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 0.2610 0.3207 1.03
kg/sec 0.3033 0.3727 1.19
m3/hr 940 1154 3700
Nm3/hr 847 1040 3334
Coal tpt TPH 1.65 2.75
kg/sec 0.46 0.76
Velocity at tpt line m/sec 25.31 31.09
Coal to air ratio 1.51 2.05
power cons kW 7.24 23.29 40.92
sp power kW/MT coal 4.39 8.47
kg of air required for
0.11 0.19
4 kg ratio
Extra air going 0.19 0.18
% Extra air going 0.62 0.49
% reduction in power
0.729 0.729
for 10% speed red
kw saving 1.0 6.3
annual cost saving 0.39 2.51

0.46 1.21 0.66

Optimization of Coal firing blower

Present PD blower details
Kiln blower PC blower
Present kW kW 23.29 7.24
Blower volume m3/hr 1154 940
Blower operating presskg/cm2 0.6 0.4

Specific power kW/m3/min 1.21 0.46

Option 1
Reduce blower speed by 10%
Savings kW 6.3 1.0
Savings Rs. Lakhs 2.5 0.4
Investment Rs. Lakhs 2 2
Payback Months 3.8 24.5
Option 2
Install High efficiency blower (Turbo blower)
Specific power kW/m3/min 0.85 0.85
Power kW 6.9 -6.1
Savings Rs. Lakhs 2.8 -2.4
Investment Rs. Lakhs 30 35
Payback Months 129.7 -173.0
 Kiln blower flow
Velocity Area m3/min
1) 4.24 0.076 19.2
2) 0.0
3) 0.0
4) 0.0

PC blower flow
Velocity Area m3/min
1) 3.58 0.073 15.7

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
1154
0
0
0 kW m3/hr mmWC kW
1154

m3/hr
940

0
0
0 kW m3/hr bar kW

940

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

0
 UTCL, Unit- Birla White Cement Line-1

Air Heater Chloride

Parameters Unit PH Fan
Fan Bypass Fan
Pitot Tube Constant 0.834 0.834 0.834
Kiln Feed Rate TPH 52 52 52
Kiln feed/Clinker Ratio 1.825 1.825 1.825
Clinker Output TPH 28.5 28.5 28.5
Fan Inlet Fan Outlet Stack
MSL mt. 350 350 350

Measured height mt. 20.00 25.00 30.00

Barometric press mmwg 9866.84 9860.65 9854.46
Temp deg C 310.00 35.00 136.00
Temp deg K 583.00 308.00 409.00
Static pressure (draught) mmwg -660.00 365.00 -4.00
Dynamic press mmwg 14.60 24.30 6.13
Density kg/Nm3 1.41 1.29 1.29
Density kg /m3 0.588 1.131 0.823
Velocity m/sec 18.40 17.12 10.09
Duct C.S. dia mt. 1.75 1.05 0.90
Duct C.S. area m2 2.41 0.87 0.64
Vol Flow m3/sec 40.99 14.82 6.42
Vol Flow m3/min 2459.70 889.39 384.99
Vol Flow m3/hr 147582 53364 23099
Vol Flow Nm3/hr 61558 46794 14694
Mass flow kg/min 1447 1006 317
Mass flow kg/hr 86797 60365 18999
Pressure at damper inlet mm WC -740.00 -50.00 -328.00
Pressure at Fan inlet mm WC -740.00 -50.00 -328.00
Pressure at Fan Outlet mm WC -20.00 365.00 -4.00
Total Static Pressure rise mm WC 720.00 415.00 324.00
Fan power kW 289.38 60.31 20.38
Motor Power Consumption kW 437.06 80.48 36.39
Motor Efficiency (Assumed) % 0.94 0.94 0.94
Efficiency % 70.44 79.72 59.58
Specific Flow Rate Nm3/kg Clinker 2.16 1.64 0.52
Specific Flow Rate kg/kg Clinker 3.05 2.12 0.67
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 880.00 1325.00 1228.00

