Clinker Weighing test result

11 September 1997
Time (hour)
Kiln Feed totalizer (T)
Kiln Coal totalizer (T)
ILC Calciner coal totalizer (T)
SLC Calciner coal totalizer
Clinker weighing total (T)

start

Stop
14.13
813041
11001.9
6312.82
12078

L min
GHV

Total
22.13
817186
11120.5
6355.32
12230.3

Ton/jam
8
4145
118.6
42.5
152.3
2719.5

518.1
14.8
5.3
19.0
339.9

8.542 kg air/kg Coal

5763 kcal/kg Coal

Fuel consumption
Kiln (PW1)
ILC Calciner (PW2)
SLC Calciner (PW3)
Total

Ton
118.6
42.5
152.3
313.4

Fuel Consumption

%
37.8%
13.6%
48.6%
100.0%

664 kcal/kg Clinker

Combustion air

ton/jam
14.8
5.3
19.0
39.2

(note:pfister feeder calibration no

334632.9 kg air/jam
5577.2 kg air/min
0.984 kg air/kg clinker

Clinker Faktor

1.52 (note:the dust return is not weighed)

Material Balance
Pulvurized
Coal Ash

kcal/kg terak

19.67 %
0.1967 x kg
3.413E-05 x kg

Raw mix to clinker

LOI 35.18
= (1 - 3.413* X*(10^-2))*100
100 - 35.18
= 1.542733724
-

CO2 From raw mix

total carbonate
= 0.524171552

Free H2O in the raw mix

H2O

5.266E-05 x

77.22 %
-

1.789E-05 x
0.5 %

Combined H2O in raw mix

=( 1.542733724

5.26559E-05 x) *

= 0.007752431

2.64602E-07 x

H2O
=( 1.542733724
= 0.017278618

Carbon from raw mix

1.12 %
5.26559E-05 x) *
5.89746E-07

C
=( 1.542733724
= 0.001697007

0.11 %
-

5.26559E-05 x) *
5.79214E-08

Excess Air
% Excess Air =

79 * %O2
0.21 * (100 - % CO2) - %O2

Stage 1 ILC

average exit gas analiysis

CO2 =
29
O2
=
3.5
Excess air =
24.2

Stage 1 SLC

average exit gas analiysis

CO2 =
32
O2
=
3.5
Excess air =
25.6

Dust in Exit Gas

10.5%

Dust rate
kiln Feed
Total

56.28 tph
511.1 tph
567.38 tph

508.5445
564.5431

CLK = KF * (efficiency) * (1 - H2O) * (1-LOI) + (Coal Ash)

335 = 567.4 * (efficiency) * (1 - 0.05) * (1-0.3518) + (39.17*0.1967)
327.6227335 =
365.936837 * Efficiency
Efficiency =
89.5%
Dust =

Water from Coal

0.177 kg dust/kg clinker

Fine Coal H2O

LHV Fine Coal
Fine Coal Consumption

2.29 %
5763 kcal/kg Coal
=

x
5763
=

Dry Coal consumption

0.000174 x

=
Water from Coal

+ (15763

kg coal/kg terak

0.0229 )

0.000169547 x

x
*
5763
=

kg coal Dry/kg terak

0.0229

3.97362E-06 x

kg air/kg terak

Combustion Air Rates:

L min
Air required

8.542 kg air/kg Coal

x *
5763

0.001482214 x

8.3976694

8.542
kg Coal

kg air

kg air/kg Clk

Kiln Primary air

Flow

150.7 kg air/min

(measurement pitot tube)

0.027 kg air/kg Clk

L min

= 2110.585833 kg air/min
=

7.14% kebutuhan udara dari total combustion of kiln fuel.

Kiln Coal Transport air

Flow

81.8 kg air/min
0.015 kg air/kg Clk

L min

= 2110.585833 kg air/min
=

3.9% kebutuhan udara dari total combustion of kiln fuel.

ILC Calciner coal transport and primary air

Flow

25.83 kg air/min
0.005 kg air/kg Clk

L min

= 756.3229167 kg air/min
=

3.4% kebutuhan udara dari total combustion of ILC Calciner.

