RADIATION CALCULATION FOR KILN 1 (From Kiln Outlet)

Ambient temperature 32 oC II Method

Kiln Avg Radiation, Heat transfer Heat transfer

Kiln Dia, Total C. S, Clinker, Radiation, Kcal/ Radiation, Kcal/
SN Location, m Length, Temp, Kcal/ kg coefficient coefficient
m m2 tph hr/m2 kg clinker
m oC clinker (Radiation) (Convection)

1 0 to 2 3.82 2 24.00 119.05 190 2544.79 0.513 12.047 6.667 0.513

2 2 to 4 3.82 2 24.00 119.05 205 2921.25 0.589 12.846 6.656 0.585
3 4 to 6 3.82 2 24.00 119.05 225 3466.47 0.699 13.974 6.625 0.689
4 6 to 8 3.82 2 24.00 119.05 220 3325.36 0.670 13.686 6.634 0.662
5 8 to 10 3.82 2 24.00 119.05 215 3187.49 0.643 13.401 6.642 0.636
6 10 to 12 3.82 2 24.00 119.05 190 2544.79 0.513 12.047 6.667 0.513
7 12 to 14 3.82 2 24.00 119.05 200 2792.77 0.563 12.576 6.661 0.560
8 14 to 16 3.82 2 24.00 119.05 205 2921.25 0.589 12.846 6.656 0.585
9 16 to 18 3.82 2 24.00 119.05 240 3909.86 0.788 14.868 6.594 0.774
10 18 to 20 3.82 2 24.00 119.05 260 4550.16 0.917 16.127 6.544 0.896
11 20 to 22 3.82 2 24.00 119.05 282 5323.88 1.073 17.600 6.480 1.044
12 22 to 24 3.82 2 24.00 119.05 304 6175.96 1.245 19.172 6.410 1.206
13 24 to 26 3.82 2 24.00 119.05 293 5739.75 1.157 18.374 6.446 1.123
14 26 to 28 3.82 2 24.00 119.05 268 4822.82 0.972 16.651 6.521 0.948
15 28 to 30 3.82 2 24.00 119.05 270 4892.52 0.986 16.785 6.516 0.961
16 30 to 32 3.82 2 24.00 119.05 230 3610.88 0.728 14.268 6.616 0.717
17 32 to 34 3.82 2 24.00 119.05 215 3187.49 0.643 13.401 6.642 0.636
18 34 to 36 3.82 2 24.00 119.05 195 2667.30 0.538 12.309 6.664 0.536
19 36 to 38 3.82 2 24.00 119.05 225 3466.47 0.699 13.974 6.625 0.689
20 38 to 40 3.82 2 24.00 119.05 223 3409.63 0.687 13.858 6.629 0.678
21 40 to 42 3.82 2 24.00 119.05 207 2973.50 0.600 12.956 6.653 0.595
22 42 to 44 3.82 2 24.00 119.05 215 3187.49 0.643 13.401 6.642 0.636
23 44 to 46 3.82 2 24.00 119.05 210 3052.81 0.615 13.122 6.650 0.610
24 46 to 48 3.82 2 24.00 119.05 225 3466.47 0.699 13.974 6.625 0.689
25 48 to 50 3.82 2 24.00 119.05 236 3788.62 0.764 14.626 6.603 0.751
26 50 to 52 3.82 2 24.00 119.05 251 4254.86 0.858 15.551 6.567 0.840
27 52 to 54 3.82 2 24.00 119.05 251 4254.86 0.858 15.551 6.567 0.840
28 54 to 56 3.82 2 24.00 119.05 251 4254.86 0.858 15.551 6.567 0.840
29 56 to 58 3.82 2 24.00 119.05 222 3390.80 0.684 13.820 6.630 0.675
30 58 to 60 3.82 2 24.00 119.05 285 5435.33 1.096 17.809 6.471 1.065
Total >> 22.89 22.49

Page 1 of 1
 RADIATION CALCULATION FOR PC AND PREHEATER

Ambient temperature 32 oC II Method

Cyclone Avg Radiation, Heat transfer Heat transfer

Clinker, Radiation,
SN Location surface Area Temp, Kcal/ kg coefficient coefficient
tph Kcal/ hr/m2
m2 oC clinker (Radiation) (Convection)

Kiln String

1.1 Cyclone - 1A 126.61 118.75 75.33 426.48 0.455 7.147 5.760

1.2 Bottom 38.85 118.75 90.00 614.79 0.201 7.663 6.091
1.3 Riser pipe 16.21 118.75 128.00 1188.56 0.162 9.145 6.521
1.4 meal pipe 9.24 118.75 264.00 4409.02 0.343 16.387 6.533
1.5 Roof 9.69 118.75 84.33 539.82 0.044 7.460 5.979
2.1 Cyclone - 1 B 126.61 118.75 91.67 637.36 0.680 7.723 6.120
2.2 Bottom 38.85 118.75 97.33 715.89 0.234 7.932 6.212
2.3 Riser pipe 16.21 118.75 125.67 1149.74 0.157 9.047 6.505
2.4 meal pipe 9.24 118.75 260.67 4303.84 0.335 16.170 6.542
2.5 Roof 9.69 118.75 91.00 628.30 0.051 7.699 6.109
3.1 Cyclone - 2 152.76 118.75 68.67 347.18 0.447 6.922 5.555
3.2 Bottom 51.19 118.75 80.00 484.36 0.209 7.308 5.881
3.3 Riser pipe 36.63 118.75 110.00 901.32 0.278 8.416 6.371
3.4 Meal pipe 9.24 118.75 147.33 1529.04 0.119 9.983 6.613
3.5 Roof 22.39 118.75 112.00 931.86 0.176 8.495 6.392
4.1 Cyclone - 3 151.13 118.75 68.67 347.18 0.442 6.922 5.555
4.2 Bottom 50.64 118.75 74.00 410.30 0.175 7.101 5.722
4.3 Riser pipe 36.92 118.75 178.00 2141.22 0.666 11.436 6.667
4.4 meal pipe 9.24 118.75 178.67 2155.56 0.168 11.469 6.667
4.5 Roof 15.10 118.75 82.67 518.29 0.066 7.401 5.943
5.1 Cyclone - 4 166.84 118.75 90.00 614.79 0.864 7.663 6.091
5.2 Bottom 53.75 118.75 105.00 826.49 0.374 8.222 6.315
5.3 Riser pipe 38.80 118.75 135.33 1313.74 0.429 9.456 6.563
5.4 Meal pipe 10.81 118.75 158.33 1738.14 0.158 10.486 6.643
5.5 Roof 16.45 118.75 83.33 526.87 0.073 7.424 5.957
6.1 Cyclone - 5 166.84 118.75 96.67 706.51 0.993 7.907 6.202
6.2 Bottom 53.75 118.75 131.67 1250.55 0.566 9.299 6.543
6.3 Riser pipe 38.80 118.75 116.67 1004.43 0.328 8.680 6.436
6.5 Meal pipe 10.81 118.75 165.67 1883.97 0.171 10.833 6.656
6.6 Roof 16.45 118.75 150.33 1584.93 0.220 10.118 6.622
6.7 Bypass 18.58 118.75 150.33 1584.93 0.248 10.118 6.622
6.8 PC 31.00 118.75 150.33 1584.93 0.414 10.118 6.622
Total >> 10.24

