1.

58

98.62 1.5 85.00 98.30

Clinker
Kiln Feed After
Raw Meal Kiln Feed After By without coal Clinker
Elements EP Analysis Kiln Feed By Pass Coal Ash add. Of Coal
Proposed Pass ash Proposed
ASH
absorption

Proposed Raw Materials Corrective Materials CaCO3 73.56 73.34 4.26

Raw Mix Pile
ELEMENTS
F=3 HSLS CLAY LATERITE Proposed CLAY LATERITE MgCO3 2.79 4.10 66.02

T.CO3 76.48 T.CO3 76.35 77.43 3.73

LOI 40.39 15.41 15.72 8.49 37.18 15.72 8.49 LOI 37.18 34.31 36.75 36.49 69.75
SiO2 7.72 60.43 51.16 16.11 13.55 51.16 16.11 SiO2 13.55 13.95 13.61 0.00 13.61 22.03 27.35 13.69 21.22

Al2O3 1.92 1.24 15.61 3.81 3.41 15.61 3.81 Al2O3 3.41 3.95 3.49 0.00 3.49 5.65 12.40 3.57 5.53

Fe2O3 1.97 0.59 5.29 49.29 2.31 5.29 49.29 Fe2O3 2.31 2.65 2.36 0.00 2.36 3.82 6.20 2.39 3.70

CaO 46.14 21.77 6.80 20.16 41.33 6.80 20.16 CaO 41.33 40.50 41.20 0.00 41.20 66.68 30.00 40.93 63.43

MgO 1.35 0.12 1.94 0.97 1.39 1.94 0.97 MgO 1.39 2.28 1.95 0.00 1.95 3.16 2.07 1.94 3.01

SO3 0.06 0.00 0.04 0.59 0.06 0.04 0.59 SO3 0.06 0.18 0.08 0.00 0.08 0.12 3.73 0.11 0.17

K2O 0.28 0.35 2.92 0.28 0.57 2.92 0.28 K2O 0.57 0.78 0.60 0.00 0.60 0.98 0.86 0.60 0.93

Na2O 0.12 0.07 0.33 0.21 0.14 0.33 0.21 Na2O 0.14 0.16 0.14 0.00 0.14 0.23 0.72 0.15 0.23

Cl 0.05 0.02 0.19 0.09 0.06 0.19 0.09 Cl 0.06 0.12 0.07 0.00 0.07 0.12 0.19 0.07 0.11

59.61 84.59 84.28 91.51

Total 100.00 100.00 100.00 100.00 0.95 Total 99.94 98.88 100.19 102.79 83.52 98.35

