To All the members of Production department.

pl find below
some very important tips during kiln operation.
It is requested to use these tips during operation:

 Every 1 % reduction in free lime increases 10 – 25

kcal/kg clinker heat consumption.

 Every 10% increase in preheater exit temp., increases

7-10 kcal/kg clinker heat consumption.

 Every 10% increase in clinker temperature, increases 2

kcal/kg of clinker heat consumption.

 Every 1% increase in kiln PH exit O2% increases 7

kcal/kg of clinker heat consumption.

 Every 1% increase in residue (kiln feed) in 90 micron,

increases 5-10 kcal/kg clinker heat consumption.

 Every 0.1 increase in silica modulus, increases

10kcal/kg clinker heat consumption.

 Every 1% increase in kiln feed LSF increases 15 kcal/kg

clinker heat consumption.

 Every 100 blain increase in cement increases 1.5

kwh/MT of power consumption.

 Every 1% reduction in primary air reduces 0.7 kcal/kg

clinker heat consumption.

 Every 10 degree centigrade increase in flame

temperature increases 1% kiln production.

 Every 100 blain increase in cement increases 1.5 Mpa of

strength.
  Every 1% increase in fine coal moisture reduces 10 to
14 degree centigrade flame temperature.

 Every 1% reduction in clinker-free lime, increases 4.0 %

C3S in clinker.

 Every 1% increase in C3S reduces 0.3 to 0.5 kwh/MT

clinker grinding energy consumption.

Hi everyone!

Anyone can tell me how to operate the rawmill without the hot gas generator. Our plan have a rawmill
without hot gas generator. The heat sourse is from the kiln, but at initial we just use the heat when heat the
kiln. So the heat sourse from heating the kiln is enough for operate the rawmill? and if increase the heat
sourse from increasing the fuel firing in Calciner is affect to refractory of the suspension preheater

 It has been observed that normally hot gas generator is used for
initial start up of the new kiln when raw mill must be started
before the kiln. In such cases, precalciner can be used as hot gas
generator even before the kiln light up without any problem. But
please remember that this arrangement is only for those plants who
intend to maintain at least 50% stock of raw meal in silo during
operation. If raw meal silo level is often taken to below 50%
level at the time of kiln shut down and raw mill capacity just
meets the required kiln feed rate then it is better to have a hot
gas generator to ensure regular supply of raw meal at start up of
kiln

 my coal ball mill is 2.5 *4m with 10 tph having coal with 7 % input moisture & 1 % output
moisture.

 it is connected with a auxiliary furnace.

 i want to calculate the amount of coal fired into the furnace to get grind the coal.

 Mill outlet temp . 80 deg

 velocity through mill 1.5 m/s

 gr. media in mill is 27 t

Dear Mr. Rajesh,

sending you two excel sheet ( pasted ) . Please send me your mill's details as shown below ( in Bold ) to get full report.

 Vikpro

Grinding and Generation of Heat.

   
Mill Dia  
Mill Length
Mill Capacity
Gypsum %
Clinker input 
Gypsum input
Power input, Mill
Clinker Temp. ( Tk )
Gypsum Temp. ( Tg)
Cement Temp. ( Tc)
Temp. of Air      ( TL )
Mill vent Air per kg of Cement.
Mill Ventilation temp Avg.
Mill surface Temp
Mill Surface Area
Specific Heat of Cement
Radiation of Mill shell / m2
Specific Heat of Air.
1) Loss of efficiency by generating heat in the Mill 
   
2) Loss by Radiation through mill shell.
   
3) Losses by heating the mill vent Air.
   
4) Losses not measurable such as sound generation &
     Vibration.
   
5) Total KWh
   
6)Total % of power converted into Heat.
   

   

   
      Heat Balanc
       
Mill Dia     2.2
Mill Length   12
Mill Capacity   18
Gypsum %   4
Clinker input    17.28
Gypsum input   0.72
Power input, Mill   2436
Power input, Motor   600
Clinker Temp. ( Tk )   15
Gypsum Temp. ( Tg)   15
Cement Temp. ( Tc)   95
 Temp. of Air      ( TL ) 15
Temp. of Water      ( Tw ) 15
Mill Ventilation temp Avg. 45
Normal H2O vapour in Dry Air 0.2
Mill surface Temp   40
Mill Surface Area 90.5
      Total Heat In
Heat entering Mill with Clinker 49248
Heat entering Mill with Gypsum 2797.2
Heat entering Mill with Air. 4.665
Heat entering Mill with Motor. 2094960
Total Heat entering Mill 2147005
      Total Heat O
Heat leaving With H2O Vapour  
Heat leaving with Air.   304367.9
Heat leaving with Cement 324900
Heat leaving through mill Surface 9854.108
       
Total Heat leaving Mill only 379196.9
Total amount of Air in Mill 10301.84
Air per ton of Cement   572.32
Total amount of Water in Mill 2431.23
Amount of Water. lit/ ton cement 135.07
water Vapour / Kg Air 0.24
       
With determined air Volume, and
without water injection, the Cement
Temp. would be ……  
       
       
   
Dear Mr. Rajesh,

sending you two excel sheet ( pasted ) . Please send me your mill's details as shown below ( in Bold ) to get full report.