Page 1 of 1
ADIATION CALCULATION FOR PC AND PREHEATER

II Method

Radiation, Kcal/
kg clinker

0.513
0.224
0.177
0.356
0.049
0.757
0.260
0.171
0.347
0.057
0.506
0.235
0.306
0.128
0.193
0.501
0.197
0.706
0.178
0.074
0.964
0.413
0.465
0.169
0.082
1.102
0.615
0.360
0.183
0.236
0.267
0.445
11.234

Page 1 of 1
 Plant Operation Audit for two production lines (Line2 &3),

Annexure 4.1 A
CLINKER CONVERSION FACTOR - LINE 2

MEASUREMENTS TAKEN ON 27.11.2013

Sn Parameter Unit Value Basis

1 Kiln feed rate tph 200.00 CCR Indication

2 Loss on Ignition (LOI) of kiln feed % 35.80 As provided by JKCL

Calculated based on data provided by JKCL during

3 Fuel Consumption (mixed coal) % 16.80
process measurements
Calculated based on data provided by JKCLduring
4 Ash content in Fuel (mixed coal ) % 16.0
process measurements
Raw meal to clinker conversion factor
5 - 1.52 Calculated
(On LOI basis) (CF 1)

6 Dust loss from Preheater % 10.00 As provided by JKCL during process measurements

Kiln feed to clinker conversion factor

7 - 1.684 Calculated
(with return dust) (CF 2)

tph 118.75 Calculated

8 Clinker produced
tpd 2850 Calculated

13170 Page 1 of 1
 Plant Operational Audit for two production lines ( Line 2&3),

Annexure 4.3 A
GAS FLOW MEASUREMENT - LINE 2
Pitot constant 0.836
Site pressure 10209 mmWG Site elevation 96 m
Clinker RMS Avg Specific air
Duct Static Velocity on Volume on RMS
Production Duct dia. Temp. Dynamic Pressure, mmWG dynamic Density consp. on
area pressure RMS Avg Average
Rate pressure RMS Avg.
S.N. Location Date
No of Nm3/kg
tph m m2 oC mmWG 1 2 3 4 5 6 7 8 9 10 mmWG Kg/ Nm3 mps m3/ h Nm3/ h
points clinker

10.0 13.0 13.0 12.0 17.0 25.0 24.0 23.0 26.0 27.0

Preheater Exit
1 26.11.13 118.75 3.5 9.625 315 -670 27.0 27.0 26.0 26.0 24.0 20.0 23.0 19.0 20.0 14.0 30 19.85 1.42 21.15 732917 314144 2.645
(WHR inlet)

16.0 18.0 20.0 21.0 16.0 17.0 16.0 15.0 26.0 25.0

15.0 18.0 18.0 17.0 18.0 19.0 18.0 17.0 16.0 17.0

Cooler exhaust 18.0 15.0 17.0 16.0 15.0 15.0 17.0 17.0 18.0 18.0
2 26.11.13 118.75 2.80 6.16 418 -27 20 16.93 1.293 21.48 476266 185418 1.56
(WHR inlet)

25.0 27.0 24.0 23.0 24.0 24.0 28.0 24.0 23.0 24.0
3 Tertiary air 26.11.13 118.75 3.1 7.55 930 -70 23.0 24.0 23.0 24.0 26.0 28.0 24.0 27.0 10.0 12.0 24 22.63 1.293 32.83 892473 198734 1.67
13.0 25.0 22.0 23.0
4.0 5.0 4.0 6.0 6.0 5.0 6.0 5.0 6.0 5.0
Cooler vent ESP
4 26.11.13 118.75 2.50 4.911 150 -6 5.0 7.0 6.0 8.0 8.0 9.0 8.0 6.0 5.0 4.0 23 5.66 1.293 9.71 171586 109349 0.92
stack Romanian
5.0 5.0 4.0
29.0 30.0 31.0 28.0 27.0 30.0 28.0 29.0 32.0 28.0
Preheater Exit
5 26.11.13 118.75 3.2 8.046 197 -770 29.0 30.0 29.0 28.0 28.0 29.0 33.0 31.0 29.0 30.0 23 29.29 1.42 23.09 668782 354863 2.988
(WHR outlet)
28.0 30.0 28.0
4.0 5.0 4.0 6.0 6.0 5.0 6.0 5.0 6.0 5.0
Cooler vent ESP
26.11.13 118.75 1.62 2.062 150 -6 5.0 7.0 6.0 8.0 8.0 9.0 8.0 6.0 5.0 4.0 23 5.66 1.293 9.71 72050 45916 0.387
stack A-tec
5.0 5.0 4.0
25.0 27.0 24.0 23.0 24.0 24.0 28.0 24.0 23.0 24.0
bypass duct 26.11.13 118.75 1.32 1.37 550 -70 23.0 24.0 23.0 24.0 26.0 28.0 24.0 27.0 10.0 12.0 24 22.63 1.293 27.16 133840 43564 0.37
13.0 25.0 22.0 23.0
25.0 27.0 24.0 23.0 24.0 24.0 28.0 24.0 23.0 24.0
Quinch air in
26.11.13 118.75 1.25 1.23 930 -70 23.0 24.0 23.0 24.0 26.0 28.0 24.0 27.0 10.0 12.0 24 22.63 1.293 32.83 145108 32312 0.27
bypass duct
13.0 25.0 22.0 23.0

