Combustion calculations in Cement

industry ( updated & complete )

Conversion of Gross Calorific value to net

Calorific value

Gross calorific value (GCV) of a fuel is the heat evolved in its

complete combustion under constant pressure at a temperature
of 25C when all the water initially present as liquid in the fuel
and that present in the combustion products are condensed to
liquid state

Net calorific value (NCV) of a fuel is the heat evolved in its

complete combustion under constant pressure at a temperature
of 25 C when the water in the system after combustion is taken
as vapour.
Ultimate analysis

The ultimate analysis is useful to calculate the theoretical

combustion air required and volume of combustion gases.

Proximate analysis

The proximate analysis involves quantitative determination of

moisture, volatile matter, carbon and ash. This analysis is for
quick preliminary appraisal of coal.

% Coal ash absorbed in Clinker

Theoretical air required to burn fuel

Kiln Shell Ovality measurement (Shelltest)
Procedure

PURPOSE

The kiln shell ovality measurement (also known as Shelltest)

measures the elastic deformation on the areas adjacent to the
tires. An excessive ovality value will have a negative impact on
the lifetime of the refractory bricks and must be kept under
acceptable limits (which vary according to kiln diameter). The
creep (relative movement must be measured as well, since they
are closely related and it is the shimming (reduction of
clearance between tire and shell) the method to reduce ovality.

As can be inferred, this measurement is relevant for kilns with

loose (floating) tires. Those equipped with the more modern
splined (toothed) tires are not affected; there is virtually no
creep and therefore the ovality measurement is not required .

HGRS recommends the measuring device “Shelltest” which is

briefly described in this paper. Nowadays, several suppliers (e.g.
Refratechnik, Phillips Kiln Services) offer an electronic version of
this device, in case a plant or Group Company needs to buy a
new one.
http://www.cementequipment.org/home/kiln-and-cooler/kiln-shell-ovality-measurement-
shelltest-procedure/