Kiln Cooler Heat Mass Balance

Page - 1/29
PLANT : Binani Cement - 20.06.2003

Kiln Feed
Kiln Feed Dividing Flap 1.657 kg-Feed/kg-Clk
O2 = 5.3% O2 = 3.2% To Raw Mill/Baghouse

K1 C1
0.566 Nm3w/kg-clk 1.449 Nm3w/kg-clk
0.134 kg-Dust/kg-Clk
K2 C2
KS Fan
844/82 kW/%
K3 C3 ESP
0.884 Nm3/kg-Clk CS Fan Cooler ESP
K4 1930/86.20 kW/%
C4
Kiln String Calciner String

K5 C5 1.092 Nm3w/kg-clk 185 kW/%
0.020 kg-Dust/kg-Clk Stack
K6 C6
Cal.
Calciner Firing Kiln Firing
0.072 kg-Coal/kg-Clk 0.044 kg-Coal/kg-Clk
0.020 Nm3w/kg-clk 0.020 Nm3w/kg-clk
0.508 Nm /kg-Clk
3
T.A. Duct
Primary Air
0.020 Nm3w/kg-clk
KILNKILN 1136 deg.C
3.56 %
Inlet O2 4.2 rpm
False Air a/c KS, Nm3w/kg-clk 0.030 50 %
False Air a/c CS, Nm3w/kg-clk 0.052 0.357 Nm3w/kg-clk Cooler
False Air a/c Cooler, Nm w/kg-clk
3
0.009
Hot air to PA Fan Clinker

1.889 Nm3w/kg-clk 251515 kg-Clk/hr
Page - 2/29

Nm3w/kg-clk kgw/kg-clk
Stoi. 0.479 0.613
Exc. 0.048 0.062
K6 C6
Cal.
Tot. 0.528 0.675 Trpt. Air
0.020 Nm3w/kg-clk
0.026 kgw/kg-clk
Trpt. Air
0.020 Nm3w/kg-clk
0.026 kgw/kg-clk Pri. Air Water Inj.
0.025 kgd/kg-clk 0.020 Nm3w/kg-clk 0.020 kg/kg-clk
T.A.DUCT 0.508 0.025 kgw/kg-clk
0.650 Vent Air
KILNKILN #REF! 1.092 Nm3w/kg-clk
1.388 kgw/kg-clk
0.311
Nm w/kg-clk
3
kgw/kg-clk 0.398
Stoi. 0.294 0.376 COOLAX COOLER False Air
Exc. 0.063 0.081 0.819 1284-3ME-IN 1.070 0.003 Nm3w/kg-clk
Ist 6 Row CIS
Tot. 0.357 0.457 1.048 1.369 0.004 kgw/kg-clk
False Air
0.006 Nm3w/kg-clk
0.007 kgw/kg-clk
Excess Air Optimisation (vol%, d)

Optimised O2 - Kiln I/L 3.6 Cooling Air
Optimised CO2 - Kiln I/L 20.7 1.889 Nm3w/kg-clk
Optimised O2 - Cal. O/L 1.4 2.417 kgw/kg-clk
Optimised CO2 - Cal. O/L 39.3
Error Minimisation-1 0.00
Optimised Excess Air, Kiln 21.5 vol%, w Error Minimisation-2 0.00
Optimised Excess Air, Cal. 10.1 vol%, w Error Minimisation-3 0.00
08/15/2019 07:43:35 433316615.xls Pic-2S LU001005-KCP#Ver.1.2D***

kgd/kg-clk
0.602
0.061
0.663
0.026 kgd/kg-clk
0.025 kgd/kg-clk
0.638
1.349
kgd/kg-clk
0.369 0.391
0.079
0.448
1.029 1.344 0.004
0.007 kgd/kg-clk
3.491 0.065 2.374 kgd/kg-clk

20.703 0.000
1.416 0.027
39.347 0.000

kgd/kg-clk
kgd/kg-clk

Page - 3/29
Kiln Basic Calculations : SLC 6-Stage II-String
Site Conditions Equipment Specifications
Clinker Production tpd 6036 Kiln Length mts 68
Clinker Production kg/hr 251515 Kiln Diameter mts 4.55
Plant Elevation mts +MSL 402 Kiln Refractory Thickness mm 220
Barometric Pressure mmWG 9827 Kiln Diameter, effective mts 4.11
Barometric Pressure mmHG 723 Slope % 4
Ambient Air Temperature deg.C 31.0 Cooler Area m2 97.03
Relative Humidity % 41 Burner Axial Area 5 mm withdrawn m2 0.01262
Pitot Constt. - S Type (L=01m) S1 0.883 Burner Radial Area X mm withdrawn m2 Blocked
Pitot Constt. - S Type (L=03m) S2 0.872 Burner - Coal Annulus m2 0.03878
False Air Analysis Raw Mix
A/c KS w.r.t. Mix - O2 Basis mass%, w 5.52 Loss on Ignition (as LOI) % 35.83
A/c CS w.r.t. Mix - O2 Basis mass%, w 6.41 CaCO3 % 75.70
A/c Cooler ESP w.r.t. Mix mass%, w 7.24 MgCO3 % 1.80
Excess Air in Kiln vol%, d 21.45 Sulphur (as pyrites) % 0.04
Excess Air in Calciner vol%, d 10.10 Combined H2O % 1.05
Water Temp. deg.C 25 Carbon in Kiln Feed % 0.20
Miscellaneous Data Moisture in Kiln Feed % 0.22
Dust with Clinker, Kiln % 2.00 Moisture in Kiln Feed kg/hr 917
Water In, Cooler m3/hr 5.0 Raw Mix - Clinker Ratio kg/kg-clk 1.522
Water In, Cooler tph 5.0 Raw Mix - Clinker Ratio kg/hr 382896
Evaporation Heat kcal/kg 539 Kiln Feed Rate kg/kg-clk 1.657
Clinker Temperature, Kiln Outlet deg.C 1450 Kiln Feed Rate kg/hr 416689
Clinker Temperature, Cooler Outlet deg.C 140 Clinker Composition
Kiln Feed Temperature deg.C 82 Silica (as SiO2) % 20.87
Fine Coal Temperature deg.C 73 Alumina (as Al2O3) % 6.15
Kiln Dust mass%, w 6.70 Iron (as Fe2O3) % 3.51
ESP I/L Dust Concn. gm/m3-dg 9.0 Lime (as CaO) % 65.23
BH Dust Returned to Kiln yes/no no Magnesia (as MgO) % 1.91
Clinker Density t/m3 1.3 Potassium Oxide (as K2O) % 0.55
Cooler Fans kWh 31877 Sodium Oxide (as Na2O) % 0.45
Cooler ESP/Stack Radiations kcal/kg-Clk 1.0 Sulphates (as SO3) % 0.50
Performance & Efficiency CCR Data
Kiln Feed Residence Time in Kiln min (d) 18.71 Kiln Speed rpm 4.20
Clinker Residence Time in Cooler min (d) 17.01 CFG Static Pressure mmWG 735
Theoretical Flame Temperature deg.C 2181 Kiln Feed Rate/Dosing Valve Position tph/% 415/78
Kiln Volumetric Loading tpd/m3 6.69 Kiln Feed Elevator Load kW 92/71
Burning Zone Loading Mcal/hr-m 2
4.95 Kiln Feed Diversion - Kiln/Calciner %/% 40.5/59.5
Percent Filling % 16.56 Coal Screw Speed - Kiln/Calciner rpm 629/673
Clinker Bed Thickness in Cooler mm 565 KS Fan Load/Speed kW/% 844/82
Clinker in Cooler tons 71 CS Fan Load/Speed kW/% 1930/86.20
Cooler Efficiency - Ref. : Amb. Temp. % 73.11 Kiln String O2 % 5.44
Percent Primary Air (AA | RA) % 6.79 0.00 Calciner String O2 % 3
P.A. Tip Velocity (AA | RA) m/sec 137 0 Kiln Inlet O2 % 3.65
Flame Momentum (AA | RA) %.m/sec 928 0 Cooler Grate-I Ch.I/II/III DP mmWG 676/123/84
Percent Coal Transport Air % 7.08 Cooler Grate-I/II/III speed spm 15.8/16.6/17.6
C.T.A. Tip Velocity m/sec 37 Cooler Grate-I/II/III load amps 69/56/55
Flame Momentum (CTA) %.m/sec 260 Burning Zone Temperature/Kiln Torque deg.C/% 1136/50
Total Flame Momentum %.m/sec 1188 Cooler ESP Fan Load kW 185
Cooler Air m3/s/m2 1.51 Cooler ESP Fan Speed % 60
Cooler Loading tpd/m2 62.2 Tert. Air Draft mmWG -38
Secondary Air Temperature deg.C 1109 Hood Draft mmWG -6
Tertiary Air Temperature deg.C 905 Dust Losses - PH % 8.11
PLANT : Binani Cement - 20.06.2003 <<< ERRORS >>>
Hot air to PA Fan (Yes/No) yes Heat-1 0.00 Heat-2 0.00
Axial Air Contribution, % 100 Heat-3 0.00 Heat-4 0.00
Heat-5 0.00 Heat-6 0.00
Heat-7 0.00 Heat-8 0.00
08/15/2019 07:43:35 433316615.xls Kiln-CalcS LU000211-KCP#Ver.2.2***

Page - 13/29
Kiln Air Flow Calculations : SLC 6-Stage II-String
Flow Analysis Kiln Calciner Total Cooler Primary Coal Trpt. Air False Air
String String PH Gas Vent Air Kiln Cal. Kiln I/L Cal. O/L Cooler
Dry Bulb Temp. deg.C 306 302 304 285 87 73 75 807 811 31
Wet Bulb Temp. deg.C - - - - 30 34 34 - - 22
Dew Point (F4) deg.C - - - 31 25 25 24 - - 15
Dew Point, calc. deg.C - - 58 31 25 25 24 - - 16
Water Vapor kg/kg-dg 0.110 0.110 0.110 0.030 0.021 0.021 0.020 0.012 0.012 0.012
Avg. Ps mmWG -575 -864 -753 -40 1020 3305 2960 -66 -234 -6
RMS Pd mmWG - - - - 9.75 50.86 50.19 - - -
Duct Diameter mts 2.80 3.00 3.75 3.55 2

0.40 0.255 0.255 - - -
O2, dry vol % 5.3 3.2 4.0 21.0 21.0 21.0 21.0 3.6 1.4 21.0
CO2, dry vol % 28.8 35.8 33.1 0.0 0.0 0.0 0.0 20.7 39.3 0.0
N2, dry vol % 65.9 61.0 62.9 79.0 79.0 79.0 79.0 75.7 59.2 79.0
Density, dry - O2 kg/m3 0.60 0.59 0.59 0.66 1.14 1.43 1.39 0.34 0.33 1.22
Density, dry - CO2 kg/m3 0.83 0.81 0.82 0.92 1.57 1.98 1.92 0.47 0.46 1.69
Density, dry - N2 kg/m3 0.53 0.52 0.52 0.58 1.00 1.26 1.22 0.30 0.29 1.07
Density - H2O kg/m 3
0.34 0.33 0.33 0.37 0.64 0.81 0.78 0.19 0.19 0.69
Mass - O2, dry kg 3.20 1.88 2.38 13.90 23.88 30.08 29.13 1.21 0.48 25.61
Mass - CO2, dry kg 24.08 29.10 27.20 0.00 0.00 0.00 0.00 9.77 18.18 0.00
Mass - N2, dry kg 34.96 31.58 32.87 46.01 79.03 99.55 96.38 22.73 17.40 84.74
Mass - H2O kg 6.85 6.88 6.87 1.77 2.16 2.72 2.51 0.40 0.43 1.32
O2, wet mass % 4.63 2.71 3.44 22.54 22.73 22.73 22.75 3.56 1.32 22.93
CO2, wet mass % 34.85 41.91 39.24 0.00 0.00 0.00 0.00 28.64 49.82 0.00
N2, wet mass % 50.61 45.47 47.42 74.59 75.21 75.21 75.29 66.62 47.67 75.88
H2O mass % 9.91 9.91 9.91 2.87 2.06 2.06 1.96 1.19 1.19 1.19
Gas Density, dry kg/Nm3 1.47 1.52 1.50 1.29 1.29 1.29 1.29 1.41 1.54 1.29
Gas Density, wet kg/Nm3 1.36 1.40 1.38 1.27 1.28 1.28 1.28 1.40 1.53 1.28
Gas Density, dry kg/m3 0.62 0.63 0.62 0.60 1.03 1.30 1.26 0.34 0.36 1.10
Gas Density, wet kg/m 3

0.57 0.57 0.57 0.59 1.02 1.28 1.24 0.33 0.36 1.10
Pitot Tube S1/S2/L - - - - L L L - - -
Gas Velocity m/s 15.2 21.2 22.1 13.1 13.7 27.9 28.2 - - -
Duct C.S. Area m 2

6.16 7.07 11.04 12.60 0.13 0.051 0.051 - - -
Gas Flow Rate, wet tph 193.68 310.38 504.06 349.20 6.31 6.57 6.42 10.69 19.89 2.84
Gas Flow Rate, wet kNm /hr 142.27

3
222.22 364.44 274.76 4.94 5.14 5.03 7.64 13.03 2.21
Gas Flow Rate, wet km3/hr 336.90 539.90 876.81 593.07 6.21 5.13 5.18 32.01 55.75 2.59
Moisture, by diff. tph 19.2 30.8 50.0 10.0 0.1 0.1 0.1 0.1 0.2 0.0
Gas Flow Rate, dry tph 174.49 279.62 454.11 339.17 6.18 6.44 6.30 10.57 19.65 2.81
Gas Flow Rate, dry kNm3/hr 118.40 183.96 302.29 262.29 4.78 4.98 4.87 7.48 12.74 2.17
Gas Flow Rate, dry km3/hr 280.37 446.96 727.32 566.15 6.00 4.96 5.02 31.35 54.49 2.55
Heat Cap., gas kcal/kg/C 0.263 0.261 0.262 0.250 0.244 0.244 0.244 0.263 0.264 0.242
Heat Content, gas Mcal/hr 15548 24527 40075 24911 134 117 118 2268 4251 21
Dust, gas tph 12.98 20.81 33.79 5.10 - - - - - -
Heat Cap., dust kcal/kg/C 0.234 0.233 0.233 0.205 - - - - - -
Heat Content, dust Mcal/hr 927 1467 2394 298 - - - - - -
Heat Content, total Mcal/hr 16475 25994 42469 25209 134 117 118 2268 4251 21