SLC Calciner coal transport and primary air

Flow

91 kg air/min
0.016 kg air/kg Clk

L min

= 2710.305417 kg air/min
=

3.4% kebutuhan udara dari total combustion of SLC Calciner.

Remaining air requirement ILC/kiln String

=[( 0.001482214 x

* (1 +

= 0.000946553 x

0.242 ))

-0.046

Remaining air requirement ILC/kiln String

=[( 0.001482214 x

* (1 +

= 0.000905049 x

Combustion products from coal

0.256 ))
-0.016

9.349 kg gas/kg coal including water in Coal

=

kcal/kg terak
5763 kcal/kg Coal

= 0.001622245 x kg gas/kg clk

9.349 kg gas/kg coal

Extra air required to burn carbon in the kiln feed

C

Air

Lb

11.53

lb/lb clk

0.0017

0.019566492

---------- > Including

24.2 % Excess air in ILC

0.024308

---------- > Including

25.6 % Excess air in SLC

0.024585

Extra Product of Combustion for ILC

CO2
N2

0.006 kg CO2/kg clk

0.0187 Kg N2/kg Clk

Extra Product of Combustion for SLC

CO2
N2

0.006 kg CO2/kg clk

0.0189 Kg N2/kg Clk

Excess Air
ILC/kiln string

= [(

37.8%

= 0.000184636 x

SLC string

=[

48.6%

= 0.000184752 x

Sistem surface losses

Radiation losses
Kiln Radiation loss

0.0047 kg air/kg clk

13.6% ) *
5763

8.542
5763

0.0050 kg air/kg clk

23

Cooler and firing hood radiation loss

Preheater and tertiary air dust radiation loss

6
28

Cooler
124 C

Average clinker discharge temperature

Heat of Cooler

=
=

1 kg/kg clk *
#NAME?

Radiation Loss

124 *

kcal/kg clk

6 kcal/kg clk

Excess Air
Flow

388554 kg/hr @

238 C

1.158726595 kg air/kg clk

CP

#NAME?

Heat Of excess Air

#NAME?

kcal/kg clk

Hot air for the raw mill

Flow

122897 kg/hr @
0.366497378 kg air/kg clk

CP

#NAME?

Heat Of excess Air

#NAME?

kcal/kg clk

Total Cooler loss

#NAME?

kcal/kg clk

407 C

(note:pfister feeder calibration not correct)

0.005025

0.0112

0.0011

OI) + (Coal Ash)

1-0.3518) + (39.17*0.1967)

pitot tube)

ombustion of kiln fuel.

ombustion of kiln fuel.

ombustion of ILC Calciner.

ombustion of SLC Calciner.

37.8% +

13.6% )]

kg air/kg clk

48.6% )]
kg air/kg clk

including water in Coal

kg gas/kg coal

-0.016

-0.027

-0.015

-0.005

CO2

N2

3.666667

8.85504

0.006222

0.015027

kg air/kg clk
kg air/kg clk

8.542 *

0.242331 ] * x + (

0.024308

kg air/kg clk

0.256494 ] * x + (

kg air/kg clk

kcal/kg clk

0.024585

0.0196 )

-0.0196 )

kcal/kg clk
kcal/kg clk

#NAME?

System Heat Input

Fuel : Combustion Heat
Free heat w/ coal
Air : Primary
Kiln Coal transport
ILC Coal transport
SLC Coal transport
Remaining ILC
Remaining SLC
Extra for C - ILC
Extra for C - SLC
Cooler : Excess Air
Hot air for RM
Water from coal
Raw Feed
Returned dust
Sum Of heat inputs

System Heat Input

Combustion Product (Coal)
Combustion Product (Carbon in mix)
CO2 - ILC
N2 - ILC
CO2 - SLC
N2 - SLC
Excess Air In exit gas - ILC
Excess Air In exit gas - ILC
CO2 from Raw Feed
Vapor from free H2O In feed
Vapor from comb H2O In feed
Dust
Radiation : Kiln
Preheater
Cooler loss : Heat in Clinker
Radiation
Hot air for mill
Excess Air
Heat of reaction
Sum Of heat inputs

kg/kg
80 0.000174 x
32
32
32
32
32 0.0009466 x
32 0.000905 x
32
32
32
32
80 3.974E-06 x
90 -5.266E-05 x
90

