1.

Volumetric loading of Kiln

D : Diameter of the Kiln (m)
Volumetric Loading (TPD/m³) tk : Lining Thickness of the Kiln (m)
Clinker Production (TPD) L : Length of the Kiln (m)
π * ((D – 2tk) ²/4) * L
TPD π D tk L
2
1200 3.14 3 0.2 4 45
1200 3.14 1.69 45
1200 238.797
5.03 TPD/m³

2. Thermal loading of Kiln

Thermal Loading
Clinker (TPD) * Heat consumption * %firing in kiln * 10³
π* ((D – 2tk) ²/4) * 24*L
Thermal Loading : (kcal/hr/m²)
Heat consumption : (kcal/kg)
D : Diameter of the Kiln (m)
tk : Lining Thickness of the Kiln (m)

TPD H.Cons. Firing% π D tk

1000 780 30 10000 3.14 3 0.2 24

234000000000.00 5731.128
40829658.6640536 10000000
4.08 kcal/hr/m²

3. Kiln Effective Volume

Effective volume (m³) π * D² * L

4
D : Kiln effective diameter (m) (ID of brick)
L : Kiln length (m)

3.14 2.6 45 4
3.14 6.76 45 4
238.797 m³
4. Kiln effective cross section
π * D²
Effective Cross Section area (m2) =
4

D : Kiln effective diameter (m) (ID of brick)

L : Kiln length (m)
π D
3.14 3 4
28.26 7.07 m2

5. Kiln % filling

3.2 * kiln capacity (TPD)

% filling =
D³ * Kiln speed (RPM) * Kiln slope (%)

D : Kiln effective diameter (m)

Typical values : 13 – 17%
TPD D RPM slope
3.2 1200 2.6 3.5 3.5
3840 17.576 215.306
17.84 % filling

6. Kiln feed Retention Time

11.2 * L
T= (min)
r*D*s

L : Kiln Length (m)

r : Kiln Speed (rpm)
D : Effective Diameter (m)
S : Slope (Degrees)
L r D s
T 11.2 45 3.2 2.6 2.5
504 20.8
24.23 (min)

7. Cooler performance
a. Thermal Efficiency of cooler
 Qc – Q1 * 100
E
Qc
E : Thermal efficiency of cooler (%)
Qc : Heat content of clinker, cooler in (kcal/kg)
Q1 : Total heat losses in cooler (kcal/kg)

Qc Q1 Qc
E
650 250 650
40000 650
61.54 %

8. Internal volume of mill Cement Mill Raw Mill

Vm = π * D² * L 3.14
4 3.14

Vm : Internal volume of the mill (m³)

D : internal diameter of the mill, liner to liner (m)
L : internal length of mill (m)

3.14 3.4 3.4 12.5 4

3.14 11.56 12.5 4
453.73 4
Ans 113.43 m³

9. Critical Speed of Ball mill

Cement Mill Raw Mill

Nc = 42.3 Nc = 42.3
(RPM)
√D √D
42.3 3.4 42.3
42.3 1.84 42.3
Ans 22.94 (RPM) Ans 22.29

10. Evaluate Expansion

Expansion at 250˚C
1st Tyre Expansion (mm) 1.2* (T˚C final - T˚C initial) * Length (m)
100
1.2 253 108 3.16
 100
1.2 1.45 3.16

Expansion (mm) 5.50 Ans.

Expansion at 250˚C
2nd Tyre Expansion (mm) 1.2* (T˚C final - T˚C initial) * Length (m)
100
1.2 265.5 141 3.16
100
1.2 1.245 3.16

Expansion (mm) 4.72 Ans.

Expansion at 250˚C
3rt Tyre Expansion (mm) 1.2* (T˚C final - T˚C initial) * Length (m)
100
1.2 277.5 150 3.16
100
1.2 1.275 3.16

Expansion (mm) 4.83 Ans.

 clinker tpd*sp. Heat cons.
crossection area*24*1000

45
Raw Mill Caol Mill

3.6 3.6 7.5 4 3.14 2.4 2.4 6 4

12.96 7.5 4 3.14 5.76 6 4
305.208 4 108.5184 4
Ans 76.30 m³ Ans 27.13 m³

Raw Mill Caol Mill

Nc = 42.3
(RPM) (RPM)
√D
3.6 42.3 2.4
1.90 42.3 1.55
22.29 (RPM) Ans 27.30 (RPM)
 253

265.5

277.5
V ∏
H(R²+r²+Rr)
3

3.14

875
1 1 0.2
0.2 2.6
0.52
464
 498 215 215
928 464
1750 5530 5500
430
1320 660

928
430
498 249

3.27 1.56
1.71 2.3 0.43
1.69119