Heat Cap - Coefficients
Gas/Mat *T^0 *T^1 *T^2 *T^3 *T^4
0.2485 -3.340E-06 4.440E-08 ### 5.597E-15 Not used in calc.
0.1244 0.000E+00 0.000E+00 ### 0.000E+00 Not used in calc.
O2 0.2130 7.796E-05 -7.563E-08 4.074E-11 -8.183E-15
CO2 0.1906 1.771E-04 -1.733E-07 9.315E-11 -1.894E-14
N2+Ar 0.2465 -3.284E-06 4.366E-08 ### 5.504E-15
H2O,steam 0.4445 2.910E-05 6.887E-08 ### 6.472E-15
H2O, liq. 1.0000
Rawmeal 0.2060 1.014E-04 -3.673E-08
Clinker 0.1742 1.414E-04 -1.283E-07 5.074E-11
A 23.5771 Sp. Gravity, dry - O2 kg/Nm3 1.429
B -4042.90 Sp. Gravity, dry - CO2 kg/Nm3 1.977
C -37.58 Sp. Gravity, dry - N2 kg/Nm3 1.257

Rho H2O-Steam, kg/Nm3 0.804 Sp. Gravity - H2O kg/Nm3 0.804
BURNER AXIAL/RADIAL ANNULUS

R/A Withd. Area A/A Withd. Area
0 0.046850 0 0.005790
2 0.045465 5 0.005790
4 0.044088 10 0.008630
6 0.042722 15 0.010610
8 0.041365 20 0.012620
25 0.014690
30 0.016800
35 0.018950
40 0.021150
45 0.024520
50 0.028210
55 0.032110
60 0.035150

Page - 14/29
Supporting Gas Analysis Cooler-ESP Air Balancing
Ambient ESP False Air To KS CS Const. Mass Temp. Sp. Heat Heat
Air Stack ESP PA Fan Fan I/L Fan I/L kg/kg-clk deg.C kcal/kg/C kcal/kg-clk
31 265 31 265 305 302 IN
22 53 22 53 80 80 Air (ESP I/L) 1.388 285 0.250 99
15 40 15 40 60 60 False Air 0.106 31 0.242 1
16 30 16 30 57 58 ESP Fan Pow. - - - 0
0.012 0.028 0.012 0.028 0.110 0.110 TOTAL 1.495 - - 100
0 3.75 0 - -610 -910 OUT
- 6.00 - - 9.07 17.51 Stack 1.470 265 0.250 97
- 4.20 - - 2.80 3.00 To PA Fan 0.025 265 0.250 2
21.0 21.0 21.0 21.0 5.7 3.4 Radiations - - - 1
0.0 0.0 0.0 0.0 24.9 34.6 TOTAL 1.495 - - 100
79.0 79.0 79.0 79.0 69.4 62.0
1.22 0.69 1.22 0.69 0.60 0.59 ESP False Air Optimisation 7.24
1.69 0.95 1.69 0.95 0.83 0.81
1.07 0.61 1.07 0.61 0.53 0.51 Error1 0.0000
0.69 0.39 0.69 0.39 0.34 0.33 Error2 0.0000
25.62 14.48 25.62 14.48 3.43 1.99
0.00 0.00 0.00 0.00 20.73 28.02
84.79 47.93 84.79 47.93 36.74 31.92
1.32 1.77 1.32 1.77 6.70 6.81
22.93 22.57 22.93 22.57 5.07 2.89
0.00 0.00 0.00 0.00 30.67 40.76
75.88 74.68 75.88 74.68 54.35 46.44
1.19 2.75 1.19 2.75 9.91 9.91
1.29 1.29 1.29 1.29 1.45 1.51
1.28 1.27 1.28 1.27 1.34 1.39
1.10 0.62 1.10 0.62 0.61 0.62
1.10 0.61 1.10 0.61 0.56 0.57
- S2 - - S2 S2
- 12.1 - - 15.5 21.4
- 13.85 - - 6.16 7.07
- 369.65 26.76 6.31 193.68 310.38
- 290.64 20.84 4.96 144.53 223.20
- 602.18 24.41 10.27 343.14 544.89
- 10.2 0.3 0.2 19.2 30.8
- 359.48 26.44 6.13 174.49 279.62
- 277.99 20.45 4.74 120.66 184.94
- 575.96 23.95 9.83 286.47 451.49
0.242 0.250 0.242 0.250 0.263 0.262
- 24450 200 417 15549 24526
- - - - 12.98 20.81
- - - - 0.234 0.233
- - - - 925 1466
- 24450 200 417 16474 25992

31.0
0.0296
-40
21.00
0.00
79.00
1.215
1.681
1.069
0.684
25.52
0.00
84.44
3.25
22.54
0.00
74.59
2.87
1.293
1.271
1.100
1.081
0.245
0.178

Page - 4/29
Kiln Heat & Mass Balance : SLC 6-Stage II-String
S. Constriants Amount Temp. Cp Heat
No. kg/hr Nm3/hr deg.C kcal/kg/ oC kcal/hr kcal/kg-Clk
INPUT
1 Combustion of Coal - - - - 172787463 687.0
2 Cooling Air, Cooler 607797 475107 35 0.243 5167950 20.5
3 Fuel (Kiln+Cal.) 29207 - 73 0.262 559117 2.2
4 False Air (KS+CS+Cooler) 33423 22885 31 0.242 250376 1.0
5 Primary Air 6307 4938 87 0.244 134126 0.5
6 Kiln Feed, dry 415773 - 82 0.214 7298375 29.0
7 Combustibles in Kiln Feed - - - - 6442978 25.6
8 Free Water in Kiln Feed 917 - 82 1.000 75171 0.3
9 Water Injection, Cooler 5000 - 25 1.000 124999 0.5
10 Coal Transport Air (Kiln+Cal.) 12994 10172 73 0.244 231628 0.9
TOTAL INPUT 1111418 193072182 767.6
OUTPUT
1 Preheater Exit Gases 504065 364436 304 0.262 40074502 159.3
2 Dust with PH Exit Gases 33794 - 304 0.233 2394225 9.5
3 Cooler Vent Air 349198 274761 285 0.250 24911420 99.0
4 Dust with Cooer Vent Air 5095 - 285 0.205 298061 1.2
5 Cold Clinker 246420 - 140 0.192 6610674 26.3
6 Total Radiations - - - - 11873278 47.2
a Kiln String - - - - 2618130 10.4
b Calciner String - - - - 3212876 12.8
c Kiln - - - - 4437254 17.6
d T.A. Duct - - - - 995312 4.0
e Cooler + Hood - - - - 609706 2.4
7 Heat of Reaction excl. Comb. - - - - 103329439 410.8
8 Evap. of Water, Kiln Feed 917 - - - 510611 2.0
9 Evap. of Water, Cooler Inj. 5000 - - - 3069969 12.2
10 Balance/Losses - - - - 2 0.00
TOTAL OUTPUT 1144488 193072182 767.6
Ref. Temp. - 0 deg.C
Mass Error = -2.89 %

Heat Cap - Coeffici
Gas/Mat *T^0 *T^1
0.2485 -3.340E-06
0.1244 0.000E+00
O2 0.2130 7.796E-05
CO2 0.1906 1.771E-04
N2+Ar 0.2465 -3.284E-06
H2O,steam 0.4445 2.910E-05
H2O, liq. 1.0000
Rawmeal 0.2060 1.014E-04
Coal 15.00-19.99% 0.237 3.525E-04
Clinker 0.1742 1.414E-04
Coal < 14.99% 0.228 3.400E-04
Coal 15.00-19.99% 0.237 3.525E-04
Coal 20.00-24.99% 0.245 3.650E-04
Coal 25.00-29.99% 0.254 3.775E-04
Coal >= 30% 0.262 3.900E-04
A 23.5771
B -4042.90
C -37.58
Rho H2O-Steam, kg/Nm3 0.804

*T^2 *T^3 *T^4
4.440E-08 -2.797E-11 5.597E-15 Not used in calc.
0.000E+00 0.000E+00 0.000E+00 Not used in calc.
-7.563E-08 4.074E-11 -8.183E-15
-1.733E-07 9.315E-11 -1.894E-14
4.366E-08 -2.750E-11 5.504E-15
6.887E-08 -3.726E-11 6.472E-15
-3.673E-08
0.000E+00
-1.283E-07 5.074E-11
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
Sp. Gravity, dry - O2 kg/Nm3 1.429
Sp. Gravity, dry - CO2 kg/Nm3 1.977
Sp. Gravity, dry - N2 kg/Nm3 1.257
Sp. Gravity - H2O kg/Nm3 0.804

Page - 5/29
Cooler Performance & Efficiency : SLC 6-Stage II-String
S. Constriants Mass Temp. Cp Heat

No. kg/kg-Clk deg.C kcal/kg/ oC kcal/hr kcal/kg-Clk
INPUT
1 Clinker to Cooler 1.000 1450 0.264 96340716 383.0
2 Dust to Cooler 0.020 1450 0.264 1926814 7.7
3 Cooling Air 2.417 35 0.243 5167950 20.5
4 False Air, In 0.004 31 0.242 7714 0.0
5 Water Injection 0.020 25 1.000 124999 0.5
6 Power Consumption - - - 1142273 4.5
TOTAL INPUT 3.461 416.3
OUTPUT
1 Secondary Air from Cooler 0.398 1109 0.266 29566604 117.6
2 Dust in Secondary Air 0.008 1109 0.242 513824 2.0
3 Tertiaruy Air from Cooler 0.650 905 0.262 38695835 153.9
4 Dust in Tertiary Air 0.012 905 0.235 662429 2.6
5 Evaporation of Injected Wate - - - 3069969 12.2
6 Cooler Vent/Excess Air 1.388 285 0.250 24911420 99.0
7 Dust in Vent/Excess Air 0.020 285 0.205 298061 1.2
8 Clinker from Cooler 0.980 140 0.192 6610674 26.3
9 Cooler Radiation - - - 381650 1.5
TOTAL OUTPUT 3.456 416.3
1a Cooler Vent/Excess Air, Amb 1.388 31 0.245 2653513 10.6
2a Dust in Vent/Excess Air, Amb 0.020 31 0.178 28189 0.1
3a Clinker from Cooler, Amb.Tm 0.980 31 0.178 1363271 5.4
1s Cooler Vent/Excess Air, Std. 1.286 285 0.250 23076812 91.8
2s Cooler Vent/Excess Air, Std. 1.286 31 0.245 2458094 9.8
1 Total Cooler Loss, Ref. - 0oC kcal/kg-Clk 140
2 Total Cooler Loss, Ref. - Amb. Temp. kcal/kg-Clk 112
3 Standard Cooler Loss kcal/kg-Clk 105
4 Cooler Efficiency, Ref. - 0oC % 66.31
5 Cooler Efficiency, Ref. - Amb. Temp. % 73.11
VDZ Efficiency
S. Constriants Mass Temp. Cp Heat
No. kg/kg-Clk deg.C kcal/kg/ oC kcal/hr kcal/kg-Clk
1 Clinker from Kiln 1.000 1450 0.264 96340716 383
2 Clinker at Amb. Temperature 1.000 31 0.178 -1391460 -6
3 Clinker from Cooler 1.000 140 0.192 -6747366 -27
4 Power to Cooler Fans - - - 1142273 5
5 Excess Air, Out 1.388 285 0.250 -24911420 -99
6 Excess Air, In 0.011 31 0.242 21291 0
7 Surface Losses - - - -381650 -2
8 Heat Absorption by Comb. Air - - - 65463843 260
9 Max. Heat Release from Clink - - - 94949256 378
COOLER EFFICIENCY, % 68.95

Heat Error 0.00
08/15/2019 07:43:36 433316615.xls Cool-EffS LU000211-KCP#Ver.2.2***

Mass Error 0.00

117.55 117.55
2.04 2.04
153.85 153.85
2.63 2.63
276.08 276.08
0.00

Page - 6/29
Fuel Combustion Calculations : SLC 6-Stage II-String
Ultimate Analysis (ADB) Air Requirement
Carbon (C) % 65.06 Clinker Production tpd 6036

Hydrogen (H) % 3.26 Clinker Production kg/hr 251515
Nitrogen (N) % 1.49 Unburnt Coal Consumption kg/hr 2500
Sulphur (S) % 0.52 Total Coal Consumption (ADB) kg/hr 29207

Oxygen (O) % 7.72 Coal Consumption (ADB) % 11.61
Ash Content % 19.90 Sp. Heat Consumption kcal/kg-Clk 687

Moisture (IM) % 2.05 Total O2 Requirement kg/hr 58452
HMB Error - 0.000007 O2 in Coal kg/hr 2256

Net O2 Requirement kg/hr 56196
Proximate Analysis (ADB) Description Kiln Cal. Total
Fixed Carbon (FC) % 55.09 Feed Ratio, % 38.00 62.00 100.00

Volatile Matter (VM) % 22.97 Coal Consump., kg-Coal/kg-Clk 0.0441 0.0720 0.1161
Ash Content % 19.90 Sp. Heat Consump., kcal/kg-Clk 261 426 687
Inher. Moisture (IM) % 2.05 Lmin., kg/hr 92846 151486 244332

Calorific Value Lmin., kg/kg-Coal 3.179 5.187 8.365
GCV (calc.) kcal/kg-Coal 6100 L, kg/hr 112766 166783 279549

NCV kcal/kg-Coal 5916 L, kg/kg-Coal 3.861 5.710 9.571
UHV kcal/kg-Coal 5872 Sp. Air Consp., kg/kg-Clk 0.422 0.689 1.111
UHV (manual) kcal/kg-Coal 6089 Ash Absorption, % - - 2.310
Value in calculations kcal/kg-Coal 5916
Combustion of Coal :
Component Wt. Fraction Fuel O2 CO2 H2O SO2
kg/hr kg/hr kg/hr kg/hr kg/hr
C 0.6506 19002 50672 69674 - -

