1.

59

98.62 1.5 92.00 98.30

Clinker Kiln Feed After

Raw Meal Kiln Feed After By Clinker
Elements EP Analysis Kiln Feed By Pass without coal Coal Ash add. Of Coal
Proposed Pass Proposed
ash absorption ASH

Proposed Raw Materials Corrective Materials CaCO3 73.56 73.44 4.26

Raw Mix Pile
ELEMENTS
F=3 HSLS CLAY LATERITE Proposed CLAY LATERITE MgCO3 2.79 4.10 66.02

T.CO3 76.48 T.CO3 76.35 77.54

3.73
LOI 40.39 15.41 15.72 8.49 37.18 15.72 8.49 LOI 37.18 34.31 36.95 36.55
69.75
SiO2 7.72 60.43 51.16 16.11 13.55 51.16 16.11 SiO2 13.55 13.95 13.58 0.00 13.58 21.98 27.35 13.66 21.18

Al2O3 1.92 1.24 15.61 3.81 3.41 15.61 3.81 Al2O3 3.41 3.95 3.46 0.00 3.46 5.59 12.40 3.53 5.47

Fe2O3 1.97 0.59 5.29 49.29 2.31 5.29 49.29 Fe2O3 2.31 2.65 2.33 0.00 2.33 3.78 6.20 2.36 3.66

CaO 46.14 21.77 6.80 20.16 41.33 6.80 20.16 CaO 41.33 40.50 41.26 0.00 41.26 66.77 30.00 40.98 63.52

MgO 1.35 0.12 1.94 0.97 1.39 1.94 0.97 MgO 1.39 2.28 1.95 0.00 1.95 3.16 2.07 1.94 3.01

SO3 0.06 0.00 0.04 0.59 0.06 0.04 0.59 SO3 0.06 0.18 0.07 0.00 0.07 0.11 3.73 0.10 0.16

K2O 0.28 0.35 2.92 0.28 0.57 2.92 0.28 K2O 0.57 0.78 0.59 0.00 0.59 0.95 0.86 0.59 0.91

Na2O 0.12 0.07 0.33 0.21 0.14 0.33 0.21 Na2O 0.14 0.16 0.14 0.00 0.14 0.23 0.72 0.15 0.23

Cl 0.05 0.02 0.19 0.09 0.06 0.19 0.09 Cl 0.06 0.12 0.07 0.00 0.07 0.11 0.19 0.07 0.11

59.61 84.59 84.28 91.51

Total 100.00 100.00 100.00 100.00 0.95 Total 99.94 98.88 100.33 102.69 83.52 98.25