LSF 1.83 0.13 0.04 0.25 0.98 0.04 0.25 L.S.F 0.98 0.89 0.94 #DIV/0! 0.94 0.94 0.31 0.93 0.93

SM 1.98 33.02 2.45 0.30 2.35 2.45 0.30 S.M 2.35 2.11 2.33 #DIV/0! 2.33 2.33 1.47 2.30 2.30

AM 0.97 2.10 2.95 0.08 1.70 2.95 0.08 A.M 1.70 1.49 1.48 #DIV/0! 1.48 1.48 2.00 1.49 1.49

H.M 2.14 1.97 2.12 #DIV/0! 2.12 2.12 0.65 2.08 2.08

Raw Mix PileTarget Raw Meal Targets C3S 60.23 54.53

LSF 0.98 LSF 0.98 C2S 17.81 19.79

SM 2.35 SM 2.35 C3A 8.53 8.39

AM 1.70 AM 1.70 C4AF 11.61 11.25

C.Index 31.69 31.39

Material %age Tons Material %age LQ.Phase 29.67 28.85

F=3 87.00 8700 Raw Mix Pile 100.00 B.Z.Temp. 1393 1372.39

HSLS 2.00 200 B.Factor 113.77 112.18

Corrective Materials
CLAY 11.00 1100 B.Index 2.99 2.78

LATERITE 0.00 0 CLAY 0.00 MSO3 0.203 0.30

Target Tons of Pile 10000 LATERITE 0.00 ASR 0.168 0.24

A.E. 0.88 0.85

Total Coal Consumption/Hr
15.50 Q.H. 438.56 416.50
(Tons)
% Coal Ash 11

% Sulpher In Coal 1

Coal Ash Absorption tons 1.71

Kiln Feed T/hr 175 0.97

Recycle Dust % 15
 Raw Mix PileTarget ELEMENTS Proposed Raw Materials Raw Mix Pile Corrective Materials Percentage of elements
Proposed
LSF 0.98 limestone HSLS CLAY LETERITE CLAY LATERITE limestone HSLS CLAY LETERITE
Raw Mix
SM 2.35 T.CO3 84.9642 39.0026 16.178 37.9218 76.48 87 2 11 0
AM 1.70 LOI 40.39 15.41 15.72 8.49 37.18 15.72 8.49 73.92 0.78 1.78 0.00 76.48
Raw Meal Targets SiO2 7.72 60.43 51.16 16.11 13.55 51.16 16.11 35.14 0.31 1.73 0.00 37.18
LSF 0.98 Al2O3 1.92 1.24 15.61 3.81 3.41 15.61 3.81 6.72 1.21 5.63 0.00 13.55
SM 2.35 Fe2O3 1.97 0.59 5.29 49.29 2.31 5.29 49.29 1.67 0.02 1.72 0.00 3.41
AM 1.70 CaO 46.14 21.77 6.8 20.16 41.33 6.8 20.16 1.71 0.01 0.58 0.00 2.31
Clinker Targets MgO 1.35 0.12 1.94 0.97 1.39 1.94 0.97 40.14 0.44 0.75 0.00 41.33
LSF 0.93 SO3 0.06 0 0.04 0.59 0.06 0.04 0.59 1.17 0.00 0.21 0.00 1.39
SM 2.30 K2O 0.28 0.35 2.92 0.28 0.57 2.92 0.28 0.05 0.00 0.00 0.00 0.06
AM 1.50 Na2O 0.12 0.07 0.33 0.21 0.14 0.33 0.21 0.24 0.01 0.32 0.00 0.57
Material %age Tons Cl 0.05 0.02 0.19 0.09 0.06 0.19 0.09 0.10 0.00 0.04 0.00 0.14
limestone 87.00 8700 59.61 84.59 84.28 91.51 0.04 0.00 0.02 0.00 0.06
HSLS 2.00 200 Total 100.00 100.00 100.00 100.00 0.95 87 2 11 0 100
CLAY 11.00 1100 LSF 1.83 0.13 0.04 0.25 0.98 0.04 0.25
LETERITE 0.00 0 SM 1.98 33.02 2.45 0.30 2.35 2.45 0.30
Target Tons of Pile 10000 AM 0.97 2.10 2.95 0.08 1.70 2.95 0.08
Clinker Kiln Feed
Raw Meal EP Kiln Feed After without After add. Clinker
Material %age Elements Kiln Feed By Pass Coal Ash
Proposed Analysis By Pass coal ash Of Coal Proposed
absorption ASH

Raw Mix Pile 100.00 CaCO3 73.56 73.34 5.50

MgCO3 2.79 3.20 109.92

Corrective Materials
T.CO3 76.35 76.54 3.73
CLAY 0.00 LOI 37.18 34.31 36.75 36.91 113.65
LETERITE 0.00 SiO2 13.55 13.95 13.61 0.00 13.61 22.03 27.35 13.72 21.27

Total Coal Consumption(Tons) 480 Al2O3 3.41 3.95 3.49 0.00 3.49 5.65 12.40 3.58 5.55

Total Coal Consumption/Hr Fe2O3

(Tons)
20.00 2.31 2.65 2.36 0.00 2.36 3.82 6.20 2.39 3.71

% Coal Ash 11 CaO 41.33 40.50 41.20 0.00 41.20 66.68 30.00 40.96 63.49
% Sulpher In Coal 2 MgO 1.39 2.28 1.52 0.00 1.52 2.47 2.07 1.53 2.36
Coal Ash Absorption tons 2.20 SO3 0.06 0.18 0.08 0.00 0.08 0.12 3.73 0.11 0.18
Kiln Feed T/hr 201 1.09 K2O 0.57 0.78 0.60 0.00 0.60 0.98 0.86 0.60 0.94