H 0.0326 953 7628 - 8581 -
N 0.0149 435 - - - -
S 0.0052 153 153 - - 305

O 0.0772 2256 - - - -
Ash 0.1990 5811 - - - -

H2O 0.0205 598 - - 598 -
Raw Mix - - - 131145 4937 -
Total 1.0000 29207 58452 200819 14116 305
PH Outlet CO2 Calculations (DB) :
Description Deg. of Calcination Feed CO2 CO2
/ Carbon in Coal Rate KS CS KS CS

% / wt.% tph tph tph kNm /hr 3
kNm3/hr
KF > KS (Deg. of Cal. - K6 Cyc.) 58.29 145.50 29.05 - 14.79 -

KF > CS (Deg. of Cal. - C6 Cyc.) 91.70 237.40 - 74.56 - 37.96
K6 Feed > Calciner 33.41 145.50 - 16.65 - 8.48
C6 Feed > Kiln 8.30 382.90 10.88 - 5.54 -

Coal Firing in Kiln 65.06 11.10 26.48 - 13.48 -
Coal Firing in Calciner 65.06 18.11 - 43.20 - 21.99

66.41 134.41 33.81 68.43
TOTAL - -
200.82 102.24
2
Page - 7/29
Coal Combustion Calculations : SLC 6-Stage II-String
Kiln Combustion Gases with Stoichiometric Air :

Comp. Mass Flow Rate Vol. Flow Rate Mass% Vol.%
S
t KS CS PH KS CS PH KS CS PH KS CS PH
d
kg/hr kg/hr kg/hr Nm3/hr Nm3/hr Nm3/hr m, % m, % m, % vol., % vol., % vol., %
CO2 37358 134413 200819 19019 68428 102235 34.23 53.44 51.53 24.90 42.23 40.38
H2O 0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00
D SO3 116 189 305 41 66 107 0.11 0.08 0.08 0.05 0.04 0.04
R
Y N2 71657 116913 188570 57325 93531 150856 65.66 46.48 48.39 75.05 57.73 59.58
O2 0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00
Total 109130 251515 389694 76384 162025 253198 100.00 100.00 100.00 100.00 100.00 100.00
CO2 37358 134413 200819 19019 68428 102235 32.31 51.29 49.37 22.52 39.06 37.26
H2O 6478 10570 17048 8062 13154 21216 5.60 4.03 4.19 9.55 7.51 7.73
W SO3 116 189 305 41 66 107 0.10 0.07 0.08 0.05 0.04 0.04
E
T N2 71657 116913 188570 57325 93531 150856 61.98 44.61 46.36 67.88 53.39 54.97
O2 0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00
Total 115609 262085 406742 84446 175179 274414 100.00 100.00 100.00 100.00 100.00 100.00
Kiln Combustion Gases incl. Excess Air :

S
d
CO2 37358 134413 200819 19019 68428 102235 28.95 50.38 47.26 20.70 39.35 36.44
H2O 0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00
D SO3 116 189 305 41 66 107 0.09 0.07 0.07 0.04 0.04 0.04
R
Y N2 86995 128693 215687 69596 102954 172550 67.41 48.23 50.76 75.76 59.20 61.50
O2 4582 3518 8100 3207 2463 5670 3.55 1.32 1.91 3.49 1.42 2.02
Total 129050 266813 424911 91862 173911 280562 100.00 100.00 100.00 100.00 100.00 100.00
CO2 37358 134413 200819 19019 68428 102235 27.52 48.43 45.39 18.98 36.54 33.82
H2O 6717 10754 17471 8359 13382 21742 4.95 3.87 3.95 8.34 7.15 7.19
W SO3 116 189 305 41 66 107 0.09 0.07 0.07 0.04 0.04 0.04
E
T N2 86995 128693 215687 69596 102954 172550 64.08 46.36 48.76 69.44 54.97 57.08
O2 4582 3518 8100 3207 2463 5670 3.37 1.27 1.83 3.20 1.31 1.88
Total 135767 277566 442382 100221 187294 302303 100.00 100.00 100.00 100.00 100.00 100.00
PH Outlet Gas Composition incl. False Air :

S
d
CO2 66406 134413 200819 33807 68428 102235 38.67 46.47 42.98 28.84 35.76 32.62
H2O 0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00
D SO3 116 189 305 41 66 107 0.07 0.07 0.07 0.03 0.03 0.03
R
Y N2 97446 145903 248114 77957 116723 198491 56.75 50.44 53.11 66.50 61.00 63.34
O2 7757 8747 17951 5430 6123 12566 4.52 3.02 3.84 5.30 3.20 4.01
Total 171725 289252 467189 117234 191340 313399 100.00 100.00 100.00 100.67 100.00 100.00
CO2 66406 134413 200819 33807 68428 102235 37.11 44.76 41.39 26.78 33.37 30.45
H2O 7230 11023 17978 8997 13717 22373 4.04 3.67 3.71 7.13 6.69 6.66
W SO3 116 189 305 41 66 107 0.06 0.06 0.06 0.03 0.03 0.03
E
T N2 97446 145903 248114 77957 116723 198491 54.45 48.59 51.14 61.76 56.92 59.11
O2 7757 8747 17951 5430 6123 12566 4.33 2.91 3.70 4.30 2.99 3.74
Total 178954 300275 485167 126231 205057 335772 100.00 100.00 100.00 100.00 100.00 100.00

FUEL : South African Coal False air a/c KS w.r.t. gas, dry vol.% 11.52
False air a/c CS w.r.t. gas, dry vol.% 10.02
False air a/c PH w.r.t. gas, dry vol.% 11.70
w.r.t. mix 10.33
w.r.t. mix 9.11
w.r.t. mix 10.48
Page - 29/29
Unburnt Coal Combustion Calculations : SLC 6-Stage II-String
Ultimate Analysis (ADB) Fuel-1 Fuel-2 Resultant Fuel
Carbon (C) % 69.28 20.00 65.06
Hydrogen (H) % 3.57 0.00 3.26
Nitrogen (N) % 1.63 0.00 1.49
Sulphur (S) % 0.57 0.00 0.52
Oxygen (O) % 5.82 28.00 7.72
Ash Content % 16.89 52.00 19.90
Moisture (IM) % 2.24 0.00 2.05
Total % 100.00 100.00 100.00
Proximate Analysis (ADB) Fuel-1 Fuel-2 Resultant Fuel
Fixed Carbon (FC) % 56.69 38.00 55.09
Volatile Matter (VM) % 24.18 10.00 22.97
Ash Content % 16.89 52.00 19.90
Inher. Moisture (IM) % 2.24 0.00 2.05
Total % 100.00 100.00 100.00
Calorific Value Fuel-1 Fuel-2 Resultant Fuel
GCV (calc.) kcal/kg-Coal 6613 611 6100
NCV kcal/kg-Coal 6412 611 5916
UHV kcal/kg-Coal 6260 1724 5872
UHV (manual) kcal/kg-Coal 6500 1700 6089
Fuel consumption kg/hr 26707 2500 29207
Fuel ratio % 91.4 8.6 100.0

Page - 8/29
Preheater Draft & Temperature Measurements : SLC 6-Stage II-String
-575 mmWG DP=85 -864 mmWG DP=139

306 deg.C DT=9.30000000000001 302 deg.C DT=19.8
K-1 C-1
DP=105 -490 mmWG DP=120 -725 mmWG

DT=139 315 deg.C DT=115 322 deg.C
K-2 C-2
-385 mmWG DP=81 -605 mmWG DP=125

454 deg.C DT=116 437 deg.C DT=147
K-3 C-3
DP=84 -304 mmWG DP=120 -480 mmWG

DT=90 570 deg.C DT=137 584 deg.C
K-4 C-4
-220 mmWG DP=80 -360 mmWG DP=126

660 deg.C DT=66 721 deg.C DT=90
K-5 C-5
DP=74 -140 mmWG DP=189 -234 mmWG

DT=81 726 deg.C DT=69 811 deg.C
K-6 C-6/Cal.
Kiln I/L Draft -66 mmWG Cal. I/L Draft -45 mmWG
Kiln I/L Temp. 807 deg.C Cal. I/L Temp. 880 deg.C

Page - 9/29
Velocity Profiles : SLC 6-Stage II-String
S Location Dimensions Ref. Eff. Gas Characteristics
No. Height Dim-1 Dim-2 Thick. Area Vol. Velo. Ret.
/ Dia. Flow, w Time
mts mm mm mm m2 km3/hr m/sec sec
1 K-1 Cyclone - 5400 - 115 5.085 336.90 18.40 -
2 K-2 Cyclone - 5400 - 179 6.212 0.00 -
3 K-3 Cyclone - 5700 - 214 6.791 0.00 -
4 K-4 Cyclone - 5700 - 214 6.791 0.00 -
5 K-5 Cyclone - 5700 - 214 6.791 0.00 -
6 K-6 Cyclone - 5700 - 214 6.791 0.00 -
7 Kiln Riser Duct 17.5 3100 3100 214 7.14 410.40 15.97 1.10
8 Smoke Chamber - 4550 3100 214 11.01 410.40 10.35 -
9 Kiln (inlet) 68.0 4550 - 200 13.53 406.33 8.34 8.15
10 C-1 Cyclone - 6300 - 115 7.009 539.90 21.40 -
11 C-2 Cyclone - 6300 - 179 8.627 0.00 -
12 C-3 Cyclone - 6600 - 214 9.308 0.00 -
13 C-4 Cyclone - 6600 - 214 9.308 0.00 -
14 C-5 Cyclone - 6600 - 214 9.308 0.00 -
15 C-6 Cyclone - 6600 - 214 9.308 0.00 -
16 Calciner 26.5 6300 - 214 27.08 814.30 8.35 3.17
17 T.A. Duct 70.0 3000 - 214 5.20 581.87 31.11 2.25
18 Kiln Hood (throat) - 5500 5480 300/214 24.75 862.93 9.68 -
08/15/2019 07:43:36 433316615.xls Vel-Prof LU001007-KCP#Ver.1.1***

Page - 10/29
Heat of Reaction : Chemical Data
RAW MIX
Chemical Analysis Unit Value Mineralogical Composition Unit Value
SiO2 % 13.02 Kaolinit % 0.00
Al2O3 % 3.80 Montmorillonit % 0.00
Fe2O3 % 2.30 Illit % 100.00
CaO % 43.10 Water of crystallisation % 1.05
MgO % 1.43 Carbon 1)
% 0.20
SO3 % 0.20 Calculated Values :
Loss on ignition (LOI) % 35.83 CaCO3 % 75.70
TOTAL % 99.68 MgCO3 % 1.80
CO2 % 34.23 Sulphur in pyrites % 0.04
K2O % 0.38 CaSO4 % 0.34
Na2O % 0.27 Silica-combined CaO % 0.71
Sulphur, total % 0.22
FUEL : South African Coal
Fuel percent in clinker % 11.61 Ash Analysis Unit Value
Sulphur, total % 0.58 SiO2 % 47.66
Ash percent in coal % 19.90 Al2O3 % 27.92
Net calorific value kJ/kg 24722 Fe2O3 % 5.34
kcal/kg 5916 CaO % 8.76
MgO % 1.65
Heat consumption, Sulphur 2)
% 2.00
kJ per kg clinker kJ/kg 2871 K2O 2)
% 0.47
kcal per kg clinker kcal/kg 687 Na2O 2)
% 0.16
RAW MIX ADJUSTMENT
Constituents Unit Raw Mix Adjustment Adjusted
Analysis from Fuel Raw Mix Analysis
SiO2 % 13.02 0.73 13.75
Al2O3 % 3.80 0.43 4.23
Fe2O3 % 2.30 0.08 2.38
CaO % 43.10 0.13 43.23
MgO % 1.43 0.03 1.46
SO3 (total) % 0.30 0.08 0.38
K2O % 0.38 0.01 0.39
Na2O % 0.27 0.00 0.27
TOTAL % 64.60 1.53 66.13
SULPHUR BALANCE AND RAW MIX/CLINKER RATIO
Adjusted raw mix, total % T: 66.13
Volatalised : U = 50% of sulphur in pyrites as SO3 % U: 0.05
SO3 in clinker (calculated) 0.49
Raw mix / clinker ratio (loss of dust = 0 %) : F = 100 / (T - U) % F: 1.513
1) Carbon as CO2 is not included.

