Coal firing blower

PC Kiln PA

Circum mm 360 360

Pipe line size Dia mm 115 115
CSA m2 0.0103 0.0103
Volume m3/sec 0.4568 0.5013 1.03
kg/sec 0.5309 0.5827 1.19
m3/hr 1644 1805 3700
Nm3/hr 1482 1626 3334
Coal tpt TPH 3.42 2.6
kg/sec 0.95 0.72
Velocity at tpt line m/sec 44.29 48.61
Coal to air ratio 1.79 1.24
power cons kW 18.03 24.77 62.95
sp power kW/MT coal 5.27 9.53
kg of air required for
0.24 0.18
4 kg ratio
Extra air going 0.29 0.40
% Extra air going 0.55 0.69
% reduction in power
0.729 0.729
for 10% speed red
kw saving 2.4 6.7
annual cost saving 0.97 2.67

0.66 0.82 1.02

Optimization of Coal firing blower

Present PD blower details
Kiln blower PC blower
Present kW kW 24.77 18.03
Blower volume m3/hr 1805 1644
Blower operating presskg/cm2 0.6 0.4

Specific power kW/m3/min 0.82 0.66

Option 1
Reduce blower speed by 10%
Savings kW 6.7 2.4
Savings Rs. Lakhs 2.7 1.1
Investment Rs. Lakhs 2 2
Payback Months 3.6 9.8
Option 2
Install High efficiency blower (Turbo blower)
Specific power kW/m3/min 0.85 0.85
Power kW -0.8 -5.3
Savings Rs. Lakhs -0.3 -2.1
Investment Rs. Lakhs 30 35
Payback Months -1127.8 -199.4
 Kiln blower flow
Velocity Area m3/min
1) 3.13 0.160 30.1
2) 0.0
3) 0.0
4) 0.0

PC blower flow
Velocity Area m3/min
1) 6.04 0.076 27.4

2) 0.0
3) 0.0
4) 0.0

PA blower flow
Velocity Area m3/min
1) 0.0
2) 0.0
3) 0.0
4) 0.0
5) 0.0
6) 0.0
0.0
 Design
m3/hr
1805
0
0
0 kW m3/hr mmWC kW
1805

m3/hr
1644

0
0
0 kW m3/hr bar kW

1644

Design
m3/hr
0
0
0
0
0 m3/hr bar kW
0 15204 2661 180

0
 UTCL, Unit- Birla White Cement Line-2

Air Heater Chloride

Parameters Unit PH Fan
Fan Bypass Fan
Pitot Tube Constant 0.834 0.834 0.834
Kiln Feed Rate TPH 78 78 78
Kiln feed/Clinker Ratio 1.74 1.74 1.74
Clinker Output TPH 44.8 44.8 44.8
Fan Inlet Fan Outlet Fan Inlet
MSL mt. 350 350 350

Measured height mt. 68.00 25.00 25.00

Barometric press mmwg 9807.56 9860.65 9860.65
Temp deg C 268.00 35.00 139.00
Temp deg K 541.00 308.00 412.00
Static pressure (draught) mmwg -622.50 263.00 -180.00
Dynamic press mmwg 8.81 17.93 5.41
Density kg/Nm3 1.41 1.29 1.29
Density kg /m3 0.632 1.120 0.802
Velocity m/sec 13.79 14.78 9.59
Duct C.S. dia mt. 1.45 1.08 0.85
Duct C.S. area m2 3.30 0.92 0.57
Vol Flow m3/sec 49.64 13.54 5.44
Vol Flow m3/min 2732.62 812.23 326.57
Vol Flow m3/hr 178713 48734 19594
Vol Flow Nm3/hr 80140 42308 12160
Mass flow kg/min 1728 910 262
Mass flow kg/hr 103668 54578 15723
Pressure at damper inlet mm WC -710.00 -50.00 -180.00
Pressure at Fan inlet mm WC -710.00 -50.00 -180.00
Pressure at Fan Outlet mm WC 6.00 263.00 -4.00
Total Static Pressure rise mm WC 716.00 313.00 176.00
Fan power kW 348.47 41.54 9.39
Motor Power Consumption kW 604.43 66.88 20.22
Motor Efficiency (Assumed) % 0.94 0.94 0.94
Efficiency % 61.33 66.08 49.41
Specific Flow Rate Nm3/kg Clinker 1.79 0.94 0.27
Specific Flow Rate kg/kg Clinker 2.31 1.22 0.35
Pressure loss across damper mmwg 0.00 0.00 0.00
Power loss across damper kW 0.00 0.00 0.00
% 0.00 0.00 0.00
Damper opening %
operating rpm 963.00 1120.00 929.00

