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The following data were obtained from a test on a rotary kiln.
Calculate the per 100 kg of clinker, the kmol of flue gas, the kg of Raw-Mix and the kg of Coal
Also
o Determine the heat of reaction
o Determine the actual amount of the compounds present in the reactants and product
o Use heat of reaction = heat of formation of products – heat of formation of reactants
o Sensible heat contents of the gases
o % Heat lost due to presence of CO in the flue gas
o % Heat lost due to water vapor
In estimation the composition of the clinker,
The following items will be considered negligible
o Free CaO
o Combined MgO
o The amount of Fe2O3 in the clinker, other than that derive from pyrites in the raw mix and
coal
o Compound of SO3
The following assumptions are employed in estimating the composition of the raw mix:
o All the MgO is in the form of MgCO3
o The rest of the carbonate is CaCO3
o Any CaO not present as carbonate is present as CaO.SiO2
o The amount of Fe2O3 in the fraction reported as Fe2O3 and Al2O3 is negligible
o All Al2O3 is present as Al2O3.SiO2
64.59 % C A, kmol
1.71 % N
79 % N2
5.07 % H
21 % O2
1.76 % S
5.97 % O
0.86 % moisture
20.04 % Ash
C, kg
G, kmol
Rotary Kiln
F, kg 73. 64 % N2
25.39 % CO2
41.97 % CaO 0.89 % SO2
33.34 % CO2 0.08 % CO
13.00 % SiO2
7.00 % Fe2O3,Al2O3
2.50 % MgO
0.65 % Graphite
0.56 % FeS2 Clinker Analysis
0.71 % H2O 63.42 % CaO
20.80 % SiO2
11.42 % Fe2O3, Al2O3
3.28 % MgO
0.63 % SO2
C + S Balance
kmol CO2 1 kmol C
(𝐹)(0.3334 kg CO2 ) ( )( )
44 kg CO2 1 kmol CO2
kmol FeS2 2 kmol S
+ (F)(0.0056 kg FeS2 ) ( )( )