LSF 1.83 0.13 0.04 0.25 0.98 0.04 0.25 L.S.F 0.98 0.89 0.94 #DIV/0! 0.94 0.94 0.31 0.93 0.93

SM 1.98 33.02 2.45 0.30 2.35 2.45 0.30 S.M 2.35 2.11 2.35 #DIV/0! 2.35 2.35 1.47 2.32 2.32

AM 0.97 2.10 2.95 0.08 1.70 2.95 0.08 A.M 1.70 1.49 1.48 #DIV/0! 1.48 1.48 2.00 1.49 1.49

H.M 2.14 1.97 2.13 #DIV/0! 2.13 2.13 0.65 2.10 2.10

Raw Mix PileTarget Raw Meal Targets C3S 61.46 55.65

LSF 0.98 LSF 0.98 C2S 16.75 18.82

SM 2.35 SM 2.35 C3A 8.43 8.30

AM 1.70 AM 1.70 C4AF 11.49 11.14

C.Index 31.16 30.90

Material %age Tons Material %age LQ.Phase 29.38 28.57

F=3 87.00 8700 Raw Mix Pile 100.00 B.Z.Temp. 1400 1379.20

HSLS 2.00 200 B.Factor 114.48 112.86

Corrective Materials
CLAY 11.00 1100 B.Index 3.09 2.86

LATERITE 0.00 0 CLAY 0.00 MSO3 0.178 0.27

Target Tons of Pile 10000 LATERITE 0.00 ASR 0.152 0.23

A.E. 0.86 0.83

Total Coal Consumption/Hr
15.50 Q.H. 439.28 417.18
(Tons)
% Coal Ash 11

% Sulpher In Coal 1

Coal Ash Absorption tons 1.71

Kiln Feed T/hr 175 0.97

Recycle Dust % 8
 Raw Mix PileTarget ELEMENTS Proposed Raw Materials Raw Mix Pile Corrective Materials Percentage of elements
Proposed
LSF 0.98 limestone HSLS CLAY LETERITE CLAY LATERITElimestone HSLS CLAY LETERITE
Raw Mix
SM 2.35 T.CO3 86.375 52.5302 13.8152 13.9034 76.48 87 2 11 0
AM 1.70 LOI 44.05 36.98 17.04 5.24 37.18 17.04 5.24 73.92 0.78 1.78 0.00 76.48
Raw Meal Targets SiO2 4.35 29.67 52.18 36.77 13.55 52.18 36.77 35.14 0.31 1.73 0.00 37.18
LSF 0.98 Al2O3 1.73 2.52 16.36 31.5 3.41 16.36 31.5 6.72 1.21 5.63 0.00 13.55
SM 2.35 Fe2O3 1.13 1.01 3.94 17.6 2.31 3.94 17.6 1.67 0.02 1.72 0.00 3.41
AM 1.70 CaO 46.85 29.24 5.39 7.28 41.33 5.39 7.28 1.71 0.01 0.58 0.00 2.31
Clinker Targets MgO 1.42 0.23 2.01 0.45 1.39 2.01 0.45 40.14 0.44 0.75 0.00 41.33
LSF 0.87 SO3 0.06 0.01 0.12 0.57 0.06 0.12 0.57 1.17 0.00 0.21 0.00 1.39
SM 2.26 K2O 0.19 0.1 2.25 0.16 0.57 2.25 0.16 0.05 0.00 0.00 0.00 0.06
AM 1.67 Na2O 0.19 0.18 0.54 0.22 0.14 0.54 0.22 0.24 0.01 0.32 0.00 0.57
Material %age Tons Cl 0.03 0.06 0.17 0.21 0.06 0.17 0.21 0.10 0.00 0.04 0.00 0.14
limestone 87.00 8700 55.95 63.02 82.96 94.76 0.04 0.00 0.02 0.00 0.06
HSLS 2.00 200 Total 100.00 100.00 100.00 100.00 0.95 87 2 11 0 100
CLAY 11.00 1100 LSF 3.13 0.34 0.03 0.05 0.98 0.03 0.05
LETERITE 0.00 0 SM 1.52 8.41 2.57 0.75 2.35 2.57 0.75
Target Tons of Pile 10000 AM 1.53 2.50 4.15 1.79 1.70 4.15 1.79
Clinker Kiln Feed
Raw Meal EP Kiln Feed After without After add. Clinker
Material %age Elements
Proposed
Kiln Feed By Pass Coal Ash
Analysis By Pass coal ash Of Coal Proposed
absorption ASH

Raw Mix Pile 100.00 CaCO3 73.56 73.40 10.58

MgCO3 2.79 3.13 211.55

Corrective Materials
T.CO3 76.35 76.52 2.80
CLAY 0.00 LOI 37.18 34.31 36.86 38.43 214.35
LETERITE 0.00 SiO2 13.55 13.95 13.60 16.59 13.35 21.60 53.25 14.53 22.51

Total Coal Consumption(Tons) 480 Al2O3 3.41 3.95 3.47 5.42 3.39 5.49 28.58 4.02 6.24

