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Calcium Fluoride Effects & Cost Analysis
Calcium Fluoride Effects & Cost Analysis
Pyro Process
Effects of Calcium Fluoride at Kiln-I Date:
Process and QC parameters
Description Without Calcium Remarks
Flouride With Calcium
Flouride
(11-11-2021)
Calcium Flouride Feed (Kg/H) Nil
Kiln Feed ( T/h) 222
Torque ( % ) 40
ID Fan Speed ( % ) 89
Preheater Top Temp (⁰C) 346
Cyclone-5 Temp (⁰C) 920
Coal at MB (TPH) 7.4
Coal at PC (TPH) 10
Coal Consumption (Pfisters) 416
Coal Consumption (DPR)
Coal NCV @ 211 (Burner Tip) 5988
Clinker Production (Ton) 3621
K.Cal / Kg of clinker 688
K.Cal / Kg of clinker (DPR)
Lit Weight 1224
FCaO 1.37
ASR 0.93
DOC 91.47
SO3 in Hot Meal 2.57
Snowman Formation Nil
Smoke Chamber Coating Heavy Coating
Kiln Ring Formation Coating at Inlet
Kiln Feed
LSF 96.6
S.M 2.51
A.M 1.48
Clinker
LSF 91.52
S.M 2.5
A.M 1.49
C3S 53.4
C2S 22.58
C3A 7.97
C4AF 10.71
Fauji Cement Company Ltd.
Pyro Process
Effects of Calcium Fluoride at Kiln-II
Batch-01 (Nov 2021)
Process and QC parameters
Without
Description Calcium With Calcium With Calcium With Calcium With Calcium Average with Remarks
Flouride Flouride (26 Flouride (27 Flouride (28 Flouride (29 Calcium
(25- Nov) Nov) Nov) Nov) Flouride
11-2021)
Calcium Flouride Feed (Kg/H) Nil 250 250 250 210 240 0.05% of Kiln Feed
Cal Floride Consmuption (Ton) Nil 6 6 6 5 6 Total 23 Ton Consumed
Kiln Feed ( T/h) 467-470 466-470 466-470 467-470 466-470 466-470
Coal at MB (TPH) 15 14 14 14 14 14 1 TPH Coal Reduction at MB
Coal at PC (TPH) 19 19 19 19 21 19
Coal Consumption (Schencks) 856 832 827 797 840 824 24 T Coal Reduction per day
Coal Consumption (DPR) Imp 676.2 600.6 601.2 576.6 580.2 60%
Coal Consumption (DPR) Afg 0 100.1 100.2 96.1 96.7 10%
Coal Consumption (DPR) Loc 289.8 300.3 300.6 288.3 290.1 30% 30% Local coal used
Coal Consumption (DPR) 966 1001 1002 961 967 983 No Coal Reduction in DPR
Coal Ratio (Imp:Afg:Loc) 70-0-30 60-10-30 60-10-30 60-10-30 60-10-30 60%-10%-30% 40% Moz, 30% USA, 30% Loc
Coal NCV @ 211 (Burner Tip) 6074 6019 6007 6203 6057 6,072
AF (PW/AC) Consumption (Ton) 60 60 60 60 0 45
Clinker Production (Ton) 7,240 7,217 7,222 6,950 7,230 7,155
K.Cal / Kg of clinker at Burner Tip 736 712 706 730 704 713
K.Cal / Kg of clinker (DPR) 733.57 733.57 733.95 733.93 733.74 733.80 K Cal/Kg remains same
Running Hrs 24 24 24 24 24
Kg Coal/Ton Clinker (Burner Tip) 118 115 115 115 116 115 3 Kg/Ton coal reduction
Lit Weight 1325 1340 1335 1331 1335 1,335
FCaO 0.96 0.91 1.03 0.92 0.98 1
ASR 1 0.91 0.86 0.87 0.93 1
DOC CCR 91.96 95.89 96.33 93.84 92.19 94.56 DOC high after Cal Fl. then C1
DOC RDF 90.15 95.84 98.62 92.93 93.17 95.14 Temp reduced to 850
SO3 in Hot Meal 0.92 0.96 1.06 1.09 0.92 1.01
Snowman Formation Nil Nil Nil Nil Nil Nil
Smoke Chamber Coating Soft Coating Soft Coating Soft Coating Soft Coating Soft Coating Soft Coating
Kiln Ring Formation 26-28 m 26-28 m 26-28 m 26-28 m 26-28 m 26-28 m
Kiln Feed
LSF 96.56 96.47 96.6 96.58 96.55 96.55
S.M 2.5 2.48 2.48 2.48 2.5 2.49
A.M 1.49 1.49 1.49 1.49 1.48 1.49
Residue 18.41 18.3 18.36
Clinker
LSF 91.61 91.63 91.65 91.86 91.73 91.72
S.M 2.49 2.47 2.47 2.49 2.49 2.48
A.M 1.51 1.53 1.52 1.53 1.54 1.53
C3 S 53.37 53.32 53.38 54.06 53.5 53.57
C2 S 22.44 22.46 22.45 21.95 22.18 22.26
C3 A 8.1 8.22 8.24 8.2 8.2 8.22
C4AF 10.66 10.65 10.7 10.53 10.5 10.60
Fauji Cement Company Ltd.
