1st cyc outlet(1A)

O2: 3.55 %, CO : 0.5%

T : 322 Deg C, P: -48 mbar 1st cyc outlet(1B)
O2: 2.9 %, CO : 0.9%
T : 327 Deg C, P: -45.2 mbar

2nd cyc outlet

O2: 4.35 %, CO : 0.007%
T : 505 Deg C, P: -37.6 mbar

I I

GCT
3rd cyc outlet
O2: 3.6 %, CO : 0.004% II
T : 650 Deg C, P: -30.2mbar

4th cyc outlet 3rd cyc inlet

O2: 1.2 %, CO : 0.039% III O2: 3,4 %, CO : 0.025%
T : 781Deg C, P: -21.7mbar T : 660 Deg C, P: -25 m

4th cyc inlet

5th cyc outlet IV O2: 1%, CO :
O2: 0%, CO : 1.03% T : 776 Deg C
T : 860 Deg C, P: -14.5 mbar

V Calci
ner
 TAD
Flow : 0.43 Nm3/
Temp : 945 Deg
Kiln inler
O2: 0%, CO : 3.195%
Temp : 1080 Deg C, P: -1.7mbar
KILN
 PH Downduct duct
O2: 5.3%, CO : 0.0089 %
T : 327 DeFlow : 1.00 Nm3/kg cl
Heat: 88.6 kcal/kg cl
Temp : 301 Deg C
1st cyc inlet g C, P: -49 mbar
O2: 2.96 %, CO : .86% Flow : 1.55 Nm3/kg cl
T :324 Deg C, P: - 40.4 mbar P : -102.5 mba
CYCL Sepa
2nd cyc inlet ONE rator
O2: 4.17 %, CO : 0.006%
T :515 Deg C, P: - 34 mbar
GCT

Cyc
P : -96 mbar
Raw mill I/L
O2: 9.0%
PH Fan P: -2 mbar RM 4
yc inlet
4 %, CO : 0.025% Raw mill O/L
0 Deg C, P: -25 mbar O2: 12.19%
False:36.6%
P : -79 mbar
4th cyc inlet
O2: 1%, CO : 0.96%
T : 776 Deg C, P: -18.7 mbar

5th cyc inlet/cal outlet

O2: 0%, CO : 6.4%
T : 835 Deg C, P: -11.4 mbar

Coooler vent
Flow : 1.3 Nm3/kg cl
Temp : 380 Deg C
P: -3.3 mbar
 Coooler vent
Flow : 1.3 Nm3/kg cl
TAD Temp : 380 Deg C
ow : 0.43 Nm3/kg cl P: -3.3 mbar
Temp : 945 Deg C

KILN
COOLER

Cooling air
Flow : 1.87 Nm3/kg clcl
 Cyc O/L
P : -102.5 mbar
Raw mill fan
Sepa CYCL
ONE O2: 12.25%
rator
False: 0.7 %
P : -114mbar

Cyc inlet
96 mbar

w mill O/L

HE False Air
Flow : 0.05 Nm3/kg cl
HE

Bag
Filter

Booster fan
O2: 16 %

To Cement mill

Cooler Vent Fan

 Cooler Vent Fan
Flow : 1.00 Nm3/kg cl
Temp : 301 Deg C
 material flow
gas flow
clinker leaving cooler
Fuel flow
Gas duct not in opn

Booster fan
O2: 16 %
 I I

GCT

II

III

5th cyc outlet

O2: 0%, CO : 0.63% IV
T : 858 Deg C, P: -18mbar

V Calci
ner
 Kiln inler
O2: 0%, CO : 6.01%
Temp : 1153 Deg C, P: -1.0 mbar KILN
 PH Downduct duct
O2: 2.98 %, CO : 0.02 %
NOx: 989 ppm,
T : 327 Deg C,P= -52.5 mbar

CYCL Sepa
ONE rator

GCT

PH Fan RM 4

5th cyc inlet/cal outlet

O2: 0%, CO : .96%
T : 875 Deg C, P: -12.7 mbar
KILN
COOLER
 Raw mill fan
Sepa CYCL
rator ONE

HE

Bag
Filter

Booster fan

To Cement mill

Cooler Vent Fan

Cooler Vent Fan
 material flow
gas flow
clinker leaving cooler
Fuel flow
Gas duct not in opn kiln feed
Flow : 1
Heat: 1

