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Kiln Pyro Heat Balance
Kiln Pyro Heat Balance
Customer Name
Supplier Name
Design Capacity 3300 tpd
Operating Capacity 2850 tpd
Type of pre-heater 5 STAGE Cooler
Type of Kiln (SLC / ILC) SLC Date
Kiln Feed tph 202 Mean Sea Level
Details
Raw meal to Clinker factor kg rm./kg Cl 1.700 Barometric pressure
tph 118.8 Ambient Temperatur
Plant
Clinker production
Production Details
Cooler details
Kiln Length m 60 Avaliable Grate Area
% 3.50 Specific loading
Kiln slope
Deg 2.01 No. of Cooler Fans
Kiln speed rpm 4.80 No of Compartments
Kiln details
3/20/2023
Mean Sea Level m 96
Barometric pressure mmwg 10209
Ambient Temperature o
C 28
Wind Velocity m/s 3
SUMMARY
m3/hr
Flow rate kg/hr
Nm3/hr
Pre Heater Fan Specific flow rate Nm3/kg clinker
Inlet
1 Temperature Deg c
(Assumed)
Specific Heat Kcal/kg deg c
Heat avaialble Mkcal
DATE: 13.04.2018
12 TAD
LOCATION Static
Temp Diff Diff
Pressure
UNITS C
o o
C mmwg mmwg
Preheater Fan inlet 256 8 -546 51
FIRST CYCLONE 264 160 -495 35
SECOND CYCLONE 424 146 -460 55
THIRD CYCLONE 570 63 -405 72
FOURTH CYCLONE 633 82 -333 43
FIFTH CYCLONE 715 225 -290 85
SIXTH CYCLONE 940 -205
kiln inlet 1060 -40
PC Outlet 917 -140
LOCATION Static
Temp Diff Diff
Pressure
UNITS C
o o
C mmwg mmwg
Preheater Fan inlet 258 19 -551 76
FIRST CYCLONE 277 142 -475 34
SECOND CYCLONE 419 148 -441 40
THIRD CYCLONE 567 90 -401 81
FOURTH CYCLONE 657 50 -320 57
FIFTH CYCLONE 707 206 -263 93
SIXTH CYCLONE 913 -170
KILN INLET 1050 -35
PC Outlet 854 -132
Preheater Stack 113 -13
erature & Pressure profile in Line 2
Date: 6/4/2018
Time: 9:40 AM
set-2 Date
Cement Mills
6 2.80 6.15 173.00
Booster Fan I/L
Avg.
Specific gas
Static pr. dynamic Density Density Velocity Volume
consumption
pressure
mm WG mm WG Kg/Nm3 Kg/m3 m/s m3/hr Nm3/hr Kg /hr Nm3/kg cli.
7/4/2018
Avg.
Specific gas
Static pr. dynamic Density Density Velocity Volume
consumption
pressure
mm WG mm WG Kg/Nm3 Kg/m3 m/s m3/hr Nm3/hr Kg /hr Nm3/kg cli.
2.08
0.18
-1.391
30.647853
1.11
6
7
8
7
Specific gas
consumption
8
Kg/kg cli. 9
8
4.04 9
8
2.501
9
10
0.970
9
10
7
6
7
8
7
Specific gas
consumption
8
5.78
0.90
7
1.52
-0.411
3.387189
-2.387189
0.58
69.35215
Theoritical air Requirement
Clinker Production Rate TPD 5415
Secondary Air Flow
Kiln Coal Firing Kg Coal /Kg Clinker 0.0691
Theoretical Combustion Volume
Kiln Coal Firing Nm3/Kg Clinker 0.5096
TAD VELOCITY
TAD Effective Diameter m 2.330
TAD Effective area 2 4.262
m
TAD velocity m/sec 45.00
tical air Requirement
CALCINER
Combustion gases generated 0.6889 Nm3/Kg cl
CO2 generated 0.2374 Nm3/Kg cl
Total gases 0.9263 Nm3/Kg cl
KILN
Static
Temperature Pressure LOI CO2
Location
O
C mmWg % Tph Nm3/hr M3/hr
Preheater Fan Inlet 256 -546 - 68 34553 64327
Cyclone-1 264 -495 35.00 68 34553 65611
Cyclone-2 424 -460 34.70 67 34257 84706
Cyclone-3 570 -405 34.40 67 33961 102090
Cyclone-4 633 -333 33.90 66 33467 108863
Cyclone-5 715 -290 31.60 61 31196 111115
Cyclone-6 940 -205 4.30 8 4245 18715
PreCalciner 917 -140
Kiln inlet 1060 -40
#REF!
