Total Feed 430 TPH Tempt 96.

0 C
Ambient Tempt 40.0 C Draft 5 mmwg
False air 149995 m3/hr Tempt 92.1 C 880674 m3/hr Tempt 96.0 C
Flow
Sensible heat 1.61 MKCal Draft -760 mmwg 583097 Nm3/hr Draft -5.8 mmwg
937470 m3/hr Heat Flow 17.65 MKCal 191339 m3/hr
Flow Flow
% Moisture Tempt Heat Flow 627332 Nm3/hr 137313 Nm3/hr
Clinker 53.5% 0% 115 5.3 MKCal Fly Ash Heat Flow 3.84 MKCal
Gypsum 6.5% 9% 33 0.2 MKCal
Pond ash 34% 12% 30 0.8 MKCal
Dry ash 6.0% 0.5% 65 0.3 MKCal
Other 0% 0% 0 0.0 MKCal
Wt. average 100.0% 5% 77.77 6.6 MKCal
Sensible heat of feed moisture 0.8 MKCal
Total heat flow 7.4 MKCal

Product
Tempt
Heat Flow

689335 m3/hr
Flow
496814 Nm3/hr
Total Inputs 44.6 MKCal Heat Flow 13.82 MKCal
Total Outputs 44.6 MKCal

Electrical Energy 5.7 MKCal

Water Spary 1.5 KL
Sensible heat 0.1 MKCal

water vapourisation 13.8 MKCal Tempt 547.0 C

Radiation losses 1.8 MKCal Draft -28 mmwg
180864 m3/hr
Flow
58315 Nm3/hr
Heat Flow 16.03 MKCal
 96.0 C
-5.8 mmwg
191339 m3/hr
137313 Nm3/hr
3.84 MKCal

Product 410 TPH

Tempt 92.0 C
Heat Flow 7.54 MKCal

689335 m3/hr
496814 Nm3/hr
13.82 MKCal
BANGUR CEMENT UNIT

PROCESS MEASUREMENT CALCULATION DURING GRINDING IN PPC CEMENT MILL-I FOR

Dept : PROCESS
Doc. No. :IMS/06/01/FOR/11
Edition No. : 01 Issue No. : 01
DATE :-17.05.18
Altitude above masl 190.0
AMBIENT TEMP. 35OC
Site Pressure 10092
Bag House Fan
Flow measurement
Fan Motor Speed (RPM) RPM 980
Damper % % 100
Temperature Deg.c 92.1
Draft(Traverse Point) mmWG -760
Dynamic Pressure(ΔH) mmWG 33.00
Density at NTP Kg/NM3 1.293
Density Kg/M3 0.873
Pitot tube constant 0.8429
Velocity of gas M/s 22.95
Duct dia M 3.80
Cross sectional area M2 11.35
Gas flow rate M3/s 260.41
Gas flow rate M3/Hr 937470
Gas flow rate(NTP) NM3/hr 627332

Designed at 95 Deg. M3/Hr 1085000

Fan Efficiency % 74.51

False Air 79158
False Air % 12.62

Coal consumption Kg/Hrs 600.0

Gas flow M3/Hr 180863.7
Gas density Kg/M3 0.4
Mas flowrate Kg/Hr 75837.5
Sp. Heat Cp Kcal/KgK 0.3
ΔT K 512.0
FAN flow M3/Hr 10694.1
Heat from hot gas Kcal 9707200.9
Coal NCV Kcal/Kg Kg coal 7488.0
Heat from coal Kcal 4492800.0
HAG Eff. % 216.1
NG IN PPC CEMENT MILL-I FOR THE MONTH OF MAY-2018

