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Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

HOLTEC
OMAN CEMENT COMPANY, OMAN
RADIATION CALCULATION FOR PC AND PREHEATER
Ambient temperature

(Draft)

23

oC

II Method

Heat
Heat
Cyclon
Radiati transfer transfer Radiatio
e
Avg Radiation,
Clinke
on,
coeffici coefficie n, Kcal/
Diameter, Length,
m
m surface
Temp,
Kcal/
r, tph
Kcal/ kg
ent
nt
kg
Area
oC
hr/m2
clinker (Radiati (Convecti clinker
m2
on)
on)

SN

Location

1.1

Cyclone IV A

5.06

3.75

59.61

98.21

92.00

740.92

0.450

7.449

6.613

0.506

1.2

Bottom

5.06

8.3

79.01

98.21

56.00

293.58

0.236

6.247

5.739

0.274

1.3

Riser pipe

1.70

10.68

98.21

42.00

151.19

0.016

5.826

4.987

0.019

1.4

Meal pipe

0.40

8.3

10.43

98.21 260.00

4407.06

0.468

15.725

6.830

0.488

1.5

Down commer duct

2.47

30

232.79

98.21

42.00

151.19

0.358

5.826

4.987

0.419

1.6

Roof

5.06

17.84

98.21

87.00

672.31

0.122

7.271

6.539

0.138

1.7

Cyclone IV B

5.06

3.75

59.61

6.00

60.00

337.77

3.356

6.372

5.890

3.876

1.8

Bottom

5.06

8.3

79.01

98.21

51.00

240.46

0.193

6.093

5.517

0.225

1.9

Riser pipe

1.70

10.68

98.21

42.00

151.19

0.016

5.826

4.987

0.019

2.0

Meal pipe

0.40

2.51

98.21 290.00

5410.22

0.138

17.735

6.728

0.144

2.1

Roof

5.06

17.84

98.21

87.00

672.31

0.122

7.271

6.539

0.138

2.2

Cyclone III A

4.83

3.7

56.14

98.21

65.00

395.03

0.226

6.531

6.053

0.260

2.3

Bottom

4.83

45.79

98.21

68.00

430.43

0.201

6.628

6.139

0.230

2.4

Riser pipe

2.60

7.5

20.20

98.21

52.00

250.89

0.052

6.124

5.565

0.060

2.5

Meal pipe

0.40

3.2

4.02

98.21 320.00

6550.17

0.268

19.928

6.618

0.278

2.7

Roof

4.83

13.01

98.21

70.00

454.46

0.060

6.693

6.193

0.069

2.8

Cyclone III B

4.83

3.7

56.14

98.21

80.00

579.70

0.331

7.029

6.416

0.377

2.9

Bottom

4.83

45.79

98.21

75.00

516.03

0.241

6.859

6.313

0.275

3.0

Riser pipe

2.60

7.5

20.20

98.21

60.00

337.77

0.069

6.372

5.890

0.080

3.1

Meal pipe

0.40

3.2

4.02

98.21 366.00

8597.45

0.352

23.663

6.443

0.364

3.2

Roof

4.83

13.01

98.21

87.00

672.31

0.089

7.271

6.539

0.101

3.3

Cyclone II

6.63

3.7

77.07

98.21 101.50

876.94

0.688

7.797

6.728

0.769

3.4

Bottom

6.63

6.5

77.90

98.21

99.00

840.42

0.667

7.704

6.701

0.747

3.5

Riser pipe

3.60

9.5

26.20

98.21 104.00

913.96

0.244

7.890

6.754

0.272

3.6

Meal pipe

0.40

3.2

4.02

98.21 366.00

8597.45

0.352

23.663

6.443

0.364

3.7

Roof

6.63

24.34

98.21

87.00

672.31

0.167

7.271

6.539

0.188

3.8

Cyclone I A

4.83

3.7

56.14

98.21

87.00

672.31

0.384

7.271

6.539

0.434

Page 1 of 1

Plant Operation Audit for two production lines (Line2 &3),

Annexure 4.1 A
CLINKER CONVERSION FACTOR - LINE 2
MEASUREMENTS TAKEN ON 27.11.2013
Sn

13170

Parameter

Unit

Value

Basis

Kiln feed rate

tph

351.00

CCR Indication

Loss on Ignition (LOI) of kiln feed

34.66

As provided by JKCL

Fuel Consumption (mixed coal)

9.42

Calculated based on data provided by JKCL during


process measurements

Ash content in Fuel (mixed coal )

5.0

Calculated based on data provided by JKCLduring


process measurements

Raw meal to clinker conversion factor


(On LOI basis) (CF 1)