Booster fan
kiln feed
Flow : 1.78 kg/kg cl
Heat: 19.38 kcal/kg cl
 1st cyc outlet(1A)
O2: 3.55 %, CO : 0.5%
NOx: 717 ppm, HC 441 PPM 1st cyc outlet(1B)
T : 322 Deg C, P: -48 mbar O2: 2.9 %, CO : 0.9%
NOx: 817 ppm, HC :450 PPM
P: 10.4 mbar, T:183Deg C T : 327 Deg C, P: -45.2 mbar
2nd cyc outlet P: 7.6 mbar T:178 Deg C
O2: 4.35 %, CO : 0.007%
NOx: 825 ppm, HC 226 PPM
T : 505 Deg C, P: -37.6 mbar
P: 7.4 mbar, T: 145 Deg C
I I

GCT
3rd cyc outlet
O2: 3.6 %, CO : 0.004%
NOx: 910 ppm II
T : 650 Deg C, P: -30.2mbar
P: 8.5mbar T: 131 Deg C

4th cyc outlet

O2: 1.2 %, CO : 0.039% 3rd cyc inlet
NOx: 770 ppm III O2: 3,4 %, CO : 0.025%
T : 781Deg C, P: -21.7mbar NOx:981ppm
T : 660 Deg C, P: -25 m
P: 7.2 mbar T: 79Deg C
4th cyc inlet
5th cyc outlet O2: 1%, CO :
O2: 0%, CO : 1.03% IV
NOx: 6 ppm
NOx: 10 ppm T : 776 Deg C
T : 860 Deg C, P: -14.5 mbar
P: 3.1mbar T: - 25 Deg C

V Calci
ner
 Kiln inler
O2: 0%, CO : 3.195%
NOx: 34 ppm KILN
Temp : 1080 Deg C, P: -1.7mbar
 PH Downduct duct
O2: 5.3%, CO : 0.0089 %
NOx: 713 ppm, HC :40 PPM
M T : 327 Deg C, P: -49 mbar
1st cyc inlet P: 2.5mbar T:3.5 Deg C
O2: 2.96 %, CO : .86% P : -102.5 mba
NOx:771 ppm, HC: 717ppm P: 6.5 mbar
T :324 Deg C, P: - 40.4 mbar
CYCL Sepa
2nd cyc inlet ONE rator
O2: 4.17 %, CO : 0.006%
NOx:981ppm, HC: 38 ppm
T :515 Deg C, P: - 34 mbar
GCT

Cyc
Raw mill I/L P : -96 mbar
PH Fan O2: 9.0% RM 4 P: 17 mbar
P: -2 mbar
yc inlet
4 %, CO : 0.025% Raw mill O/L
981ppm O2: 12.19%
0 Deg C, P: -25 mbar False:36.6%
P : -79 mbar
4th cyc inlet P: 77 mbar
O2: 1%, CO : 0.96%
NOx: 6 ppm
T : 776 Deg C, P: -18.7 mbar

5th cyc inlet/cal outlet

O2: 0%, CO : 6.4%
NOx: 10 ppm
T : 835 Deg C, P: -11.4 mbar
KILN
COOLER
 Cyc O/L
P : -102.5 mbar
P: 6.5 mbar Raw m
Raw mill fan
O2: 12.25%
Sepa CYCL False: 0.7 %
ONE
rator P : -114mbar
P: 11.5 mbar

Cyc inlet
96 mbar
17 mbar

w mill O/L

HE False Air
HE Flow : 0.05 Nm3/kg cl

Bag
Filter

Booster fan

To Cement mill

Cooler Vent Fan

Cooler Vent Fan
 Raw mill fan
12.25%
se: 0.7 %
-114mbar
11.5 mbar

material flow
gas flow
clinker leaving cooler
Fuel flow
Gas duct not in opn kiln feed
Flow : 1
Heat: 1

Booster fan Booster Fan

O2: 16 %
kiln feed
Flow : 1.78 kg/kg cl
Heat: 19.38 kcal/kg cl
LHV 918.51 btu/ft3
gas density 0.92 kg/m3
gas flow 8452 kg/hr
gas flow 7775.84 m3/hr
gas flow 274588.2379 ft3/hr
Q 252212042.4 btu/hr
SAR 2627208.775 ft3/hr 2745882.3792
SAR 74392.04368 m3/hr 77735.930155152
density of air 1.157340984 kg/m3 89966.9778673343
SAR 86096.961 kg/hr 69580.0292864148
SAR 66586.9768 nm3/hr
clinker production 123529.41 kg/hr
SAR 0.539037431 nm3/kgcl
with 15% excess air 0.619893046