120 kg FeS2 1 kmol FeS2
kmol C kmol C kmol S
+ (F)(0.0065 kg graphite) ( ) + (C)(0.6459 kg C) ( ) + (C)(0.0176 kg S) ( )
12 kg C 12 kg C 32 kg S
kmol SO2 1 kmol S 1 kmol C
= (0.0063)(100) kg SO2 ( )( ) + (G)(0.2539) kmol CO2 ( )
64 kg SO2 1 kmol SO2 1 kmol CO2
1 kmol C
+ (G)(0.0008) kmol CO ( )
1 kmol CO
Eqn. 1:
0.00821𝐹 + 0.0544𝐶 = 0.00984 + 0.2547𝐺
N2 Balance
kmol N2 0.5 kmol N2
(𝑪)(𝟎. 𝟎𝟏𝟕𝟏 𝒌𝒈 𝑵𝟐 )( )( ) + (𝐴)(0.79 𝑘𝑚𝑜𝑙 N2 ) = (𝐺)(0.7364 𝑘𝑚𝑜𝑙 N2 )
14 kg 𝑁2 1 kmol N2
0.0171
( )𝐶 + 0.79𝐴 = 0.7364𝐺
(2)(14)
Eqn. 2:
0.0006107𝐶 + 0.79𝐴 = 0.7364𝐺
Active O2 Balance
kmol CO2 kmol O 0.5 kmol O2
(F)(0.3334 kg CO2 ) ( ) + (C)(0.0597 kg O) ( )( ) + (A)(0.21 kmol O2 )
44 kg CO2 16 kg O 1 kmol O
1 kmol O2
= (G)(0.2359 kmol CO2 ) ( ) + (G)(0.0089 kmol O2 )
1 kmol CO2
0.5 kmol O2 kmol SO2 1 kmol O2
+(G)(0.0008 kmol CO) ( ) + (0.0063)(100) kg SO2 ( )( )
1 kmol CO 64 kg SO2 1 kmol SO2
Eqn. 3:
0.007577𝐹 + 0.001866𝐶 + 0.21𝐴 = 0.2632𝐺 + 0.00984
Eqn. 4:
0.6447𝐹 + 0.2004𝐶 = 98.92
Summary:
F = 135.67 kg
C = 57.14 kg
G = 16.54 kmol
A = 15.37 kmol
Amount of Fe2O3
11
2𝐹𝑒𝑆2 + 𝑂 → 𝐹𝑒2 𝑂3 + 4𝑆𝑂2
2 2
1 1 160
𝐹𝑒2 𝑂3 (𝑖𝑛 𝑟𝑎𝑤 𝑚𝑖𝑥) = 0.0056𝐹 𝑏𝑦 𝐹𝑒𝑆2 ( )( )( ) (135.67)
120 2 1
𝐹𝑒2 𝑂3 (𝑖𝑛 𝑟𝑎𝑤 𝑚𝑖𝑥) = 0.5065 𝑏𝑦 𝐹𝑒2 𝑂3
@ Clinker
𝐹𝑒2 𝑂3 𝑖𝑛 𝐶𝑙𝑖𝑛𝑘𝑒𝑟 = (1.42 + 0.5065)𝑘𝑔 𝐹𝑒2 𝑂3 = 1.9265 𝑘𝑔 𝐹𝑒2 𝑂3
𝐴𝑙2 𝑂3 𝑖𝑛 𝐶𝑙𝑖𝑛𝑘𝑒𝑟 = 0.07(135.67) = 9.4969 𝑘𝑔 𝐴𝑙2 𝑂3
20.80
𝑆𝑖𝑂2 = = 0.3467 𝑘𝑚𝑜𝑙
60
9.4969
𝐴𝑙2 𝑂3 = = 0.0931 𝑘𝑚𝑜𝑙
102
1.9265
𝐹𝑒2 𝑂3 = = 0.1204 𝑘𝑚𝑜𝑙
160
63.42
𝐶𝑎𝑂 = = 1.1325 𝑘𝑚𝑜𝑙
56
@ Raw Mix, F
45.23
𝐶𝑂2 = = 1.0280 𝑘𝑚𝑜𝑙
44
56.94
𝐶𝑎𝑂 = = 1.0168 𝑘𝑚𝑜𝑙
56
17.64
𝑆𝑖𝑂2 = = 0.2939 𝑘𝑚𝑜𝑙
60
9.50
𝐴𝑙2 𝑂3 = = 0.0931 𝑘𝑚𝑜𝑙
102
3.39
𝑀𝑔𝑂 = = 0.0848 𝑘𝑚𝑜𝑙
40