Total Coal Consumption/Hr

(Tons)
20.00 Fe2O3 2.31 2.65 2.35 3.81 2.29 3.70 4.34 2.40 3.73

% Coal Ash 21 CaO 41.33 40.50 41.23 63.38 40.28 65.19 6.36 40.80 63.24
% Sulpher In Coal 0.6 MgO 1.39 2.28 1.49 3.04 1.44 2.33 1.07 1.49 2.31
Coal Ash Absorption tons 4.23 SO3 0.06 0.18 0.07 2.42 0.03 0.05 2.80 0.13 0.20
Kiln Feed T/hr 202 2.10 K2O 0.57 0.78 0.59 1.57 0.57 0.92 0.61 0.60 0.93

Recycle Dust % 11 Na2O 0.14 0.16 0.14 0.10 0.14 0.23 0.23 0.15 0.23
Cl 0.06 0.12 0.07 0.03 0.07 0.11 0.19 0.07 0.11
Total 99.94 98.88 99.81 99.64 97.43 99.49
L.S.F 0.98 0.89 0.94 1.14 0.94 0.94 0.03 0.87 0.87
S.M 2.35 2.11 2.34 1.80 2.35 2.35 1.62 2.26 2.26
A.M 1.70 1.49 1.48 1.42 1.48 1.48 6.59 1.67 1.67
H.M 2.14 1.97 2.12 2.45 2.12 2.12 0.07 1.95 1.95
C3S 58.92 39.10
C2S 1.618385 0.00 100.00 1.55 98.62 17.57 35.14
C3A 8.28 10.23
C4AF 11.26 11.33
C.Index 30.81 36.74
LQ.Phase 28.04 30.31
B.Z.Temp. 1392 1294.92
B.Factor 113.22 105.13
B.Index 3.02 1.81
MSO3 0.096 0.35
ASR 0.079 0.29
A.E. 0.84 0.84

Q.H. 423.46 406.73

 Material %age Tons Proposed Raw Materials
Elements
limestone 87.00 8700 limestone HSLS CLAY BAUXITE
HSLS 2.00 200 SiO2 4.35 29.67 52.18 36.77
Clay 11.00 1100 Al2O3 1.73 2.52 16.36 31.5
Bauxite 0 Fe2O3 1.13 1.01 3.94 17.6
Target Tons of Pile 10000 CaO 46.85 29.24 5.39 7.28
Total Coal Consumption(Tons) 480 MgO 1.42 0.23 2.01 0.45

Total Coal Consumption/Hr (Tons) 20.00 SO3 0.06 0.01 0.12 0.57

% Coal Ash 21.17 K2O 0.19 0.1 2.25 0.16

% Sulpher In Coal 0.6 Na2O 0.19 0.18 0.54 0.22
Coal Ash Absorption tons 22.46 Cl 0.03 0.06 0.17 0.21
Kiln Feed T/hr 202
Recycle Dust % 11
% Coal Ash SiO2 Al2O3 Fe2O3 MgO SO3 K2O Na2O Cl

21.17 22.51 6.24 3.73 2.31 0.20 0.93 0.23 0.11

21.17
 EP coal ash
By Pass coal ash Raw Mix
Analysis Coal MIX 100% indo 100%
13.95 16.59 53.25 13.55 53.25 57.93 48.72
3.95 5.42 28.58 3.41 28.58 28.93 28.23
2.65 3.81 4.34 2.31 4.34 4.96 3.73
40.50 63.38 6.36 41.33 6.36 3.02 9.7
2.28 3.04 1.07 1.39 1.07 0.72 1.43
0.18 2.42 2.80 0.06
2.8 0.92 3.25
0.78 1.57 0.61 0.57 0.61 0.69 0.53
0.16 0.10 0.23 0.14 0.23 0.32 0.14
0.12 0.03 0.19 0.06 0.19 0.19 0.19

L.S.F S.M A.M H.M Cao C3S C2S C3A C4AF C.Index

0.87 2.26 1.67 1.95 63.24 39.10 35.14 10.23 11.33 36.74
S.A

LQ.Phase B.Z.Temp. B.Index MSO3 ASR A.E. Q.H.