1.52

Calculated

Dust loss from Preheater

9.00

As provided by JKCL during process measurements

Kiln feed to clinker conversion factor


(with return dust) (CF 2)

1.674

Calculated

Clinker produced

tph

209.69

Calculated

tpd

5033

Calculated

Page 1 of 1

Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

Kiln 1 Heat Balance


Kiln feed rate
Clinker prouction

Tph
'tph
'tpd

165
98.2143
2357.14
KF to clinker conversion factor
1.68
oC
Raw meal temperature
60
Raw meal moisture
%
0.5
PH exit gas O2
%
6.0
Clinker temperature
oC
156.0
Natural Gas temperature to kil oC
75
Natural Gas temperature to PC oC
75
Kg/nm3
Atmosphere Gas density
1.293
Ambiant temperature
oC
23
Dust loss (assumed)
%
8.00
Cooler radiation
Kcal/kg clin
5
Drop in temp at two end of TA oC
96

Plant Operational Audit for two production lines ( Line 2&3),

Annexure 4.3 A

GAS FLOW MEASUREMENT - LINE 2


Pitot constant
Site pressure

S.N.

Location

Preheater
Exit (WHR
inlet)

0.836

9859

mmWG

Site elevation
Duct dia.

Date

Clinker
Production
Rate
tph

26.11.13

209.69

3.5

374

Duct
area

Temp.

Static
pressure

m2

oC

mmWG

9.625

315

-670

Cooler
exhaust
26.11.13
(WHR inlet)

209.69

2.80

6.16

418

-27

Tertiary air

209.69

2.18

3.73

930

-70

13170

26.11.13

RMS Avg
dynamic
pressure

Density

Velocity on
RMS Avg

No of
points

mmWG

Kg/ Nm3

mps

m3/ h

Nm3/ h

Nm3/kg
clinker

30

19.85

1.42

21.55

746746

308326

1.470

20

16.93

1.293

21.86

484669

182203

0.87

24

22.63

1.293

33.41

449173

96568

0.46

Dynamic Pressure, mmWG

10

10.0

13.0

13.0

12.0

17.0

25.0

24.0

23.0

26.0

27.0

27.0

27.0

26.0

26.0

24.0

20.0

23.0

19.0

20.0

14.0

16.0

18.0

20.0

21.0

16.0

17.0

16.0

15.0

26.0

25.0

15.0

18.0

18.0

17.0

18.0

19.0

18.0

17.0

16.0

17.0

18.0

15.0

17.0

16.0

15.0

15.0

17.0

17.0

18.0

18.0

25.0

27.0

24.0

23.0

24.0

24.0

28.0

24.0

23.0

24.0

23.0

24.0

23.0

24.0

26.0

28.0

24.0

27.0

10.0

12.0

13.0

25.0

22.0

23.0

Volume on
RMS
Average

Specific air
consp. on
RMS Avg.

Page 4 of 2

Plant Operational Audit for two production lines ( Line2 &3),

Annexure 4.3 A

GAS FLOW MEASUREMENT - LINE 2


COOLING AIR FANS
Site pressure
S.N.

Fan No

9859

mmWG

Site elevation

374

Suction duct
dia.

Duct area

tph

m2

Fan outlet
Static
pressure
mmWC

Date

Temp.
oC

CF 1

26.11.13

209.69

0.71

0.396

+821

28

CF 2

26.11.13

209.69

0.71

0.396

+741

28

CF 3

26.11.13

209.69

0.63

0.312

+754

28

CF 4

26.11.13

209.69

0.90

0.636

+374

28

CF 5

26.11.13

209.69

0.9

0.636

+347

28

CF 6

26.11.13

209.69

0.9

0.636

+335

28

CF 7

26.11.13

209.69

0.9

0.636

+305

28

CF 8

26.11.13

209.69

1.12

0.985

+287

28

CF 9

26.11.13

209.69

1.12

0.985

+283

28

10

CF 10

26.11.13

209.69

1.12

0.985

+245

28

No of
values

Air Velocity, mps


1

10

9.4

9.3

9.6

10.2

10.3

13.0

12.6

12.4

12.2

11.0

9.9

16.6

12.2

13.3

13.4

12.3

12.6

9.2

11.2

10.2

10.7

11.1

9.0

8.8

9.7

9.3

8.6

9.3

8.6

9.9

9.8

11.2

12.7

12.4

11.8

10.9

15.7

16.6

16.8

15.7

14.7

17.3

17.3

15.8

16.9

16.0

16.7

16.4

16.4

17.3

17.7

17.3

17.1

17.2

17.8

17.4

17.0

17.1

17.5

15.4

16.7

16.3

17.2

24.3

21.6

21.8

24.5

23.8

24.0

25.8

25.7

26.7

25.9

26.2

24.2

25.0

26.1

24.9

23.9

24.1

21.5

21.5

22.7

22.0

20.8

22.8

23.5

21.6

20.6

23.4

14.5

14.8

13.6

15.5

13.0

14.0

12.0

14.8

14.9

15.0

14.0

15.8

15.7

15.4

13.8

13.0

13.2

13.2

12.9

14.3

13.7

14.1

12.6

12.0

12.0

13.7

12.3

12.5

13.9

11.7

10.9

11.0

10.0

12.3

11.6

10.0

13.6

12.4

12.5

10.0

13.1

11.0

11.0

Avg
velocity

Volume

Volume

Specific gas consp.