0.027
0.015
0.005
0.016
-0.04622
-0.01628
0.02431
0.02459
1.15873
0.3665
1.54273
0.177

kg/kg
348 0.0016222 x
348
348
348
348
348 0.0001846 x
348 0.0001848 x
348 -1.789E-05 x
348
348
348

kcal/kg
1
0.2932 0.004070102
0.2377
0.2377
0.2377
0.2377
0.2377 0.007200951
0.2377 0.006885208
0.2377
0.2377
0.2377
0.2377
1.0000 0.00031789
#NAME?
#NAME?
#NAME?
#NAME?

kcal/kg C

kcal/kg
kcal/kg C
0.2579 0.145595223
0.006
0.0187
0.006
0.019
0.0047
0.00502
0.52417
0.00775
0.01728
0.177

0.2319
0.2517
0.2319
0.2517
0.2450 0.015742344
0.2450 0.01575218
0.2319 -0.00144354
788
0.4600
0.2367

124

0.1927

407
238

0.3665
1.15873

0.2464
0.2425
0.17564621

#NAME? x +
0.17565 x

#NAME?
665.394721

#NAME? x =
x =

#NAME?
#NAME?

Summary
C

#NAME?
#NAME?
#NAME?

System Heat Input

Fuel : Combustion Heat
Free heat w/ coal
Air : Primary
Kiln Coal transport
ILC Coal transport
SLC Coal transport
Remaining ILC
Remaining SLC
Extra for C - ILC
Extra for C - SLC
Cooler : Excess Air
Hot air for RM
Water from coal
Raw Feed
Returned dust
Sum Of heat inputs

0.5020577
1.6349262
0.5020577
1.6535638
0.4042731
0.4278995
42.293343
6.1089155
2.7657381
14.590608
23
28
23.894304
6
36.748299
66.868735
410
665.39472

System Heat Input

Combustion Product (Coal)
Combustion Product (Carbon in mix)
CO2 - ILC
N2 - ILC
CO2 - SLC
N2 - SLC
Excess Air In exit gas - ILC
Excess Air In exit gas - ILC
CO2 from Raw Feed
Vapor from free H2O In feed
Vapor from comb H2O In feed
Dust
Radiation : Kiln
Preheater
Cooler loss : Heat in Clinker
Radiation
Hot air for mill
Excess Air
Heat of reaction
Sum Of heat inputs

kcal/kg
x
x

x
x

x
x +
x +

0.2051346
0.1113471
0.0351601
0.1238703
-0.3516419
-0.1238703
0.1849249
0.187033
8.8150728
2.7881479

kcal/kg
x

x
x
x

x
=

80
32
32
32
32
32
32
32
32
32
32
80
90
90

348
348
348
348
348
348
348
348
348
348
348

124
407
238

Kcal/kg

kg/kg

kcal/kg C

kcal/kg
#NAME?
#NAME?
0.205135
0.111347
0.03516
0.12387
#NAME?
#NAME?
0.184925
0.187033
8.815073
2.788148
#NAME?
#NAME?
#NAME?
#NAME?

#NAME?
0.027
0.015
0.005
0.016
#NAME?
#NAME?
0.024308
0.024585
1.158727
0.366497
#NAME?
#NAME?
0.177

0.2932
0.237736
0.237736
0.237736
0.237736
0.237736
0.237736
0.237736
0.237736
0.237736
0.237736
1
#NAME?
#NAME?

kg/kg
#NAME?

kcal/kg C kcal/kg
0.2579 #NAME?

0.006
0.019
0.006
0.019
#NAME?
#NAME?
#NAME?
0.007752
0.017279
0.177156

0.231857
0.251656
0.231857
0.251656
0.245004
0.245004
0.231857
788
0.459963
0.236667

0.502058
1.634926
0.502058
1.653564
#NAME?
#NAME?
#NAME?
6.108915
2.765738
14.59061
23
28
1 0.192696 23.8943
6
0.366497 0.246361 36.7483
1.158727 0.242474 66.86874
410
#NAME?