Reference Guide for

“Kiln Systems”
 When doing calculations on cement kilns it is usual to work withspecific quantities referred to 1 kg of clinker. Therefore the fuel consumption is expressed as q in
MJ/kg cliand the kiln gas volume as VKilngasin Nm3/kg cli.

Excess air

Therefore the kiln exhaust gas volume VKilngas, wetwith excess air at the actual measured O2concentration is for kilns with drykiln feed:

Secondary Air and Air to Kiln

Ideal Gas Conversion

Barometric Pressure

with:

Material Residence Time in Kiln

with:

with:
Required Kiln Drive Power to be Installed

with:

Clinker Cooler Exit Temperature

with:

Transport Efficiency of Grate Cooler

with:
with:

Thermal Power (from Fuels)

with:

Specific Axial Impulsion of Burner

with:

with:
Electrical Power Requirement for Fan

with:

Total Pressure Increase (Rough Estimation)

with:

Influence of Fan Speed on Volume flow, Static Pressure and Power Consumption

with:

with:

with:
Water Dew Point

with:

with:

Cooling Water Injection for Gas Cooling

with:

Air Inleakagein Process Filters from Temperature Reading

with:
Air Inleakagein Process Filters from Oxygen Measurement

with:
Reference Guide for

“Material Technology”
Lime Saturation (LS)

Silica Ratio (SR)

Alumina Ratio (AR)

Total Alkali (total %)

Molar alkali/sulfurratio

Molar alkali/CI ratio

Degree of precalcination
 Typical Moduli of Industrial Clinker

LS and SR Moduli in Holcim Clinker

AR and SR Moduli in Holcim Clinker

Physcio-chemical Burnability Model

Example for Physcio-chemical Burnability Model

Classification of Raw Mix Components:

Mineral Composition of Raw Mixes:

Liquid Phase (LP)

Correlation of Quantity of Liquid Phase with Silica Ratio

Correlation between the main clinker Minerals and the main moduli
Correlation with Alumina Ratio
 Uniformity Indicator Clinker

Uniformity Indicators Cement

Impacts of Cement uniformity

Uniform Kiln Feed Quality: A Key to Excellent Kiln Performance

Electromagnetic spectrum

Radiation
General Conversion

Conversion of US and UK units into SI units

Frequency table

Measure of location
Mean

Measure of variability
Significance of standard deviation

Range

Criteria for normal distribution

Kurtosis

Skewness

Standardised normal distribution (Z)

 Reference Guide for

“Mechanical Process Technology”

 [t/h]

[kN]

[kW]

[kN/m2]

[N/mm2]

[kWh/t]

[kWh/t]
β Clinker2.3 –2.85 [°]
 β RawMaterial 2.85–4.0 [°]
β Slag1.7 –2.3 [°]
β= attack angle

K ≤ 6000 kN/m2

α Clinker6.9 –9.2 [°]

α RawMaterial 9.2–12.6 [°]
α Slag5.7 –7.5 [°]
α= nip angle

E Cliinker2.5 –3 [kWh/t]
E RawMaterial2.0 –2.5 [kWh/t]
E Slag~ 3 [kWh/t]

Ec= Closed circuit (with separator or/and slab recirculation)

or
Fig. 8: duct-slope for limestone, slag, cement dedusting
Filter bag dimension

Filter bag dimension

DedustingAir Quantities
Venting Hood Design
Duct Elbow, Joint and Branch Design
 Fig. 19: Example vertical curve

Belt width shall not be less than 800 mm, for special applications 650 mm belts may be used.
Packing plants 500 mm flat belts may be applicable.
The minimum belt width for reversible conveyors shall not be less than 800 mm.
mwet= mass wet [kg]mdry= mass dry[kg]mH2O= mass water
 Table 1 –Material Bulk Densities

C
li
n
k
e
r
C
e
m
e
n
t
Lumpy

Fine, dry

Wet
C
la
y
G
y
p
s
u
m
(r
a
w
<
2
5
m
m
)
Ir
o
n
O
r
e
K
il
n
D
u
st
Li
m
e
st
o
n
e
(c
r
u
s
h
e
d
)
Coarse, wet
P Ground, dry
u
z
z
ol
a
n
Aerated
R Not aerated
a
w
M
e
al
S
a
n
d
(
D
r
y)
S
h
al
e
(c
r
u
s
h
e
d
)
Fl
y
a
s
h
Crushed

Granular,
wet
Ground
S Granulated
la blast
g furnace
(GGBFS)