Type of control LRS/GRR VFD VFD

Design Flow m3/hr 150000 36360 28500
Design Head mm WC 800 612 452
Installed Motor Capacity kW 450 132 55
Fan Efficiency % 76 84 83
 Speed rpm 990 1480 1480
Temperature Deg C 330.00 40 220
Dia of impeller 2840.00 1306 1413
Make
Specific power 15.34 2.82 1.28

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

Air Heater Fan 53363.52 46794 1.64
PA fan 3700.00 3334 0.12
Calciner Coal 939.54 847 0.03
kiln coal 1154.34 1040 0.04
calcination gas 0.26
False air ,excess air 0.12

Total input air 2.20

outlet gas volume
cooler vent air
preheater gas 147581.77 61558 2.16
Chloride bypass gas 5886.71 1215 0.04

Total output air 2.20

Kiln Inlet Air infiltration Chloride bypass

Temp 1050 35 136.00
Sp. Heat 0.37 0.31 0.31
Flow a 0.52-a 0.52
388.5a 5.642-10.85a 21.7
377.65 16.1
0.043

5.642
10.85
 Baghouse Fan
Dryer Fan
Compound
0.834 0.834
52 52 Air Ingress Across PH
1.825 1.825 Before Air Heater 4.75
28.5 28.5 683.8 Kiln Inlet 4
Stack Fan Inlet 4.41
350 350 Air Ingress Across Air Heater
After Air Heater 5.95
30.00 30.00 Before Air Heater 4.75
9854.46 9854.46 7.38
127.00 183.00 Air Ingress Across Fan
400.00 456.00 After PH Fan 6.7
-10.00 -163.00 After Air Heater 5.95
15.58 6.57 4.98
1.29 1.36 Total Air Ingress
0.839 0.777 15.88
15.92 10.74
1.30 2.20
1.33 3.80 Water Consumption
21.13 40.82 2.57
1268.04 2449.32 1.89
76082 146959 Water
49457 83939 Clinker
1063 1903 Dryer Air
63799 114157 Radiation
-322.00 -163.00 Clinker
-322.00 -163.00
-10.00 -10.00 GRR Loss in PH
312.00 153.00 0.111111
64.65 61.23 53.87545 1.89
109.89 169.48 490.94
0.94 0.94
62.58 38.44 PH RABH
1.74 2.95 61.64 79.00558
2.24 4.01 2.16 2.77
0.00 0.00
0.00 0.00
0.00 0.00

927.00 945.00

VFD VFD As Per Curve

70500 169920 204960
500 250 310
90 200
81 85 79
1480 980 972
500 120.00
1350 1710.00
5405.941
3.86 5.95 0.189728

388.5
10.85
22.6304
5.642
28.272
399.35
0.070795

0.05
Kiln Inlet 4
Stack 19.50
91.18
0.12

0.186 0.186 0.206 0.206

0.000054 0.0783 101 0.10605
0 -37 -0.040793
0.2643 0.271258
 21.85 kW 0.77

2408400
7539288
1947113
427397
899329
 Heat input data sheet

Variable Variable name Value

a1 Datum temperature 0 Deg C

a2 kiln feed rate 52 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 413 Kcal/kg
a7 Moisture in KF 0.5 % by wt
a8 PH String exit gas temp 310 Deg C
a9 SA + TA temp 35 Deg C
a10 Efficiency of first stage cyclone 86 %
a14 Clinker temp at kiln outlet 1450 Deg C
a15 Clinker production 28.5 TPH
a18 Kiln feed to clinker factor 1.83
a19 Fuel rate 4.40 TPH
a20 PH String exit gas volume 2.16 Nm3/kg cl
a21 SA + TA volume 1.64 Nm3/kg cl
a23 Dust concentration In ph gas 0.12 Kg/Nm3
a24 moisture in Kiln coal dust 3.5 %
a25 moisture in PC coal dust 3.5 %
a26 Coal dust temperature 60 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 23.6 2.0