mps

m3/ h

Nm3/ h

Nm3/kg clinker

17

11.79

16802

14540

0.069

19

10.23

14581

12618

0.060

13

16.32

18314

15849

0.076

14

17.07

39088

33826

0.161

23.20

53124

45973

0.219

25.51

58421

50557

0.241

13

22.55

51650

44697

0.213

16

14.37

50949

44091

0.210

13

13.10

46476

40220

0.192

14

11.50

40803

35310

0.168

Total specific cooling air

13170

1.61

Page 2 of 2

Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

Page 1 of 1

COOLER AIR & HEAT BALANCE

Plant capacity
Sp. heat capacity
Fuel firing in Kiln
Air density
Ambient temp.
Combustion air for kiln
Combustion air for PC
Primary air to kiln
Primary air to PC
Secondary air to kiln
Tertiary air to PC
Cooler vent air
Total Cooling air

t/d
Kcal/kgclk.
%
Kg/nm3
oC
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink

2357
800
40
1.293
23
0.494
0.382
0.748
0.579
0.029
0.022
#REF!
#REF!
0.465
0.360
#REF!
#REF!
1.124
0.869
#REF!
#REF!

Flow

Temp

Heat balance
Sn
1
2

Item
Secondary air to kiln
Tertiary air to PC

(Draft)

kg/ kg clink 0C
0.46514271
1060
#REF!
883

Cp

Heat

Kcal/ kg 0 Kcal/ kg clinker


0.26
128.1933322
0.25
#REF!

Page 1 of 1

Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

(Draft)

Page 1 of 1

Page 1 of 1

Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

(Draft)

Page 1 of 1

Page 1 of 1

Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

Page 1 of 1

COOLER HEAT BALANCE

M
Kg/kg
clk

#REF!

Tertiary air
Cp
T

oC

Kcal/
kgoC

Kcal/kg
clk

883

0.25

#REF!

Secondary air
Cp
T

Kg/kg
clk

OC

0.47

1060

Kcal/ Kcal/kg
Kiln clk
kgoC

0.26

128

Cooler

M
Kg/kg
clk

1.00

Hot clinker
Cp
T

OC

Kcal/
kgoC

Kcal/kg
clk

1450

0.26

377

M
Kg/kg
clk

#REF!

Cooling air
Cp
T

OC

Kcal/
kgoC

Kcal/kg
clk

23

0.24

#REF!

#REF!
Recuperatuion Efficiency
:
%

(Draft)

Page 1 of 1

RADIATION CALCULATION FOR COOLER


Ambient temperature

SN

Location

oC

Cyclone
surface Area
m2

Clinker,
tph

II Method

Avg
Temp,
oC

Radiation,
Kcal/ hr/m2

Radiation,
Kcal/ kg
clinker

Heat transfer
coefficient
(Radiation)

Heat transfer
coefficient
(Convection)

1.1

Cooler

145.04

93.24

113.11

1319.99

2.053

7.521

7.991

1.2

Cooler roof

61.48

93.24

138.50

1757.03

1.159

8.518

8.021

Total >>

3.21

Page 1 of 1

RADIATION CALCULATION FOR COOLER


II Method

Radiation, Kcal/
kg clinker

2.347
1.299
3.646

Page 1 of 1

RADIATION CALCULATION FOR PC AND PREHEATER


Ambient temperature

SN

Location

oC

Cyclone
surface Area
m2

Clinker,
tph

II Method

Avg
Temp,
oC

Radiation,
Kcal/ hr/m2

Radiation,
Kcal/ kg
clinker

Heat transfer
coefficient
(Radiation)

Heat transfer
coefficient
(Convection)