 Vikpro

Grinding and Generation of Heat.

   
Mill Dia  
Mill Length
Mill Capacity
Gypsum %
Clinker input 
Gypsum input
Power input, Mill
Clinker Temp. ( Tk )
Gypsum Temp. ( Tg)
Cement Temp. ( Tc)
Temp. of Air      ( TL )
Mill vent Air per kg of Cement.
Mill Ventilation temp Avg.
Mill surface Temp
Mill Surface Area
Specific Heat of Cement
Radiation of Mill shell / m2
Specific Heat of Air.
1) Loss of efficiency by generating heat in the Mill 
   
2) Loss by Radiation through mill shell.
   
3) Losses by heating the mill vent Air.
   
4) Losses not measurable such as sound generation &
     Vibration.
   
5) Total KWh
   
6)Total % of power converted into Heat.
   
   
   
      Heat Balance ( Mill )    
               
Mill Dia     2.2m      
Mill Length   12m      
Mill Capacity   18t/h      
Gypsum %   4%      
Clinker input    17.28t/h      
Gypsum input   0.72t/h      
Power input, Mill   2436Kw      
Power input, Motor   600Kw      
Clinker Temp. ( Tk )   15C      
Gypsum Temp. ( Tg)   15C      
Cement Temp. ( Tc)   95C      
Temp. of Air      ( TL ) 15C      
Temp. of Water      ( Tw ) 15C      
Mill Ventilation temp Avg. 45C      
Normal H2O vapour in Dry Air 0.2 0.28kg H2O vapour / kg d
Mill surface Temp   40C      
Mill Surface Area 90.5M2      
      Total Heat Input      
Heat entering Mill with Clinker 49248K cal / hr      
Heat entering Mill with Gypsum 2797.2K cal / hr      
Heat entering Mill with Air. 4.665K cal /kg air    
Heat entering Mill with Motor. 2094960K cal / hr      
 Total Heat entering Mill 2147005K cal / hr      
      Total Heat Output    
Heat leaving With H2O Vapour     621.7K cal / kg H2
Heat leaving with Air.   304367.9K cal / kg  29.545K cal / kg air
Heat leaving with Cement 324900Kcal / Hr      
Heat leaving through mill Surface 9854.108Kcal / Hr      
               
Total Heat leaving Mill only 379196.9K cal / hr      
Total amount of Air in Mill 10301.84Kg / hr      
Air per ton of Cement   572.32Kg / ton      
Total amount of Water in Mill 2431.23Lit/ hr      
Amount of Water. lit/ ton cement 135.07lit/ ton      
water Vapour / Kg Air 0.24kg/kg Air      
               
With determined air Volume, and        
without water injection, the Cement        
Temp. would be ……   482.72C    
               
               
 
Dear Mr. Rajesh,

sending you two excel sheet ( pasted ) . Please send me your mill's details as shown below ( in Bold ) to get full report.
 
 Vikpro

Grinding and Generation of Heat.

        
Mill Dia      
Mill Length    
Mill Capacity    
Gypsum %    
Clinker input     
Gypsum input    
Power input, Mill    
Clinker Temp. ( Tk )    
Gypsum Temp. ( Tg)    
Cement Temp. ( Tc)    
Temp. of Air      ( TL )   
Mill vent Air per kg of Cement.   
Mill Ventilation temp Avg.   
Mill surface Temp    
Mill Surface Area    
Specific Heat of Cement     0.184
Radiation of Mill shell / m2   
Specific Heat of Air.    
1) Loss of efficiency by generating heat in the Mill 
        
2) Loss by Radiation through mill shell.  
        
3) Losses by heating the mill vent Air.  
        
4) Losses not measurable such as sound generation &
     Vibration.     
        
5) Total KWh    
        
6)Total % of power converted into Heat.  
        