𝑚𝑜𝑙𝑒 𝑀𝑔𝐶𝑂3 = 0.0848 𝑘𝑚𝑜𝑙
1 1 1
𝑚𝑜𝑙𝑒 𝐶𝑎𝐶𝑂3 = 1.0280 ( ) − 0.0848 ( ) ( ) = 0.9432 𝑘𝑚𝑜𝑙
1 1 1
1 kmol CaO 1 kmol CaO ∙ SiO2
mol CaO ∙ SiO2 = 1.0168 kmol CaO − 0.9432 kmol CaCO3 ( )( )
1 kmol CaCO3 1 kmol CaO
mol CaO ∙ SiO2 = 0.0736 𝑘𝑚𝑜𝑙 CaO ∙ SiO2
𝑚𝑜𝑙 𝐴𝑙2 O3 ∙ SiO2 = 0.0931 𝑘𝑚𝑜𝑙 𝐴𝑙2 O3 ∙ SiO2
𝑟𝑒𝑚𝑎𝑖𝑛𝑖𝑛𝑔 𝑆𝑖O2
1 kmol 𝑆𝑖O2
= 0.2939 𝑘𝑚𝑜𝑙 𝑆𝑖O2 − 0.0736 𝑘𝑚𝑜𝑙 CaO ∙ SiO2 ( )
1 kmol CaO ∙ SiO2
1 kmol SiO2
− 0.0931 𝑘𝑚𝑜𝑙 𝐴𝑙2 O3 ∙ SiO2 ( )
1 kmol 𝐴𝑙2 O3 ∙ SiO2
𝑟𝑒𝑚𝑎𝑖𝑛𝑖𝑛𝑔 𝑆𝑖O2 = 0.1272 𝑘𝑚𝑜𝑙 𝑆𝑖O2
Composition of the Raw Mix:
n (kmol) 𝐤𝐠 Mass (kg) % by mass
MW (𝐤𝐦𝐨𝐥)
𝑆𝑖O2 0.1272 60 7.63 5.64
𝐴𝑙2 O3 ∙ SiO2 0.0931 162 15.08 11.15
CaO ∙ SiO2 0.0736 116 8.54 6.31
CaCO3 0.9432 100 94.32 69.72
MgCO3 0.0848 84 7.12 5.26
𝐻2 𝑂 0.96 0.71
𝐹𝑒𝑆2 0.76 0.56
Graphite 0.88 0.65
For CO2
𝐵𝑡𝑢
𝐶𝑝 = 0.21
𝑙𝑏 − ℉
𝑇 = 1410℉
𝑥𝐶𝑂2 = 0.2539
44 𝑘𝑔 𝐶𝑂2 2.2 𝑙𝑏 𝐵𝑡𝑢
𝑞𝐶𝑂2 = (0.2539)(16.54 𝑘𝑚𝑜𝑙 𝐶𝑂2 ) ( )( ) (0.21 ) (1410℉ − 32℉)
1 𝑘𝑚𝑜𝑙 𝐶𝑂2 1 𝑘𝑔 𝑙𝑏 ∙ ℉
𝒒𝑪𝑶𝟐 = 𝟏𝟏𝟕𝟔𝟑𝟔. 𝟒𝟗𝟒𝟗 𝑩𝒕𝒖
For O2
𝐵𝑡𝑢
𝐶𝑝 = 0.22
𝑙𝑏 − ℉
𝑇 = 1410℉
𝑥𝑂2 = 0.0089
32 𝑘𝑔 𝑂2 2.2 𝑙𝑏 𝐵𝑡𝑢
𝑞𝑂2 = (0.0089)(16.54 𝑘𝑚𝑜𝑙 𝑂2 ) ( )( ) (0.22 ) (1410℉ − 32℉)
1 𝑘𝑚𝑜𝑙 𝑂2 1 𝑘𝑔 𝑙𝑏 ∙ ℉
𝒒𝑶𝟐 = 𝟑𝟏𝟒𝟏. 𝟕𝟑𝟖𝟖 𝑩𝒕𝒖
For CO
𝐵𝑡𝑢
𝐶𝑝 = 0.24
𝑙𝑏 − ℉
𝑇 = 1410℉
𝑥𝐶𝑂 = 0.0008
28 𝑘𝑔 𝐶𝑂 2.2 𝑙𝑏 𝐵𝑡𝑢
𝑞𝐶𝑂 = (0.0008)(16.54 𝑘𝑚𝑜𝑙 𝐶𝑂) ( )( ) (0.24 ) (1410℉ − 32℉)
1 𝑘𝑚𝑜𝑙 𝐶𝑂 1 𝑘𝑔 𝑙𝑏 ∙ ℉
𝒒𝑪𝑶 = 𝟐𝟔𝟗. 𝟓𝟔𝟕𝟎 𝑩𝒕𝒖
% Heat lost due to the presence of CO
𝐻𝑉 𝑜𝑓 𝐶𝑂
%𝐻𝑒𝑎𝑡 𝑙𝑜𝑠𝑡 𝑡𝑜 𝐶𝑜 𝑖𝑛 𝐺 = 𝑥 100 %
𝐻𝑉 𝑜𝑓 𝐶𝑜𝑎𝑙
𝐵𝑇𝑈 28 𝑘𝑔 𝐶𝑂 2.2𝑙𝑏
(4344 ) [(0.008)(16.54 𝑘𝑚𝑜𝑙 𝐶𝑂) ( )( )]
𝑙𝑏 1 𝑘𝑚𝑜𝑙 𝐶𝑂 𝑘𝑔
= 𝑥 100 %
𝐵𝑇𝑈 2.2𝑙𝑏
(1280 ) (57.14 𝑘𝑔)( )
𝑙𝑏 𝑘𝑔
%𝑯𝒆𝒂𝒕 𝒍𝒐𝒔𝒕 𝒕𝒐 𝑪𝒐 𝒊𝒏 𝑮 = 22.0051 %
𝐵𝑇𝑈 2.2𝑙𝑏
(972 ) [(0.0062) ( )]
𝑙𝑏 𝑘𝑔
= 𝑥 100 %
𝐵𝑇𝑈 2.2𝑙𝑏
(1280 ) (57.14 𝑘𝑔)( )
𝑙𝑏 𝑘𝑔