763.56

0.461

6.210

7.736

Kiln String
1.1

Cyclone - 1A

126.61

209.69

75.33

1.2

Bottom

38.85

209.69

90.00

966.76

0.179

6.695

7.877

1.3

Riser pipe

16.21

209.69

128.00

1569.83

0.121

8.094

8.018

1.4

meal pipe

9.24

209.69

264.00

4846.82

0.213

15.000

7.619

1.5

Roof

9.69

209.69

84.33

886.35

0.041

6.504

7.830

2.1

Cyclone - 1 B

126.61

209.69

91.67

990.86

0.598

6.752

7.889

2.2

Bottom

38.85

209.69

97.33

1074.40

0.199

6.949

7.925

2.3

Riser pipe

16.21

209.69

125.67

1529.48

0.118

8.002

8.015

2.4

meal pipe

9.24

209.69

260.67

4740.74

0.209

14.791

7.634

2.5

Roof

9.69

209.69

91.00

981.20

0.045

6.730

7.884

3.1

Cyclone - 2

152.76

209.69

68.67

676.47

0.493

5.999

7.648

3.2

Bottom

51.19

209.69

80.00

826.48

0.202

6.361

7.788

3.3

Riser pipe

36.63

209.69

110.00

1270.02

0.222

7.405

7.981

3.4

Meal pipe

9.24

209.69

147.33

1921.85

0.085

8.888

8.016

3.5

Roof

22.39

209.69

112.00

1302.05

0.139

7.480

7.988

4.1

Cyclone - 3

151.13

209.69

68.67

676.47

0.488

5.999

7.648

4.2

Bottom

50.64

209.69

74.00

745.88

0.180

6.168

7.720

4.3

Riser pipe

36.92

209.69

178.00

2549.28

0.449

10.268

7.956

4.4

meal pipe

9.24

209.69

178.67

2563.92

0.113

10.300

7.954

4.5

Roof

15.10

209.69

82.67

863.15

0.062

6.449

7.815

5.1

Cyclone - 4

166.84

209.69

90.00

966.76

0.769

6.695

7.877

5.2

Bottom

53.75

209.69

105.00

1191.32

0.305

7.223

7.963

5.3

Riser pipe

38.80

209.69

135.33

1699.59

0.314

8.388

8.021

5.4

Meal pipe

10.81

209.69

158.33

2136.80

0.110

9.366

8.001

5.5

Roof

16.45

209.69

83.33

872.41

0.068

6.471

7.821

6.1

Cyclone - 5

166.84

209.69

96.67

1064.45

0.847

6.926

7.921

6.2

Bottom

53.75

209.69

131.67

1634.15

0.419

8.240

8.020

6.3

Riser pipe

38.80

209.69

116.67

1378.02

0.255

7.655

8.000

6.5

Meal pipe

10.81

209.69

165.67

2286.29

0.118

9.695

7.987

6.6

Roof

16.45

209.69

150.33

1979.39

0.155

9.016

8.012

6.1

Cyclone - 6

166.84

209.69

122.50

1475.44

1.174

7.878

8.011

6.2

Bottom

53.75

209.69

136.67

1723.67

0.442

8.443

8.021

6.3

Riser pipe

38.80

209.69

466.67

14940.49

2.765

32.124

6.687

6.5

Meal pipe

10.81

209.69

225.00

3696.67

0.191

12.690

7.790

6.6

Roof

16.45

209.69

101.33

1134.84

0.089

7.091

7.946

Calciner String
1.1

Cyclone - 1

148.64

209.69

83.33

872.41

0.618

6.471

7.821

1.2

Bottom

49.94

209.69

153.33

2037.74

0.485

9.146

8.009

1.3

Riser pipe

26.28

209.69

67.33

659.45

0.083

5.958

7.628

1.4

meal pipe

9.24

209.69

194.33

2920.98

0.129

11.067

7.906

1.5

Roof

20.87

209.69

100.00

1114.56

0.111

7.043

7.939

3.1