2) Calculated from analysis of solid fuel.
08/15/2019 07:43:36 433316615.xls Heat-Rxn LU000303-RMD#Ver.1.3***

Page - 11/29
Heat of Reaction : Calculations
Conv. Calc. Contributions
CALCULATIONS
Factor Raw Mix Clinker
Contributions to Heat of Reaction kJ/kg/% kJ/kg kJ/kg
A : DECOMPOSITION INTO OXIDES
Raw Mix
CaCO3 75.70 -17.78 -1345.95 -2036.91
MgCO3 1.80 -15.10 -27.18 -41.13
Water of crystallisation 1.05 -42.70 -44.84 -67.85
Silica-combined CaO 0.71 -17.00 -12.04 -18.21
Alkali silicates :
(K2O + Na2O)rawmix 0.65 -14.80 -9.62 -14.56
Heat of Decomposition : -1439.62 -2178.67
B: HEAT OF FORMATION
Property Component Adj. Raw Mix
C3S CaO 43.23 -0.46 -19.89 -30.10
C2S SiO2 13.75 21.43 294.62 445.87
C3A Al2O3 4.23 1.21 5.11 7.74
C4AF Fe2O3 2.38 2.46 5.86 8.87
SO3 in clinker from fuel and pyrites 0.33 59.60 19.45 29.44
Heat of Formation : 305.16 461.82
C : HEAT OF COMBUSTION
Carbon 0.20 327.86 65.57 99.23
Sulphur in pyrites 0.04 129.14 5.17 7.82
Heat of Combustion : 70.74 107.05
A+B+C: HEAT OF REACTION (kJ/kg clinker) -1610

HEAT OF REACTION (kcal/kg clinker) -385.21
A+B: HEAT OF REACTION excl. HEAT OF COMBUSTION (kJ/kg clinker) -1717

HEAT OF REACTION excl. HEAT OF COMBUSTION (kcal/kg clinker) -410.83

-410.83

Page - 12/29
Mechanism of Volatile Matters in Kiln
LOI in kiln feed, % 35.83 Raw mix to clinker (calc.) 1.484
BH/ESP dust, kg/kg-clk 0.134 Kiln feed to clinker (calc.) 1.618
LOI in BH/ESP dust, % 35.30 M S/A input to system 1.71
LOI in K6 stage mat., % 14.95 M S/A C6 stage mat. 4.50
LOI in C6 stage mat., % 2.97 M S/A clinker 0.66
Fuel consumption, % 11.61 Excess SO3 in I/P, g/100 kg-clk 684
Ash content in fuel, % 19.90
Analysis K2O Na2O Cl SO3 Cl-free

K2O
Kiln Feed, % 0.380 0.270 0.005 0.200 0.373
Total input on clinker (LFKF), % 0.683 0.444 0.018 1.480 0.659
BH/ESP Dust, % 0.381 0.271 0.005 0.201 0.374
Lowest Stage, % 1.640 0.320 0.660 3.850 0.764
Clinker, % 0.550 0.450 0.007 0.500 0.541

Kiln Fuel (SO3 as Sulphur), % 0.470 0.160 0.044 2.000 0.412
Evaporation factor, E 0.69 -0.29 0.990 0.88 0.35
Circulation factor, K 2.65 0.80 40.730 2.87 1.28
Residual in clinker, R 0.82 1.03 0.397 0.34 0.83
Preheater valve, Vc 0.10 0.15 0.015 0.22 0.32
BH/ESP valve, Vf 1.00 0.99 0.998 1.00 1.00
Combined valve, Vx 0.10 0.12 0.015 0.26 0.37
Concept of Volatile Matter
e
d
E V
b
c a
K
Burning Zone Back End

R
Legends
Evaporation Factor, E = d/b = (b-c)/b Residual Component, R = c/a
Circulation Factor, K = b/a Valve, V = e/d = (a-c)/(b-c)
08/15/2019 07:43:36 433316615.xls Alkali LU010408-KCP#Ver.1.0**

K2O Na2O Cl SO3 LOI
Kiln Feed, % 0.500 0.180 0.012 0.120 35.540
BH/ESP Dust, % 0.530 0.140 0.013 0.130 36.220
Lowest Stage, K6, % 1.400 0.210 0.015 0.930 17.760
Lowest Stage, C6, % 1.520 0.410 0.059 0.880 3.060
Clinker, % 0.710 0.210 0.019 0.043 0.230
Kiln Fuel (SO3 as Sulphur), % 0.570 0.120 0.005 1.780 -
UBC (SO3 as Sulphur), % 0.420 1.720 0.026 4.670 -

ASW 0.046 GVFW 0.086 GVCW 0.985
GVKA(1) 0.600 GVKA(2) 0.426 GVKA(3) 0.008
GVFA(1) 0.597 GVFA(2) 0.424 GVFA(3) 0.008
GVMA(1) 1.811 GVMA(2) 0.353 GVMA(3) 0.729
GVCA(1) 0.558 GVCA(2) 0.457 GVCA(3) 0.007
ALK(1) 0.055 ALK(2) 0.019 ALK(3) 0.005
ALC(1) 0.055 ALC(2) 0.019 ALC(3) 0.005
GVRA(1) 0.600 GVRA(2) 0.427 GVRA(3) 0.008
RA(1) 0.380 RA(2) 0.270 RA(3) 0.005
GVSRW 0.985 GVRW 0.939 GVFW 0.086

Calciner (SO3 as Sulphur), % 0.47 0.16 0.044
Kiln feed, % 0.38 0.27 0.005

ALK(4) 0.590 ALC(4) 0.590
GVKA(4) 0.316 GVKA(5) 0.590
GVFA(4) 0.315 GVFA(5) 0.586
GVMA(4) 4.251 GVMA(5) 0.844
GVCA(4) 0.508 GVCA(5) 0.549
ALK(4) 0.236 ALK(5) 0.049
ALC(4) 0.236 ALC(5) 0.049
GVRA(4) 0.316 GVRA(5) 0.590
RA(4) 0.200 RA(5) 0.373
GVKW 1.025 VP 11.61
2.00 0.41 VAS 19.90
0.20 0.37

Page - 15/29
Water Spray System

S. Description Kiln Calciner
No. String String
A Inlet Gas Conditions
1 Volume flow of gas, wet m3/hr 336905 539902
2 Mass flow of gas, wet kg/hr 193683 310382
3 Gas temperature deg.C 305.7 302.2
4 Gas density, wet kg/m3 0.575 0.575
5 Heat capacity of gas kcal/kg/C 0.263 0.261
6 Heat content in gas (calc.) kcal/hr 15547937 24527222
7 Heat content in gas (diff.) kcal/hr 15547937 24527222
8 Error kcal/hr 0.000 0.000
B Water Injection
1 Volume flow of water m3/hr 0.00 0.00
2 Mass flow of water kg/hr -2.51 1.49
3 Water pressure Bar 14.1 15.8
4 Water temperature deg.C 25 25
5 Heat capacity of water kcal/kg/C 1 1
6 Heat content in water kcal/hr -63 37
7 Evaporation of water kcal/hr -1353 802
C Compressed Air Injection
1 Volume flow of air m3/hr 0.0 0.0
2 Mass flow of air kg/hr 0 0
3 Air pressure Bar 7.1 7.1
4 Air temperature deg.C 60 60
5 Air density kg/m3 8.434 8.434
6 Heat capacity of air kcal/kg/C 0.242 0.242
7 Heat content in air kcal/hr 0 0
D Outlet Gas Conditions
1 Volume flow of gas, wet m3/hr 343144 544887
2 Mass flow of gas, wet kg/hr 193680 310384
3 Gas temperature deg.C 305.0 302.0
4 Gas density, wet kg/m3 0.564 0.570
5 Heat capacity of gas kcal/kg/C 0.263 0.262
6 Heat content in gas kcal/hr 15549227 24526458
E Water Balance
1 Water In, gas kg/hr 19196 30757
2 Water In, spray kg/hr -3 1
3 Water In, total kg/hr 19194 30759
4 Water Out, gas kg/hr 19194 30759
5 Water Vapor, PH Exit kg/kg-dg 0.1100 0.1100
6 Error kg/hr 0.000 0.000
08/15/2019 07:43:36 433316615.xls H2O-SprS LU010522-KCP#Ver.2.3***
Page - 16/29
Cooler Air Flow Calculations : SLC 6-Stage II-String
Flow Analysis COOLER FANS
FN1 FN2 FN3 FN4 FN5 FN6 FN7 FN8 FN9 FNA FNB FNC FNH Total
Dry Bulb Temp. deg.C 35.0 35.0 35.0 35.0 35.0 35.0 35.0 35.0 35.0 35.0 35.0 35.0 35.0 35.0
Wet Bulb Temp. deg.C 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0
Dew Point (F4) deg.C 22.0 22.0 22.0 22.0 22.0 22.0 22.0 22.0 22.0 22.0 22.0 22.0 22.0 22.0
Dew Point, calc. deg.C 22.7 22.7 22.7 22.7 22.7 22.7 22.7 22.7 22.7 22.7 22.7 22.7 22.7 22.7
Water Vapor kg/kg-dg 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181
Avg. Ps mmWG 660 685 866 827 795 788 645 625 640 655 570 515 565 651
Moisture, by diff. tph 0.49 0.51 0.48 0.46 0.66 0.73 1.60 0.76 0.57 1.09 1.32 1.53 0.61 10.81
Gas Flow Rate, dry tph 27.1 28.0 26.4 25.3 36.5 40.5 88.4 42.0 31.6 60.0 73.1 84.5 33.7 597.0
Gas Flow Rate, dry kg/min 451 466 440 422 609 675 1474 700 527 1000 1218 1408 561 9950
Gas Flow Rate, dry kNm /hr3

20.9 21.6 20.4 19.6 28.2 31.3 68.4 32.5 24.5 46.4 56.5 65.3 26.0 461.7
Gas Flow Rate, dry km /hr

3
23.3 24.0 22.7 21.8 31.4 34.8 76.0 36.1 27.2 51.6 62.8 72.6 29.0 513.3
Gas Flow Rate, dry m3/min 388 401 378 363 524 580 1267 602 453 860 1047 1211 483 8556
Sp. Heat, gas kcal/kg/C 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243 0.243
Heat Content, gas Mcal/hr 234 242 228 219 316 350 766 363 274 519 632 731 291 5168
Fan Speed rpm 2765 2757 1341 1342 1371 1365 1412 - - 1475 1488 1475 1489 -
Fan Load kW 70 69 89 84 104 107 188 90 75 120 144 122 68 1328
Fan Load amps 108 106 138 130 160 165 291 139 116 185 222 188 105 2053
Fan Damper % 100 100 100 100 100 100 100 100 100 100 100 100 100 -
Sp. Air Consmp. kg/kg-Clk 0.110 0.113 0.107 0.102 0.148 0.164 0.358 0.170 0.128 0.243 0.296 0.342 0.136 2.417
Sp. Air Consmp. Nm3/kg-Clk 0.086 0.088 0.084 0.080 0.116 0.128 0.280 0.133 0.100 0.190 0.231 0.267 0.107 1.889
Sp. Air Consmp. m /kg-Clk

3
0.095 0.098 0.093 0.089 0.129 0.142 0.311 0.148 0.111 0.211 0.257 0.297 0.118 2.100
374 374 631 631 946 946 1439 507 507 1014 1014 1099 500 9982
399 412 389 373 539 597 1304 619 467 885 1078 1246 497 8804.61
Gas/Mat *T^0 *T^1 *T^2 *T^3 *T^4
0.2485 -3.340E-06 4.440E-08 -2.797E-11 5.597E-15 Not used in calc.
0.1244 0.000E+00 0.000E+00 0.000E+00 0.000E+00 Not used in calc.
O2 0.2130 7.796E-05 -7.563E-08 4.074E-11 -8.183E-15
CO2 0.1906 1.771E-04 -1.733E-07 9.315E-11 -1.894E-14
N2+Ar 0.2465 -3.284E-06 4.366E-08 -2.750E-11 5.504E-15
H2O,steam 0.4445 2.910E-05 6.887E-08 -3.726E-11 6.472E-15
H2O, liq. 1.0000
Cooler Fans Flow : SLC 6-Stage II-String(with transmeter pezo pressure)
Kiln Output = 6035 tpd Sp. Air Consp. = 1.87 Nm3/kg-Clk Plant Elevation = 402.00 mts +MSL
Ambient Air = 36.0 deg.C Air Density = 1.086 kg/m3 Barometric Press. = 9827 mmWG
S. Fan I/L Dia I/L Area Fan kW Fan Speed (rpm) Damper FACTOR Ps Ps Flow (m3/min)
inlet outlet Fan Fan
No. 471 m m2 Rated Run amps Rated Run % mmwg mmwg Inlet Outlet
1 FN1 0.45 0.159 90 58 85 2900 2663 100 40.56 143.63 660.00 413 398
2 FN2 0.45 0.159 90 56 82 2900 2616 100 40.56 153.50 685.00 427 411
3 FN3 0.56 0.246 132 90 132 1450 1376 100 62.81 59.13 866.00 411 388
4 FN4 0.56 0.246 132 92 134 1450 1407 100 62.81 53.88 827.00 392 372
5 FN5 0.71 0.396 180 117 171 1480 1411 100 100.97 43.13 795.00 564 537
6 FN6 0.71 0.396 190 117 172 1480 1394 100 100.97 52.88 788.00 624 595
7 FN7 0.90 0.636 225 202 296 1485 1492 100 162.24 98.13 645.00 1366 1319
8 FN8 0.56 0.246 90 - - 1485 - 95 62.81 142.50 625.00 637 617
9 FN9 0.56 0.246 90 0 1485 80 62.81 81.25 640.00 481 465
10 FNA 0.80 0.503 160 138 202 1485 1481 100 128.19 70.38 655.00 914 882
11 FNB 0.80 0.503 160 145 212 1485 1476 100 128.19 102.75 570.00 1104 1074
12 FNC 0.90 0.636 132 - - 1485 - 100 162.24 84.88 515.00 1270 1242
13 FNH 0.56 0.246 90 76 112 1470 1496 - 62.81 187.63 565.00 731 712
- - - - - - - - 9335 9012
PLANT : Binani Cement, Sirohi (Rajasthan)

Measured on : 20.02.2003 (10:30-11:30 hrs)
a) Kiln feed 415 tph b) Coal - Kiln/Cal. 521/525 rpm c) Gr. load - I/II/III 55/60/52 amps
d) DG - Kiln/Cal. 39.6/61.4 %/% e) Hood draft/ESP temp. -4/320 mmWG/deg.C f) Gr. DP-I/II/III 165/145/97mmWG
g)U.G.P.(CIS) 665 mm h) Fan outlet temp 45 deg.C I)U.G.P.(CFG) 760 mmWG
96 120 156 112

FN1 143.625
159 172 164 170
c:\work\prdn\excel\433316615.xls : ClrF-IL Prodn. Deptt. - Binani Cement Ltd.

146 147 144 137
FN2 153.5
158 178 160 158
54 52 68 64
FN3 59.125
55 51 71 58
66 53 62 68
FN4 53.875
49 47 43 43
43 47 55 50
FN5 43.125
43 37 33 37
66 64 61 49
FN6 52.875
55 43 42 43
107 122 122 124

FN7 98.125
80 80 76 74
139 158 179 152

FN8 142.5
124 138 130 120
90 100 101 99
FN9 81.25
67 66 65 62
73 89 107 75
FNA 70.375
54 53 60 52
118 101 130 135

FNB 102.75
82 91 80 85
100 105 106 107

FNC 84.875
63 69 66 63
244 246 205 247

FNH 187.625
149 139 134 137
c:\work\prdn\excel\433316615.xls : ClrF-IL Prodn. Deptt. - Binani Cement Ltd.