Pyro Process
Effects of Calcium Fluoride at Kiln-II
Batch-02 (Dec 2021)
Without Calcium
Flouride With Calcium Flouride
Description Average/ Total
11-Dec 12-Dec 13-Dec 14-Dec 15-Dec 16-Dec 17-Dec 18-Dec 19-Dec 20-Dec 21-Dec 22-Dec 23-Dec 24-Dec 25-Dec 26-Dec 27-Dec 28-Dec 29-Dec 30-Dec 31-Dec
Calcium Flouride Feed (Kg/H) Nil 250 280 270 300 270 300 275 300 270 200 250 280 275 275 275 300 275 300 275 275 276
Cal Floride Consmuption (Ton) Nil 6 6.72 6.48 7.2 6.48 7.2 6.6 7.2 6.48 4.8 6 6.72 6.6 6.6 6.6 7.2 6.6 7.2 6.6 6.6 6.63
Kiln Feed ( T/h) 470 470 470 466 466 466 466 465 466 466 466 450 450 450 466 455 460 460 465 466 466 462
Coal at MB (TPH) 15.2 14.9 15.0 15.5 15.2 15.3 15.5 15.8 16.0 16.0 16.0 13.9 16.2 15.8 16.5 13.4 16.0 16.2 16.8 16.3 16.3 15.6
Coal at PC (TPH) 21.4 20.3 19.4 19.6 19.7 21.5 21.3 22.0 23.3 23.1 23.0 18.2 23.1 23.9 23.9 18.4 23.0 23.9 23.0 24.0 23.3 22.0
Coal at MB (TPD) 365 358 360 372 364 366 371 379 383 383 235 333 388 378 395 322 389 404 403 391 390 369
Coal at PC (TPD) 513 486 465 470 472 515 512 529 558 555 338 437 554 573 573 442 531 567 553 576 560 515
Coal Consumption (Schencks) 878 844 825 842 836 881 883 908 941 938 573 770 942 951 968 764 920 971 956 967 950 883
Coal Consumption (DPR) Imp 597.1 595.7 589 587 174 174 181 181 180 178 108 142 175 170 174 135 183 188 191 187 189 1%
Coal Consumption (DPR) Afg 0 0 0 0 435 435 452 452 451 445 270 284 347 337 344 267 364 376 380 372 377 2%
Coal Consumption (DPR) Loc 255.9 255.3 252 252 261 262 272 271 270 268 163 284 347 337 344 267 364 377 380 372 377 2%
Coal Consumption (DPR) 853 851 841 839 870 871 905 904 901 891 541 710 869 844 862 669 911 941 951 931 943 16,194
Coal Ratio (Imp:Afg:Loc) 50-20-30 50-20-30 50-20-30 20-50-30 20-50-30 20-40-40 20-40-40 20-40-40 20-40-40 20-50-30 20-50-30 20-50-30 20-50-30 50-0-50 50-0-50 50-0-50 50-0-50 50-0-50 50-0-50 50-0-50 50-0-50 30%-30%-40%
Coal NCV @ 211 (Burner Tip) 5983 6127 6178 6169 5914 5887 5882 5653 5683 5683 5734 5578 5536 5748 5672 5816 5816 5803 5909 5898 5898 5,814
AF (PW/AC/TW)) Cons. (Ton) 25 25 0 25 40 25 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5
Clinker Production (Ton) 7250 7277 7277 7222 7214 7214 7214 7198 7214 7214 4323 5375 6960 6944 7104 5462 6890 7106 7191 7251 7242 129,615
Kcal/Kg at burner Tip 725 711 700 719 685 719 720 713 741 739 760 799 749 787 773 814 777 793 786 787 774 754