Type of control LRS/GRR VFD VFD

Design Flow m3/hr 208200 54150 28500
Design Head mm WC 780 600 452
Installed Motor Capacity kW 750 132 55
 Speed rpm 980 1472 1476
Temperature Deg C 220 40 220
Dia of impeller 2670 1413 1413
Make
Specific power 13.48 1.49 0.45

Cooling air input m3/hr Nm3/hr Nm3/kg clk

Air Heater Fan 48733.54 42308 0.94
PA fan 3700.00 3334 0.07
Calciner Coal 1644.39 1482 0.03
kiln coal 1804.80 1626 0.04
calcination gas 0.26
False air ,excess air 0.46

Total input air 1.81

outlet gas volume
cooler vent air
preheater gas 178713.48 80140 1.79
Chloride bypass gas 5041.50 1040 0.02

Total output air 1.81

Kiln Inlet Air infiltration Chloride bypass

Temp 1050 35 139.00
Sp. Heat 0.37 0.31 0.31
Flow a 0.27-a 0.27
388.5a 2.925-10.85a 11.7
377.65 8.8
0.023

2.9295
10.85
Decoloriser Main Baghouse
Fan Fan Compound
0.834 0.834
78 78 Air Ingress Across PH
1.74 1.74 Before Air Heater 4.9
44.8 44.8 1075.9 Kiln Inlet 4
Stack Stack 5.29
350 350 Air Ingress Across Air Heater
After Air Heater 6.45
30.00 30.00 Before Air Heater 4.9
9854.46 9854.46 9.63
173.00 162.00 Air Ingress Across Fan
446.00 435.00 After PH Fan 7
-20.00 -17.00 After Air Heater 6.45
14.68 14.58 3.78
1.29 1.36 Total Air Ingress
0.751 0.815 17.65
16.33 15.62
1.60 2.40
2.01 4.52
32.82 70.67
1969.50 4240.04
118170 254402
68823 152446
1480 3455
88781 207327
-300.00 -334.00
-300.00 -334.00
-75.00 -48.00 GRR Loss in PH
225.00 286.00 0.027273
72.41 198.15 16.93358
120.12 260.61 621.36
0.94 0.94
64.13 80.88
1.54 3.40
1.98 4.62 pressure reduction 33.76684
0.00 0.00 air ingress 30.22132
0.00 0.00
0.00 0.00

979.00 940.00 27.33671328671

VFD VFD
100002 235000
305 325
132
 980
150
2060 2102.00

2.68 5.81

0.26
Kiln Inlet 4
Stack 19.50
91.18
0.46

Chloride bypass
 Heat input data sheet

Variable Variable name Value

a1 Datum temperature 0 Deg C

a2 kiln feed rate 78 TPH
a3 kiln feed temp 60 Deg C
a4 NCV of Kiln coal** 7950 Kcal/kg
a5 NCV of PC coal** 7200 Kcal/kg
a6 Heat of formation 416 Kcal/kg
a7 Moisture in KF 0.5 % by wt
a8 PH String exit gas temp 268 Deg C
a9 SA + TA temp 35 Deg C
a10 Efficiency of first stage cyclone 89 %
a14 Clinker temp at kiln outlet 1450 Deg C
a15 Clinker production 44.8 TPH
a18 Kiln feed to clinker factor 1.74
a19 Fuel rate 6.02 TPH
a20 PH String exit gas volume 1.79 Nm3/kg cl
a21 SA + TA volume 0.94 Nm3/kg cl
a23 Dust concentration In ph gas 0.11 Kg/Nm3
a24 moisture in Kiln coal dust 3.5 %
a25 moisture in PC coal dust 3.5 %
a26 Coal dust temperature 70 Deg C

Note : ** coal CV is taken from the lab and the

coal feed rate is back calculated .
 Output sheet I

Kiln heat balance SET I

Heat input (in Kcal /Kg of clinker )

