LINE-2 PYRO PROCESS SITE DATA-BHARATHI CEMENTS KADAPA

Customer Name
Supplier Name
Design Capacity tpd
Operating Capacity 5415 tpd
Type of pre-heater ILC- 6 STAGE Cooler
Type of Kiln (SLC / ILC) ILC Date
Kiln Feed tph 361 Mean Sea Level

Details
Raw meal to Clinker factor kg rm./kg Cl 1.600 Barometric pressure

Plant
tph 225.6 Ambient Temperatur
Clinker production
Production Details

tpd 5415 Wind Velocity

Net Calorific value Kcal/kg coal 5380
Kiln coal tph 7.53 Fixed Inlet Slope
PC coal tph 22.6 Fixed Inlet Dimension
Total Coal Consumption tph 30.13 Fixed Inlet Dimension
Coal consumption tpd 723.12 Fixed Inlet Dimension
Kiln Coal firing % 25.0 Fixed Inlet Effec. Area
PC Coal firing % 75.0 Cooler Length
Spe. Heat Consumption Kcal /kg cl 718.4 Cooler Width
Kiln Diameter m 4.35 Area With out blockin

Cooler details
Kiln Length m 67 Avaliable Grate Area
% 4.00 Specific loading
Kiln slope
Deg 2.29 No. of Cooler Fans
Kiln speed rpm 4.60 No of Compartments
Kiln details

Refractory lining thinckness mm 200.00

Effective diameter m 3.95
Effective area m2 12.25
Effective volume m3 821
Specific thermal loading M kcal/hr/m 2
3.31
Retention time min 16.28
Filling % 15.28
Specific volumetric loading tpd/m3 6.60
CEMENTS KADAPA

6/4/2018
Mean Sea Level m 165
Barometric pressure mmwg 10121
Ambient Temperature o
C 38
Wind Velocity m/s 3

Fixed Inlet Slope Deg

Fixed Inlet Dimension -Width m
Fixed Inlet Dimension -Breadh m
Fixed Inlet Dimension - Length m
Fixed Inlet Effec. Area m2
Cooler Length m
Cooler Width m
Area With out blocking horse shoe m2
Avaliable Grate Area m2 117.00
Specific loading tpd/m2 46.28
No. of Cooler Fans 8.0
No of Compartments 5.0
 HEAT INPUT
Heat
Mass flow Kg/Kg Sp.heat Capacity Temperature
Kcal/kg
clinker Kcal/Kg deg C deg C
clinker

Sensible heat of kiln feed 1.600 0.214 78 26.7

Sensible heat of Cooling air 3.9 0.238 38 35.7

Sensible heat of Cooling water in Cooler 0.073 1.00 35 2.6

Sensible heat of leak air -2.25 0.238 38 -20.4

Sensible heat of Coal 0.11 0.288 65 2.0

Primary air 0.05 0.238 38 0.5

Sensible heat of Conveying Air 0.07 0.238 38 0.7

Heat of Coal Combustion in kiln 184.4

Heat of Coal Combn in Secondary Firing 553.2

Total Input 3.60 785

HEAT OUTPUT
Heat
Mass flow Kg/Kg Sp.heat Capacity Temperature
Kcal/kg
clinker Kcal/Kg deg C deg C
clinker

Heat of PH Exit gases 1.37 0.239 380 124.0

Heat of PH Exit dust 0.06 0.24 380 5.8

Heat of clinkerisation 415

Heat through Cooler Vent 1.17 0.243 240 68.15

Heat through Clinker 1.0 0.195 170 33.2

heat for evaporation of coal & RM moisture 2.6

Heat of Evaporation of Water in Cooler 56.4

Radiation loss from Preheater

46.0
Radiation loss from kiln & Cooler

Total Output 3.60 751

 BHARATHI CEMENT CORPORATION LIMITED

SUMMARY

S.No Location Parameter Unit

m3/hr
Flow rate kg/hr
Nm3/hr
Pre Heater Fan Specific flow rate Nm3/kg clinker
Inlet
1 Temperature Deg c
(Assumed)
Specific Heat Kcal/kg deg c
Heat avaialble Mkcal

Pre Heater Temperature Deg c

String Outlet Static Pressure mmWg
m3/hr
Flow rate kg/hr
Nm3/hr
Specific flow rate Nm3/kg clinker
2 Tertiary Air Duc
Temperature Deg c
(Assumed)

Specific Heat Kcal/kg deg c

Heat avaialble Mkcal
m3/hr
Flow Rate kg/hr
Cooler Vent Nm3/hr
(With water
spray) Specific flow rate Nm3/kg clinker
Temperature Deg c

3 Specific Heat Kcal/kg deg c

Heat avaialble Mkcal
m3/hr
Water Spray Quantity
Cooler Vent
Without water
spray
3

Water Spray Quantity

Cooler Vent Nm3/hr
Without water
spray Flow Rate at Cooler
Vent after removing Nm3/hr
water quantity
Calculated cooler vent
temp Deg c
PORATION LIMITED

DATE: 13.04.2018

Present After After After

Operating at Upgradation Upgradation Upgradation
5300-5400 tpd at 6000 tpd at 6200 tpd at 6500 tpd