30.31 1294.92 1.81 0.35 0.29 0.84 406.730

 Effects of coal ash on kiln burning

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Case Study
the above results shows the relationship between the clinker composition and the ash% of coal used for burning.
The final results indicating that in case of increase the coal ash by 11% ,there is increase in heat of formation of clinker upto 4 %
As heat of formation direclty put influence on clinker quality and mostly it is the indicator of coal consumption for desired production.
In other hand it can be say the it decrease the production rate at same quantity of coal used.

Calculation
Bases of 100% S.A coal Bases of 100% INDONESIAN coal Bases of 50% INDONESIAN coal

kiln feed = 201.875 t/h kiln feed = 201.875 t/h kiln feed = 201.875 t/h
Kiln production 2850.00 TPD Kiln production 2850.00 TPD Kiln production 2850.00 TPD

coal consumed = 480 ton coal consumed = 468 ton coal consumed = 474 ton
= = =
20.00 t/h 19.50 t/h 19.75 t/h
= 168.42 kg/ton-cli = 164.21 kg/ton-cli = 166.32 kg/ton-cli

Coal NCV 5700 Kcal/kg Coal NCV 5844 Kcal/kg Coal NCV 5772 Kcal/kg
Ash in coal 15.37 % Ash in coal 27.00 % Ash in coal 21.17 %

sulpher sulpher sulpher

0.6 0.68 0.68
Ash in coal 73.78 t/hr Ash in coal 126.36 t/hr Ash in coal 100.35 t/hr
moisture in coal 8.00 % moisture in coal 8.00 % moisture in coal 8.00 %

Ash withiut moisture Ash withiut moisture Ash withiut moisture

67.87 116.25 92.32
Ash absorbed in clinker 4.49 ton Ash absorbed in clinker 7.89 ton Ash absorbed in clinker 6.19 ton

Total Sp.heat 960.00 Kcal/kg Total Sp.heat 959.65 Kcal/kg Total Sp.heat 959.97 Kcal/kg

406.445 403.712 406.726

Heat of formation Kcal/kg-cli Heat of formation Kcal/kg-cli Heat of formation Kcal/kg-cli
Dust recycling 11 % Dust recycling 11 % Dust recycling 11 %
heat utilized without heat of heat utilized without heat of
heat utilized without heat of formation
553.55 Kcal/kg-cli formation 555.93 Kcal/kg-cli formation 553.25 Kcal/kg-cli
coal cunsumed in heat of coal cunsumed in heat of coal cunsumed in heat of
formation 203.22 t/day formation 196.88 t/day formation 200.83 t/day
= 42 % of total coal = 42 % of total coal = 42 % of total coal
Less coal in case of 50%
less coal in case of 100% indonesian = 6.34 ton/day indonesian = 2.40

Conclusion
from the above data it seems that by decreasing the coal ash percentage in clinker the production is increases upto 12 ton and 2 ton coal consumption decreases.
on the other end as coal ash contribute major part in clinker chemistry and liquid phase and heat of formation, we can say that by incrase in coal ash %
the behavior of kiln operation remains unslable and there is chance to distrube the following parameters during the burning
1- kiln dust formation
2- tempreture profile inside the kiln and ain preheater can be increased.
3- high free lime
4- decrease in C3S.
5-ASH ring formation in kiln.
5- snowman.
6- ID high pressure drop

Prepared by : IRFAN AHMED ABRO DM Process

where: 200
KF = Kiln Feed in tonnes per day (t/d) 4800
DR = Dust Return correction in percentage (%) 0.1136893 %
P = Clinker Production in tonnes per day (t/d) 2823.5294
F = Fuel consumption in tonnes per day (t/d) 508
FA = Fuel Ash content in percentage (%) 16
ARM = Additional Raw Materials in tonnes per day (t/d) 0
LOIARM= Loss On Ignition of additional raw materials in percentage (%) 0
BypassD = Bypass Dust in tonnes per day (t/d) 24
LOIBypassD = Loss On Ignition of bypass dust in percentage (%) 4
LOIRM = Loss On Ignition of raw meal in percentage (%) 35