LOSS ON IGNITION
Kiln Feed
Cyclone
no.
1
2
Net Kiln Feed Tph 193.9 3
4
Net Kiln feed on LOI basis Tph 130.694
5
6
O2
False Air Flow
PH String PH String
35.00 1.31
34.70 2.60
34.40 3.89
33.90 6.00
31.60 15.32
4.30 91.76
Outlet
Flow Diameter Outlet Area Inlet Inlet Area
8.8 7.6
8.2 9.8
9.7 11.9
10.4 12.7
11.2 13.7
11.4 14.0
SET-1
Date: 7/4/2018
Suction
Power Cooler Duct Area Temp. Draft Density
duct dia
Sl.
Fan No.
No.
KW RPM m m2 o
C
mmWG Kg/m3
Sl. Suction
Fan No. Power Fan Speed Duct Area Temp. Draft Density
No. duct dia
KW RPM m m2 o
C mmWG Kg/m3
SET-2
Date: 7/4/2018
Suction
Power Cooler Duct Area Temp. Draft Density
duct dia
Sl.
Fan No.
No.
KW RPM m m2 o
C
mmWG Kg/m3
m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
15.13 40236 45244 34992 0.29 0.38
14.90 51879 58314 45099 0.38 0.49
16.48 53332 59918 46340 0.39 0.50
14.59 51729 58350 45127 0.38 0.49
13.76 44534 49925 38612 0.32 0.42
13.76 69324 77035 60175 0.51 0.65
11.97 60296 66635 52053 0.44 0.56
11.02 46363 50999 40001 0.34 0.43
417693 466419 362399 3.05 3.93
Specific gas
Velocity Volume kg/kg clinker
consumption
m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
13.88 10610 11930 9019 0.08 0.10
Specific gas
Velocity Volume
consumption
m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
15.78 41952 47339 36252 0.16 0.21
15.42 53703 60766 46532 0.21 0.27
14.78 47818 53751 41160 0.18 0.24
15.08 53450 60511 46337 0.21 0.27
13.62 44070 49468 37879 0.17 0.22
13.60 68514 77048 58997 0.26 0.34
11.76 59213 66578 50979 0.23 0.30
11.56 48605 54291 41571 0.18 0.24
417325 469751 359708 1.59 2.08
Specific gas
Velocity Volume kg/kg clinker
consumption
m/sec Nm3/kg
m3/hr Kg/hr Nm3/hr kg/kg clinker
clinker
13.79 10536 11789 9117 0.04 0.10
2.21 8276 9201 7116 0.03 0.08
1.82 6818 7580 5863 0.03 0.06
LINE-2 PYRO PROCESS SITE DATA-BHARATHI CEMENTS KADAPA
COOLER EFFICIENCY
Base Data
Clinker production TPH 118.8
Clinker temp Deg C 1450
Specific heat of Clinker Kcal/kg oC 0.26
Cooling air Temp Deg C 38
Cooling air Nm3/kg clink 1.59
Cooling air Kg/kg clink 2.08
Specific heat of Cooling air Kcal/kg oC 0.24
Cooler Vent gas flow Nm3/hr 228876
Vent gas temp Deg C 300
Cooler Vent gas flow Nm3/kg clink 1.01
Cooler Vent gas flow Kg/kg clink 1.31
Specific heat of Cooler vent gas Kcal/kg oC 0.244
Out Clinker temp Deg C 170
Specific heat of Clinker Kcal/kg oC 0.20
Cooler water spray change in enthalpy Kcal/kg clink 94.6
Power consumption of cooler fans KWh 1040.0
Heat Balance
Heat Input Heat Loss
Heat energy enter into the cooler Kcal/Kg clink 383 Heat through cooler vent
Sensible heat of cooling air Kcal/Kg clink 18.68 Heat through clinker out
Cooler fans power Kcal/Kg clink 7.5 Radiation losses from cooler
Total 409
7/4/2018
Heat Loss
Kcal/Kg clink 190.5
Kcal/Kg clink 33.2
Kcal/Kg clink 5
229
Kiln Performance & Efficiency
S. Description Symbol Formula
No.