593687 836295 871646 925537

308009 354115 365623 383329
231586 256605 264944 277775
1.47 1.47 1.47 1.47

258 265 267 270

0.242 0.243 0.243 0.243

19.26 22.77 23.70 25.14
264.00 270.00 272.00 275.00
-495 -595 -620 -660
438484 496295 504190 528606
116456 129037 133230 139682
438484 99796 103040 108030
0.40 0.40 0.40 0.40

1017 1018 1020 1025

0.260 0.260 0.260 0.261

30.84 34.21 35.40 37.31
209993
139391
107805
0.48
300
0.244
10.20
16.5
20625

87180 230750 238442 249980

440 420 430 440

 KILN ASSESSEMENT
Proposed Proposed Proposed
Description UOM Existing Capacity Capacity Capacity
Kiln feed tph 361.0 400.0 413.0 433.0
Sl.NO
Raw meal to Clinker Factor - 1.6 1.6 1.6 1.6
tpd 5415.0 6000.0 6195.0 6495.0
Clinker Production
tph 225.63 250.0 258.1 270.6
1 Kiln Motor Installed Power Kw 641 641 641 641.0
2 Kiln Motor Power Kw 250 277 286 300
3 Kiln Drive Margin % 156.4 131.4 124.1 113.8
4 Fuel firing in Kiln % 25.0 25.0 25.0 25.0
5 Thermal loading TL 3.306 3.66 3.782 3.965
6 Degree of filling DF 15.28 16.2 16.25 16.21
7 Volumetric loading VL 6.60 7.31 7.55 7.91
8 Material residence time in kiln RTK 16.28 15.60 15.13 14.40
% 90 microns 24.08 24.08 24.08 24.08
9 Kiln feed Residue
% 212 microns 3.8 3.8 3.8 3.8
COOLER ASSESSMENT
Sl.NO Clinker Production tpd 5415.0 6000.0 6195.0 6495.0
1 Cooler Grate area m 2
117.0 117.0 117.0 117.0
2 Cooler Loading tpd/m2 46.3 51.3 52.9 55.5
Cooler grate area required at
3 m2 130 135 141
46 tpd/m2
Excess area required for 46
4 m2 13 18 24
tpd /m2
5 Total Cooling air Volume Nm3/hr 681736 450000 464625 487125
6 Specific Cooling air Nm /kg Clinker
3
3.022 1.8 1.8 1.8
7 Recuperation Nm3/kg Clinker 2.54 0.79 0.79 0.79
8 Cooler vent Nm3/kg Clinker 0.48 1.01 1.01 1.01
9 Cooler ESP fan flow Nm3/hr 107805 252500 260706 273331
10 Cooler ESP fan flow m /hr
3
209993 232680 240242 251876

11 PREHEATER FAN FLOW ASSESSMENT

Preheater Fan Inlet flow m3/hr 593687 836295 871646 925537
Preheater Fan Inlet flow Nm /hr 3
231586 256605 264944 277775
Specific Volume Nm /kg Clinker
3
1.47 1.47 1.47 1.47
Static Pressure mmwg -477 -585.6 -624.3 -686.2
Motor Power kw 1445 1965.7 2163.7 2493.5

12 TAD

Specific air Nm3/kg Clinker 0.40 0.40 0.40 0.40

TAD Flow Nm3/hr 90066 99796 103040 108030
TAD Flow m3/hr 438484 496295 512424 537239
 Temperature & Pressure pr

LOCATION Static
Temp Diff Diff
Pressure
UNITS C
o o
C mmwg mmwg
Preheater Fan inlet 256 8 -546 51
FIRST CYCLONE 264 160 -495 35
SECOND CYCLONE 424 146 -460 55
THIRD CYCLONE 570 63 -405 72
FOURTH CYCLONE 633 82 -333 43
FIFTH CYCLONE 715 225 -290 85
SIXTH CYCLONE 940 -205
kiln inlet 1060 -40
PC Outlet 917 -140

Temperature & Pressure pr

LOCATION Static
Temp Diff Diff
Pressure
UNITS C
o o
C mmwg mmwg
Preheater Fan inlet 258 19 -551 76
FIRST CYCLONE 277 142 -475 34
SECOND CYCLONE 419 148 -441 40
THIRD CYCLONE 567 90 -401 81
FOURTH CYCLONE 657 50 -320 57
FIFTH CYCLONE 707 206 -263 93
SIXTH CYCLONE 913 -170
KILN INLET 1050 -35
PC Outlet 854 -132
Preheater Stack 113 -13
erature & Pressure profile in Line 2
Date: 6/4/2018
Time: 9:40 AM

O2 CO2 CO NO NOX NOX NOX at 10% O2

SO2

% % ppm ppm ppm mg/Nm3 mg/Nm3 ppm

4 15.5 342 386 406 832.3 538.547058824 0
3.6 15.6 162 388 410 0
NA NA NA NA NA 0
NA NA NA NA NA 0
3.3 16.1 312 510 530 0
3.1 16.3 100 372 395 0
2.9 18.1 4658 510 535 0
2.8 -
1.1 30 367 390

erature & Pressure profile in Line 2

Date: 8/4/2018
Time: 10:15 AM

O2 CO2 CO NO NOX NOX NOX at 10% O2

SO2

% % ppm ppm ppm mg/Nm3 mg/Nm3 ppm

4.4 15.2 148 406 426 873.3 578.7 0
4.0 15.4 372 364 382 0
NA NA NA NA NA 0
NA NA NA NA NA 0
3.6 15.8 228 328 345 0
3.4 16 308 452 475 0
2.6 17.2 33 460 483 0
3
1.2 18 2489 415 435
10.1 9.9 226 279 293 600.7 606.2 0
 set-1 Date