HAG FAN-2 LOCAL

HAG O/L Duct Stack Duct HAG FAN-1 FLOW
FLOW FURNACE
NA NA 2600 NA
100 100 100 NA
547.0 95.2 40.0 402.0
-27.5 -5.8 -11.0 -11.0
5.25 1.20 0.00 1.85
1.293 1.293 1.293 1.293
0.42 0.94 1.10 0.51
0.8429 0.8429 0.8429
13.21 4.23 7.50 7.11
2.20 4.00 0.71 2.20
3.803 12.571 0.396 0.000 3.803
50.24 53.15 2.97 0.00 27.04
180864 191339 10694 0 97330
58155 137313 9023 0 38081

16800 16800
 Shree Cement Ltd., UP Grinding Unit, Bulandshahar
Basis

Mill output rate tph 400

Conversion Factor - 1.80
Total fly ash % 37.00
Pond ash % 75.675676
Cement Tempt 85
Sno Description Clinker Gypsum Dry fly ash Pond fly ash
1 Unit % % % %
1.2 Cement constituents 54.50 8.50 9.00 28.00
1.3 Feed moisture (%) 0.00 6.40 0.50 10.00
1.4 Material temp.-Deg. C 100 28 57 25
1.5 Thermal efficiency of HAG % 85
1.6 Cost of USA coal Rs./ t 10700
1.7 USA coal heat value kcal/ kg. 7400
2 Mill Product, (Dry basis) t/h 400
Moisture in feed (excluding
2.1 % 3.39
water spray)
2.2 Moisture in product % 0.00
2.3 Mill Product (on dry basis) t/h 400.0
2.4 Total Mill feed (on wet basis) t/h 414.03
2.5Moisture to be evaporated t/h 14.032
2.6Moisture residual t/h 0.000
3 Site pressure Mmwg 10073
4 Power (MVR + Separator) kW 7400
5 False air in mill circuit % 14
7 Ambient temperature Deg C 40
8 System exit gas temp Deg C 92
9 Hot gas temperature Deg C 580
Heat Balance for PPC Grinding in MVR with 100 % Dry fly ash
Flow Cp Temp. Heat
SN Stream
kg/hr kcal/kg 0C 0C Kcal/ Hour
1 Feed (Dry) 400000 0.20 69 5520800
2 Feed (water) 14031.5 1.00 35 491103
3 System exit gas recirculation 606080 0.24 92 13382255
4 HAG gas 60000 0.27 580 9396000
5 False air 148541 0.237 40 1408164
6 Electrical energy - 5854880
7 Water spray (0.16%) 4000 1.00 40 160000
 1232652
Total heat input 36213203
HEAT OUTPUTS
1 Total feed heating 400000 0.20 85.0 6800000
2 Feed moisture evaporation 14032 - 8867926
3 System exit gas 814621 0.24 87.0 16938484
5 Water spray evaporation 4000 - 2560000

Other losses with radiation &

6 - - 1086396
convection (Assumed as 5%)

7 Residual moisture 0.0 1.00 85.0 0

1232652
Total heat output 36252806

HAG Capacity required Mkcal/hr 9.40

USA coal required for HAG Kg/hr 1493.8
USA coal required for HAG Kg/t PPC 3.7
Cost of USA coal Rs/ t 11102
Cost/ t PPC Rs/ t PPC 41.5
r

Total/
Average
%
100.00
3.39
69.01

Air Balance
Details m3/hr kg/hr
Bag House fan 942994 824463
Hot gas from HAG 150000 60000
False air (17%) 132019 148541
Recirculation 693215 606080
Stack exhaust 226958 218382

h
Heat
%
15.25
1.36
36.95
25.95
3.89
16.17 Water spray KL/hr
0.44 4.00
100.0
Minimum heat required
18.76 Total feed heating 1279200
Feed moisture
24.46 8867926
evaporation
46.72 System exit gas 2560000
Water spray
7.06 1931026.81887831
evaporation
Minimum heat
3.00 14638153
required

Minimum Coal
0.00 1.14068478330444
required per hour
Minimum cost per 11977.1902246966
hour
100.00 Cost Per MT 30

8.2685245299407E-05
r Balance
Temp, Deg C Density (kg/m3)
95 0.87
580 0.40
40 1.13
92 0.90
93 0.96