Kiln Performance & Efficiency

S. Description Symbol Formula Example

No.
1 Degree of filling DF 3.2 * P P 6000 7500
3
% Deff * n * s Deff 4.76 4.76
P Clinker production, tpd n 4 4.5
Deff Burning zone effective diameter, mts S 3.5 3.5
n Kiln speed, rpm DF 12.72 14.13
s Kiln slope, % Target 14-16 14-16
2 Thermal loading TL Formula-1 F 15680 19760
or Gcal/hr/m2 F * NCV NCV 4500 4500
Burning zone loading A * 1000 * 1000 A 17.79 17.79
F Fuel rate in kiln, kg/hr TL 3.97 5.00
NCV Net calorific value of fuel, kcal/kg-fuel Target 4.0-5.0 4.0-5.0
A Burning zone cross-sectional area, m2

Formula-2 P 6000 7500

P*H H 282 282
A * 24 * 1000 A 17.79 17.79
P Clinker production, tpd TL 3.96 4.95
H Specific heat consumption in kiln, kcal/kg-clinker Target 4.0-5.0 4.0-5.0
A Burning zone cross-sectional area, m2
3 Volumetric loading VL P P 6000 7500
tpd/m3 A*L A 17.79 17.79
P Clinker production, tpd L 61 61
A Burning zone cross-sectional area, m2 VL 5.53 6.91
L Kiln length, mts Target 5.0-6.0 5.0-6.0
4 Material residence time in kiln RTK 19 * L L 61 61
min Deff * n * s Deff 4.76 4.76
L Kiln length, mts n 4 4
Deff Burning zone effective diameter, mts S 3.5 3.5
n Kiln speed, rpm RTK 17.4 17.4
s Kiln slope, % Target 20-25 20-25
5 Clinker residence time in cooler RTC 1.55 * A * Ps A 131.6 131.6
(Empirical relationship from min P Ps 1200 1200
F.L. Smidth) A Cooler grate cross-sectional area, m2 P 6000 7500
Ps Static pressure at clinker droping area, mmWg RTC 40.8 32.6
P Clinker production, tpd Target 20-25 20-25
6 True CO2 in kiln exit gas TCO2 100 * ( CO2 + CO ) CO2 36.5 36.5
vol% 100 + ( 1.89 * CO ) - ( 4.78 * O2 ) CO 0.002 0.002
CO2 Kiln exit gas CO2, vol% O2 4.2 4.2
CO2 Kiln exit gas CO, vol% TCO2 45.7 45.7
O2 Kiln exit gas O2, vol% Target - -
7 Excess air EA 79 * O2 O2 2.8 2.8
% 0.21 * ( 100 - CO2 ) - O2 CO2 26.5 26.5
O2 O2 content in gas, vol% EA 17.5 17.5
CO2 CO2 content in gas, vol% Target 10-15 10-15
8 Radiation heat losses RHL 4 * 10-8 * ( T4 - t4 ) T 517 517
kcal/hr/m2 T Radiating body temperature, K t 305 305
t Ambient air temperature, K RHL 2512 2512
Target - -
9 Convection heat losses CHL 80.33 * ( ( T + t ) / 2 )-0.724 * ( T - t )1.333 T 443 443
kcal/hr/m2 T Radiating body temperature, K t 308 308
t Ambient air temperature, K CHL 760 760
Target - -
10 Forced convection heat losses FCHL 28.03 * ( ( T + t ) / 2 )-0.351 * v0.805 * D-0.195 * ( T - t ) T 525 525
(when wind speed > 3.0 m/s) kcal/hr/m2 T Radiating body temperature, K t 302 302
t Ambient air temperature, K v 5 5
v Wind speed, m/s D 4.15 4.15
D Radiating body diameter, mts FCHL 2088 2088
Target - -
11 %Ash absorption in clinker %AA CC * Ash CC 26 26
% P Ash 15 15
CC Coal consumption, tph P 208 208
Ash Ash content in fuel (as fired basis), % %AA 1.88 1.88