Recycle Dust % 15 Na2O 0.14 0.16 0.14 0.00 0.14 0.23 0.72 0.15 0.23
Cl 0.06 0.12 0.07 0.00 0.07 0.12 0.19 0.07 0.11
Total 99.94 98.88 99.76 102.10 83.52 97.85
L.S.F 0.98 0.89 0.94 #DIV/0! 0.94 0.94 0.31 0.93 0.93
S.M 2.35 2.11 2.33 #DIV/0! 2.33 2.33 1.47 2.30 2.30
A.M 1.70 1.49 1.48 #DIV/0! 1.48 1.48 2.00 1.50 1.50
H.M 2.14 1.97 2.12 #DIV/0! 2.12 2.12 0.65 2.08 2.08
C3S 60.23 54.20
C2S 1.618385 0.00 100.00 1.55 98.62 17.81 20.18
C3A 8.53 8.44
C4AF 11.61 11.28
C.Index 31.69 31.58
LQ.Phase 28.98 28.30
B.Z.Temp. 1393 1370.30
B.Factor 113.08 111.33
B.Index 2.99 2.75
MSO3 0.203 0.31
ASR 0.168 0.25
A.E. 0.88 0.85

Q.H. 434.09 412.56

Raw Mix PileTarget Proposed Raw Materials
Elements EP Analysis
LSF 0.98 limestone HSLS CLAY BAUXITE

SM 2.35 SiO2 7.72 60.43 51.16 36.77 13.95

AM 1.70 Al2O3 1.92 1.24 15.61 31.5 3.95
Raw Meal Targets Fe2O3 1.97 0.59 5.29 17.6 2.65
LSF 0.98 CaO 46.14 21.77 6.8 7.28 40.50
SM 2.35 MgO 1.35 0.12 1.94 0.45 2.28
AM 1.70 SO3 0.06 0 0.04 0.57 0.18
K2O 0.28 0.35 2.92 0.16 0.78
Raw Meal Targets %age
Na2O 0.12 0.07 0.33 0.22 0.16
Cl 0.05 0.02 0.19 0.21 0.12
Raw Mix Pile 100.00
Elements Clinker Proposed
Corrective Materials
SiO2 21.27 L.S.F 0.93 LQ.Phase 28.30
CLAY 0.00 Al2O3 5.55 S.M 2.30 B.Z.Temp. 1370.30
Letrite 0.00 Fe2O3 3.71 A.M 1.50 B.Factor 111.33
Material %age Tons CaO 63.49 H.M 2.08 B.Index 2.75
limestone 87.00 8700 MgO 2.36 C3S 54.20 MSO3 0.31
HSLS 2.00 200 SO3 0.18 C2S 20.18 ASR 0.25
Clay 11.00 1100 K2O 0.94 C3A 8.44 A.E. 0.85
Bauxite 0 Na2O 0.23 C4AF 11.28
Target Tons of Pile 10000 Cl 0.11 C.Index 31.58 Q.H. 412.56
Total Coal
Total Coal
Consumption(Tons) 480
Consumption/Hr 20.00
(Tons)
% Coal Ash 11
% Sulpher In Coal 2
Coal Ash Absorption tons 2.20
Kiln Feed T/hr 201 1.09
Recycle Dust % 15
By Pass

0.00 1 % decrease in limestone

0.00
0.00 total pile capacity 10000
0.00
0.00 coal NCV 5700
0.00 total production 2850
0.00 total coal consumed 480
0.00 Total Kcal/kg-cli. 960
0.00 Heat of formation 412.56

coal equivalent to HOF 206.28

= 42.98

0
C Out of 480 ton of T.coal cosumed effective coal for HOF 206
After decrease 6 kcal/kg of HOF effective coal is 203
Total coal required for 203 ton effective coal 472.37

Diff. in total coal consumed 7.63

Rate of i ton of coal 14000

Price of coal saved 106852.82

Kcal/kg

12% Additives used in cement mill

cement mill feed 70

Additives 12
% of Gypsum 3.5
Pozzolona 2.83
GGBS 2.83
HSLS 2.83
Fly Ash
CLINKER 61.6

12% CLINKER SAVED 8.4

Difference of saving between clinker and additives 458568.24

Summary

By decreasing 6% C3S we can save 106852.82

By using additives to save 12% clinker 458568.24

Diff. in saving 351715.42
 6.04 kcal/kg-cli decreases

ton

Kcal/kg-coal
tons
tons
kcal/kg-cli
Kcal/kg-cli.

tons
% of total coal

TONS
TONS
tons

tons
PKR

rupees per day

TPH 1680 TPD rate/ton rupees

%
% 58.8 2057 120951.6
47.544 1650 78447.6
47.544 1720 81775.68
47.544 270 12836.88
30 450 13500
1034.88 total 307511.8

TONS 201.6 3800 766080

rupees per day

Rupees/day

Rupees/day
Rupees/day