Description Unit Value

Kiln Feed TPH 200
Conversion factor 1.68
Clinker Production TPD 2857
Ambient Temperature o
C 32
Kiln feed temp o
C 75
Clinker Temperature o
C 110
Cooler water spray kg/hr 0
Cooler Vent Avg Temperature o
C 150

Duct dia. Duct area Temp.

Sl.
Location Speed
No.
m m2 o
C

1 PH fan I/L 4.25 14.18 256

2 Cooler Vent 3.35 8.81 348

3 TAD Outlet - 2.33 4.26 1011

set-2 Date

Description Unit Value

Kiln Feed TPH 361
Conversion factor 1.6
Clinker Production TPD 5415
Ambient Temperature o
C 37
Kiln feed temp o
C 70
Clinker Temperature o
C 170
Cooler water spray kg/hr 16500
Cooler Vent Avg Temperature o
C 300
 Duct dia. Duct area Temp.
Sl.
Location Speed
No.
m m2 o
C

1 PH fan I/L 3.60 10.17 380

The above Flow is Calculated with water Spray at 14007 kg/hr at 377275 kg/r Preheater fan flow ;
When water Spray is stopped ;(i.e 37725kg/hr -14007 kg/hr=363275 kg/hr at 310 o C & 0.574 kg/m3
Flow becomes=(363275)/(0.574) = 632831 m3/hr at 310 o C;
Design Flows:
Boiler Inlet expected flow at 310 at higher production
When we increase the clinker production from 3796 tpd to 4000 tpd;
The expected Fan Flow(m3/hr) in Preheater =632831*(4000/3796)
=666840m3/hr
The expected Static Pressure at higher production from 3732 Tpd to 4600 tpd;
=640*(4000/3796)^2
=710mmwg
Boiler Outlet expected flow at 200 o C at higher production
=(666840*.574)/(.708)
=540630

Duct dia. Duct area Temp.

Sl.
Location Speed
No.
m m2 o
C

Cooler Vent
2 2.80 6.15 240
(Romanian)
Cooler Vent
3.00 7.07 200
(A-Tech)

3 TAD Outlet - 2.33 4.26 1017

4 Raw Mill Fan I/L 4.30 14.51 73

5 Coal Mill Fan I/l 1.65 2.14 61

Cement Mills
6 2.80 6.15 173.00
Booster Fan I/L

7 bypass - 1.32 1.38 1011

Description Units Down Comer

CO % 0.0054
O2 % 14.00
 CO2 % 6.30
N2 % 79.69
Density kg/Nm 3 1.33
 7/4/2018

Avg.
Specific gas
Static pr. dynamic Density Density Velocity Volume
consumption
pressure
mm WG mm WG Kg/Nm3 Kg/m3 m/s m3/hr Nm3/hr Kg /hr Nm3/kg cli.

-546 1.33 0.635 14.84 757316 362051 3.04

10.6 481123

-38 1.293 0.55 16.90 535874 229811 1.93

12.0 297146

-76 1.293 0.27 28.11 431232 89106 0.75

16.00 115214

7/4/2018
 Avg.
Specific gas
Static pr. dynamic Density Density Velocity Volume
consumption
pressure
mm WG mm WG Standerd Kg/m3 m/s m3/hr Nm3/hr Kg /hr Nm3/kg cli.

-477 10.33 1.33 0.519 16.21 593687 231586 308009 1.03

1.324

Avg.
Specific gas
Static pr. dynamic Density Density Velocity Volume
consumption
pressure
mm WG mm WG Standerd Kg/m3 m/s m3/hr Nm3/hr Kg /hr Nm3/kg cli.

-150 4.520 1.293 0.66 9.48 209993 107805 139391 0.48

-350 4.400 1.293 0.71 9.07 230707 125878 162760 0.56

-89 16.44 1.293 0.27 28.58 438484 90066 116456 0.40

-1144 14.35 1.33 0.91 14.41 753078 516066 686368 2.29

-754 15.20 1.31 0.97 14.38 110601 81926 107323 0.36

-34 6.53 1.293 0.77 10.56 234046 139810 180774 0.62

-76 16.00 1.293 0.27 28.11 139243 28772 37202 0.24

 6
7
8
7

Specific gas
consumption
8

Kg/kg cli. 9
8
4.04 9
8
2.496
9
10
0.968
9
10
7

6
7
8
7
Specific gas
consumption
8

Kg/kg cli. 9
8
1.37 9

Specific gas
consumption

Kg/kg cli.
8
1.17
583

1.37 9
10
0.98
9

5.77

0.90
7
1.52

0.312
 Theoritical air Requirement
Clinker Production Rate TPD 5415
Secondary Air Flow
Kiln Coal Firing Kg Coal /Kg Clinker 0.0343
Theoretical Combustion Volume
Kiln Coal Firing Nm3/Kg Clinker 0.2527