From kiln feed b1 22.5 2.1

From cooling air b2 10.2 1.0

From fuel b3 1033 96.5

Coal dust sensible heat b4 2.7 0.3

Primary air b5 0.8 0.1

Kiln coal convyeying air b6 0.4 0.0

Calciner coal conveying air b7 0.4 0.0

Total heat input b1+b2+b3 1070.5 100

Heat output (in Kcal /Kg of clinker )

Heat of formation c1 415.7 38.8

Kiln feed moisture evoparation c2 4.7 0.4

Coal dust moisture evoparation c3 2.5 0.2

Heat through Chloride bypass c4 8.1 0.8

Heat through PH c5 172.5 16.1

Heat through dust entrained in PH exhaust gas c6 12.2 1.1

Heat through Clinker c7 382.8 35.8

Radiation & Convection heat loss c8 72.0 6.7

Total heat output c1+..+c8 1070.5 100.0

 Radiation Loss

Plant: UTCL, Unit-Birla White Cement Kiln No.: 2 Date:

Kiln: 3 x 48 m Production: 1076 t/d Time:

Surface Area: F = 452 m2 Spec. Surf.: SF = 0.420 m2/t/d

FORCED
FROM SURFACE SURFACE NATURAL
AMBIENT RADIATION CONVECTIO
OUTLET AREA TEMP. CONVECTION
N
m m2 o
C o
C kcal/m2 x h kcal/m x h
2
kcal/m2 x h
1 9.42 30 190 1503 939 0
2 9.42 30 320 4613 1852 0
3 9.42 30 320 4613 1852 0
4 9.42 30 347 5578 2041 0
5 9.42 30 365 6296 2166 0
6 9.42 30 377 6809 2250 0
7 9.42 30 370 6506 2201 0
8 9.42 30 375 6721 2236 0
9 9.42 30 340 5316 1992 0
10 9.42 30 382 7031 2284 0
11 9.42 30 341 5353 1999 0
12 9.42 30 265 3017 1465 0
13 9.42 30 240 2436 1289 0
14 9.42 30 278 3353 1556 0
15 9.42 30 310 4288 1782 0
16 9.42 30 272 3195 1514 0
17 9.42 30 264 2992 1458 0
18 9.42 30 210 1842 1078 0
19 9.42 30 322 4681 1866 0
20 9.42 30 292 3743 1655 0
21 9.42 30 258 2846 1416 0
22 9.42 30 275 3273 1535 0
23 9.42 30 276 3300 1542 0
24 9.42 30 274 3247 1528 0
25 9.42 30 273 3221 1521 0
26 9.42 30 260 2894 1430 0
27 9.42 30 241 2457 1296 0
28 9.42 30 180 1349 870 0
29 9.42 30 172 1233 815 0
30 9.42 30 162 1096 746 0
31 9.42 30 147 909 645 0
32 9.42 30 140 828 598 0
33 9.42 30 130 719 532 0
34 9.42 30 135 772 565 0
35 9.42 30 167 1163 780 0
36 9.42 30 194 1567 967 0
37 9.42 30 192 1535 953 0
38 9.42 30 188 1471 925 0
 39 9.42 30 187 1455 918 0
40 9.42 30 165 1136 767 0
41 9.42 30 183 1394 890 0
42 9.42 30 170 1205 801 0
43 9.42 30 170 1205 801 0
44 9.42 30 180 1349 870 0
45 9.42 30 175 1276 835 0
46 9.42 30 170 1205 801 0
47 9.42 30 185 1425 904 0
48 9.42 30 190 1503 939 0

452.39 1290 591 0

Total = 1881 Mcal/h

Radiation: Mcal/h x 24 x 1.05 = 42.0 kcal/kg

P

Spec Radiation: Mcal x 1.05 x 1000 4366 kcal/h x m2

F
 WIND
SPEED

m/s
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
23.03.2017

PH-1
Temp Temp Diff. Pressure Pressure Diff.
1A 387 16 626 68
1B 379 24 630 72
2 403 316 558 141
3 719 91 417 124
4 810 -34 293 87
5 776 66 206 85
PC 842 121
Standard Temperature profile
Temp Temp Diff. Pressure Pressure Diff