Page - 17/29
Kiln Radiations : SLC 6-Stage II-String
Amb. Air 31.0 deg.C Emissivity

Production 6036 tpd Kiln Inlet 0.85
Kiln Diameter 4.55 mts Rest Kiln 0.85
Total Radiation 4437254 * kcal/hr
Sp. Radiation 17.64 kcal/kg-clk Wind Vel., m/s 5.00
* Inclusive of restriction due to kiln tyres and girth gear 5.00 %
Kiln Surface Area Corr. Factor Corr. Area Temperature Radiation

mts m2 - m2 deg.C kcal/hr
0 14.3 1.00 14.3 200 48732
1 14.3 1.00 14.3 210 52653
2 14.3 1.00 14.3 183 42408
3 14.3 1.00 14.3 277 83349
4 14.3 1.00 14.3 220 56731
5 14.3 1.00 14.3 102 17214
6 14.3 1.00 14.3 232 61843
7 14.3 1.00 14.3 216 55081
8 14.3 1.00 14.3 230 60974
9 14.3 1.00 14.3 235 63160
10 14.3 1.00 14.3 239 64940
11 14.3 1.00 14.3 242 66294
12 14.3 1.00 14.3 227 59684
13 14.3 1.00 14.3 216 55081
14 14.3 1.00 14.3 215 54672
15 14.3 1.00 14.3 219 56316
16 14.3 1.00 14.3 222 57566
17 14.3 1.00 14.3 214 54265
18 14.3 1.00 14.3 190 44962
19 14.3 1.00 14.3 180 41335
20 14.3 1.00 14.3 177 40274
21 14.3 1.00 14.3 178 40626
22 14.3 1.00 14.3 201 49118
23 14.3 1.00 14.3 219 56316
24 14.3 1.00 14.3 212 53456
25 14.3 1.00 14.3 201 49118
26 14.3 1.00 14.3 195 46829
27 14.3 1.00 14.3 203 49892
28 14.3 1.00 14.3 251 70454
29 14.3 1.00 14.3 313 103567
30 14.3 1.00 14.3 319 107227
31 14.3 1.00 14.3 245 67664
32 14.3 1.00 14.3 346 124813
Page - 18/29
Kiln Radiations : SLC 6-Stage II-String

mts m 2
- m 2
deg.C kcal/hr
33 14.3 1.00 14.3 90 14045
34 14.3 1.00 14.3 336 118081
35 14.3 1.00 14.3 329 113523
36 14.3 1.00 14.3 332 115461
37 14.3 1.00 14.3 324 110344
38 14.3 1.00 14.3 317 105997
39 14.3 1.00 14.3 330 114167
40 14.3 1.00 14.3 328 112883
41 14.3 1.00 14.3 323 109716
42 14.3 1.00 14.3 321 108466
43 14.3 1.00 14.3 325 110975
44 14.3 1.00 14.3 319 107227
45 14.3 1.00 14.3 318 106611
46 14.3 1.00 14.3 304 98237
47 14.3 1.00 14.3 285 87594
48 14.3 1.00 14.3 113 20228
49 14.3 1.00 14.3 98 16144
50 14.3 1.00 14.3 128 24522
51 14.3 1.00 14.3 160 34483
52 14.3 1.00 14.3 165 36148
53 14.3 1.00 14.3 163 35478
54 14.3 1.00 14.3 129 24817
55 14.3 1.00 14.3 118 21635
56 14.3 1.00 14.3 240 65389
57 14.3 1.00 14.3 245 67664
58 14.3 1.00 14.3 256 72831
59 14.3 1.00 14.3 256 72831
60 14.3 1.00 14.3 85 12760
61 14.3 1.00 14.3 190 44962
62 14.3 1.00 14.3 177 40274
63 14.3 1.00 14.3 174 39224
64 14.3 1.00 14.3 184 42769
65 14.3 1.00 14.3 231 61408
66 14.3 1.00 14.3 249 69517
67 14.3 1.00 14.3 253 71399
68 14.3 1.00 14.3 256 72831
Total/Wt. Avg. 986.3 986.3 229 4437254
Page - 19/29
Kiln String Radiations : SLC 6-Stage II-String

Production 6036 tpd Preheater 0.75
Total Radiation 2618130 ** kcal/hr Riser Duct 0.75
Sp. Radiation 10.41 kcal/kg-clk
** Exclusive of amount as per FLS norms 5.00 %
KS Surface Area Corr. Factor Corr. Area Temperature Radiation

Cyclone-1 m2 - m2 deg.C kcal/hr
Roof 27.4 1.20 32.9 65.0 15536
Vertical Inlet 51.5 1.01 52.0 70.0 27622
Conical Inlet 25.0 1.00 25.0 67.0 12762
Cylindrical Part 122.6 1.00 122.6 56.0 38720
Conical Part 53.7 1.00 53.7 58.0 19331
Material Pipes 11.1 1.01 11.2 175.0 28619
Riser Cylindrical 97.6 1.01 98.6 75.0 57314
Riser Rest 79.1 1.01 79.9 65.0 35751
Total/Wt. Avg. 468.0 475.9 67.2 235656

Cyclone-2 m 2
- m2
deg.C kcal/hr
Roof 26.4 1.20 31.7 75.0 19714
Vertical Inlet 47.7 1.01 48.2 70.0 25703
Conical Inlet 29.7 1.00 29.7 66.0 14560
Conical Part 53.2 1.00 53.2 65.0 24402
Material Pipes 13.4 1.01 13.5 85.0 11055
Riser Rest 86.7 1.01 87.6 71.0 46301
Total/Wt. Avg. 369.3 376.6 71.7 209742

Cyclone-3 m 2
- m2
deg.C kcal/hr
Roof 29.4 1.20 35.3 90.0 29941
Vertical Inlet 52.9 1.01 53.4 90.0 44254
Conical Inlet 33.2 1.00 33.2 70.0 18121
Conical Part 59.2 1.00 59.2 60.0 22826
Material Pipes 11.3 1.01 11.4 70.0 6662
Riser Rest 96.9 1.01 97.9 90.0 78294
Total/Wt. Avg. 394.6 402.6 84.8 303471
Page - 20/29
Kiln String Radiations : SLC 6-Stage II-String
Cyclone-4 m 2
- m 2
deg.C kcal/hr
Roof 29.4 1.20 35.3 98.0 34441
Vertical Inlet 52.9 1.01 53.4 75.0 32213
Conical Inlet 33.2 1.00 33.2 70.0 18121
Conical Part 59.2 1.00 59.2 125.0 82517
Material Pipes 8.3 1.01 8.4 162.0 19313
Riser Rest 97.0 1.01 98.0 110.0 108700
Total/Wt. Avg. 384.2 392.1 97.6 375334

Cyclone-5 m 2
- m 2
deg.C kcal/hr
Roof 29.4 1.20 35.3 100.0 35585
Vertical Inlet 52.9 1.01 53.4 60.0 20732
Conical Inlet 33.2 1.00 33.2 75.0 20601
Conical Part 59.2 1.00 59.2 80.0 39825
Material Pipes 67.4 1.01 68.1 150.0 124992
Riser Rest 96.9 1.10 106.6 130.0 153133
Total/Wt. Avg. 464.4 481.8 99.9 479334

Cyclone-6 m 2
- m 2
deg.C kcal/hr
Roof 27.3 1.20 32.8 70.0 17896
Vertical Inlet 69.2 1.01 69.9 75.0 41469
Conical Inlet 33.2 1.01 33.5 115.0 42339
Conical Part 67.3 1.00 67.3 82.0 46920
Material Pipes 54.8 1.01 55.3 103.0 57059
Total/Wt. Avg. 315.0 322.0 89.4 265350

Riser Duct m 2
- m 2
deg.C kcal/hr
Rectangular Pipe 199.6 1.20 239.5 130.0 330299
Smoke Chamber 101.0 1.20 121.2 160.0 239268
Rest 183.0 1.15 210.5 96.0 179676
Total/Wt. Avg. 483.6 571.2 123.8 749243
Page - 21/29
Calciner String Radiations : SLC 6-Stage II-String
Production 6036 tpd Preheater 0.75
Total Radiation 3212876 ** kcal/hr Calciner 0.75
*
*** Exclusive of amount as per FLS norms 5.00 %
CS Surface Area Corr. Factor Corr. Area Temperature Radiation

Roof 37.0 1.20 44.4 70.0 23806
Vertical Inlet 69.4 1.01 70.1 75.0 41582
Conical Inlet 34.6 1.00 34.6 75.0 21416
Conical Part 73.0 1.01 73.7 90.0 59944
Material Pipes 7.7 1.01 7.8 205.0 25842
Riser Rest 108.4 1.10 119.2 78.0 73611
Total/Wt. Avg. 607.9 628.7 84.5 458270

Cyclone-2 m 2
- m 2
deg.C kcal/hr
Roof 35.8 1.20 43.0 72.0 24340
Vertical Inlet 64.1 1.01 64.7 75.0 38588
Conical Inlet 41.0 1.00 41.0 75.0 25117
Conical Part 65.8 1.01 66.5 70.0 34774
Material Pipes 11.3 1.01 11.4 98.0 11914
Riser Rest 118.0 1.10 129.8 65.0 56424
Total/Wt. Avg. 464.4 485.3 71.7 266797

Cyclone-3 m 2
- m 2
deg.C kcal/hr
Roof 39.2 1.20 47.0 83.0 34207
Vertical Inlet 70.1 1.01 70.8 85.0 52369
Conical Inlet 45.1 1.00 45.1 82.0 32194
Conical Part 72.3 1.01 73.0 80.0 48520
Material Pipes 12.2 1.01 12.3 125.0 18735
Riser Rest 132.3 1.10 145.5 86.0 105389
Total/Wt. Avg. 504.9 528.0 83.0 374579
Page - 22/29
Calciner String Radiations : SLC 6-Stage II-String

Roof 39.2 1.20 47.0 83.0 34207
Vertical Inlet 70.1 1.01 70.8 85.0 52369
Conical Inlet 45.1 1.00 45.1 82.0 32194
Conical Part 72.3 1.01 73.0 80.0 48520
Material Pipes 10.5 1.01 10.6 125.0 16264
Riser Rest 132.3 1.10 145.5 86.0 105389
Total/Wt. Avg. 503.2 526.3 82.9 372108

Roof 39.2 1.20 47.0 92.0 40716
Vertical Inlet 70.1 1.01 70.8 85.0 52369
Conical Inlet 45.1 1.00 45.1 90.0 37726
Conical Part 72.3 1.01 73.0 85.0 53915
Material Pipes 107.4 1.01 108.5 152.0 198686
Riser Rest 132.3 1.10 145.5 95.0 124604
Total/Wt. Avg. 635.9 660.3 99.7 638915

Cyclone-6 m 2
- m 2
deg.C kcal/hr
Roof 36.4 1.20 43.7 145.0 77845
Vertical Inlet 90.7 1.01 91.6 95.0 80483
Conical Inlet 45.1 1.01 45.6 85.0 34574
Conical Part 72.3 1.00 72.3 175.0 168377
Material Pipes 31.1 1.01 31.4 175.0 76140
Total/Wt. Avg. 362.1 371.0 121.6 511027
Calciner Surface Area Corr. Factor Corr. Area Temperature Radiation

m 2
- m 2
deg.C kcal/hr
Roof 31.2 1.10 34.3 125.0 49272
Cal.-C6 Duct 121.3 1.20 145.6 100.0 135579
Bottom Cone 51.3 1.00 51.3 115.0 63260
Bend Area 67.3 1.10 74.0 125.0 101967
Total/Wt. Avg. 628.1 662.2 97.2 591179
Page - 23/29
Cooler.Hood.TAD Radiations : SLC 6-Stage II-String

Production 6036 tpd Cooler 0.75
****
Total Radiation 1605018 **** kcal/hr Kiln Hood 0.75
**** Exclusive of amount as per FLS norms 5.00 %
Grate Surface Area Corr. Factor Corr. Area Temperature Radiation

Cooler m2 - m2 deg.C kcal/hr
Front-Kiln End 14.6 1.30 19.0 100.0 19852
Grate1-L/Side 33.3 1.10 36.6 102.0 38060
Grate1-Roof 42.8 1.50 64.2 112.0 75007
Grate1-R/Side 33.3 1.10 36.6 115.0 46023
Grate2-L/Side 22.3 1.10 24.5 95.0 23256
Grate2-Roof 28.6 1.50 42.9 95.0 39360
Grate2-R/Side 22.3 1.10 24.5 96.0 23656
Grate3-L/Side 23.3 1.10 25.6 98.0 25492
Grate3-Roof 29.9 1.50 44.9 92.0 38928
Grate3-R/Side 23.3 1.10 25.6 110.0 30646
Back End 13.4 1.10 14.7 122.0 21371
Total/Wt. Avg. 287.1 359.3 103.1 381650