13170 Page 5 of 2
 Plant Operational Audit for tproduction lines ( Line2 ),

Annexure 4.3 A
GAS FLOW MEASUREMENT OF IKN (TYPE-GRATE)COOLER - LINE 2 Design Prod. 3300
PRODUCTION 2850 TPD Design Prod. 137.5 tph
COOLING AIR FANS 118.75 TPH Design temp 40
Site pressure 10209 mmWG Site elevation 96 m Design Specifications
Fan outlet Avg Total Head
Suction Temp No of Specific gas Fan inlet Design Design Nm3/k
Duct area Static Air Velocity, mps velocit Volume designed Volume Power developed Efficiency Design , KW Avg velocity
duct dia. . values consp. Pressure Pressure capacity g clink
pressure y by fan
S.N. Fan No Date Nm3/hr
tph m m2 mmWC oC m3/ h m3/ s kg/m3 kg/hr kg/kg_cli m3/ s Nm3/ h Nm3/kg clinker kW mmWC mmWC % KW mmWC m3/ h
1 2 3 4 5 6 7 8 9 10 mps mps

21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4
1 CF 1 26.11.13 118.75 0.5 0.196 960 32 17 21.39 15120 4.2 1.3 18916 0.16 4.2 13371 0.113 55 -18 978 0.82 55.00 21.39 960.47

21.4 21.4 21.4 21.4 21.4 21.4 21.4 15120 14260 0.1037

22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4
2 CF 2 26.11.13 118.75 0.5 0.196 960 32 19 22.41 15841 4.4 1.3 19816 0.17 4.4 14009 0.118 58 -31 991 0.82 55.00 22.41 959.55

22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4 15840 14938 0.1086

22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4 22.4
3 CF 3 26.11.13 118.75 0.5 0.196 960 32 13 22.41 15841 4.4 1.3 19816 0.17 4.4 14009 0.118 57 -14 974 0.82 55.00 22.41 959.55

22.4 22.4 22.4 15840 14938 0.1086

20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1 20.1
4 CF 4 26.11.13 118.75 0.9 0.636 602 32 14 20.12 46079 12.8 1.2 55796 0.47 12.8 40751 0.343 94 -16 618 0.92 110.00 20.12 601.63

20.1 20.1 20.1 20.1 46080 42062 0.3059

20.4 20.4 20.4 20.4 20.4

5 CF 5 26.11.13 118.75 1 0.785 550 32 5 20.37 57595 16.0 1.2 69404 0.58 16.0 50935 0.429 122 -23 573 0.82 110.00 20.37 549.63

57600 52325 0.3805

18.6 18.6 18.6 18.6 18.6 18.6 18.6 18.6 18.6

6 CF 6 26.11.13 118.75 1 0.785 488 32 9 18.59 52562 14.6 1.2 62979 0.53 14.6 46484 0.391 103 -43 531 0.82 90.00 18.59 488.44

52560 47475 0.3453

20.8 20.8 20.8 20.8 20.8 20.8 20.8 20.8 20.8 20.8
7 CF 7 26.11.13 118.75 1 0.785 449 32 13 20.75 58669 16.3 1.2 70036 0.59 16.3 51885 0.437 105 -34 483 0.82 110.00 20.75 448.68

20.8 20.8 20.8 58680 52806 0.384

21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4
8 CF 8 26.11.13 118.75 0.9 0.636 379 32 16 21.38 48965 13.6 1.2 58071 0.49 13.6 43303 0.365 72 -16 395 0.82 75.00 21.38 379.33

21.4 21.4 21.4 21.4 21.4 21.4 48960 43772 0.3183

0.972333333333333 1.67 274746 1

Fan outlet Total Head

Suction Temp Fan inlet
Duct area Static developed Efficiency
duct dia. . Air Velocity, mps Pressure
pressure Total specific cooling air 2.31 665 by fan 660.000 14.141 2.0551
BLOWERS tph m m2 mmWC oC mps m3/ h m3/ s KG/M3 kg/hr kg/kg_cli m3/ s Nm3/ h Nm3/kg clinker kW mmWC mmWC % KW mps mmWC m3/ h 282575
Main firing -Primary air
1 26.11.13 118.75 0.28 0.06 9 35 28.40 28.40 28.40 28.40 28.40 28.40 28.40 28.40 28.40 28.40 10 28.40 6073 1.69 1.13 6882 0.06 1.67 5318 0.045 28.84 -1274.640 1283.640 0.818 28.400 28.116 1274.640 6012.000 5829.431 0.042
(BLOWER) fan - Kiln

Main firing -Primary air

26.11.13 118.75 0.32 0.08 8 43 26.69 26.69 26.69 26.69 26.69 26.69 26.69 26.69 26.69 26.69 10 26.69 7488 2.08 1.10 8271 0.07 2.08 6392 0.054 56.73 -2039.430 2047.430 0.818 56.000 26.690 2039.430 7488.000 7744.142 0.056
(BLOWER) fan - PC