O2 % at Kiln Inlet % 1.8

Excess Air Nm /Kg Clinker
3
0.0237
Total Air for Kiln Firing Nm3/Kg Clinker 0.2763
Primary Air Flow Nm3/Kg Clinker 0.077
Kiln Coal Transport Air Nm3/Kg Clinker 0.032
Secondary Air Requirement Nm3/Kg Clinker 0.1682
Secondary Air Volume Nm3/hr 37956
Secondary Air Volume m3/hr 194208
Tertiary Air Flow
PC Coal Firing Kg/Kg Clinker 0.1028
Theoretical Combustion Volume
PC Coal Firing Nm3/Kg Clinker 0.6473
O2 % after PC Firing % 1.1
Excess Air Nm3/Kg Clinker 0.0358
Total Air for PC Firing Nm3/Kg Clinker 0.6831
PC Coal Transport Air Nm3/Kg Clinker 0.0260
Tertiary Air Requirement Nm3/Kg Clinker 0.6571
Tertiary Air Volume Nm3/hr 148256
Tertiary Air Volume m3/hr 684290
Secondary + Tertiary Air Nm3/Kg Clinker 0.8253
Secondary + Tertiary Air Nm3/hr 186211

TAD VELOCITY
TAD Effective Diameter m 2.330
TAD Effective area 2 4.262
m
TAD velocity m/sec 44.60
tical air Requirement

Description Kiln PC Units

Clinker production 5415 tpd
Mixing Coal +
Fuel Australian AFR
Lmin 1.17 1.17 Nm3/1000 kcal
SHC 737.7 Kcal/kg
Coal CV 6300 5380 Kcal/kg
Firing 7.73 23.20 tph
Jet air 1 Nm3/hr
Jet air 2 Nm3/hr
Swirl air Nm3/hr
Total Volume 0.0 Nm3/hr
Kiln Coal Transport air 7115.9 Nm3/hr
Nm3/hr
Total Volume 7115.9 Nm3/hr
PC Coal Transport air 5862.5 Nm3/hr
Calculation for Kiln and Calciner velocity

Mean sea level 165 m

Barometric pressure 10121.2 mmwc
Production 5415 tpd
Feed factor 1.6

Coal consumption 0.1371 Kg/Kg cl

Net Calorific value 6300 Kcal/Kg coal

Kiln diameter 3.95 m

Kiln length 67 m
Calciner diameter 7.5 m
Calciner height 39.5 m
LOI of feed 35.30 %
LOI of last stage material 4.30 %
Calcination of material entering calciner 15.32 %
Excess air 8 %
Burning zone temperature 1450 C
Calciner temperature 917 C
Calciner pressure -140 mmwc
% calcination 91.76 %

CALCINER
Combustion gases generated 0.6831 Nm3/Kg cl
CO2 generated 0.2234 Nm3/Kg cl
Total gases 0.9065 Nm3/Kg cl

KILN

Combustion gases generated 0.2763 Nm3/Kg cl

Total gas 0.2763 Nm3/Kg cl
1.7433 m3/Kg cl
6556 m3/min

Total amount of gas passing thru calciner 1.1828 Nm3/Kg cl

5.1898 m3/Kg cl

Total Volumetric flow of gases 19516 m3/min

Calciner velocity 8.29 m/s

Retention time in Calciner 4.77 s
Velocity through kiln 11.04 m/s
Site Mean Level MSL 165
Barometric Pressure mm Wg 10124
Kiln Feed TPH 361
KF to Clinker Factor - 1.60
Clinker Production TPD 5415
Kg Cl/Hr 225625

PH String Fan Flow M3/HR 593687

NM3/HR 231586
Net Kiln Feed

Net Kiln feed on LOI basis

Preheater Gas Density Kg/NM3 1.03
Return Dust % 4.0
PH String

Static
Temperature Pressure LOI CO2
Location
O
C mmWg % Tph Nm3/hr M3/hr
Preheater Fan Inlet 256 -546 - 121 61751 115909
Cyclone-1 264 -495 35.00 121 61751 118227
Cyclone-2 424 -460 34.70 120 61221 152640
Cyclone-3 570 -405 34.40 119 60692 183974
Cyclone-4 633 -333 33.90 117 59810 196190
Cyclone-5 715 -290 31.60 110 55752 200255
Cyclone-6 940 -205 4.30 15 7587 33731
PreCalciner 917 -140
Kiln inlet 1060 -40
 #REF!

LOSS ON IGNITION
Kiln Feed

Cyclone
no.