Hood m 2
- m 2
deg.C kcal/hr
Right Side 13.8 1.50 20.7 106.0 23636
Left Side 27.5 1.50 41.3 95.0 37932
Kiln Side 12.0 1.50 18.0 150.0 35405
Burner Side 18.0 1.50 27.0 115.0 34510
Roof 53.5 1.50 80.3 115.0 96572
Total/Wt. Avg. 124.8 187.2 113.0 228056
TA Duct & Surface Area Corr. Factor Corr. Area Temperature Radiation
Settling Chamb. m 2
- m 2
deg.C kcal/hr
Connecting Duct 57.0 1.10 62.7 133.0 95945
Tert. Pipe 582.8 1.00 582.8 143.4 899367
Total/Wt. Avg. 639.8 645.5 142.4 995312
Wt. Avg. Dia. <= 3.05 >3.05
2859 4.55 39811 48732
3002 4.55 43473 52653
2616 4.55 33962 42408
3960 4.55 72754 83349
3145 4.55 47307 56731
1458 4.55 11897 17214
3316 4.55 52142 61843
3088 4.55 45752 55081
3288 4.55 51318 60974
3359 4.55 53393 63160
3416 4.55 55086 64940
3459 4.55 56376 66294
3245 4.55 50096 59684
3088 4.55 45752 55081
3073 4.55 45368 54672
3130 4.55 46915 56316
3173 4.55 48095 57566
3059 4.55 44985 54265
2716 4.55 36314 44962
2573 4.55 32977 41335
2530 4.55 32007 40274
2544 4.55 32329 40626
2873 4.55 40169 49118
3130 4.55 46915 56316
3030 4.55 44226 53456
2873 4.55 40169 49118
2787 4.55 38042 46829
2902 4.55 40892 49892
3588 4.55 60350 70454
4474 4.55 92386 103567
4560 4.55 95958 107227
3502 4.55 57683 67664
4946 4.55 113176 124813
1286 4.55 9369 14045
4803 4.55 106575 118081
4703 4.55 102113 113523
4746 4.55 104010 115461
4631 4.55 99004 110344
4531 4.55 94758 105997
4717 4.55 102743 114167
4689 4.55 101486 112883
4617 4.55 98390 109716
4588 4.55 97169 108466
4646 4.55 99621 110975
4560 4.55 95958 107227
4546 4.55 95357 106611
4345 4.55 87194 98237
4074 4.55 76860 87594
1615 4.55 14375 20228
1401 4.55 11034 16144
1830 4.55 18006 24522
2287 4.55 26762 34483
2359 4.55 28260 36148
2330 4.55 27656 35478
1844 4.55 18258 24817
1687 4.55 15552 21635
3431 4.55 55514 65389
3502 4.55 57683 67664
3659 4.55 62627 72831
3659 4.55 62627 72831
1215 4.55 8371 12760
2716 4.55 36314 44962
2530 4.55 32007 40274
2487 4.55 31050 39224
2630 4.55 34293 42769
3302 4.55 51729 61408
3559 4.55 59453 69517
3616 4.55 61255 71399
3659 4.55 62627 72831
225563 3794136 4437254
15.09 17.64
2137 6.470 9795 15536
3641 8.138 18344 27622
1675 5.642 7988 12762
6866 12.494 25143 38720
3115 8.269 12085 19331
1962 3.778 22258 28619
7393 11.203 40379 57314
5193 10.086 23799 35751
31981 159792 235656
2376 6.351 12977 19714

3372 7.832 16991 25703
1960 6.149 9168 14560
4786 8.467 29830 42203
3458 8.230 15848 24402
1150 4.151 7171 11055
3670 8.479 16819 25803
6217 10.559 31865 46301
26990 140668 209742
3175 6.702 20923 29941

4809 8.248 31686 44254
2324 6.502 11709 18121
4803 8.970 26624 38643
3552 8.682 14527 22826
799 3.812 4025 6662
5878 7.897 49710 64730
8808 11.163 58041 78294
34148 217244 303471
3457 6.702 24639 34441
4007 8.248 21886 32213
2324 6.502 11709 18121
4803 8.970 26624 38643
7400 8.682 64659 82517
1358 3.267 14516 19313
4141 7.261 30044 41384
10777 11.169 84851 108700
38268 278928 375334
3528 6.702 25597 35585

3206 8.248 13111 20732
2490 6.502 13600 20601
5056 8.970 29622 42352
4736 8.682 27747 39825
10211 9.310 102863 124992
5026 8.944 29444 42113
13857 11.650 124894 153133
48109 366878 479334
2293 6.458 11553 17896

5242 9.433 28629 41469
3856 6.534 31501 42339
6194 8.970 44138 59666
5519 9.257 33173 46920
5701 8.395 42444 57059
28804 191438 265350
31138 17.463 280652 330299

19392 12.422 205300 239268
20203 16.369 141331 179676
70733 627284 749243
7.88 10.41
3108 7.519 15659 23806
5257 9.447 28712 41582
2595 6.637 14173 21416
14457 14.630 91165 120752
6636 9.689 43725 59944
1594 3.147 20488 25842
10193 11.877 68572 91317
9301 12.322 53040 73611
53141 335533 458270
3093 7.396 16118 24340

4856 9.079 26519 38588
3075 7.225 16795 25117
5638 9.985 29378 42789
4652 9.199 23438 34774
1118 3.812 7971 11914
3947 8.027 22508 32851
8437 12.856 38667 56424
34816 181394 266797
3904 7.739 23762 34207

6018 9.495 37514 52369
3698 7.578 22230 32194
6488 10.495 35432 50680
5842 9.642 34226 48520
1540 3.961 13458 18735
3814 7.791 22344 32485
12516 13.612 78924 105389
43820 267890 374579
3904 7.739 23762 34207
6018 9.495 37514 52369
3698 7.578 22230 32194
6488 10.495 35432 50680
5842 9.642 34226 48520
1326 3.675 11583 16264
3814 7.791 22344 32485
12516 13.612 78924 105389
43605 266015 372108
4328 7.739 29113 40716

6018 9.495 37514 52369
4059 7.578 26746 37726
7353 10.495 45832 63243
6207 9.642 38691 53915
16488 11.752 167799 198686
7545 10.331 49715 67656
13825 13.612 95799 124604
65822 491209 638915
6334 7.458 62155 77845

8703 10.800 60303 80483
3872 7.616 24135 34574
8045 10.495 54663 73606
12653 9.595 143544 168377
5497 6.324 62363 76140
45102 407164 511027
4290 6.610 37485 49272

14556 13.614 105608 135579
30345 21.320 189156 241101
5900 8.082 48192 63260
9254 9.709 80857 101967
64344 461298 591179
9.58 12.77
1898 4.916 13771 19852
3736 6.829 27582 38060
7190 9.041 57471 75007
4212 6.829 34411 46023
2330 5.589 16148 23256
4076 7.391 28240 39360
2355 5.589 16474 23656
2512 5.713 17900 25492
4126 7.557 27758 38928
2819 5.713 22198 30646
1798 4.332 15411 21371
37053 277362 381650
2194 5.134 16744 23636

3919 7.247 27154 37932
2700 4.787 27199 35405
3105 5.863 25364 34510
9229 10.108 75389 96572
21147 171850 228056
8339 8.935 76522 95945

83569 27.240 813103 899367
91908 889625 995312
5.32 6.38
CCR Mimic - PR_W103 Preheater, Calciner & Kiln Feed Page - 24/29
08/15/2019 07:43:36 433316615.xls Aux-Pag LU010519-KCP#Ver.1.2*

CCR Mimic - PR_W104 Kiln & Kiln Auxiliaries Page - 25/29

CCR Mimic - PR_W105 Cooler Page - 26/29

CCR Mimic - PR_W109 Cooler Parameters Page - 27/29

CCR Mimic - Kiln Shell Scanner Page - 28/29

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PROCESS, EFFICIENCY & PERFORMANCE MONITORING
Section : KILN & COOLER - 6 Stage II String SLC Time : Date :
Site Conditions & Constants :
Plant Elevation : mts +MSL
Ambient Air DBT / WBT : deg.C
Pitot Constant (S-Type : L=01m) : 0.883 (P.S. No. 601)
Pitot Constant (S-Type : L=02m) : 0.847 (P.S. No. V422)
Pitot Constant (L-Type : L=01/02m) : 1.000 -
Process Parameters :
Clinker Prodn., tpd : Kiln Feed Temp., deg.C :
Kiln/Cal. Coal Feed Rate, tph : Kiln I/L O2, % :
Burner Axial/Radial Area, m2 : Cal. O/L O2, % :
Water in Cooler (3rd Gr.), m3/hr : KF Residue +90/+212 µm, % :
Water Spray (ESP I/L), m3/hr : ESP I/L Temp./Draft, deg.C/mmWG :
Clinker Temp. (Cooler O/L), deg.C : Sec./Tert. Air Temp., deg.C :
Raw Mix / Clinker / Coal Parameters :
Raw Mix Clinker Coal (ADB) Coal Ash
S/A, % SiO2, % Carbon, % SiO2, %
F/C, % Al2O3, % Hydrogen, % Al2O3, %
M/LOI, % Fe2O3, % Nitrogen, % Fe2O3, %
K/N, % CaO, % Sulphur, % CaO, %
SO3, % MgO, % Oxygen, % MgO, %
CC/MC, % S, % Ash, % S, %
S(pyr.), % K2O, % Moisture, % K2O, %
C/F H2O, % Na2O, % VM, % Na2O, %
CCR Parameters :
Kiln Speed, rpm : ESP Fan Load/Speed, kW/% :
CFG Gr.I Static Pressure, mmWG : KS/CS O2, %/% :
KF Rate / Dosing Valve, tph/% : KS/CS CO, %/% :
KF Elev. Load, kW/kW : Kiln Inlet O2/CO, %/% :
KS/CS Diversion, %/% : Gr.1 Chb.1/2/3 DP, mmWG :
Coal Screw Speed, rpm/rpm : Gr.1/2/3 Speed, spm :
KS Fan Load/Speed, kW/% : Gr.1/2/3 Load, amps :
CS Fan Load/Speed, kW/% : BZ Temp./Kiln Torque, deg.C/% :
sheet 2 of 5
08/15/2019 07:43:36 433316615.xls Mon-Form LU990611-RMP#Ver.1.3*

Flow Measurement & Gas Analysis :
Flow/Gas Analysis Tapping Location
KS Fan CS Fan PA Fan Cooler CTA CTA
Inlet Inlet Outlet ESP Stack Kiln Cal.
Dry Bulb Temperature deg.C
Wet Bulb Temperature deg.C
Static Pressure "WG
Dynamic Pressure "WG
O2, dry - OPTIFUEL250 vol.%, d
O2, dry - ORSAT vol.%, d
CO2, dry - ORSAT vol.%, d
Time Period hh.mm - hh.mm
sheet 3 of 5

Flow Measurement & Gas Analysis :
471FN1 471FN2 471FN3 471FN4 471FN5 471FN6 471FN7
Static Pressure "WG
Fan Load amps
Fan Speed rpm
471FN8 471FN9 471FNA 471FNB 471FNC 471FNH
Static Pressure "WG
Fan Load amps
Fan Speed rpm

Radiations sheet 4 of 5
Kiln Inlet 0.85 Preheater 0.75 Preheater 0.75 Cooler 0.75

Rest Kiln 0.85 Riser Duct 0.75 Riser Duct 0.75 Kiln Hood 0.75
Kiln Kiln String Cal. String Cooler
Length Temp. Area Temp. Area Temp. Area Temp.
mts deg.C deg.C deg.C deg.C
0 Cyclone-1 Cyclone-1 Front-Kiln/S
1 Roof Roof Gr.1-L/Side
2 Vert. Inlet Vert. Inlet Gr.1-Roof
3 Con. Inlet Con. Inlet Gr.1-R/Side
4 Cyl. Part Cyl. Part Gr.2-L/Side
5 Con. Part Con. Part Gr.2-Roof
6 Mat. Pipes Mat. Pipes Gr.2-R/Side
7 Riser Cyl. Riser Cyl. Gr.3-L/Side
8 Riser Rest Riser Rest Gr.3-Roof
9 Cyclone-2 Cyclone-2 Gr.3-R/Side
10 Roof Roof Back End
11 Vert. Inlet Vert. Inlet Hood
12 Con. Inlet Con. Inlet Right Side
13 Cyl. Part Cyl. Part Left Side
14 Con. Part Con. Part Kiln Side
15 Mat. Pipes Mat. Pipes Burner Side
16 Riser Cyl. Riser Cyl. Roof
17 Riser Rest Riser Rest TAD
18 Cyclone-3 Cyclone-3 Conn. Duct
19 Roof Roof Tert. Pipe
20 Vert. Inlet Vert. Inlet
21 Con. Inlet Con. Inlet
22 Cyl. Part Cyl. Part
23 Con. Part Con. Part
24 Mat. Pipes Mat. Pipes
25 Riser Cyl. Riser Cyl.
26 Riser Rest Riser Rest
27 Cyclone-4 Cyclone-4
28 Roof Roof
37 Roof Roof
46 Roof Roof
52 Kiln Riser Duct Calciner
53 Rect. Pipe Roof
54 Smk. Chmb. Cyl. Part
55 Rest Con.Part
56 Kiln (contd.) Bend.
57 63 Rest
58 64
59 65
60 66
61 67
62 68

sheet 5 of 5
PH Temperature & Draft Profile
mmWG mmWG
deg.C deg.C
K-1 C-1
mmWG mmWG
deg.C deg.C
mmWG
deg.C
K-2 C-2
mmWG
deg.C
mmWG mmWG
deg.C deg.C
K-3 C-3
mmWG mmWG
deg.C deg.C
mmWG
deg.C
K-4 C-4
mmWG
deg.C
mmWG mmWG
deg.C deg.C
K-5 C-5
mmWG mmWG
deg.C deg.C
mmWG mmWG
deg.C deg.C
K-6 mmWG C-6/Cal.

deg.C
mmWG mmWG
deg.C deg.C
Kiln I/L Draft mmWG Cal. I/L Draft mmWG
Kiln I/L Temp. deg.C Cal. I/L Temp. deg.C

Kiln String Fan Calciner String Fan Cooler ESP Fan PA Fan
2800 3000 4200 400
0.97 2716 8 2.83 2910 15 3.87 4074 3 372
0.92 2576 9 3.00 2760 17 4.12 3864 3 300
0.85 2380 11 3.32 2550 21 4.58 3570 3 100
0.77 2156 11 3.32 2310 24 4.90 3234 3 28
0.66 1848 11 3.32 1980 23 4.80 2772 3 372
0.34 952 11 3.32 1020 22 4.69 1428 300
0.23 644 12 3.46 690 13 3.61 966 100
0.15 420 9 3.00 450 10 3.16 630 28
0.08 224 9 3.00 240 17 4.12 336
0.03 84 9 3.00 90 11 3.32 126

10 3.15590279 4.11714508
9.95972242 16.9508836
16.9508836

PA Fan
400
10.00
11.00
10.00
8.00
10.00
11.00
10.00
9.00
9.875

Coolax Cooler : 1284-3ME-IN
F.L. Smidth & Co. A/S
Grate-I (CFG) Grate-II (RFT)