Kiln Coal conveying root

2
blower
26.11.13 118.75 0.25 0.05 18.7 35 19.19 19.19 19.19 19.19 19.19 19.19 19.19 19.19 19.19 19.19 10 19.19 3500 0.97 1.13 3971 0.03 0.97 3065 0.026 132.32 -10197.160 10215.860 0.818 132.000 19.189 10197.160 3500.400 6031.181 0.044

PC Coal conveying root

3
blower
26.11.13 118.75 0.30 0.07 18.7 35 14.14 14.14 14.14 14.14 14.14 14.14 14.14 14.14 14.14 14.14 10 14.14 3715 1.03 1.13 4214 0.04 1.03 3253 0.027 140.41 -10197.160 10215.860 0.818 107.660 14.141 10197.160 3714.600 6400.247 0.047

Fan outlet Total Head

Suction duct Avg Fan inlet Design Design
dia.
Duct area Static Temp. No of values
velocity
Volume designed Volume Specific gas consp. Power
Pressure
developed by Efficiency Design , KW Avg velocity
Pressure capacity Nm3/kg
S.N. Fan No Date Air Velocity, mps fan Nm3/hr
pressure clink
tph m m2 mmWC oC mps m3/ h m3/ s KG/M3 kg/hr kg/kg_cli m3/ s Nm3/ h Nm3/kg clinker kW mmWC mmWC % KW mps mmWC m3/ h
10.0 13.0 13.0 12.0 17.0 25.0 24.0 23.0 26.0 27.0
Preheater Exit (WHR inlet) 26.11.13 118.75 3.6 10.18 315 380 27.0 27.0 26.0 26.0 24.0 20.0 23.0 19.0 20.0 14.0 30 19.85 727515.7 202.09 0.55 400548.66 3.37 12 300510 2.531 877.57 -11 326 1 78 0 379 5643 5045 0.04
16.0 18.0 20.0 21.0 16.0 17.0 16.0 15.0 26.0 25.0
15.0 18.0 18.0 17.0 18.0 19.0 18.0 17.0 16.0 17.0
Cooler exhaust (WHR inlet) 26.11.13 118.75 3.60 10.18 418 320 18.0 15.0 17.0 16.0 15.0 15.0 17.0 17.0 18.0 18.0 20 16.93 620311.6 172.31 0.61 379761.59 3.20 23 282154 2.376 984.66 -11 429 1 78 0 379 5643 5045 0.04

25.0 27.0 24.0 23.0 24.0 24.0 28.0 24.0 23.0 24.0
Tertiary air 26.11.13 118.75 3.1 7.55 930 550 23.0 24.0 23.0 24.0 26.0 28.0 24.0 27.0 10.0 12.0 24 22.63 614864.7 170.80 0.46 284295.91 2.39 12 201516 1.697 2140.86 -11 941 1 78 0 379 5643 5045 0.04
13.0 25.0 22.0 23.0
9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0
Cooler vent ESP stack
26.11.13 118.75 2.80 6.16 150 240 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 30 9.00 199503.7 55.42 0.69 137624.85 1.16 58 104897 0.883 221.46 -150 300 1 200 9 -150 210000 178362 1.30
Romanian
9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0
29.0 30.0 31.0 28.0 27.0 30.0 28.0 29.0 32.0 28.0
Preheater Exit (WHR
26.11.13 118.75 3.6 10.18 197 210 29.0 30.0 29.0 28.0 28.0 29.0 33.0 31.0 29.0 30.0 23 29.29 1073189 298.11 0.74 789874.84 6.65 23 599321 5.047 825.96 -11 208 1 78 0 379 5643 5045 0.04
outlet)
28.0 30.0 28.0
6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
Cooler vent ESP stack A-
26.11.13 118.75 3 7.07 9 100 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 30 6.00 152681.4 42.41 0.94 142885.71 1.20 42 110410 0.930 372.30 -650 659 1 500 6 -650 150000 121069 0.88
tech
6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0
25.0 27.0 24.0 23.0 24.0 24.0 28.0 24.0 23.0 24.0
bypass duct 26.11.13 118.75 1.32 1.37 5 250 23.0 24.0 23.0 24.0 26.0 28.0 24.0 27.0 10.0 12.0 24 22.63 111481.8 30.97 0.67 74377.88 0.63 12 57495 0.484 125.81 -300 305 1 160 27 300 134000 118904 0.86
13.0 25.0 22.0 23.0
25.0 27.0 24.0 23.0 24.0 24.0 28.0 24.0 23.0 24.0
Quinch air in bypass duct 26.11.13 118.75 1.25 1.23 4 100 23.0 24.0 23.0 24.0 26.0 28.0 24.0 27.0 10.0 12.0 24 22.63 99971.5 27.77 0.94 93511.77 0.79 12 72293 0.609 75.46 -200 204 1 75 21 200 93960 82581 0.60
13.0 25.0 22.0 23.0

13170 Page 2 of 2
 Plant Operational Audit for two production lines ( Line2& 3),
J K Lakshmi Cement Ltd, Sirohi Rajasthan

Annexure 4.4A
KILN SHELL TEMPERATURE LINE 2

S.N. Location (From kiln outlet), m Average temperature, oC

1 0 to 2 364

2 2 to 4 280

3 4 to 6 281

4 6 to 8 291

5 8 to 10 246

6 10 to 12 204

7 12 to 14 165

8 14 to 16 347

9 16 to 18 318

10 18 to 20 351

11 20 to 22 201

12 22 to 24 225

13 24 to 26 257

14 26 to 28 327

15 28 to 30 215

16 30 to 32 318

17 32 to 34 309

18 34 to 36 305

19 36 to 38 307

20 38 to 40 257

21 40 to 42 260

22 42 to 44 215

23 44 to 46 228

24 46 to 48 221

25 48 to 50 212

26 50 to 52 218

27 52 to 54 209

28 54 to 56 209

29 56 to 58 222
30 58 to 60 285

13170 Page 1 of 1
 Plant Operational Audit for two production lines ( Line 2& 3),
J K Lakshmi Cement Ltd, Sirohi Rajasthan

