Assumption

i. All weights & gas volumes are relative to " 1 " Kg Clinker.
ii. Temperatures ( oC ) are relative to 30 oC (Ambient).
iii. Calorific value of fuel is 9500 Kcal / Kg fuel
 Performance Test
Clinker Weighing Test
Period 72 hrs From 8/10/2005 at 13 00
To 10/10/2005 at 13 00

Kiln Feed (Total) 4844.36 Ton

Average 1614.79 Ton / d
67.28 Ton / h
67282.78 Kg / h

Main Burner Consumption 181.25 m3 % 44.359

Calciner Burners Consumption 227.35 m3 % 55.641
Total Fuel Consumption 408.6 m3
Average 5050.75 Kg / h

Calorific Value 9500 Kcal / Kg fuel

Fuel Density 890 Kg / m3

Total Clinker Weight 2748.85 Ton

Average 916.28 Ton / d
38.18 Ton / h
38178.5 Kg / h

Clinker Factor 0.5674

Calorific Consumption 1256.78 Kcal / Kg ck
1- Fuel
i. Main Burner 2240.45 Kg/hr SS3 / CCR Performance Test
ii.Calciner Burners 2810.29 Kg/hr SS3 / CCR Performance Test
iii.Specific Heat 0.47 Kcal/Kg C
o
Chart
iv.Temperature 115 o
C Thermometer Site measurments

2- Air
i. Primary Air 3000 Nm3/hr Process Flow Sheet
ii.Secondary Air 43600 Nm3/hr Process Flow Sheet
iii.Quench Air 8300 Nm3/hr Process Flow Sheet

3- Water
i. ByPass Cond. Tower 3700 Kg/hr Site Flowmeter Process Flow Sheet
ii.Clinker Crusher 36000 Kg/hr Site Flowmeter Process Flow Sheet
iii.Cooler 17500 Kg/hr Site Flowmeter Process Flow Sheet

4- Kiln Feed
i. Flow Rate 67283 Kg/hr SS3 / CCR Performance Test
ii.Temperature 83 o
C Thermometer Site measurments
iii.Specific Heat 0.22 Kcal/Kg
Refrences
i. The Cement Plant Operations Handbook ,

ii. Cement Manufacturer's Handbook ,

iii. F.L.Smidth International Cement Production Seminar.

iv. ASEC Cement Manufacturing Course.

v. El-Minya White Cement Plant (files,documents,flow sheets,

drawings,reports,………….etc.)
 Heat Balance Site Measurments
i. Kiln System
Point No. Location Dimensions Temp. Pressure FlowRate
1 Preheater Cyclone 1 Outlet Gas
2A Cyclone 1A (east) Outlet Gas
2B Cyclone 1B (west) Outlet Gas
3 Kiln Feed Airslide
4A Cyclone 1A Cone
4B Cyclone 1B Cone
5 Cyclone 2 Gas Inner Pipe (Before Kiln Feed)
6 Cyclone 3 Outlet Gas + Material
7 Cyclone 2 Cone
8 Cyclone 3 Outlet Gas
9 Cyclone 2 Outlet Material Pipe
10 Cyclone 4 Outlet Gas + Material
11 Cyclone 3 Cone
12 Cyclone 4 Outlet Gas
13 P.C. to Cyclone 4 Duct
14 Cyclone 3 Outlet Material Pipe (Before Diverter)
15 Cyclone 3 Diverter to P.C.
16 Cyclone 3 Diverter to Riser Duct
17 Cyclone 4 Cone
18 Cyclone 4 Outlet Material Pipe
19 P.C.
20 Secondary Air to P.C.
21 Secondary Air Outlet From Heat Exch.
22 Secondary Air to M.B.
23 Riser Duct Down
24 Riser Duct Up
25 ByPass Duct (After Quench)
 26 Quench Air Fan Duct
Point No. Location Dimensions Temp. Pressure FlowRate
27 Cond.Tower Outlet to EP Filter
28 EP Filter to ByPass Fan
29 ByPass Stack
30 Main EP Stack
31 Secondary Air Fan
32 Heat Exch. Inlet (At Cyclone 1 Gas Analyser)
33 Heat Exch. Outlet to ID Fan
34 Primary Air Fan
35 Cooler Outlet Gas to EP
36 Cooler Stack

Kiln Inlet Zone

Heat Exchanger Stages

Clinker Temp.