1
2
Net Kiln Feed Tph 346.6 3
4
Net Kiln feed on LOI basis Tph 233.567
5
6

O2
False Air Flow

% % % Nm3/hr M3/hr Nm3/hr M3/hr

4.0 2.35 13.53 22978 43130 231586 593687
3.6 0.57 12.95 22002 41923 230610 443390
3.5 0.57 12.96 22076 55040 230155 573833
3.4 0.57 12.39 21173 64182 228723 693319
3.3 1.13 11.26 19342 63445 226009 741361
3.1 1.12 10.14 17834 64058 220444 791807
2.9 9.94 0.20 443 1970 154887 688653
1.1
1.7
SS ON IGNITION
Degree Of Calcination
35.30

PH String PH String

35.00 1.31
34.70 2.60
34.40 3.89
33.90 6.00
31.60 15.32
4.30 91.76

Outlet
Flow Diameter Outlet Area Inlet Inlet Area

M3/Sec Nm3/Kg Clinker Meter M2 Width Height M2

164.9 1.03
123.2 1.02 20.90 3.825 6.37 24.37
159.4 1.02 29.30 3.825 6.37 24.37
192.6 1.01 29.76 3.825 6.37 24.37
205.9 1.00 29.76 3.825 6.37 24.37
219.9 0.98 29.76 3.825 6.37 24.37
191.3 0.69 29.76 3.825 6.37 24.37
 Inlet
Outlet
Velocity Velocity
Velocity
m/sec m/sec

5.9 5.1
5.4 6.5
6.5 7.9
6.9 8.5
7.4 9.0
6.4 7.9
SET-1

Date: 7/4/2018

COOLER AIR FLOW

Feed rate in TPH 361

Kiln feed to Clinker Fac 1.60
Clinker production 225.625

Suction
Power Cooler Duct Area Temp. Draft Density
duct dia
Sl.
Fan No.
No.
KW RPM m m2 o
C
mmWG Kg/m3

1 Cooler Fan-1 0.97 0.74 38 116 1.12

2 Cooler Fan-2 1.11 0.97 38 112 1.12
3 Cooler Fan-3 1.07 0.90 38 107 1.12
4 Cooler Fan-4 1.12 0.98 37 115 1.13
5 Cooler Fan-5 1.07 0.90 38 85 1.12
6 Cooler Fan-6 1.335 1.40 37 64 1.11
7 Cooler Fan-7 1.335 1.40 38 41 1.11
8 Cooler Fan-8 1.22 1.17 38 35 1.10
Total Cooler Fan Input Volume

Sl. Suction
Fan No. Power Fan Speed Duct Area Temp. Draft Density
No. duct dia
KW RPM m m2 o
C mmWG Kg/m3

1 PA Fan 0.52 0.21 36 50 1.12

SET-2
Date: 7/4/2018

Feed rate in TPH 200

Kiln feed to Clinker Fac 1.68
Clinker production 119.048

Suction
Power Cooler Duct Area Temp. Draft Density
duct dia
Sl.
Fan No.
No.
KW RPM m m2 o
C
mmWG Kg/m3

1 Cooler Fan-1 0.97 0.74 38 152 1.13

2 Cooler Fan-2 1.11 0.97 36 114 1.13
3 Cooler Fan-3 1.07 0.90 37.9 109 1.12
4 Cooler Fan-4 1.12 0.98 35.6 106 1.13
5 Cooler Fan-5 1.07 0.90 37.7 88 1.12
6 Cooler Fan-6 1.335 1.40 36 51 1.12
7 Cooler Fan-7 1.335 1.40 35.9 46 1.12
8 Cooler Fan-8 1.22 1.17 37.7 38 1.12
Total Cooler Fan Input Volume
Sl. Suction
Fan No. Power Fan Speed Duct Area Temp. Draft Density
No. duct dia
KW RPM m m2 o
C mmWG Kg/m3

1 PA Fan kiln 0.52 0.21 36 0 1.12

2 Kiln Blower 0.51*0.51 1.04 38 0 1.11
3 PC Blower 0.51*0.53 1.04 38 0 1.11
3 PA Fan pc 0.51*0.53 1.04 38 0 1.11
 Specific gas
Velocity Volume
consumption

m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
15.13 40236 45244 34992 0.16 0.20
14.90 51879 58314 45099 0.20 0.26
16.48 53332 59918 46340 0.21 0.27
14.59 51729 58350 45127 0.20 0.26
13.76 44534 49925 38612 0.17 0.22
13.76 69324 77035 60175 0.27 0.34
11.97 60296 66635 52053 0.23 0.30
11.02 46363 50999 40001 0.18 0.23
417693 466419 362399 1.61 2.07

Specific gas
Velocity Volume kg/kg clinker
consumption
m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
13.88 10610 11930 9019 0.04 0.05

Specific gas
Velocity Volume
consumption

m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
15.78 41952 47339 36252 0.30 0.40
15.42 53703 60766 46532 0.39 0.51
14.78 47818 53751 41160 0.35 0.45
15.08 53450 60511 46337 0.39 0.51
13.62 44070 49468 37879 0.32 0.42
13.60 68514 77048 58997 0.50 0.65
11.76 59213 66578 50979 0.43 0.56
11.56 48605 54291 41571 0.35 0.46
417325 469751 359708 3.02 3.95
 Specific gas
Velocity Volume kg/kg clinker
consumption
m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
13.79 10536 11789 9117 0.08 0.05
2.21 8276 9201 7116 0.06 0.04
1.82 6818 7580 5863 0.05 0.03
0.00 0 0 0 0.00 0.00
 LINE-2 PYRO PROCESS SITE DATA-BHARATHI CEMENTS KADAPA