Annexure 4.5A

CHEMICAL ANALYSIS OF CLINKER LINE 2

Component Unit Value

SiO2 % 20.94

Al2O3 % 5.71

Fe2O3 % 3.75

CaO % 63.87

MgO % 3.02

SO3 % 1.45

K2O % 0.73

Na2O % 0.31

Cl % 0.00

Free CaO % 1.89

13170 Page 1 of 1
 Plant Operational Audit for production lines ( Line 2& 3),

Annexure 4.7 A
COOLER HEAT BALANCE LINE 2

Secondary air Tertiary Air

Mass -1.19 Kg/ kg clk Mass 2.16 Kg/ kg clk

Temp. 1140 0
C Temp. 930 0
C
Heat flow -357.45 Kcal/ kg clk. Heat flow 519.98 Kcal/ kg clk.

Cooler exhaust

Mass 2.02 Kg/ kg clk

Temp. 418 0
C
Heat flow 208.11 Kcal/ kg clk.

Clinker

Mass 1.00 Kg/ kg clk

Temp. 130 0
C
Clinker Heat flow 25.09 Kcal/ kg clk.

Mass 1.00 Kg/ kg clk

Temp. 1450 0
C
Heat flow 383.24 Kcal/ kg clk.
Total cooling air Cooler radiation losses
Heat recuperation efficiency 2.69 Kcal/ kg clk.
40.8 % Mass 2.99 Kg/ kg clk
Total Cooler losses Temp. 32 0
C
235.9 kcal/kg clinker Heat flow 22.76 Kcal/ kg clk.

13170 Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

HOLTEC
OMAN CEMENT COMPANY, OMAN

RADIATION CALCULATION FOR KILN 1 (From Kiln1 Outlet)

Ambient temperature 32 oC II Method

Heat Heat
Radiati Radiati
transfer transfer
Kiln Avg on, on,
Kiln Dia, Total C. Clinke Radiation, coeffici coefficien
S NLocation, m Lengt Temp, Kcal/ Kcal/
m S, m2 r, tph Kcal/ hr/m2 ent t
h, m oC kg kg
(Radiati (Convecti
clinker clinker
on) on)

1 0 to 2 3.82 2 24.00 119.05 190 2406.48 0.485 12.047 6.667 0.513

2 2 to 4 3.82 2 24.00 119.05 205 2759.76 0.556 12.846 6.656 0.585
3 4 to 6 3.82 2 24.00 119.05 225 3270.49 0.659 13.974 6.625 0.689
4 6 to 8 3.82 2 24.00 119.05 220 3138.41 0.633 13.686 6.634 0.662
5 8 to 10 3.82 2 24.00 119.05 215 3009.29 0.607 13.401 6.642 0.636
6 10 to 12 3.82 2 24.00 119.05 190 2406.48 0.485 12.047 6.667 0.513
7 12 to 14 3.82 2 24.00 119.05 200 2639.25 0.532 12.576 6.661 0.560
8 14 to 16 3.82 2 24.00 119.05 205 2759.76 0.556 12.846 6.656 0.585
9 16 to 18 3.82 2 24.00 119.05 240 3685.14 0.743 14.868 6.594 0.774
10 18 to 20 3.82 2 24.00 119.05 260 4282.99 0.864 16.127 6.544 0.896
11 20 to 22 3.82 2 24.00 119.05 282 5004.16 1.009 17.600 6.480 1.044
12 22 to 24 3.82 2 24.00 119.05 304 5797.04 1.169 19.172 6.410 1.206
13 24 to 26 3.82 2 24.00 119.05 293 5391.29 1.087 18.374 6.446 1.123
14 26 to 28 3.82 2 24.00 119.05 268 4537.27 0.915 16.651 6.521 0.948
15 28 to 30 3.82 2 24.00 119.05 270 4602.25 0.928 16.785 6.516 0.961
16 30 to 32 3.82 2 24.00 119.05 230 3405.61 0.687 14.268 6.616 0.717
17 32 to 34 3.82 2 24.00 119.05 215 3009.29 0.607 13.401 6.642 0.636
18 34 to 36 3.82 2 24.00 119.05 195 2521.50 0.508 12.309 6.664 0.536
19 36 to 38 3.82 2 24.00 119.05 225 3270.49 0.659 13.974 6.625 0.689
20 38 to 40 3.82 2 24.00 119.05 223 3217.30 0.649 13.858 6.629 0.678
21 40 to 42 3.82 2 24.00 119.05 207 2808.75 0.566 12.956 6.653 0.595
22 42 to 44 3.82 2 24.00 119.05 215 3009.29 0.607 13.401 6.642 0.636
23 44 to 46 3.82 2 24.00 119.05 210 2883.09 0.581 13.122 6.650 0.610
24 46 to 48 3.82 2 24.00 119.05 225 3270.49 0.659 13.974 6.625 0.689
25 48 to 50 3.82 2 24.00 119.05 236 3571.82 0.720 14.626 6.603 0.751
26 50 to 52 3.82 2 24.00 119.05 251 4007.39 0.808 15.551 6.567 0.840
27 52 to 54 3.82 2 24.00 119.05 251 4007.39 0.808 15.551 6.567 0.840
28 54 to 56 3.82 2 24.00 119.05 251 4007.39 0.808 15.551 6.567 0.840
29 56 to 58 3.82 2 24.00 119.05 222 3199.67 0.645 13.820 6.630 0.675
30 58 to 60 3.82 2 24.00 119.05 285 5107.93 1.030 17.809 6.471 1.065
Total >> 21.57 22.49