P Clinker production, tph Target - -
 Kiln Performance & Efficiency
S. Description Symbol Formula Example
No.
12 Raw Mix:Clinker ratio RMCK 100 - %AA %AA 1.74 1.74
(dust to kiln) - 100 - LOI LOI 35.58 35.58
%AA %Ash absorption, % RMCK 1.525 1.525
LOI Loss on ignition of raw mix, % Target - -
13 Raw Mix:Clinker ratio RMCS ( 100 - %AA ) * 100 %AA 1.74 1.74
(dust to silo) - ( 100 - LOI ) * ( 100 - DL ) LOI 35.58 35.58
%AA %Ash absorption, % DL 8.5 8.5
LOI Loss on ignition of raw mix, % RMCS 1.667 1.667
DL Dust losses from preheater, % Target - -
14 Heat of reaction HR ( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMCK ) CaCO3 75.1 75.1
or kcal/ + ( 222 * Al2O3 / ( 100 - LOI ) ) + ( 11.6 * CH2O * RMCK ) RMCK 1.53 1.53
Theoretical heat required to kg-clinker - ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) ) MgCO3 1.6 1.6
produce 1 kg of clinker - ( 1000 * ( K2O + Na2O ) / ( 100 - LOI ) ) LOI 34.5 34.5
or - ( 79 * C * RMCK ) - ( 32 * S * RMCK ) Al2O3 4.17 4.17
Clinkerisation heat CaCO3 CaCO3 content in kiln feed, % CH2O 1.05 1.05
RMCK Kiln feed:Clinker ratio, - SiO2 13.47 13.47
(including Heat of combustibles) MgCO3 MgCO3 content in kiln feed, % Fe2O3 2.41 2.41
LOI LOI content in kiln feed, % K2O 0.38 0.38
Al2O3 Al2O3 content in clinker, % Na2O 0.27 0.27
CH2O Water of crystalisation in kiln feed, % C 0.2 0.2
SiO2 SiO2 content in clinker, % S 0.04 0.04
Fe2O3 Fe2O3 content in clinker, % HR 389 389
K2O K2O content in clinker, % Target - -
Na2O Na2O content in clinker, %
C Carbon content in kiln feed, %
S Sulphur as pyrites in kiln feed, %
15 False air w.r.t. mix FAMO ( O2mix - O2gas ) * 100 O2mix 3.6 3.6
(based on O2 analysis) % 21 - O2gas O2gas 2.8 2.8
O2mix O2 content in mixture of gas, vol% FAMO 4.4 4.4
O2gas O2 content in unmixed gas, vol% Target 5-7 5-7
16 False air w.r.t. gas FAGO ( O2mix - O2gas ) * 100 O2mix 3.6 3.6
(based on O2 analysis) % 21 - O2mix O2gas 2.8 2.8
O2mix O2 content in mixture of gas, vol% FAGO 4.6 4.6
O2gas O2 content in unmixed gas, vol% Target 5-7 5-7
17 False air w.r.t. mix FAMC ( CO2gas - CO2mix ) * 100 CO2mix 32.1 32.1
(based on CO2 analysis) % CO2gas CO2gas 34.5 34.5
CO2mix CO2 content in mixture of gas, vol% FAMC 7.0 7.0
CO2gas CO2 content in unmixed gas, vol% Target 5-7 5-7
18 False air w.r.t. gas FAGC ( CO2gas - CO2mix ) * 100 CO2mix 32.1 32.1
(based on CO2 analysis) % CO2mix CO2gas 34.5 34.5
CO2mix CO2 content in mixture of gas, vol% FAMC 7.5 7.5
CO2gas CO2 content in unmixed gas, vol% Target 5-7 5-7

19 Cooler Loading Cla P P 6000 7500

tpd/m2 A A 131.6 131.6
P Clinker production, tpd CL 45.59 56.99
A Cooler cross-sectional area, m2 Target 45-60 45-60
20 Cooler Loading CLw P P 6000 7500
tpd/m W W 4 4
P Clinker production, tpd CLw 1500 1875
W Cooler Width, m Target 1500 1500