1 M 700-800 mmWG 37 M
471FN2 2 F 471FN1 38 F 450-550 mmWG
3 M Grate Area = 3.56 m2 39 M 471FN8
4 F Min. Flow = 273.73 m3/min 40 F 7.09 m2
450-600 mmWG 5 M Nor. Flow = 320.33 m3/min 41 M 349.45 m3/min
471FNH 6 F 42 F 407.70 m3/min
7.12 m2 7 M 43 M
262.08 m3/min 8 F 600-700 mmWG 450-550 mmWG 44 F
308.68 m3/min 9 M 471FN9 45 M
10 F 7.09 m2 46 F
11 M 349.45 m3/min 47 M
471FN4 12 F 471FN3 407.70 m3/min 48 F
13 M 7.13 m2 49 M
14 F 436.81 m3/min 50 F
15 M 512.53 m3/min 51 M
16 F 400-500 mmWG 52 F
450-600 mmWG 17 M 471FNA 53 M
471FN7 18 F 11.81 m2 54 F
35.64 m2 19 M 693.07 m3/min 55 M
990.10 m3/min 20 F 500-600 mmWG 815.40 m3/min 56 F
1164.80 m3/min 21 M 4665 57 M
22 F 58 F
23 M
24 F Grate-III (RFT)
25 M 59 M
471FN6 26 F 471FN5 60 F
27 M 10.69 m2 61 M
28 F 646.48 m3/min 62 F
29 M 762.97 m3/min 63 M
30 F 64 F 400-500 mmWG
31 M 65 M 471FNB
32 F 66 F 16.54 m2
33 M 67 M 693.07 m3/min
34 F 68 F 815.40 m3/min
35 M 69 M
36 F 70 F
71 M
72 F
73 M
74 F
75 M
Cooler Fans 76 F
Fan Vol. Flow, Density Temp. D.P. Power, Speed Grate 77 M 300-400 mmWG
design min. Plates 78 F 471FNC
m3/min kg/m3 o
C mmWG kW rpm nos. 79 M 14.18 m2
471FN1 374 1.04 45 1000 83 2900 36 80 F 739.67 m3/min
471FN2 374 1.04 45 1000 83 2900 36 81 M 873.63 m3/min
471FN3 631 1.04 45 900 122 1450 72 82 F
471FN4 631 1.04 45 900 122 1450 72 83 M
471FN5 946 1.04 45 800 165 1480 108 84 F
471FN6 946 1.04 45 800 165 1480 108
471FNH 500 1.04 45 300 90 1470 Press. Fan
471FN7 1439 1.04 45 700 225 1485 Press. Fan Cooler Grates
471FN8 507 1.04 45 700 76 1485 72 Grate Length Area Power Plates Rows
471FN9 507 1.04 45 700 76 1485 72 mts m2 kW nos. nos.
471FNA 1014 1.04 45 600 136 1485 120 I 11.88 43.01 60 432 36
471FNB 1014 1.04 45 600 136 1485 168 II 7.26 26.28 45 264 22
471FNC 1099 1.04 45 500 123 1485 144 III 8.30 30.05 45 312 26
Total 9982 1602 1008 Total 27.44 99.33 1008 84
Miscellaneous Fans Length of one grate plate, eff. = 330.0 mm

Fan Vol. flow, Density Temp. D.P. Power, Speed Grate Width of one grate plate, eff. = 298.0 mm
design min. Plates Area of one grate plate, eff. = 983.40 cm2
m3/min kg/m3 o
C mmWG kW rpm nos. Width of cooler, eff. = 3.62 mts
Cooler 12370 0.56 320 150 455 590 nil
Vent Fan Mass flow rate, normal = 4750 t/24h
Primary 176 1.04 45 160 75 2980 nil Grate area = 99.33 m2
Air Fan Specific load = 47.82 t/d/m2
Norms :
1. Depending upon the particle size distribution of the clinker, the expected air load for normal operation corresponds to about :
a) ~90 kg/m2/min for 1st/2nd part of Grate-I c) ~45 kg/m2/min for 1st Sealing Air Fan e) ~55 kg/m2/min for Grate-II
b) ~80 kg/m2/min for 3rd part of Grate-I d) ~35 kg/m2/min for 2nd Sealing Air Fan f) ~50 kg/m2/min for Grate-III
2. Minimum air flow rates are about 85% of the normal flow rates.
08/15/2019 07:43:37 433316615.xls Cooler-Pic

Coolax Cooler : 1284-3ME-IN
Grate-II (RFT)
1 11 1 M
471FN1 6 F
471FN2 Nor. Pr. = 723 mm WG 3 M
723 mm WG Grate Area = 3.6 m2 4 F
3.6 m2
CIS 244 m3/min 5 M
Min. Flow =
244.29 m3/min Nor. Flow = 287 m3/min 6 F
287.4 m3/min 471FNA 1 M
1 F 525 mm WG 2 F
2 Grate-I (CFG) M 7.09 m2 3 M
471FN4 3 F 532 m3/min 4 F 471FN8
765 mm WG 4 M 626 m3/min 5 M 450 mm WG
6.5 m2 5 F 471FN3 6 F 7.09 m2
498 m3/min 6 M 765 mm WG 1 M 532 m3/min
586 m3/min 7 F 6.5 m2 2 F 626 m3/min
471FN9 8 M 498 m3/min 3 M
615 mm WG 9 F 586 m3/min 4 F
13 m2 10 M 471FN7 5 M
425 m3/min 11 F 375 mm WG 6 F
500 m3/min 1 M 11.81 m2 7 M
471FNH 2 F 1065 m3/min 8 F
530 mm WG 2 M 1253 m3/min 9 M
21.38 m2 4 F 10 F
431 m3/min 5 M
507 m3/min 6 F Grate-III (RFT)
7 M 1 M
471FN6 8 F 471FN5 2 F
680 mm WG 9 M 680 mm WG 3 M
10.69 m2 10 F 10.69 m2 4 F
646.48 m3/min 11 M 646.48 m3/min 5 M
762.97 m3/min 12 F 762.97 m3/min 6 F
13 M 7 M 471FNB
14 F 8 F 300 mm WG
15 M 9 M 16.54 m2
16 F 10 F 693.07 m3/min
17 M 11 M 815.40 m3/min
18 F 12 F
13 M
14 F
1 M
2 F
3 M
Cooler Fans 4 F
Fan Vol. Flow, Density Temp. D.P. Power, Speed Grate 5 M
m3/min kg/m3 o
C mmWG kW rpm nos. 7 M 300 mm WG
471FN1 373 1.04 45 1000 83 2900 27 8 F 14.18 m2
471FN2 373 1.04 45 1000 83 2900 27 9 M 739.67 m3/min
471FN3 631 1.04 45 900 122 1450 60 10 F 873.63 m3/min
471FN4 631 1.04 45 900 122 1450 60 11 M
471FN9 500 1.04 45 800 76 1485 Press. Fan 12 F
471FN5 946 1.04 45 800 165 1480 108
471FN6 946 1.04 45 800 165 1480 108
471FNH 507 1.04 45 700 90 1470 Press. Fan Cooler Grates
471FN7 1439 1.04 45 700 225 1485 72 Grate Length Area Power Plates Rows
471FN8 507 1.04 45 700 76 1485 72 mts m2 kW nos. nos.
471FNA 1014 1.04 45 600 136 1485 120 CIS 2.4 6.48 - 54 6
471FNB 1446 1.04 45 500 136 1485 168 I 9.57 34.64 60 348 29
471FNC 1099 1.04 45 500 123 1485 144 II 7.26 26.28 45 264 22
Total 10413 1602 822 III 8.58 31.06 45 312 26
Total 27.81 98.46 - 924 83

m3/min kg/m3 o
Cooler
12370 0.56 320 150 455 590 nil Mass flow rate, normal = 6100 t/24h
Vent Fan
Primary Grate area = 98.46 m2
176 1.04 45 160 75 2980 nil Specific load = 61.95 t/d/m2
Air Fan
Norms :
08/15/2019 07:43:37 433316615.xls Cooler-Pic (2)

08/15/2019 07:43:38 433316615.xls Cooler-Pic (2)
Coolax Cooler : 1284-3ME-IN (Modify with CIS )
Grate-II (RFT)
1 11 1 M
471FN1 6 F
471FN2 Nor. Pr. = 723 mm WG 3 M
3.24 m2
CIS 244 m3/min 5 M
Min. Flow =
244.29 m3/min Nor. Flow = 287 m3/min 6 F
287.4 m3/min 471FNA 1 M
1 F 525 mm WG 2 F
471FN4 3 F 532 m3/min 4 F 471FN8
765 mm WG 4 M 626 m3/min 5 M 450 mm WG
6.5 m2 5 F 471FN3 6 F 7.09 m2
498 m3/min 6 M 765 mm WG 1 M 532 m3/min
586 m3/min 7 F 6.5 m2 2 F 626 m3/min
471FN9 8 M 498 m3/min 3 M
615 mm WG 9 F 586 m3/min 4 F
13 m2 10 M 471FN7 5 M
425 m3/min 11 F 375 mm WG 6 F
500 m3/min 1 M 11.81 m2 7 M
471FNH 2 F 1065 m3/min 8 F
530 mm WG 2 M 1253 m3/min 9 M
21.38 m2 4 F 10 F
431 m3/min 5 M
507 m3/min 6 F Grate-III (RFT)
7 M 1 M
471FN6 8 F 471FN5 2 F
680 mm WG 9 M 680 mm WG 3 M
10.69 m2 10 F 10.69 m2 4 F
646.48 m3/min 11 M 646.48 m3/min 5 M
762.97 m3/min 12 F 762.97 m3/min 6 F
13 M 7 M 471FNB
14 F 8 F 300 mm WG
15 M 9 M 16.54 m2
16 F 10 F 693.07 m3/min
17 M 11 M 815.40 m3/min
18 F 12 F
13 M
14 F
1 M
2 F
3 M
Cooler Fans 4 F
m3/min kg/m3 o
471FN1 373 1.04 45 1000 83 2900 27 8 F 14.18 m2
471FN2 373 1.04 45 1000 83 2900 27 9 M 739.67 m3/min
471FN3 631 1.04 45 900 122 1450 66 10 F 873.63 m3/min
471FN4 631 1.04 45 900 122 1450 66 11 M
471FN9 500 1.04 45 800 76 1485 Press. Fan 12 F
471FN5 946 1.04 45 800 165 1480 108
471FN6 946 1.04 45 800 165 1480 108
471FN7 1439 1.04 45 700 225 1485 72 Grate Area Plates Rows
471FN8 507 1.04 45 700 76 1485 72 m2 nos. nos.
471FNA 1014 1.04 45 600 136 1485 120 CIS 6.48 54 6
471FNB 1446 1.04 45 500 136 1485 168 I 34.22 348 29
471FNC 1099 1.04 45 500 123 1485 144 II 25.96 264 22
Total 10413 1602 978 III 30.68 312 26
Total 97.35 978 83

m3/min kg/m3 o
Cooler
Vent Fan
Air Fan
Norms :
Note :
First 07 rows+1(Zero) Row = Total Eight Rows of CFG replaced with CIS (06 Rows) in the month of Jun -2001
08/15/2019 07:43:38 433316615.xls Cooler-Pic (3)

08/15/2019 07:43:38 433316615.xls Cooler-Pic (3)
Coolax Cooler : 1284-3ME-IN ( Modify With CIS )
Grate-II (RFT)
1 11 1 M
471FN1 6 F
471FN2 Nor. Pr. = 1000 mm WG 3 M
3.24 m2
CIS 373 m3/min 5 M
Op. Flow =
373 m3/min 6 F
471FNA 1 M
1 F 525 mm WG 2 F
471FN4 3 F 532 m3/min 4 F 471FN8
900 mm WG 4 M 626 m3/min 5 M 450 mm WG
6.5 m2 5 F 471FN3 6 F 7.09 m2
631 m3/min 6 M 900 mm WG 1 M 532 m3/min
7 F 6.5 m2 2 F 626 m3/min
471FN9 8 M 631 m3/min 3 M
800 mm WG 9 F 4 F
13 m2 10 M 471FN7 5 M
500 m3/min 11 F 375 mm WG 6 F
1 M 11.81 m2 7 M
471FNH 2 F 1065 m3/min 8 F
700 mm WG 2 M 1253 m3/min 9 M
21.38 m2 4 F 10 F
507 m3/min 5 M
6 F Grate-III (RFT)
7 M 1 M
471FN6 8 F 471FN5 2 F
800 mm WG 9 M 800 mm WG 3 M
10.69 m2 10 F 10.69 m2 4 F
946 m3/min 11 M 946 m3/min 5 M
12 F 6 F
13 M 7 M 471FNB
14 F 8 F 300 mm WG
15 M 9 M 16.54 m2
16 F 10 F 693.07 m3/min
17 M 11 M 815.40 m3/min
18 F 12 F
13 M
14 F
1 M
2 F
3 M
Cooler Fans 4 F
Operating min. Plates 6 F 471FNC
m3/min kg/m3 o
471FN1 373 1.04 45 1000 83 2900 27 8 F 14.18 m2
471FN2 373 1.04 45 1000 83 2900 27 9 M 739.67 m3/min
471FN3 631 1.04 45 900 122 1450 66 10 F 873.63 m3/min
471FN4 631 1.04 45 900 122 1450 66 11 M
471FN9 500 1.04 45 800 76 1485 Press. Fan 12 F
471FN5 946 1.04 45 800 165 1480 108
471FN6 946 1.04 45 800 165 1480 108
471FN7 1439 1.04 45 700 225 1485 72 Grate Area Plates Rows
471FN8 507 1.04 45 700 76 1485 72 m2 nos. nos.
471FNA 1014 1.04 45 600 136 1485 120 CIS 6.48 54 6
471FNB 1446 1.04 45 500 136 1485 168 I 34.22 348 29
471FNC 1099 1.04 45 500 123 1485 144 II 25.96 264 22
Total 10413 1602 978 III 30.68 312 26
Total 97.35 978 83

m3/min kg/m3 o
Cooler
Vent Fan
Air Fan
Norms :
08/15/2019 07:43:38 433316615.xls Cooler-Pic Op.