(Draft) Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

HOLTEC

(Draft) Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

HOLTEC
OMAN CEMENT COMPANY, OMAN
RADIATION CALCULATION FOR PC AND PREHEATER

Ambient temperature 32 oC II Method

Heat Heat
Cyclon
Radiati transfer transfer Radiatio
e Avg Radiation,
Clinke on, coeffici coefficie n, Kcal/
SN Location Diameter, m Length, m surface Temp, Kcal/
r, tph Kcal/ kg ent nt kg
Area oC hr/m2
clinker (Radiati (Convecti clinker
m2
on) on)
1.1 Cyclone – I A 5.06 3.75 59.61 119.05 92.00 641.91 0.321 7.736 6.126 0.358
1.2 Bottom 5.06 8.3 79.01 119.05 56.00 208.11 0.138 6.512 5.009 0.158
1.3 Riser pipe 1.70 2 10.68 119.05 42.00 74.87 0.007 6.083 3.909 0.008
1.4 Meal pipe 0.40 8.3 10.43 119.05 260.00 4282.99 0.375 16.127 6.544 0.389
1.5 Down commer duct 3.6 30 339.29 119.05 42.00 74.87 0.213 6.083 3.909 0.245
1.6 Roof 5.06 - 17.84 119.05 87.00 574.75 0.086 7.555 6.034 0.096
1.7 Cyclone – I B 5.06 3.75 59.61 6.00 60.00 250.31 2.487 6.639 5.210 2.834
1.8 Bottom 5.06 8.3 79.01 119.05 51.00 157.78 0.105 6.355 4.706 0.120
1.9 Riser pipe 1.70 2 10.68 119.05 42.00 74.87 0.007 6.083 3.909 0.008
2.0 Meal pipe 0.40 2 2.51 119.05 290.00 5283.89 0.112 18.160 6.455 0.115
2.1 Roof 5.06 - 17.84 119.05 87.00 574.75 0.086 7.555 6.034 0.096
2.2 Cyclone – II 4.83 3.7 56.14 119.05 65.00 305.31 0.144 6.801 5.421 0.164
2.3 Bottom 4.83 5 45.79 119.05 68.00 339.47 0.131 6.900 5.532 0.148
2.4 Riser pipe 2.60 7.5 20.20 119.05 52.00 167.62 0.028 6.386 4.772 0.033
2.5 Meal pipe 0.40 3.2 4.02 119.05 320.00 6421.91 0.217 20.377 6.357 0.224
2.7 Roof 4.83 - 13.01 119.05 70.00 362.71 0.040 6.966 5.599 0.045
2.8 Cyclone – III 4.83 3.7 56.14 119.05 80.00 484.36 0.228 7.308 5.881 0.257
2.9 Bottom 4.83 5 45.79 119.05 75.00 422.42 0.162 7.135 5.751 0.183
3.0 Riser pipe 2.60 7.5 20.20 119.05 60.00 250.31 0.042 6.639 5.210 0.048
3.1 Meal pipe 0.40 3.2 4.02 119.05 366.00 8466.77 0.286 24.151 6.198 0.294
3.2 Roof 4.83 - 13.01 119.05 87.00 574.75 0.063 7.555 6.034 0.070
3.3 Cyclone – IV 6.63 3.7 77.07 119.05 101.50 775.38 0.502 8.089 6.270 0.555
3.4 Bottom 6.63 6.5 77.90 119.05 99.00 739.51 0.484 7.995 6.236 0.536
3.5 Riser pipe 3.60 9.5 26.20 119.05 104.00 811.78 0.179 8.184 6.302 0.197
3.6 Meal pipe 0.40 3.2 4.02 119.05 366.00 8466.77 0.286 24.151 6.198 0.294
3.7 Roof 6.63 - 24.34 119.05 87.00 574.75 0.118 7.555 6.034 0.131
3.8 Cyclone – V 4.83 3.7 56.14 119.05 87.00 574.75 0.271 7.555 6.034 0.303

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Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

Kiln 1 Heat Balance

Kiln feed rate Tph 200.00

Clinker prouction 'tph 119.048
'tpd 2857.14
KF to clinker conversion factor 1.68
Raw meal temperature oC 60
Raw meal moisture % 0.5
PH exit gas O2 % 6.0
Clinker temperature oC 110.0
Natural Gas temperature to kiln oC 75
Natural Gas temperature to PC oC 75
Atmosphere Gas density Kg/nm3 1.293
Ambiant temperature oC 32
Dust loss (assumed) % 10.00
Cooler radiation Kcal/kg clinker 2.95
Drop in temp at two end of TAD oC 96
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman Page 1 of 1

COOLER AIR & HEAT BALANCE

Plant capacity t/d 2357

Sp. heat capacity Kcal/kgclk. 800
Fuel firing in Kiln % 40
Air density Kg/nm3 1.293
Ambient temp. oC 23
Combustion air for kiln Kg/kg clinker 0.494
Nm3/kg clinker 0.382
Combustion air for PC Kg/kg clinker 0.748
Nm3/kg clinker 0.579
Primary air to kiln Kg/kg clinker 0.058
Nm3/kg clinker 0.045
Primary air to PC Kg/kg clinker 0.070
Nm3/kg clinker 0.054
Secondary air to kiln Kg/kg clinker 0.436
Nm3/kg clinker 0.337
Tertiary air to PC Kg/kg clinker 0.679
Nm3/kg clinker 0.525
Cooler vent air Kg/kg clinker 2.019
Nm3/kg clinker 1.561
Total Cooling air Kg/kg clinker 3.081
Nm3/kg clinker 2.383

Heat balance

Sn Item Flow Temp Cp

kg/ kg clinker 0C Kcal/ kg 0C
1 Secondary air to kiln 0.43630348201145 1060 0.26
2 Tertiary air to PC 0.679 883 0.25

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Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman Page 1 of 1