1 Degree of filling DF
%
P
Deff
n
s
2 Thermal loading TL Formula-1
or Gcal/hr/m2
Burning zone loading
F
NCV
A
Formula-2
P
H
A
3 Volumetric loading VL
tpd/m3
P
A
L
4 RTK
Material residence time in kiln
min
L
Deff
n
s
5 Clinker residence time in RTC
cooler min
(Empirical relationship from A
F.L. Smidth) Ps
P
6 True CO2 in kiln exit gas TCO2
vol%
CO2
CO2
O2
7 Excess air EA
%
O2
CO2
8 Radiation heat losses RHL
T
kcal/hr/m2
t
3.2 * P P 2852
Deff * n * s
3
Deff 3.75
Clinker production, tpd n 4.80
Burning zone effective diameter, mts S 3.50
Kiln speed, rpm DF 10.30
Kiln slope, % Target 14-16
F 7500
F * NCV NCV 5320
A * 1000 * 1000 A 7.55
Fuel rate in kiln, kg/hr TL 5.3
Net calorific value of fuel, kcal/kg-fuel Target 4.0-5.0
Burning zone cross-sectional area, m2
P 2852
P*H H 244
A * 24 * 1000 A 7.55
Clinker production, tpd TL 3.8
Specific heat consumption in kiln, kcal/kg-clinker Target 4.0-5.0
Burning zone cross-sectional area, m2
P P 2852
A*L A 7.55
Clinker production, tpd L 60
Burning zone cross-sectional area, m2 VL 6.30
Kiln length, mts Target 5.0-5.5
19 * L L 60
Deff * n * s Deff 3.10
Kiln length, mts n 4.80
Burning zone effective diameter, mts S 3.50
Kiln speed, rpm RTK 21.9
Kiln slope, % Target 20-25
1.55 * A * Ps A 66
P Ps 700
Cooler grate cross-sectional area, m2 P 3700
Static pressure at clinker droping area, mmWg RTC 19.4
Clinker production, tpd Target 20-25
100 * ( CO2 + CO ) CO2 36.5
100 + ( 1.89 * CO ) - ( 4.78 * O2 ) CO 0.002
Kiln exit gas CO2, vol% O2 4.2 5588.151
Kiln exit gas CO, vol% TCO2 45.7
Kiln exit gas O2, vol% Target -
79 * O2 O2 2.8
0.21 * ( 100 - CO2 ) - O2 CO2 26.5
O2 content in gas, vol% EA 17.5
CO2 content in gas, vol% Target 10-15
4 * 10 * ( T - t )
-8 4 4
T 517
Radiating body temperature, K t 305 21.13715
Ambient air temperature, K RHL 2512
Target -
80.33 * ( ( T + t ) / 2 ) -0.724
*(T-t) 1.333
T 443
Radiating body temperature, K t 308
Ambient air temperature, K CHL 760 1171.5
Target - 1007
28.03 * ( ( T + t ) / 2 ) -0.351
*v 0.805
*D
-0.195
*(T-t) T 525
Radiating body temperature, K t 302
Ambient air temperature, K v 5
Wind speed, m/s D 4.15
Radiating body diameter, mts FCHL 2088
Target -
CC * Ash CC 28.00
P Ash 23.8 4.979
Coal consumption, tph P 119
Ash content in fuel (as fired basis), % %AA 5.61
Clinker production, tph Target -
100 - %AA %AA 5.61
100 - LOI LOI 35.25