COOLER EFFICIENCY

Base Data
Clinker production TPH 225.6
Clinker temp Deg C 1450
Specific heat of Clinker Kcal/kg oC 0.26
Cooling air Temp Deg C 38
Cooling air Nm3/kg clink 3.02
Cooling air Kg/kg clink 3.95
Specific heat of Cooling air Kcal/kg oC 0.24
Cooler Vent gas flow Nm3/hr 107805
Vent gas temp Deg C 240
Cooler Vent gas flow Nm3/kg clink 0.48
Cooler Vent gas flow Kg/kg clink 0.62
Specific heat of Cooler vent gas Kcal/kg oC 0.243
Out Clinker temp Deg C 170
Specific heat of Clinker Kcal/kg oC 0.20
Cooler water spray change in enthalpy Kcal/kg clink 56.4
Power consumption of cooler fans KWh 1040.0
Heat Balance
Heat Input Heat Loss
Heat energy enter into the cooler Kcal/Kg clink 383 Heat through cooler vent
Sensible heat of cooling air Kcal/Kg clink 35.40 Heat through clinker out
Cooler fans power Kcal/Kg clink 4.0 Radiation losses from cooler
Total 423

Cooler efficiency % 69.1

MENTS KADAPA

7/4/2018

Heat Loss
Kcal/Kg clink 92.4
Kcal/Kg clink 33.2
Kcal/Kg clink 5
131
 KILN RADIATION
Kiln Diameter m 3 Ambient Temp °C 35
Kiln length m 52.3 Kin Feed tph 32.0
Circumference Of Kiln m 9.42 Clinker tpd 498.7
F.
Radiation Wind Total
Length Area Temp N. Convection Convectio Heat Loss
Loss Speed radiation
n
m m² °C Kcal/hr. m2 m/s Kcal/hr. m2 Kcal/hr. m2 Kcal/hr Kcal/Kg. Cl
1 8.482 180.0 1324.5 3.5 0 700.84 17178.59 0.827
2 8.482 162.0 1072.3 3.5 0 619.02 14345.54 0.690
3 8.482 142.0 826.5 3.5 0 526.55 11476.51 0.552
4 8.482 151.0 932.8 3.5 0 568.37 12732.99 0.613
5 8.482 150.0 920.7 3.5 0 563.74 12590.64 0.606
6 8.482 165.0 1112.2 3.5 0 632.74 14800.58 0.712
7 8.482 235.0 2303.9 3.5 0 943.28 27542.72 1.325
8 8.482 210.0 1817.0 3.5 0 834.44 22489.34 1.082
9 8.482 260.0 2868.3 3.5 0 1050.01 33235.08 1.599
10 8.482 260.0 2868.3 3.5 0 1050.01 33235.08 1.599
11 8.482 252.0 2678.8 3.5 0 1016.08 31339.97 1.508
12 8.482 240.0 2410.3 3.5 0 964.79 28627.97 1.378
13 8.482 210.0 1817.0 3.5 0 834.44 22489.34 1.082
14 8.482 215.0 1908.5 3.5 0 856.38 23452.02 1.129
15 8.482 210.0 1817.0 3.5 0 834.44 22489.34 1.082
16 8.482 208.0 1781.1 3.5 0 825.63 22110.73 1.064
17 8.482 195.0 1558.9 3.5 0 768.06 19737.19 0.950
18 8.482 170.0 1180.6 3.5 0 655.54 15573.97 0.749
19 8.482 190.0 1478.2 3.5 0 745.75 18863.47 0.908
20 8.482 210.0 1817.0 3.5 0 834.44 22489.34 1.082
21 8.482 224.0 2080.6 3.5 0 895.66 25244.38 1.215
22 8.482 220.0 2002.9 3.5 0 878.24 24438.19 1.176
23 8.482 196.0 1575.3 3.5 0 772.51 19914.50 0.958
24 8.482 190.0 1478.2 3.5 0 745.75 18863.47 0.908
25 8.482 190.0 1478.2 3.5 0 745.75 18863.47 0.908
26 8.482 190.0 1478.2 3.5 0 745.75 18863.47 0.908
27 8.482 190.0 1478.2 3.5 0 745.75 18863.47 0.908
28 8.482 190.0 1478.2 3.5 0 745.75 18863.47 0.908
29 8.482 181.0 1339.4 3.5 0 705.35 17343.40 0.835
30 8.482 168.0 1152.9 3.5 0 646.43 15262.34 0.735
31 8.482 164.0 1098.8 3.5 0 628.17 14648.16 0.705
32 8.482 185.0 1400.1 3.5 0 723.34 18010.76 0.867
33 8.482 195.0 1558.9 3.5 0 768.06 19737.19 0.950
34 8.482 194.0 1542.5 3.5 0 763.60 19560.74 0.941
35 8.482 202.0 1676.3 3.5 0 799.14 20996.64 1.010
36 8.482 200.0 1642.2 3.5 0 790.28 20632.42 0.993
37 8.482 205.0 1728.2 3.5 0 812.40 21549.64 1.037
38 9.425 208.0 1781.1 3.5 0 825.63 24568.35 1.182
39 9.425 208.0 1781.1 3.5 0 825.63 24568.35 1.182
40 9.425 208.0 1781.1 3.5 0 825.63 24568.35 1.182
41 9.425 210.0 1817.0 3.5 0 834.44 24989.04 1.203
42 9.425 219.0 1983.8 3.5 0 873.87 26933.23 1.296
43 9.425 224.0 2080.6 3.5 0 895.66 28050.30 1.350
44 9.425 215.0 1908.5 3.5 0 856.38 26058.72 1.254
45 9.425 218.5 1974.3 3.5 0 871.69 26823.00 1.291
46 9.425 218.0 1964.8 3.5 0 869.51 26713.03 1.286
47 9.425 220.0 2002.9 3.5 0 878.24 27154.51 1.307
48 9.425 223.0 2061.0 3.5 0 891.31 27824.74 1.339
49 9.425 223.0 2061.0 3.5 0 891.31 27824.74 1.339
50 9.425 222.0 2041.5 3.5 0 886.95 27600.25 1.328
51 9.425 217.0 1946.0 3.5 0 865.13 26493.87 1.275
52 9.425 216.0 1927.2 3.5 0 860.76 26275.77 1.265
53
54
55
56
57
58
59
60
61
62
63
64
65
Total Radiation Loss (Kcal/Kg Cl) 55.58
 8.482