Kcal/Kg in DPR 734.28 733.86 734.33 733.98 733.64 733.76 733.36 733.39 732.78 736.35 758.61 739.79 736.68 735.44 739.67 739.25 736.41 733.65 734.8 734.53 737
Running Hrs 24 24 24 24 24 24 24 24 24 24 14.44 20.4 24 24 24 19.27 23.75 24 24 24 24
Kg Coal/Ton Clinker (Dry Basis) 121 116 113 117 116 122 122 126 130 130 133 143 135 137 136 140 134 137 133 133 131 130
Lit Weight 1318 1325 1352 1320 1322 1315 1325 1325 1320 1330 1330 1320 1340 1340 1338 1330 1315 1305 1295 1325 1325 1,325
FCaO 1.2 1.08 0.82 1.16 1.11 1.06 1.07 1 1.01 1.05 1 0.89 0.88 0.92 1.14 1.05 1.13 1.2 1.04
DOC CCR 95 91.62 90.9 94.91 96.82 91.95 91.8 96.82 97.32 92.97 93.96 95.76 92.23 95.36 91.25 92.92 94.36 94.42 92.42 96 95.9 94.11
DOC RDF 94.91 91.15 90.31 92.91 95.14 93.87 88.95 95.19 91.76 93.81 92.93 93.26 90.52 92.6 93.63 91.37 92.93 91.34 90.51 92.28 93.52 92.46
SO3 in Hot Meal 1.43 1.75 1.68 1.54 1.58 1.16 1.13 1.18 1.08 1.19 1.48 1.44 1.32 1.06 1.28 1.27 1.39 1.32 1.44 1.33
Snowman Formation Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil
Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft
Smoke Chamber Coating Soft Coating
Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating
Kiln Ring Formation
Kiln Feed #DIV/0!
LSF 97.3 96.52 96.6 96.35 96.3 96.61 96.82 96.75 96.75 96.63 96.88 96.51 96.59 96.52 96.88 96.6 96.78 96.83 96.75 96.5 96.52 96.64
S.M 2.35 2.39 2.44 2.45 2.47 2.45 2.46 2.46 2.46 2.46 2.45 2.47 2.44 2.48 2.47 2.48 2.48 2.48 2.48 2.46 2.46 2.46
A.M 1.28 1.4 1.53 1.47 1.48 1.48 1.47 1.49 1.49 1.51 1.51 1.5 1.48 1.47 1.49 1.48 1.49 1.49 1.46 1.47 1.49 1.49
Clinker
LSF 92.68 92.24 91.73 92.82 92.58 92.59 92.61 92.46 92.46 92.53 92.45 92.48 92.49 91.81 92.03 92.06 92.06 91.99 92.16 91.86 91.92 92.43
S.M 2.33 2.35 2.44 2.4 2.44 2.46 2.44 2.46 2.43 2.45 2.47 2.44 2.43 2.42 2.44 2.45 2.45 2.47 2.49 2.49 2.44 2.44
A.M 1.26 1.36 1.46 1.45 1.46 1.46 1.45 1.48 1.48 1.5 1.51 1.51 1.5 1.49 1.5 1.5 1.5 1.49 1.49 1.49 1.48 1.46
C 3S 56.29 54.47 53.69 55.98 55.76 55.64 55.77 55.49 55.32 55.61 55.21 55.73 55.52 53.82 54.29 54.5 54.5 54.63 54.86 54.17 54.06 55.27
C 2S 19.21 20.54 22.08 19.56 20.09 20.01 19.99 20.47 20.5 20.41 20.51 20.65 20.58 22.11 21.55 21.46 21.46 21.64 21.1 21.86 21.69 20.44