DR = 0.11 200 22.737858

 5610

11.368929 %

TON
 % Coal ash absorbed in Clinker
SiO2 Al2O3 Fe2O3 CaO
clinker 22.51 6.24 3.73 63.24
raw mix 13.55 3.41 2.31 41.33
Ash 48.72 28.23 3.73 9.70

supposeto
tal coal 480
consumpti
on=
% of
X1 X2 X3 X4 Moisture 6.5
in fine coal
is=

17.652585 8.68378 2.70241 0.7998224 Total Ash 76.8

in coal=

Total ash 22.45534586

absorbed
in clinker=
% COAL ASH ABSORBED IN CLINKER 29.2387
ton

0.16

ton

tons
 % Coal ash absorbed in Clinker
SiO2 Al2O3 Fe2O3 CaO
clinker 22.51 6.24 3.73 63.24
raw mix 13.55 3.41 2.31 41.33
Ash 57.93 28.93 4.96 3.02

supposeto
tal coal 480
consumpti
on=
% of
X1 X2 X3 X4 Moisture 6.5
in fine coal
is=

8.2290735 8.728 2.70534 0.95324 Total Ash 76.8

in coal=

Total ash 15.28375674

absorbed
in clinker=
% COAL ASH ABSORBED IN CLINKER 19.9007
ton

0.16

ton

tons
 % Coal ash absorbed in Clinker
SiO2 Al2O3 Fe2O3 CaO
clinker 22.52 6.24 3.73 63.23
raw mix 13.55 3.41 2.38 41.33
Ash 53.25 28.58 4.34 6.36

supposeto
tal coal 480 ton
consumpti
on=
% of
X1 X2 X3 X4 Moisture 16 0.16
in fine coal
is=

15.401572 8.71554 2.71069 0.8016129 Total Ash 76.8 ton

in coal=

Total ash 20.757659 tons

absorbed
in clinker=
% COAL ASH ABSORBED IN CLINKER 27.0282
 Lime Stone Analysis Clay Analysis
Compound Value Compound Value
SiO2 4.35% SiO2 52.18%
Al2O3 1.75% Al2O3 16.36%
Fe2O3 1.13% Fe2O3 3.94%
CaO 46.85% CaO 5.39%
MgO 1.42% MgO 2.01%
SO3 0.00% SO3 0.12%
K2O 0.19% K2O 2.25%
Na2O 0.19% Na2O 0.54%
Cl 0.03% Cl 0.17%
LSF 3.13% LSF 0.03%
SM 1.51% SM 2.57%
AM 1.55% AM 4.15%

Laterite Analysis Bauxite Analysis

Compound Value Compound Value
SiO2 26.70% SiO2 36.77%
Al2O3 10.45% Al2O3 31.50%
Fe2O3 42.20% Fe2O3 17.60%
CaO 7.69% CaO 7.28%
MgO 0.81% MgO 0.45%
SO3 0.63% SO3 0.57%
K2O 0.36% K2O 0.16%
Na2O 0.21% Na2O 0.22%
Cl 0.11% Cl 0.21%
LSF 0.06% LSF 0.04%
SM 0.51% SM 0.75%
AM 0.25% AM 1.79%