Cyclone - 2

145.34

209.69

97.00

1069.42

0.741

6.937

7.923

3.2

Bottom

48.93

209.69

74.00

745.88

0.174

6.168

7.720

3.3

Riser pipe

35.80

209.69

88.33

942.86

0.161

6.639

7.864

3.4

Meal pipe

9.24

209.69

155.33

2077.09

0.091

9.234

8.006

Page 1 of 1

3.5

Roof

13.67

209.69

107.33

1227.81

0.080

7.307

7.972

4.1

Cyclone - 3

141.69

209.69

112.33

1307.42

0.883

7.492

7.989

4.2

Bottom

48.36

209.69

78.00

799.31

0.184

6.296

7.767

4.3

Riser pipe

35.14

209.69

115.00

1350.69

0.226

7.592

7.996

4.4

meal pipe

9.24

209.69

156.33

2096.90

0.092

9.277

8.004

4.5

Roof

13.45

209.69

67.33

659.45

0.042

5.958

7.628

5.1

Cyclone - 4

151.13

209.69

95.67

1049.58

0.756

6.891

7.915

5.2

Bottom

50.64

209.69

125.00

1518.03

0.367

7.976

8.014

5.3

Riser pipe

36.92

209.69

138.00

1747.91

0.308

8.498

8.021

5.4

Meal pipe

9.24

209.69

193.67

2905.27

0.128

11.033

7.908

5.5

Roof

14.92

209.69

121.67

1461.35

0.104

7.846

8.010

6.1

Cyclone - 5

151.13

209.69

100.00

1114.56

0.803

7.043

7.939

6.2

Bottom

50.64

209.69

117.33

1389.02

0.335

7.680

8.001

6.3

Riser pipe

36.92

209.69

98.67

1094.41

0.193

6.996

7.932

6.5

Meal pipe

9.24

209.69

206.33

3211.98

0.141

11.682

7.863

6.6

Roof

14.92

209.69

98.33

1089.40

0.078

6.984

7.930

6.1

Cyclone - 6

151.13

209.69

101.00

1129.76

0.814

7.079

7.944

6.2

Bottom

50.64

209.69

136.67

1723.67

0.416

8.443

8.021

6.3

Riser pipe

36.92

209.69

154.67

2063.93

0.363

9.204

8.007

6.5

Meal pipe

9.24

209.69

181.67

2630.35

0.116

10.444

7.946

6.6

Roof

14.92

209.69

165.67

2286.29

0.163

9.695

7.987

PC

1.988

Riser ducts

3.128

Total >>

26.94

Page 1 of 1

ADIATION CALCULATION FOR PC AND PREHEATER


II Method

Radiation, Kcal/
kg clinker

0.545
0.209
0.137
0.226
0.048
0.697
0.231
0.134
0.221
0.053
0.587
0.238
0.254
0.094
0.159
0.581
0.213
0.491
0.124
0.073
0.897
0.351
0.353
0.122
0.080
0.982
0.472
0.291
0.130
0.173
1.332
0.496
2.882
0.204
0.103
0.726
0.539
0.099
0.140
0.128
0.859
0.206
0.188
0.101
Page 1 of 1

0.092
1.010
0.218
0.258
0.102
0.050
0.878
0.415
0.345
0.139
0.118
0.928
0.382
0.223
0.153
0.090
0.940
0.467
0.403
0.127
0.179

24.686

Page 1 of 1

RADIATION CALCULATION FOR KILN 1 (From Kiln Outlet)


Ambient temperature

oC

II Method

SN

Location, m

Kiln Dia,
m

Kiln
Length,
m

Total C. S,
m2

Clinker,
tph

0 to 2

4.27

26.83

209.69

2 to 4

4.27

26.83

209.69

4 to 6

4.27

26.83

6 to 8

4.27

26.83

8 to 10

4.27

10 to 12

4.27

12 to 14

4.27

14 to 16

4.27

Avg
Temp,
oC

Radiation, Kcal/
hr/m2

Radiation,
Kcal/ kg
clinker

Heat transfer
coefficient
(Radiation)

Heat transfer
coefficient
(Convection)