%Ash absorption, % RMCK 1.458
Loss on ignition of raw mix, % Target -
( 100 - %AA ) * 100 %AA 5.61
( 100 - LOI ) * ( 100 - DL ) LOI 35.25
%Ash absorption, % DL 6
Loss on ignition of raw mix, % RMCS 1.551
Dust losses from preheater, % Target -
( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMCK ) CaCO3 75.1
+ ( 222 * Al2O3 / ( 100 - LOI ) ) + ( 11.6 * CH2O * RMCK ) RMCK 1.53
- ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) ) MgCO3 1.6
- ( 1000 * ( K2O + Na2O ) / ( 100 - LOI ) ) LOI 34.5
- ( 79 * C * RMCK ) - ( 32 * S * RMCK ) Al2O3 4.17
CaCO3 content in kiln feed, % CH2O 1.05
Kiln feed:Clinker ratio, - SiO2 13.47
MgCO3 content in kiln feed, % Fe2O3 2.41
LOI content in kiln feed, % K2O 0.38
Al2O3 content in clinker, % Na2O 0.27
Water of crystalisation in kiln feed, % C 0.2
SiO2 content in clinker, % S 0.04
Fe2O3 content in clinker, % HR 389
K2O content in clinker, % Target -
Na2O content in clinker, %
Carbon content in kiln feed, %
Sulphur as pyrites in kiln feed, %
( O2mix - O2gas ) * 100 O2mix 3.6
21 - O2gas O2gas 2.8
O2 content in mixture of gas, vol% FAMO 4.4
O2 content in unmixed gas, vol% Target 5-7
( O2mix - O2gas ) * 100 O2mix 3.6
21 - O2mix O2gas 2.8
O2 content in mixture of gas, vol% FAGO 4.6
O2 content in unmixed gas, vol% Target 5-7
( CO2gas - CO2mix ) * 100 CO2mix 32.1
CO2gas CO2gas 34.5
CO2 content in mixture of gas, vol% FAMC 7.0
CO2 content in unmixed gas, vol% Target 5-7
( CO2gas - CO2mix ) * 100 CO2mix 32.1
CO2mix CO2gas 34.5
CO2 content in mixture of gas, vol% FAMC 7.5
CO2 content in unmixed gas, vol% Target 5-7
5.56962
LINE-2 PYRO PROCESS SITE DATA-BHARATHI CEMENTS KAD
QUALITY DATA(07/04/2018)
DATE :
S.No Parameter Unit Kiln Feed Clinker
1 LOI %
35.3
2 SiO2 % 13.20 21.63
3 Al2O3 % 3.46 5.72
4 Fe2O3 % 3.07 4.60
5 CaO % 43.28 65
6 MgO % 0.81 1.2
7 So3 % 0.14 0.65
8 LSF - 92
9 SM - 2.10
10 AM - 1.24
11 FCaO % - 1.64
12 C3S % 50.71
13 C2S % 22.81
14 C3A % 7.41
15 C4AF % 13.92
16 Liquid % 28.81
17 Litre Weight gm/lit -
18 Residue 90 mic 24.0
19 Residue 212 mic 3.84
HEAT OF REACTION :
7.646 *CaO + 6.484*MgO + 4.11*Al2O3 - 5.116* SiO2 - 0.589*Fe2O3
CLINKER COMPOSITION :-
CaO SiO2 Al2O3 Fe2O3 Mgo
65.00 21.63 5.72 4.60 1.20
A(07/04/2018)
DATE :
Fired fuel in Kiln & PC
1 Inherent Moisture %
2 Volatilt matter %
3 Ash %
4 NCV Kcal/kg
5 GCV Kcal/kg
SPECIFIC POWER CONSUMPTION