C 3A 6.69 7.45 7.91 7.86 7.82 7.8 7.76 7.97 8.05 8.12 8.11 8.21 8.2 8.2 8.15 8.11 8.11 8.04 7.94 8 8.02 7.85
C4AF 12.48 11.78 11.09 11.15 10.98 10.87 11.06 10.81 10.97 10.81 10.62 10.86 10.92 11.02 10.9 10.81 10.81 10.81 10.68 10.74 10.95 11.02
Total Calcium Fluoride Consumption = 207.0 Tons
Remarks
13-Dec 14-Dec 15-Dec 16-Dec 17-Dec 18-Dec 19-Dec 20-Dec 21-Dec 22-Dec 23-Dec
280 270 300 270 300 275 300 270 200 250 280
6.72 6.48 7.2 6.48 7.2 6.6 7.2 6.48 4.8 6 6.72
470 466 466 466 466 465 466 466 466 450 450
15.0 15.5 15.2 15.3 15.5 15.8 16.0 16.0 16.0 13.9 16.2
19.4 19.6 19.7 21.5 21.3 22.0 23.3 23.1 23.0 18.2 23.1
825 842 836 881 883 908 941 938 573 770 942
589 587 174 174 181 181 180 178 108 142 175
0 0 435 435 452 452 451 445 270 284 347
252 252 261 262 272 271 270 268 163 284 347
841 839 870 871 905 904 901 891 541 710 869
50-20-30 20-50-30 20-50-30 20-40-40 20-40-40 20-40-40 20-40-40 20-50-30 20-50-30 20-50-30 20-50-30
6178 6169 5914 5887 5882 5653 5683 5683 5734 5578 5536
0 25 40 25 0 0 0 0 0 0 0
7277 7222 7214 7214 7214 7198 7214 7214 4323 5375 6960
700 719 685 719 720 713 741 739 760 799 749
733.86 734.33 733.98 733.64 733.76 733.36 733.39 732.78 736.35 758.61 739.79
24 24 24 24 24 24 24 24 14.44 20.4 24
113 117 116 122 122 126 130 130 133 143 135
1352 1320 1322 1315 1325 1325 1320 1330 1330 1320 1340
0.82 1.16 1.11 1.06 1.07 1 1.01 1.05 1 0.89
90.9 94.91 96.82 91.95 91.8 96.82 97.32 92.97 93.96 95.76 92.23
90.31 92.91 95.14 93.87 88.95 95.19 91.76 93.81 92.93 93.26 90.52
1.68 1.54 1.58 1.16 1.13 1.18 1.08 1.19 1.48 1.44 1.32
Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil
Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft Soft
Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating Coating
96.6 96.35 96.3 96.61 96.82 96.75 96.75 96.63 96.88 96.51 96.59
2.44 2.45 2.47 2.45 2.46 2.46 2.46 2.46 2.45 2.47 2.44
1.53 1.47 1.48 1.48 1.47 1.49 1.49 1.51 1.51 1.5 1.48
91.73 92.82 92.58 92.59 92.61 92.46 92.46 92.53 92.45 92.48 92.49
2.44 2.4 2.44 2.46 2.44 2.46 2.43 2.45 2.47 2.44 2.43
1.46 1.45 1.46 1.46 1.45 1.48 1.48 1.5 1.51 1.51 1.5
53.69 55.98 55.76 55.64 55.77 55.49 55.32 55.61 55.21 55.73 55.52
22.08 19.56 20.09 20.01 19.99 20.47 20.5 20.41 20.51 20.65 20.58
7.91 7.86 7.82 7.8 7.76 7.97 8.05 8.12 8.11 8.21 8.2
11.09 11.15 10.98 10.87 11.06 10.81 10.97 10.81 10.62 10.86 10.92
de (Batch-II)
Average/ Total