Radiation, Kcal/
kg clinker

364

9418.04

1.205

22.304

7.148

1.179

280

5703.77

0.730

16.032

7.545

0.726

209.69

281

5740.67

0.735

16.098

7.540

0.731

209.69

291

6118.62

0.783

16.770

7.494

0.777

26.83

209.69

246

4540.15

0.581

13.899

7.700

0.585

26.83

209.69

204

3325.53

0.425

11.561

7.872

0.436

26.83

209.69

165

2388.36

0.306

9.665

7.988

0.320

26.83

209.69

347

8558.33

1.095

20.913

7.228

1.074

16 to 18

4.27

26.83

209.69

318

7223.53

0.924

18.686

7.366

0.911

10

18 to 20

4.27

26.83

209.69

351

8755.29

1.120

21.235

7.209

1.098

11

20 to 22

4.27

26.83

209.69

201

3247.30

0.415

11.406

7.883

0.427

12

22 to 24

4.27

26.83

209.69

225

3904.14

0.500

12.690

7.790

0.507

13

24 to 26

4.27

26.83

209.69

257

4897.79

0.627

14.564

7.651

0.628

14

26 to 28

4.27

26.83

209.69

327

7620.71

0.975

19.358

7.323

0.960

15

28 to 30

4.27

26.83

209.69

215

3621.73

0.463

12.142

7.830

0.472

16

30 to 32

4.27

26.83

209.69

318

7223.53

0.924

18.686

7.366

0.911

17

32 to 34

4.27

26.83

209.69

309

6841.09

0.875

18.030

7.408

0.865

18

34 to 36

4.27

26.83

209.69

305

6675.73

0.854

17.745

7.427

0.845

19

36 to 38

4.27

26.83

209.69

307

6758.06

0.865

17.887

7.418

0.855

20

38 to 40

4.27

26.83

209.69

257

4886.69

0.625

14.544

7.653

0.627

21

40 to 42

4.27

26.83

209.69

260

4987.13

0.638

14.729

7.639

0.639

22

42 to 44

4.27

26.83

209.69

215

3621.73

0.463

12.142

7.830

0.472

23

44 to 46

4.27

26.83

209.69

228

3991.38

0.511

12.858

7.778

0.518

24

46 to 48

4.27

26.83

209.69

221

3789.64

0.485

12.469

7.806

0.493

25

48 to 50

4.27

26.83

209.69

212

3539.47

0.453

11.982

7.842

0.462

26

50 to 52

4.27

26.83

209.69

218

3695.80

0.473

12.287

7.820

0.481

27

52 to 54

4.27

26.83

209.69

209

3449.38

0.441

11.805

7.855

0.451

28

54 to 56

4.27

26.83

209.69

209

3449.38

0.441

11.805

7.855

0.451

28

56 to 58

4.27

26.83

209.69

222

3827.58

0.490

12.542

7.801

0.498

28

58 to 60

4.27

26.83

209.69

285

5889.90

0.754

16.364

7.522

0.749

Total >>

20.18

20.15

Page 1 of 1

HEAT BALANCE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Kiln feed temperature


Kiln feed moisture
Fine Coal moisture
PH exit gas CO2
O2
N2
Clinker temperature
Temperature of Coal fired in kiln
Temperature of Coal fired in PC
Gas density
Ambiant temperature
Dust loss
Cooler radiation
Kiln radiation
PH radiation

C
%
%
%
%
%
o
C
o
C
o
C
Kg/nm3
o
C
%
Kcal/kg clinker
Kcal/kg clinker
Kcal/kg clinker
o

60
0.2
0.5
18
4.0
78.0
130
50
50
1.293
28
9.00
3.21
20.2
26.94

C
Primary air temp
%
%
%
%
%
o
C
o
C
o
C
Kg/nm3
o
C
%
Kcal/kg clinker
Kcal/kg clinker
Kcal/kg clinker
o

Deg C

50

KILN, PREHEATER AND COOLER -Kiln 2


Clinker production
S.
N.

Stream

5033
Gas flow, Nm3/kg
Flow, Kg/ Kg clinker
clinker

tpd
Temp, oC

Heat,
Kcal/ kg clk

% Heat

Mass flow
tph

Sp. heat
Kcal/KgoC

Sensible Heat of kiln feed

1.671

60

21.24

2.78

350.30

0.21

Sensible Heat of kiln feed moisture

0.003

60

0.20

0.03

0.70

1.00

Sensible Heat of Fuel

0.094

50

1.31

0.17

19.64

0.28

Sensible Heat of fine fuel moisture

0.0005

50

0.01

0.001

0.10

0.28

Sensible Heat of Primary air to Kiln

0.022

0.029

50

0.35

0.05

6.09

0.24

Sensible heat of coal conveying air to kiln

0.009

0.012

50

0.15

0.02

2.58

0.24

Sensible Heat of Cooler air

1.610

2.082

28

13.86

1.82

436.62

0.24

Sensible Heat of false air

0.305

0.394

28

2.62

0.34

82.66

0.24

Sensible heat of coal conveying air to PC

0.014

0.017

50

0.21

0.03

3.66

0.24

723

94.77

0.00

763

100.00

902.4

10

Heat from Fuel

11

Calcination Gases

0.278

12

Combustion Gases only

0.024

Total Heat Input >>

2.26

4.30
Heat Output

Heat loss through Clinker

Heat loss through PH exhaust gas

Heat loss through PH return dust

Heat loss through Cooler exhaust air

Heat of Formation for Clinker

Evaporation of Moisture in kiln feed

0.003

Evaporation of Moisture in fine fuel

0.0005

Preheater radiation losses

Kiln and cooler radiation losses


Total Heat Output >>

1.426
0.87

2.30

1.000

130

25.09

3.29

209.69

0.193

2.025

315

157.0

20.57

424.69

0.25

0.151

315

11.11

1.46

31.59

0.23

1.124

418

115.8

15.18

235.59

0.25

401.1

52.57

315

2.27

0.30

0.70

0.46

315

0.32

0.04

0.10

0.46

26.94

3.53

0.00

23.39

3.07

0.00

763.0

100.00

902

4.30

Cooler 2 Heat Balance -Kiln 2


Data
Clinker Production
Specific Heat Consumption
% of fuel to Kiln
% of fuel to PC
Clinker temperature
Cooler Exhaust Temperature
Secondary
Tertiary Air Temperature
Primary air to kiln
Primary air to PC
Secondary Air Quantity
Tertiary quantity
Density of air
Ambient Air Temperature