Original 0.769824 1100 23.814967
Option 1 0.805332 1100 22.764936
Option 2 0.693876 1100 26.421624
Option 3 0.616116 1100 29.756297
08/15/2019 07:43:39 433316615.xls Cooler-Pic Op.

08/15/2019 07:43:39 433316615.xls Cooler-Pic Op.
Flow
6 5 4 3 2 1
400 0 0 0 0 0
A
60 0 0 0 0 0
300 400 400 400 400 0 300 Dp(mmWG)

B
120 100 100 100 80 0 120 Flow (Kg/Min-m2)
300 300 300 300 400 400

C
120 120 120 120 100 100
300 300 300 300 300 400

D
120 120 120 120 120 100 Total Area of CIS
300 300 300 300 300 400 Blocked Area

E
120 120 120 120 120 100 Eff. Area
300 300 300 300 300 400

F
120 120 120 120 120 100
300 300 300 300 300 400

G
120 120 120 120 120 100
300 300 300 300 300 400

H
120 120 120 120 120 100
300 300 300 300 400 400

I
120 120 120 120 100 100
300 400 400 400 400 0

J
120 100 100 100 80 0
400 400 0 0 0 0
K
80 100 0 0 0 0
7.92
1.44
6.48
Kiln Performance & Efficiency
S. Constraint Symbol Unit Formula
NO.
1 Degree of Filling DoF % 3.2 x TPDclk
Deff3 x n x S
mts rpm %
2 Burning Zone BZL Gcal/ kg/hr kcal/kg
Loading hr-m2 Coalkiln x NCVcoal

C.S. Areakiln
m2
kcal/kg-clk
TPDclk x Sp. Heat Consp.

C.S. Areakiln x 24 x 1000
m2
3 Volumetric Loading VL tpd/m3 TPDclk

C.S. Areakiln x L
m2 mts
4 Burner Tip BTV m/sec 4 x Ps0.5

Velocity mmWG
5 Combustion Air, Lmin kg/sec 1.41 x Coal

Minimum Mcal/sec
kg-air/ 0.11594xC + 0.34783x(H-O/8)

kg-coal + 0.04348xS
C, H, O, S - %
6 Percent Primary Air %PA % Primary Air x 100

Lmin
7 Flame Momentum or FM or %.m/sec %PA x Tip Velocity
08/15/2019 07:43:39 433316615.xls Kln-Forml LU001016-KCP#Ver.1.2*

Relative Impulse RI %.m/sec m/sec
8 Feed Residence RT-K min mts
Time, Kiln (decimal) 19 x L

Deff x n x S
mts rpm %
9 Clinker Residence RT-C min m2 mmWG
Time, Cooler (decimal) 1.55 x A x Ps

TPDclk
10 Combustion Air CAR kg-air/ % kcal
Requirement kg-coal 10.478 x (100 - m) x GCV

100 x 7000
11 Sulphur-Alkali Q - SO3/80
Ratio (K2O/94)-(Na20/62)-(Cl/71)
gms/kg-clk
12 Theoretical Flame TFT deg.C kcal/kg-coal
Temperature Hv
1.11 x A x s
Comb. Air Sp. Heatcomb. gas
kg/kg-fuel 0.29
Hv
Vxs
Nm3/kg-fuel 0.38
13 True CO2 in Kiln T-CO2 % 100 x (CO2 + CO)

Exit Gas 100 + (1.89 x CO) - (4.78 x O2)
14 Kiln Feed Ratio, KFR-S kg-feed/ dec.
Dust to Silo kg-clk 1 - Ash Abs.

(1 - LOI) * (1 - D/L)
Dust to Kiln KFR-K 1 - Ash Abs.

1 - LOI
dec.
15 Ash Absorption AA % tons %
Coal Consp. x Ashcoal

Clinker Prodn.
tons
kcal/kg-clk %
Sp. Heat Consp. x Ashcoal

NCVcoal
kcal/kg-coal
16 Excess Air in Kiln EAK % 189 x (2xO2 - CO)

N2 - [1.89 x (2xO2 - CO)]
O2, N2, CO - Kiln exit gas
79 x O2
0.21 x ( 100 - CO2 ) - O2
17 Major Pluging
Problems, if
18 Radiation kcal/hr/m2 4*10-8 (T4 - t4)

T=Shell Temp. and t=Amb. Air Temp.
T & t - deg.K
19 Convection kcal/hr/m2 80.33 x ((T+t)/2)-0.724 x (T-t)1.333
Forced Convection kcal/hr/m2 28.03 x ((T+t)/2)-0.351 x

(if amb. air vel. is v0.805 x D-0.195 x (T-t)
more than 3.0 m/s) v=amb. air vel., m/sec

D=Shell dia., mts

Coal Combustion Analysis
S. Constraint Symbol Unit Formula
NO.
1 Ultimate Analysis UA wt.% C+H+N+S+O+Ash = 100
O - Determined by difference
2 Proximate Analysis PA wt.% VM+FC+Ash+m = 100

FC - Determined by difference
3 Gross Calorific Value GCV kcal/ 80.8*C + 22.45*S + 339.53*H - 35.89*O

kg-coal C, S, H, O - Ultimate Analysis (wt.%)
4 Net Calorific Value NCV kcal/ GCV - 52.53*H - 6*m

kg-coal
5 Useful Heat Value UHV kcal/ 8900 - 138*(Ash + m)
kg-coal Ash, m - Proximate Analysis (wt.%)
6 Methods of Expressing ARB, r "As Received Basis"

Solid Fuel Analysis AA, a/ADB "As Analysed" or "Air Dry Basis"
DB, d "Dry Basis"
AFB, f "As Fired Basis"
CB, c "Combustible Basis (moist. & ash free)"
7 Conversion from "As Yd wt.% (Yr * 100) / (100 - mr)
Received" to "Dry where Y - C, S, N, Ash
Basis" Hd wt.% ((Hr - 0.1119 * mr) * 100) / (100 - mr)
Od wt.% 100 - (Yd + Hd)
8 Conversion from "As Yc wt.% (Yr * 100) / (100 - (Ashr + mr))
Received" to where Y - C, S, N, Ash
"Combustible Basis" Hc wt.% ((Hr-0.1119*mr)*100)/(100-(Ashr+mr))
Oc wt.% 100 - (Yc + Hc)
9 Conversion from "As Yd wt.% (Ya * 100) / (100 - ma)
Analysed / Air Dry where Y - C, S, N, Ash
08/15/2019 07:43:39 433316615.xls Comb-Forml LU981125-KCP#Ver.1.1*

Basis" to "Dry Basis" Hd wt.% ((Ha - 0.1119 * ma) * 100) / (100 - ma)
Od wt.% 100 - (Yd + Hd)
10 Conversion from "Dry Yr wt.% (Yd * (100 - mr)) / 100
Basis" to "As Received where Y - C, S, N, Ash
Basis" Hr wt.% (Hd * ((100 - mr) / 100) + 0.1119 * mr
Or wt.% 100 - (Yr + Hr)
11 Conversion from "Dry Yf wt.% (Yd * (100 - mf)) / 100
Basis" to "As Fired where Y - C, S, N, Ash
Basis" Hf wt.% (Hd * ((100 - mf) / 100) + 0.1119 * mf
Of wt.% 100 - (Yf + Hf)
12 Conversion from Yf wt.% (Yc * 100) / ((100 - (Ashf + mf)) / 100)
"Combustible Basis" where Y - C, S, N, Ash
to "As Fired Basis" Hf wt.% (Hc*(100-(Ashf+mf))/100) + 0.1119*mf
Of wt.% 100 - (Yf + Hf)
13 Ash Absorption AA % tons %
Coal Consp. x Ashcoal

Clinker Prodn.
tons
kcal/kg-clk %
Sp. Heat Consp. x Ashcoal

NCVcoal
kcal/kg-coal
14 Effect of Coal Ash on % (LOI free Coal Ash x Ash Absorption)

Clinker Composition + ((100-LOI free Coal Ash) x Theoretical
Clinker)
15 Theoretical Fuel kg-coal/ (K1*V) / ((K2*W) - (K3*V))
Consumption 100 kg-clk K1 = (400 * m)/(100 - n)
K2 = (b/3) + c + (a*d/7) - (e/8) + (f/8)
K3 = (b/3) - ((m*g) / (2500-25*n))

V = (a*s) - q - (t/2)
W=p+t
where,
a = constant, 0.266
b = %FC in dry coal
c = %H in dry coal
d = %N in dry coal
e = %O in dry coal
f = %S in dry coal
g = %Ash in dry coal
m = %True CO2 in exit gas
q = %O2 in exit gas
s = %N2 in exit gas
t = %CO in exit gas
16 True CO2 in Exit Gas T-CO2 % 100xCO2 + CO
100 + 1.89xCO - 4.78xO2
17 Standard Coal Factor SCF - ((100-mf)/100) * (NCVf/7000)
% kcal-kg-coal
18 Combustion Air, Lmin kg/sec 1.41 x Coal

Minimum Mcal/sec
kg-air/ 0.11594xC + 0.34783x(H-O/8)

kg-coal + 0.04348xS
C, H, O, S - %
kg-air/ 10.478 x SCF

kg-coal
19 Combustion Air, L Lmin * 1.10
Incl. Extra
20 Theoretical Flame TFT deg.C kcal/kg-coal

Temperature Hv
1.11 x A x s
Comb. Air Sp. Heatcomb. gas
kg/kg-fuel 0.29

Kiln Cooler Heat Mass Balance

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Page - 1/29

PLANT : Binani Cement - 20.06.2003

O2 = 5.3% O2 = 3.2% To Raw Mill/Baghouse

Kiln String Calciner String

Hot air to PA Fan Clinker

PLANT : Binani Cement - 20.06.2003

Excess Air Optimisation (vol%, d)

08/15/2019 07:43:35 433316615.xls Pic-2S LU001005-KCP#Ver.1.2D***

3.491 0.065 2.374 kgd/kg-clk

08/15/2019 07:43:35 433316615.xls Pic-2S LU001005-KCP#Ver.1.2D***

08/15/2019 07:43:35 433316615.xls Pic-2S LU001005-KCP#Ver.1.2D***

08/15/2019 07:43:35 433316615.xls Kiln-CalcS LU000211-KCP#Ver.2.2***

Wet Bulb Temp. deg.C - - - - 30 34 34 - - 22

Dew Point (F4) deg.C - - - 31 25 25 24 - - 15

Dew Point, calc. deg.C - - 58 31 25 25 24 - - 16

RMS Pd mmWG - - - - 9.75 50.86 50.19 - - -

Duct Diameter mts 2.80 3.00 3.75 3.55 2

Gas Density, wet kg/m 3

Pitot Tube S1/S2/L - - - - L L L - - -

Duct C.S. Area m 2

Gas Flow Rate, wet kNm /hr 142.27

Dust, gas tph 12.98 20.81 33.79 5.10 - - - - - -

Heat Cap., dust kcal/kg/C 0.234 0.233 0.233 0.205 - - - - - -

Heat Content, dust Mcal/hr 927 1467 2394 298 - - - - - -

08/15/2019 07:43:35 433316615.xls Kiln-CalcS LU000211-KCP#Ver.2.2***

0.2485 -3.340E-06 4.440E-08 ### 5.597E-15 Not used in calc.

0.1244 0.000E+00 0.000E+00 ### 0.000E+00 Not used in calc.

O2 0.2130 7.796E-05 -7.563E-08 4.074E-11 -8.183E-15

CO2 0.1906 1.771E-04 -1.733E-07 9.315E-11 -1.894E-14

N2+Ar 0.2465 -3.284E-06 4.366E-08 ### 5.504E-15

H2O,steam 0.4445 2.910E-05 6.887E-08 ### 6.472E-15

H2O, liq. 1.0000

Rawmeal 0.2060 1.014E-04 -3.673E-08

Clinker 0.1742 1.414E-04 -1.283E-07 5.074E-11

A 23.5771 Sp. Gravity, dry - O2 kg/Nm3 1.429

B -4042.90 Sp. Gravity, dry - CO2 kg/Nm3 1.977

C -37.58 Sp. Gravity, dry - N2 kg/Nm3 1.257

BURNER AXIAL/RADIAL ANNULUS

08/15/2019 07:43:35 433316615.xls Kiln-CalcS LU000211-KCP#Ver.2.2***

31 265 31 265 305 302 IN

22 53 22 53 80 80 Air (ESP I/L) 1.388 285 0.250 99

15 40 15 40 60 60 False Air 0.106 31 0.242 1

16 30 16 30 57 58 ESP Fan Pow. - - - 0

0.012 0.028 0.012 0.028 0.110 0.110 TOTAL 1.495 - - 100

0 3.75 0 - -610 -910 OUT

- 6.00 - - 9.07 17.51 Stack 1.470 265 0.250 97

- 4.20 - - 2.80 3.00 To PA Fan 0.025 265 0.250 2

21.0 21.0 21.0 21.0 5.7 3.4 Radiations - - - 1

0.0 0.0 0.0 0.0 24.9 34.6 TOTAL 1.495 - - 100

79.0 79.0 79.0 79.0 69.4 62.0

1.69 0.95 1.69 0.95 0.83 0.81

1.07 0.61 1.07 0.61 0.53 0.51 Error1 0.0000

0.69 0.39 0.69 0.39 0.34 0.33 Error2 0.0000

25.62 14.48 25.62 14.48 3.43 1.99

0.00 0.00 0.00 0.00 20.73 28.02

84.79 47.93 84.79 47.93 36.74 31.92

1.32 1.77 1.32 1.77 6.70 6.81

22.93 22.57 22.93 22.57 5.07 2.89

0.00 0.00 0.00 0.00 30.67 40.76

75.88 74.68 75.88 74.68 54.35 46.44

1.19 2.75 1.19 2.75 9.91 9.91

1.29 1.29 1.29 1.29 1.45 1.51

1.28 1.27 1.28 1.27 1.34 1.39

1.10 0.62 1.10 0.62 0.61 0.62

Gas/Mat T^0 T^1

T^2 T^3 *T^4