Kcal/Kg. Cl
`
 Kiln Performance & Efficiency
S. Description Symbol Formula
No.
1 Degree of filling DF
%
P
Deff
n
s
2 Thermal loading TL Formula-1
or Gcal/hr/m2
Burning zone loading
F
NCV
A

Formula-2

P
H
A
3 Volumetric loading VL
tpd/m3
P
A
L
4 RTK
Material residence time in kiln
min
L
Deff
n
s
5 Clinker residence time in RTC
cooler min
(Empirical relationship from A
F.L. Smidth) Ps
P
6 True CO2 in kiln exit gas TCO2
vol%
CO2
 CO2
O2
7 Excess air EA
%
O2
CO2
8 Radiation heat losses RHL
T
kcal/hr/m2
t

9 Convection heat losses CHL

T
kcal/ hr/m2
t

10 Forced convection heat losses FCHL

kcal/ T
(when wind speed > 3.0 m/s)
hr/m2 t
v
D

11 %Ash absorption in clinker %AA

%
CC
Ash
P
12 Raw Mix:Clinker ratio RMCK
(dust to kiln) -
%AA
LOI
13 Raw Mix:Clinker ratio RMCS
(dust to silo) -
%AA
LOI
DL
14 Heat of reaction HR
or kcal/
Theoretical heat required to kg-clinker - ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) )
produce 1 kg of clinker
or
Clinkerisation heat CaCO3
RMCK
(including Heat of MgCO3
combustibles)
 (including Heat of
combustibles) LOI
Al2O3
CH2O
SiO2
Fe2O3
K2O
Na2O
C
S
15 False air w.r.t. mix FAMO
(based on O2 analysis) %
O2mix
O2gas
16 False air w.r.t. gas FAGO
(based on O2 analysis) %
O2mix
O2gas
17 False air w.r.t. mix FAMC
(based on CO2 analysis) %
CO2mix
CO2gas
18 False air w.r.t. gas FAGC
(based on CO2 analysis) %
CO2mix
CO2gas
Kiln Performance & Efficiency
Formula Example

3.2 * P P 5415
Deff * n * s
3
Deff 3.75
Clinker production, tpd n 4.60
Burning zone effective diameter, mts S 4.00
Kiln speed, rpm DF 17.86
Kiln slope, % Target 14-16
F 7530
F * NCV NCV 5380
A * 1000 * 1000 A 12.25
Fuel rate in kiln, kg/hr TL 3.3
Net calorific value of fuel, kcal/kg-fuel Target 4.0-5.0
Burning zone cross-sectional area, m2