Sn

Description

tpd
kcal/kg clinker
%
%
Deg C
Deg C
Deg C
Deg C
kg/kg clinker
kg/kg clinker
kg/kg clinker
kg/kg clinker
kg/nm3
Deg C

5033
723
31.1
68.9
130
418
1140
930
0.029
0.017
0.363
0.595
1.293
28

Flow

Temperature

kg/kg clinker

Deg C

Cp

Heat

kcal/kg oC kcal/kg clinker

HEAT INPUT
1

Hot Clinker

1.00

1450

0.264

383

Cooling Air

2.08

28

0.238

13.9

Total

3.08

397.1

HEAT OUTPUT
3

Heat loss through Cooler Exhaust air

1.12

418

0.247

115.8

Secondary air

0.363

1140

0.263

109.0

Tertiary Air

0.595

930

0.258

143.1

Heat loss through Clinker

1.00

130

0.193

25.1

Cooler Radiation losses


Total

3.2
3.08

396.2

% of Heat Recuperation Efficiency

64

Total Cooler losses

144

Plant Operational Audit for production lines ( Line 2& 3),

Annexure 4.7 A

COOLER HEAT BALANCE LINE 2


Secondary air
Mass
Temp.
Heat flow

0.36
1140
109.00

Kg/ kg clk
0
C
Kcal/ kg clk.

Tertiary Air
Mass
Temp.
Heat flow

0.60
930
143.09

Kg/ kg clk
0
C
Kcal/ kg clk.

Cooler exhaust
Mass
Temp.
Heat flow

1.12
418
115.82

Kg/ kg clk
C
Kcal/ kg clk.

Clinker
Mass
Temp.
Heat flow

Clinker
Mass
Temp.
Heat flow

1.00
1450
383.24

Kg/ kg clk
C
Kcal/ kg clk.

Kg/ kg clk
0
C
Kcal/ kg clk.
Total cooling air

Heat recuperation efficiency


63.6 %
Total Cooler losses
144.1 kcal/kg clinker

13170

1.00
130
25.09

Cooler radiation losses


3.21

Mass
Temp.
Heat flow

2.08
28
13.86

Kcal/ kg clk.

Kg/ kg clk
C
Kcal/ kg clk.

Page 1 of 1

Plant Operational Audit for two production lines ( Line2& 3),


J K Lakshmi Cement Ltd, Sirohi Rajasthan

Annexure 4.4A
KILN SHELL TEMPERATURE LINE 2

S.N.

13170

Location (From kiln outlet), m

Average temperature, oC

0 to 2

364

2 to 4

280

4 to 6

281

6 to 8

291

8 to 10

246

10 to 12

204

12 to 14

165

14 to 16

347

16 to 18

318

10

18 to 20

351

11

20 to 22

201

12

22 to 24

225

13

24 to 26

257

14

26 to 28

327

15

28 to 30

215

16

30 to 32

318

17

32 to 34

309

18

34 to 36

305

19

36 to 38

307

20

38 to 40

257

21

40 to 42

260

22

42 to 44

215

23

44 to 46

228

24

46 to 48

221

25

48 to 50

212

26

50 to 52

218

27

52 to 54

209

28

54 to 56

209

29

56 to 58

222

30

58 to 60

285

Page 1 of 1

Plant Operational Audit for two production lines ( Line 2& 3),
J K Lakshmi Cement Ltd, Sirohi Rajasthan

Annexure 4.5A

CHEMICAL ANALYSIS OF CLINKER LINE 2

13170

Component

Unit

Value

SiO2

20.94

Al2O3

5.71

Fe2O3

3.75

CaO

63.87

MgO

3.02

SO3

1.45

K2O

0.73

Na2O

0.31

Cl

0.00

Free CaO

1.89

Page 1 of 1

Heat loss by
Radiation

Heat loss through Cooler Vent

6.60%

15.18%

Sensible heat of Kiln Feed

Heat loss through Preheater exhaust gas

2.78%

20.57%

Heat loss through clinker


Heat input by Fuel

3.29%
Heat Balance of Kiln 2

94.77%

Specific Heat Consumption


Kcal/ kg clinker
763.0

Heat of Formation
52.57%

Estimation of Phase Density

Kiln

Pipe line size

Dia
CSA

Volume

Coal tpt
Velocity at tpt line
Coal to air ratio
power cons
sp power
kg of air required for 4
kg ratio
Extra air going
% Extra air going
% reduction in power
for 20% speed red
kw saving
annual cost saving

