 316607 kg/hr with GCT 3% False air and Downcomer 4% false air the total volume should be handle by ID fan= 338770 kg/hr .

01 kg/kk 2000 Kiln Hood 0.07 kg/kk 14000 2.03 kg/kk 6000 Kiln inlet 0.64% 50.1876 2.13% 45.1355 0.14% 48.241 1.37 5.11% 0. .502 1693.4 1628 1694 3.29% 47.4 1364 5.17% 48.9232 4.43 37 37 37.45% 2.78% 1.76 63.24% 41.794 2.54% 56.17% 0.7524 4.957 1670.74% 2.352 1687.08% 49.11% 49.1 34.6 37 38.85% 49.0971 60.35% 50.176 0.208 1661.57% measured values 14% PC string 33063 kg/h Kiln string Kiln inlet analysis is not correct and also ccr va take.29% 47.62% 47.86% 0.3516 58.20% 0.18 1766.74 4.205 0.7188 1650.845 2.79 2.1 31 0.935 63.32 71.12% 0.5 39.41% 48.084 60.07% 2.4717 59.76 1720.24% 5.0983 0.1692 0.1044 0.28 82.68 11.1684 0.5 39.84% 0.4345 60.08% 53.7376 2.55% 0.57 2.43 1.14% 48.76 2.6608 60.09% 49.24 0.36 1628 1628 1654.4 1518 1720.4729 77.1056 59.24 77.15% 52.48% 0.86% 0.7152 1692.166 1682.43 2.96% False Air Across GCT 50125 kg/hr by standard values 45000 kg/hr for all over system False Air According to Standard Values Calciner 0.21% 49.49% 0.2567 0.03 kg/kk 6000 Cy Kiln 0.2733 63.98 1.928 7.76 89.False air Calculation Analysis Data O2 CO2 CO N2 O2 CO2 CO N2 wt% O2 CO2 CO N2 B61 o/l B61 o/l B51o/l B51 B52 B53 B54 B55 GCT OL 2.84 173.652 1777.

Cy PC 0.085 kg/kk 17000 45000 .

3317.72 not correct and also ccr values can not be .