From cooling air b2 17.8 1.5

From fuel b3 1130 96.1

Coal dust sensible heat b4 2.7 0.2

Primary air b5 1.3 0.1

Kiln coal convyeying air b6 0.4 0.0

Calciner coal conveying air b7 0.3 0.0

Total heat input b1+b2+b3 1176.0 100

Heat output (in Kcal /Kg of clinker )

Heat of formation c1 413.2 35.1

Kiln feed moisture evoparation c2 4.9 0.4

Coal dust moisture evoparation c3 2.9 0.2

Heat through Chloride bypass c4 14.9 1.3

Heat through PH c5 241.1 20.5

Heat through dust entrained in PH exhaust gas c6 18.6 1.6

Heat through Clinker c7 382.8 32.6

Radiation & Convection heat loss c8 97.5 8.3

Total heat output c1+..+c8 1176.0 100.0

 Radiation Loss

Plant: UTCL, Unit-Birla White Cement Kiln No.: 1 Date:

Kiln: 3 x 48 m Production: 684 t/d Time:

Surface Area: F = 452 m2 Spec. Surf.: SF = 0.662 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 30 270 3143 1500 0
2 9.42 30 273 3221 1521 0
3 9.42 30 277 3326 1549 0
4 9.42 30 215 1933 1113 0
5 9.42 30 263 2967 1451 0
6 9.42 30 267 3067 1479 0
7 9.42 30 226 2145 1190 0
8 9.42 30 213 1896 1099 0
9 9.42 30 258 2846 1416 0
10 9.42 30 245 2545 1324 0
11 9.42 30 232 2267 1232 0
12 9.42 30 242 2479 1303 0
13 9.42 30 236 2350 1261 0
14 9.42 30 234 2308 1247 0
15 9.42 30 254 2751 1387 0
16 9.42 30 293 3772 1662 0
17 9.42 30 279 3380 1564 0
18 9.42 30 235 2329 1254 0
19 9.42 30 257 2822 1408 0
20 9.42 30 278 3353 1556 0
21 9.42 30 260 2894 1430 0
22 9.42 30 245 2545 1324 0
23 9.42 30 204 1736 1036 0
24 9.42 30 197 1617 988 0
25 9.42 30 207 1788 1057 0
26 9.42 30 250 2658 1359 0
27 9.42 30 254 2751 1387 0
28 9.42 30 270 3143 1500 0
29 9.42 30 253 2728 1380 0
30 9.42 30 268 3092 1486 0
31 9.42 30 282 3461 1585 0
32 9.42 30 207 1788 1057 0
33 9.42 30 193 1551 960 0
34 9.42 30 183 1394 890 0
35 9.42 30 193 1551 960 0
36 9.42 30 190 1503 939 0
37 9.42 30 185 1425 904 0
38 9.42 30 196 1600 981 0
 39 9.42 30 194 1567 967 0
40 9.42 30 186 1440 911 0
41 9.42 30 190 1503 939 0
42 9.42 30 195 1583 974 0
43 9.42 30 219 2009 1141 0
44 9.42 30 253 2728 1380 0
45 9.42 30 251 2681 1366 0
46 9.42 30 237 2371 1268 0
47 9.42 30 230 2226 1218 0
48 9.42 30 200 1667 1008 0

452.39 1074 565 0

Total = 1638 Mcal/h

Radiation: Mcal/h x 24 x 1.05 = 57.5 kcal/kg

P

Spec Radiation: Mcal x 1.05 x 1000 3802 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 520 53 645 85
1B 412 161 651 91
2 573 81 560 231
3 654 121 329 62
4 775 8 267 116
5 783 42 151 64
PC 825 87

15.552 kcal/kg 24 kW
0.85
 Standard Temperature profile
Pressure Diff. Temp Temp Diff. Pressure Pressure Diff
1 267 207 -362 64
2 474 157 -298 52
3 631 154 -246 54
4 785 110 -192 61
5 895 5 -131
PC 900
Pressure Diff