kW

mm
m2
m3/sec
kg/sec
m3/hr
Nm3/kg clinker
TPH
kg/sec
m/sec

PC

141.2
0.0157
0.6393
0.7224
2301
0.009
6
1.67
40.82
2.31
110
18.33

179.2
0.0252
0.9098
1.0280
3275
0.014
13.4
3.72
36.07
3.62
110
8.21

0.42

0.93

0.31
0.42

0.10
0.09

0.512

0.512

53.7
8.59

0.0
0.00

32.13610586
321.3610586

Kiln 2 - Energy Saving Proposals,


Power cost

3.880
present level

Increasing Gas residence time in existing precalciner

Reduction of preheater calciner exit temperature

Reduce pressure drop across duct from WHR outlet to ph fan inlet

Arresting of false air

Reduce bypass in pyro section

Reduce pressure drop across Top stage cyclone

Reduce false air across CT system -Pyro

Replacement of existing cooling fans

Upgradation of heat exchanger in cooler vent system

Installation of Precalciner

10

Increasing kiln inlet area


Reduction of dust accumulation inside Tertiary Air Duct (TAD) & Improving Tertiary
air flow.

11

70.0

278.0

471 FN2,3,4,5,6,7
7

Reduce pressure drop across cyclone & cyclone outlet bend in Raw mill circuit

Reduce false air in GCT and VRM circuit

Reduce damper loss in Kiln/raw mill Bag House Fan

10

Reduce false air in coal mill circuit

11

Reduce pressure drop in coal mill bag hose to Fan duct

115.0

12

47.0

13

Reduce damper loss in coal mill booster fan


Reduce speed of kiln & PC coal conveying blowers by 20 % by installing VFD and
reduce pipe dia /size to maintain 35 m/s transportation velocity

14

Installation of automation system

15

Reduce pressure drop across damper in Sepax fan Slag HPGR roller press

80.0

16

Reduce pressure drop across damper in bag house fan in Slag VRM

113.0

17

Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF1)

64.0

18

Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF3)

303.0

19

Avoid damper loss by installing VFD in Auxilary bag filter fan (221BF1)

440.0

Long term energy saving proposals


Installation of new clinker cooler

160.0

40.0

INR
new one

Coal cost

861.6

present power fan head

INR/ mio kcal

saving power Running hrs savings in Lakhs

10.19
40

1893.0
1893.0

742.0
742.0

77
94.65

7920
7920

23.5
29.1
40.76

90

2075.1

830.0

235

8000

7.3

2075.1

830.00

92.1

8000

1.43

75.0

8000

23.3

8000

45.0
0.0

8000

3.06

130

20.0

8000

6.2

1580.0

903.0

52.5

7000

14.3

1580.0

903.0

145

7000

39.4

803.0

294.0

27.3

8000

8.5

380.0

893.0

39

5000

7.6

40

380.0

893.0

31.9

5000

6.2

20

60.0

141.0

11.5

5000

2.2

67.0

8000

20.8

109

8000

33.8

20

20

400.0

464.0

25.9

7000

7.0

20

1435.0

686.0

97.3

7000

26.4

10

22.0

351.0

3.4

5000

0.7

10

45.0

496.0

13.3

5000

2.6

10

55.0

515.0

23.0

5000

4.5

157.0

417

Thermal savings

Electrical savings

investement Lakhs

payback, months

kcal/kg

MTOE/ year

KW

10

1171

101

5.1

0.5

3.6

424

40.00

20

20.0

2.2

0.1

40

2.40

235

0.13

1.1

92.1

2.5

1.3

2.5
2.3

0.6

2.0
1.5

5.9

77

40

77.3

20

16.8

20

6.1

0.0

25

39.4

25

48.5

16.2

20

11.5

50

17.7

0.0

0.0

36.6

18.6

10.8

600

45.9

826

Electrical savings
kW/ t of clinker
0.68

6.6
39895

1.6
0.6
0.5

59996

0.11

False air %

43376

11890

Primary air_kiln _ PC

Primary air to kiln


Air required for kiln firing
% primary air to kiln

Primary air to precalciner


Air required for PC firing
% primary air toPC
Savings from Recommended action

The O2 at PH exit may be reduced to 3.5%


by identifying the leakages in the Cyclones,
riser ducts, meal chutes, PC, kiln seals, etc. 29.314989 Kcal/ kg clinker
Primary air to PC may be reduced to
maximum 6 % i.e. 0.045 Kg/ kg clinker.
From 0.06kg /kg clinker
Primary air to kiln may be reduced to
maximum 6 % i.e. 0.04 Kg/ kg clinker.
From 0.025kg /kg clinker
Temperature drop across the T A Duct may
be reduced to 50 Deg C from 96

3.1788 Kcal/ kg clinker

3.7332 Kcal/ kg clinker


5.87328 Kcal/ kg clinker

Page 1