Heat
Kcal/ kg clinker
120.24523964236
149.79718832906

(Draft) Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman Page 1 of 1

COOLER HEAT BALANCE

Tertiary air
M T Cp H
Kg/kg Kcal/kg
oC Kcal/ kgoC
clk clk
0.68 883 0.25 150

Secondary air
M T Cp H
Kg/kg Kcal/kg
clk
OC Kcal/ kgoC
clk
0.44 1060 0.26 120

Kiln

Hot clinker
Cooler
M T Cp H
Kg/kg Kcal/kg
clk
OC Kcal/ kgoC
clk
1.00 1450 0.26 377

Cooling air
M T Cp H
Kcal/kg
Kg/kg clk OC Kcal/ kgoC
clk
3.08 23 0.24 17

Recuperatuion Efficiency : 68.54 %

(Draft) Page 1 of 1
 RADIATION CALCULATION FOR COOLER

Ambient temperature 32 oC II Method

Avg Radiation, Heat transfer Heat transfer

surface Area Clinker, Radiation,
SN Location Temp, Kcal/ kg coefficient coefficient
m2 tph Kcal/ hr/m2
oC clinker (Radiation) (Convection)

1.1 Cooler 248.40 118.75 113.11 948.97 1.985 8.538 6.403

1.2 Cooler roof 61.48 118.75 138.50 1369.28 0.709 9.593 6.578
Total >> 2.69

Page 1 of 1
RADIATION CALCULATION FOR COOLER

II Method

Radiation, Kcal/
kg clinker

2.180
0.767
2.946

Page 1 of 1
 HEAT BALANCE

1 Kiln feed temperature o

C 60 o
C Primary air temp Deg C 50
2 Kiln feed moisture % 0.2 %
3 Fine Coal moisture % 0.5 %
4 PH exit gas CO2 % 18 %
5 O2 % 4.0 %
6 N2 % 78.0 %
7 Clinker temperature o
C 130 o
C
8 Temperature of Coal fired in kiln o
C 50 o
C
9 Temperature of Coal fired in PC o
C 50 o
C
10 Gas density Kg/nm3 1.293 Kg/nm3
11 Ambiant temperature o
C 28 o
C
12 Dust loss % 10.00 %
13 Cooler radiation Kcal/kg clinker 2.69 Kcal/kg clinker
14 Kiln radiation Kcal/kg clinker 22.9 Kcal/kg clinker
15 PH radiation Kcal/kg clinker 10.24 Kcal/kg clinker
KILN, PREHEATER AND COOLER -Kiln 2
Clinker production 2850 tpd
Sp. heat
S. Gas flow, Nm3/kg Heat, Mass flow
Stream Flow, Kg/ Kg clinker Temp, oC % Heat Kcal/KgoC
N. clinker Kcal/ kg clk tph

1 Sensible Heat of kiln feed 1.681 60 21.37 2.21 199.60 0.21

2 Sensible Heat of kiln feed moisture 0.003 60 0.20 0.02 0.40 1.00
3 Sensible Heat of Fuel 0.167 50 2.34 0.24 19.85 0.28
4 Sensible Heat of fine fuel moisture 0.0008 50 0.01 0.001 0.10 0.28
5 Sensible Heat of Primary air to Kiln 0.045 0.058 50 0.69 0.07 6.88 0.24

6 Sensible heat of coal conveying air to kiln 0.026 0.033 50 0.40 0.04 3.96 0.24

7 Sensible Heat of Cooler air 2.314 2.991 28 19.91 2.06 355.25 0.24
8 Sensible Heat of false air 0.305 0.394 28 2.62 0.27 46.81 0.24

9 Sensible heat of coal conveying air to PC 0.027 0.035 50 0.42 0.04 4.21 0.24
10 Heat from Fuel 920 95.04 0.00
11 Calcination Gases 0.278
12 Combustion Gases only 0.043
Total Heat Input >> 3.04 5.36 968 100.00 637.1

Heat Output
1 Heat loss through Clinker 1.000 130 25.09 2.59 118.75 0.193
2 Heat loss through PH exhaust gas 2.566 3.644 315 282.4 29.18 432.70 0.25
3 Heat loss through PH return dust 0.168 315 12.42 1.28 20.00 0.23
4 Heat loss through Cooler exhaust air 1.56 2.019 418 208.1 21.50 239.75 0.25
5 Heat of Formation for Clinker 401.1 41.44
6 Evaporation of Moisture in kiln feed 0.003 315 2.28 0.24 0.40 0.46
7 Evaporation of Moisture in fine fuel 0.0008 315 0.58 0.06 0.10 0.46
8 Preheater radiation losses 10.24 1.06 0.00

9 Kiln and cooler radiation losses 25.58 2.64 0.00

Total Heat Output >> 4.13 6.84 967.8 100.00 812

 Cooler 2 Heat Balance -Kiln 2

Data
Clinker Production tpd 2850
Specific Heat Consumption kcal/kg clinker 920
% of fuel to Kiln % 31.1
% of fuel to PC % 68.9
Clinker temperature Deg C 130
Cooler Exhaust Temperature Deg C 418
Secondary Deg C 1140
Tertiary Air Temperature Deg C 930
Primary air to kiln kg/kg clinker 0.058
Primary air to PC kg/kg clinker 0.035
Secondary Air Quantity kg/kg clinker -1.191
Tertiary quantity kg/kg clinker 2.164
Density of air kg/nm3 1.293
Ambient Air Temperature Deg C 32

Sn Description Flow Temperature Cp Heat

kg/kg clinker Deg C kcal/kg oC kcal/kg clinker
HEAT INPUT
1 Hot Clinker 1.00 1450 0.264 383
2 Cooling Air 2.99 32 0.238 22.8
Total 3.99 406.0
HEAT OUTPUT
3 Heat loss through Cooler Exhaust air 2.02 418 0.247 208.1
4 Secondary air -1.191 1140 0.263 -357.5
5 Tertiary Air 2.164 930 0.258 520.0
6 Heat loss through Clinker 1.00 130 0.193 25.1
7 Cooler Radiation losses 2.7
Total 3.99 398.4
% of Heat Recuperation Efficiency 41
Total Cooler losses 236
 Heat loss by
Heat loss through Cooler Vent
Radiation