High Silicious Analysis Raw Meal Analysis

Compound Value Compound Value
SiO2 29.67% SiO2 12.84%
Al2O3 2.52% Al2O3 3.32%
Fe2O3 1.01% Fe2O3 2.19%
CaO 29.24% CaO 42.06%
MgO 0.23% MgO 1.77%
SO3 0.01% SO3 0.068%
K2O 0.10% K2O 0.306%
Na2O 0.18% Na2O 0.266%
Cl 0.06% Cl 0.063%
LSF 0.34% LSF 1.02%
SM 8.41% SM 2.33%
AM 2.50% AM 1.51%
 Hot Meal Analysis ClinkerAnalysis
Compound Value Compound Value
SiO2 22.07% SiO2 22.25%
Al2O3 4.62% Al2O3 4.76%
Fe2O3 4.03% Fe2O3 4.34%
CaO 66.31% CaO 63.57%
MgO 2.51% MgO 2.53%
SO3 0.618% SO3 0.391%
K2O 0.804% K2O 0.607%
Na2O 0.175% Na2O 0.173%
Cl 0.021% Cl 0.007%
LSF 0.949% LSF 0.899%
SM 2.55% SM 2.440%
AM 1.14% AM 1.10%
C3S 63.60% C3S 50.36%
C2S 15.64% C2S 26.07%
C3A 5.41% C3A 5.28%
C4AF 12.27% C4AF 13.21%
Liquid Phase 26.18% Liquid Phase 27.11%
ASR 0.69% ASR 0.56%
MSO3 0.68% MSO3 0.53%

Coal Ash Analysis

Coal Brand = South African Compound Value
GCV 6650 SiO2 48.17%
Moisture(As recvd. basis ) 7.98 Al2O3 22.45%
Ash 14.83 Fe2O3 1.98%
Volatile Matters 27.62 CaO 4.81%
Sulphur 0.86 MgO 1.63%
Fixed Carbon 57.55 SO3 1.75%
K2O 1.48%
Na2O 0.53%
Cl 0.03%
LSF 0.02%
SM 1.970%
AM 11..34%
 COMPARASION OF COST LOSS WITH DIFFERENT COAL COMPOSITION

At 100% INDONESIAN COAL. S.A COAL 100% Indo. COAL At 50% INDONESIAN COAL. S.A COAL 50% Indo.COAL

Heat of formation 406.445 403.712 kcal/kg-cli Heat of formation 406.445 406.726 kcal/kg-cli

deff. In heat of formation 2.733 kcal/kg-cli deff. In heat of formation 0.281 kcal/kg-cli

Coal equivelent to H.F 1.390 TON Coal equivelent to H.F 0.140 TON

Cost of coal saved in heat of Cost of coal saved in heat of

21545.000 PKR/day 2254.000 PKR/day
formation formation

Coal Consumption 480.00 468.00 Ton/day Coal Consumption 490.00 489.86 T/day

Coal Cost 16700.00 15500.00 PKR/t Coal Cost 16700.00 16100.00 PKR/t

Clinker Cost 4661.00 4661.00 PKR/t Clinker Cost 4661.00 4661.00 PKR/t

Coal Cost 8016000.00 7254000.00 PKR/day Coal Cost 8183000.00 7886746.00 PKR/day

Coal Cost saving incase of use Coal Cost saving incase of use
762000.00 PKR/day 296254.00 PKR/day
100% indo. Coal 50% indo. Coal

coal cost saving in case of coal cost saving in case of total

783545.00 PKR/day 298508.00 PKR/day
total coal consumption coal consumption

clinker Production 2850.00 2850.00 Ton/day clinker Production 2850.00 2850.00 PKR/day

Ash% in coal 15.37 27.00 % Ash% in coal 15.37 27.00 ton

Total ash in coal 73.78 126.36 ton/day Total ash in coal 75.31 132.26 ton/day

Ash% absorbed in clinker 29.24 19.90 % Ash% absorbed in clinker 29.24 27.03 %

Total Ash absorbed in clinker 21.57 25.15 ton/day Total Ash absorbed in clinker 22.02 35.75 ton/day

Production increased adding Production increased adding coal

2871.57 2875.15 t/day 2872.02 2885.75 t/day
coal ash ash

Cost of clinker prodused 13384397.57 13401053.83 PKR/d Cost of clinker prodused 13386492.31 13450482.95 PKR/d

cost saving in case of increase cost saving in case of increase in

16656.26 PKR/d 63990.64 PKR/d
in production production

Total saving with use of 100% Total saving with use of 50% Indo.
800201.26 PKR/day 362498.64 PKR/day
Indo. Coal. Coal.

More saving with 100% Indonesian coal 437702.62 PKR/day