P 5415
P*H H 244
A * 24 * 1000 A 12.25
Clinker production, tpd TL 4.5
Specific heat consumption in kiln, kcal/kg-clinker Target 4.0-5.0
Burning zone cross-sectional area, m2
P P 5415
A*L A 12.25
Clinker production, tpd L 67
Burning zone cross-sectional area, m2 VL 6.60
Kiln length, mts Target 5.0-5.5
19 * L L 67
Deff * n * s Deff 3.95
Kiln length, mts n 4.60
Burning zone effective diameter, mts S 4.00
Kiln speed, rpm RTK 17.5
Kiln slope, % Target 20-25
1.55 * A * Ps A 66
P Ps 700
Cooler grate cross-sectional area, m2 P 3700
Static pressure at clinker droping area, mmWg RTC 19.4
Clinker production, tpd Target 20-25
100 * ( CO2 + CO ) CO2 36.5
100 + ( 1.89 * CO ) - ( 4.78 * O2 ) CO 0.002
Kiln exit gas CO2, vol% O2 4.2 5588.151
 Kiln exit gas CO, vol% TCO2 45.7
Kiln exit gas O2, vol% Target -
79 * O2 O2 2.8
0.21 * ( 100 - CO2 ) - O2 CO2 26.5
O2 content in gas, vol% EA 17.5
CO2 content in gas, vol% Target 10-15
4 * 10 * ( T - t )
-8 4 4
T 517
Radiating body temperature, K t 305 11.1317
Ambient air temperature, K RHL 2512
Target -
80.33 * ( ( T + t ) / 2 ) -0.724
*(T-t) 1.333
T 443
Radiating body temperature, K t 308
Ambient air temperature, K CHL 760 1171.5
Target - 1007
28.03 * ( ( T + t ) / 2 ) -0.351
*v 0.805
*D
-0.195
*(T-t) T 525
Radiating body temperature, K t 302
Ambient air temperature, K v 5
Wind speed, m/s D 4.15
Radiating body diameter, mts FCHL 2088
Target -
CC * Ash CC 28.00
P Ash 23.8 4.979
Coal consumption, tph P 226
Ash content in fuel (as fired basis), % %AA 2.95
Clinker production, tph Target -
100 - %AA %AA 2.95
100 - LOI LOI 35.25
%Ash absorption, % RMCK 1.499
Loss on ignition of raw mix, % Target -
( 100 - %AA ) * 100 %AA 2.95
( 100 - LOI ) * ( 100 - DL ) LOI 35.25
%Ash absorption, % DL 6
Loss on ignition of raw mix, % RMCS 1.594
Dust losses from preheater, % Target -
( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMCK ) CaCO3 75.1
+ ( 222 * Al2O3 / ( 100 - LOI ) ) + ( 11.6 * CH2O * RMCK ) RMCK 1.53
- ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) ) MgCO3 1.6
- ( 1000 * ( K2O + Na2O ) / ( 100 - LOI ) ) LOI 34.5
- ( 79 * C * RMCK ) - ( 32 * S * RMCK ) Al2O3 4.17
CaCO3 content in kiln feed, % CH2O 1.05
Kiln feed:Clinker ratio, - SiO2 13.47
MgCO3 content in kiln feed, % Fe2O3 2.41
LOI content in kiln feed, % K2O 0.38
Al2O3 content in clinker, % Na2O 0.27
Water of crystalisation in kiln feed, % C 0.2
SiO2 content in clinker, % S 0.04
Fe2O3 content in clinker, % HR 389
K2O content in clinker, % Target -
Na2O content in clinker, %
Carbon content in kiln feed, %
Sulphur as pyrites in kiln feed, %
( O2mix - O2gas ) * 100 O2mix 3.6
21 - O2gas O2gas 2.8
O2 content in mixture of gas, vol% FAMO 4.4
O2 content in unmixed gas, vol% Target 5-7
( O2mix - O2gas ) * 100 O2mix 3.6
21 - O2mix O2gas 2.8
O2 content in mixture of gas, vol% FAGO 4.6
O2 content in unmixed gas, vol% Target 5-7
( CO2gas - CO2mix ) * 100 CO2mix 32.1
CO2gas CO2gas 34.5
CO2 content in mixture of gas, vol% FAMC 7.0
CO2 content in unmixed gas, vol% Target 5-7
( CO2gas - CO2mix ) * 100 CO2mix 32.1
CO2mix CO2gas 34.5
CO2 content in mixture of gas, vol% FAMC 7.5
CO2 content in unmixed gas, vol% Target 5-7
5.56962
 LINE-2 PYRO PROCESS SITE DATA-BHARATHI CEMENTS KAD

QUALITY DATA(07/04/2018)
DATE :
S.No Parameter Unit Kiln Feed Clinker

1 LOI %
35.3
2 SiO2 % 13.20 21.63
3 Al2O3 % 3.46 5.72
4 Fe2O3 % 3.07 4.60
5 CaO % 43.28 65
6 MgO % 0.81 1.2
7 So3 % 0.14 0.65
8 LSF - 92
9 SM - 2.10
10 AM - 1.24
11 FCaO % - 1.64
12 C3S % 50.71
13 C2S % 22.81
14 C3A % 7.41
15 C4AF % 13.92
16 Liquid % 28.81
17 Litre Weight gm/lit -
18 Residue 90 mic 24.0
19 Residue 212 mic 3.84

HEAT OF REACTION :
7.646 *CaO + 6.484*MgO + 4.11*Al2O3 - 5.116* SiO2 - 0.589*Fe2O3

CLINKER COMPOSITION :-
CaO SiO2 Al2O3 Fe2O3 Mgo
65.00 21.63 5.72 4.60 1.20

HEAT OF REACTION : 415 Kcal/kg clinker

A-BHARATHI CEMENTS KADAPA

A(07/04/2018)
DATE :
Fired fuel in Kiln & PC

S.No Parameter Unit

Mixed Coal

1 Inherent Moisture %
2 Volatilt matter %
3 Ash %
4 NCV Kcal/kg
5 GCV Kcal/kg
 SPECIFIC POWER CONSUMPTION

Kiln Feed 361  Date:06/04/2018

Clinker Production 225.6  Time: 11:30 hrs

S.No Equipment / Drive Kwh Kwh/Mt

1 ESP Fan 187.92 0.83
2 Cooler section 160.38 0.71
3 Preheater Fan 1502.75 6.66
4 Kiln main Drive 299.75 1.33
5 Cooler ID Fans 1040.71 4.61
6 Fine Coal Dosing 241.71 1.07
7 RABH Fan 386.08 1.71
Total 3819.3 16.93