3.70% 21.50%

Sensible heat of Kiln Feed Heat loss through Preheater exhaust gas

2.21% 29.18%

Heat loss through clinker

Heat input by Fuel 2.59%

Heat Balance of Kiln 2
95.04%

Specific Heat Consumption

Kcal/ kg clinker

967.8 Heat of Formation

41.44%
 Estimation of Phase Density

Kiln PC

Pipe line size Dia mm 141.2 179.2

CSA m2 0.0157 0.0252
Volume m3/sec 0.9723 1.0318
kg/sec 1.0987 1.1660
m3/hr 3500 3715
Nm3/kg clinker 0.026 0.027
Coal tpt TPH 6 13.4
kg/sec 1.67 3.72
Velocity at tpt line m/sec 62.09 40.91
Coal to air ratio 1.52 3.19
power cons kW 110 110
sp power 18.33 8.21
kg of air required for 4
0.42 0.93
kg ratio
Extra air going 0.68 0.24
% Extra air going 0.62 0.20
% reduction in power
0.512 0.512
for 20% speed red
kw saving 53.7 0.0
annual cost saving 8.59 0.00
32.13610586
321.3610586
 Kiln 2 - Energy Saving Proposals,

Power cost 3.880

present level

1 Increasing Gas residence time in existing precalciner

2 Reduction of preheater calciner exit temperature

3 Reduce pressure drop across duct from WHR outlet to ph fan inlet 70.0

4 Arresting of false air

4 Reduce bypass in pyro section

5 Reduce pressure drop across Top stage cyclone 278.0

6 Reduce false air across CT system -Pyro

7 Replacement of existing cooling fans

8 Upgradation of heat exchanger in cooler vent system

9 Installation of Precalciner

10 Increasing kiln inlet area

Reduction of dust accumulation inside Tertiary Air Duct (TAD) & Improving Tertiary
11 air flow.
 471 FN2,3,4,5,6,7

7 Reduce pressure drop across cyclone & cyclone outlet bend in Raw mill circuit 160.0

8 Reduce false air in GCT and VRM circuit

9 Reduce damper loss in Kiln/raw mill Bag House Fan 40.0

10 Reduce false air in coal mill circuit

11 Reduce pressure drop in coal mill bag hose to Fan duct 115.0

12 Reduce damper loss in coal mill booster fan 47.0

Reduce speed of kiln & PC coal conveying blowers by 20 % by installing VFD and
13 reduce pipe dia /size to maintain 35 m/s transportation velocity

14 Installation of automation system

15 Reduce pressure drop across damper in Sepax fan Slag HPGR roller press 80.0

16 Reduce pressure drop across damper in bag house fan in Slag VRM 113.0

17 Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF1) 64.0

18 Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF3) 303.0

19 Avoid damper loss by installing VFD in Auxilary bag filter fan (221BF1) 440.0

Long term energy saving proposals

Installation of new clinker cooler

 INR Coal cost 861.6 INR/ mio kcal

new one present power fan head saving power Running hrs savings in Lakhs

10.19

40 2367.5 938.0 76 7920 23.3

2367.5 938.0 118.3746327 7920 36.4

40.76

90 2075.1 830.0 235 8000 7.3

2075.1 830.00 92.1 8000 1.43

75.0 8000 23.3

8000 45.0

0.0

8000 3.06
 20.0 8000 6.2

130 1580.0 903.0 52.5 7000 14.3

1580.0 903.0 145 7000 39.4

20 803.0 294.0 27.3 8000 8.5

380.0 893.0 39 5000 7.6

40 380.0 893.0 31.9 5000 6.2

20 60.0 141.0 11.5 5000 2.2

67.0 8000 20.8

109 8000 33.8

20 400.0 464.0 25.9 7000 7.0

20 1435.0 686.0 97.3 7000 26.4

10 22.0 351.0 3.4 5000 0.7

10 45.0 496.0 13.3 5000 2.6

10 55.0 515.0 23.0 5000 4.5

157.0

417
 Thermal savings Electrical savings

investement Lakhs payback, months kcal/kg MTOE/ year KW

0 0 10 1171 101

5.1 0.5 6.5 762

40.00 21 76

20.0 7 5

2.2 0.1 40

2.40 4 235

0.13 1.1 92.1

2.5 1.3

2.5

2.3 0.6

2.0

1.5 5.9
40 77.3

20 16.8

20 6.1

0 0.0

25 39.4

25 48.5

3 16.2

20 11.5

50 17.7

0 0.0

0 0.0

2 36.6

4 18.6

4 10.8

600 45.9

826
Electrical savings

kW/ t of clinker

0.68

6.5

40719 0.11 False air %

1.6

0.6 59996

0.5
43376

11890
 Primary air_kiln _ PC

Primary air to kiln

Air required for kiln firing
% primary air to kiln

Primary air to precalciner

Air required for PC firing
% primary air toPC

Savings from Recommended action

The O2 at PH exit may be reduced to 3.5%

by identifying the leakages in the Cyclones,
riser ducts, meal chutes, PC, kiln seals, etc. 29.314989 Kcal/ kg clinker
Primary air to PC may be reduced to
maximum 6 % i.e. 0.045 Kg/ kg clinker.
From 0.06kg /kg clinker 3.1788 Kcal/ kg clinker
Primary air to kiln may be reduced to
maximum 6 % i.e. 0.04 Kg/ kg clinker.
From 0.025kg /kg clinker 3.7332 Kcal/ kg clinker
Temperature drop across the T A Duct may
be reduced to 50 Deg C from 96 5.87328 Kcal/ kg clinker

Page 1