% Moles Moles of O2 Kg air needed/100 kg fuel

Methane 97.2549 0.972549 1.945098 1672.41852206922
Ethane 0.9732 0.009732 0.068124 15.6252723711312
Propane 0.2801 0.002801 0.014005 4.38092288731128
Butane 0.1372 0.001372 0.017836 2.11642974108266
Pentane 0.0519 0.000519 0.004152 0.793792663726906
Hexane 0.096 0.00096 0.01824 1.45979092336578
Co2 0.513 0.00513
N2 0.6937 0.006937

total air 1696.79473066 kg air/100 kg fuel

total air per kg fuel 16.9679473066 kg air/kg fuel
air needed for actual fuel 143413.090635 kg air/hr
air needed for actual fuel 110914.996624 Nm3/hr
clinker production 123529.41
air needed for actual fuel 0.90 nm3/kg clinker

CH4 + 2 O2 -> CO2 + 2 H2O 16.042 3.98952749033786

2) 2 C2H6 + 7 O2 -> 4 CO2 + 6 H2O 30.068 3.72489024876946
3) C3H8 + 5 O2 -> 3 CO2 + 4 H2O 44.094 3.6286116024856
4) 2 C4H10 + 13 O2 -> 10 H2O + 8 CO2 58.12 3.57880247763248
5) C5H12 + 8 O2 -> 5 CO2 + 6 H2O 72.146 3.54836026945361
6) 2 C6H14 + 19 O2 -> 14 H2O + 12 CO2 86.172 3.52782806480063
carbon % 74.14359165
hydrogen% 24.59506035
N2 0.6937
Co2 0.513
 3407
5049

0.0104

17.19624
16.05556
15.64057
15.42587
15.29466
15.20616
Kiln feed : 1.7kg/kg cl
Heat: 20.88 kcal/kg cl
Temp : 78 Deg C I I

GCT

II

III
PH fan
Flow : 1.55 Nm3
Heat: 165.9 kcal
Temp : 317 Deg C
IV

V Calci
ner
KILN
 CYCL Sepa
ONE rator
Raw mill I/l
Flow : 1.33 Nm3/kg cl
Heat: 132.7 kcal/kg cl
GCT
Temp : 273 Deg C

RM 4

PH Fan
Raw mill O/L
PH fan Flow : 2.80 Nm3/kg cl
w : 1.55 Nm3/kg cl Heat: 81.9 kcal/kg cl
t: 165.9 kcal/kg cl Temp : 102 Deg C
p : 317 Deg C

PH fan going HE
Flow : 0.22 Nm3/kg cl
Heat: 20 kcal/kg cl
Temp : 273 Deg C

Coooler vent
Flow : 1.3 Nm3/kg cl
Heat: 147 kcal/kg cl
Temp : 380 Deg C
 Coooler vent
Flow : 1.3 Nm3/kg cl
Heat: 147 kcal/kg cl
Temp : 380 Deg C

KILN
COOLER Clinker leaving cooler
Flow : 1 kg/kg cl
Heat: 33 kcal/kg cl @
190 Deg C
Cooling air
Flow : 1.87 Nm3/kg clcl
Heat: 8.9 kcal/kg cl

1.862
 Raw m
Raw mill fan
Flow : 2.87 Nm3
Sepa CYCL Heat: 68.8 kcal/
ONE
rator Temp : 87 Deg C

O/L
cl
l HE false air
HE Flow : 0.05 Nm3/kg cl

Bag
Filter

Booster fan

To Cement mill

Cooler Vent Fan

 Cooler Vent Fan
Coooler vent fan
Flow : 1.00 Nm3/kg cl
Heat: 88.6 kcal/kg cl
Temp : 301 Deg C

ving cooler
/kg cl
kcal/kg cl @
190 Deg C

14
16 4.7
 Raw mill fan
w : 2.87 Nm3/kg cl
at: 68.8 kcal/kg cl
mp : 87 Deg C

material flow
gas flow
clinker leaving cooler
Fuel flow
Gas duct not in opn kiln feed
Flow : 1
Heat: 1

Booster fan
Booster fan
Flow : 4.15 Nm3/kg cl
Heat: 178.9kcal/kg cl
Temp : 149 Deg C
kiln feed
Flow : 1.78 kg/kg cl
Heat: 19.38 kcal/kg cl

56.7653