          75 % of m
        
      Heat Balance ( Mill )      
                 
Mill Dia     2.2m        
Mill Length   12m        
Mill Capacity   18t/h        
Gypsum %   4%        
Clinker input    17.28t/h        
Gypsum input   0.72t/h        
Power input, Mill   2436Kw        
Power input, Motor   600Kw        
Clinker Temp. ( Tk )   15C        
Gypsum Temp. ( Tg)   15C        
Cement Temp. ( Tc)   95C        
Temp. of Air      ( TL ) 15C        
Temp. of Water      ( Tw ) 15C        
Mill Ventilation temp Avg. 45C        
Normal H2O vapour in Dry Air 0.2 0.28kg H2O vapour / kg dry air.  
Mill surface Temp   40C        
Mill Surface Area 90.5M2        
      Total Heat Input        
Heat entering Mill with Clinker 49248K cal / hr        
Heat entering Mill with Gypsum 2797.2K cal / hr        
Heat entering Mill with Air. 4.665K cal /kg air      
Heat entering Mill with Motor. 2094960K cal / hr        
Total Heat entering Mill 2147005K cal / hr        
      Total Heat Output      
Heat leaving With H2O Vapour     621.7K cal / kg H2O vapour / Kg Air
Heat leaving with Air.   304367.9K cal / kg  29.545K cal / kg air  
Heat leaving with Cement 324900Kcal / Hr        
Heat leaving through mill Surface 9854.108Kcal / Hr        
                 
Total Heat leaving Mill only 379196.9K cal / hr        
Total amount of Air in Mill 10301.84Kg / hr        
Air per ton of Cement   572.32Kg / ton        
Total amount of Water in Mill 2431.23Lit/ hr        
Amount of Water. lit/ ton cement 135.07lit/ ton        
water Vapour / Kg Air 0.24kg/kg Air        
                  
With determined air Volume, and          
without water injection, the Cement          
Temp. would be ……   482.72C      
                 
         
xxxx, whoever you are,

The picture below shows what a typical answer to your question might be. (never trust any model !)
For this calculation, I made some assumptions that might not be suitable for your application (specially
concerning safety):

- coal with Low Heat Value of 25.9 GJ/t (wet basis 1% moisture)
- coal analysis CHONS-Ash = { 66%, 5%, 5% , 1.5%, 1%, 20.5%}
- recirculation of 70% of the hot gases
- mill power consumption of 400 kW, fan power consumption of 40 kW

As you can see, 51 kg/h of coal are needed, in this case.

This is equivalent to an heat consumtion of 2.05GJ/tWaterVapor.
This is rather low and it is explained by the heat generated by the mill itself.
The sensible heat from the hot gases represent a power of 367 kW, which is slightly lower than the power
of the mill.
The oxygen content in the exhaust gases is rather high: 16.5% .
This might be very undesirable depending on the volatile content and the fineness.
I maintained the requested gas speed at mill end (1.5 m/s).
Finally, the dew point of the exhaust gases is 54°C which is nearly 30°C between the gas temperature.

Increasing the recirculation will decrease the oxygen level.

Increasing the recirculation will also decrease the heat consumption.
For example, with a recirculation of 90%, the oxygen level drops to 9.7% and the heat consumption to 38
kg(coal)/h  or 1.53 GJ/tWaterVapor.
Note that increasing the recirculation also increases the dew point in the gas circuit. Eventually, the dew
point will come too close to the gas temperature, and the risk of condensation on cold points will increase.
Here, for 90% recirculation, the dew point rises to 77°C which is only 7°C below the gas temperature.

Overall, I like pictures!

What should be ideal tyre migration values for all three stations for a 6.2x90 , 10000 TPD kiln? Is there any
relation between Kiln dia and ideal value?
The normal maximum design ovality for a tyre is .2% relative to the inside diameter of
the kiln shell. This would give a difference to 8 mm between the horizontal and vertical
outside dimension on a tyre for a 4000 mm kiln. Under ideal conditions, this would result
in a shell ovality of 0.23%, but in practice this is rarely achieved. Experience has shown
that ovalities become very critical at .5% and this should, therefore, be treated as an
absolute maximum, with .4% being the point at which correction should be made.
Under cold conditions, it would be normal to find ovalities approaching .5% or, in some
cases, even more. It is, therefore, important to obtain the minimum cold gap, but at the
same time giving ample clearance to allow the shell to expand within the tyre without
waisting occurring. It is normal to assume a temperature differential of 200°C at the
hottest tyres which would fall to 100°C at the coldest tyre. The differential of 200°C
would normally assume a maximum shell temperature of about 325°C. Hotter shell
temperatures will require larger cold gaps and thus increase ovality and refractory stress
when turning the kiln cold or at low shell temperatures for any appreciable length of time.
High shell temperatures also reduce the stress and deflection resistance capabilities of the
shell which result in reduced shell life.
Best regards
