Kiln Heat Balance 1

Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman
HOLTEC
OMAN CEMENT COMPANY, OMAN
RADIATION CALCULATION FOR PC AND PREHEATER
Ambient temperature
(Draft)
23
oC
II Method
Heat
Heat
Cyclon
Radiati transfer transfer Radiatio
e
Avg Radiation,
Clinke
on,
coeffici coefficie n, Kcal/
Diameter, Length,
m
m surface
Temp,
Kcal/
r, tph
Kcal/ kg
ent
nt
kg
Area
oC
hr/m2
clinker (Radiati (Convecti clinker
m2
on)
on)
SN
Location
1.1
Cyclone IV A
5.06
3.75
59.61
98.21
92.00
740.92
0.450
7.449
6.613
0.506
1.2
Bottom
5.06
8.3
79.01
98.21
56.00
293.58
0.236
6.247
5.739
0.274
1.3
Riser pipe
1.70
10.68
98.21
42.00
151.19
0.016
5.826
4.987
0.019
1.4
Meal pipe
0.40
8.3
10.43
98.21 260.00
4407.06
0.468
15.725
6.830
0.488
1.5
Down commer duct
2.47
30
232.79
98.21
42.00
151.19
0.358
5.826
4.987
0.419
1.6
Roof
5.06
17.84
98.21
87.00
672.31
0.122
7.271
6.539
0.138
1.7
Cyclone IV B
5.06
3.75
59.61
6.00
60.00
337.77
3.356
6.372
5.890
3.876
1.8
Bottom
5.06
8.3
79.01
98.21
51.00
240.46
0.193
6.093
5.517
0.225
1.9
Riser pipe
1.70
10.68
98.21
42.00
151.19
0.016
5.826
4.987
0.019
2.0
Meal pipe
0.40
2.51
98.21 290.00
5410.22
0.138
17.735
6.728
0.144
2.1
Roof
5.06
17.84
98.21
87.00
672.31
0.122
7.271
6.539
0.138
2.2
Cyclone III A
4.83
3.7
56.14
98.21
65.00
395.03
0.226
6.531
6.053
0.260
2.3
Bottom
4.83
45.79
98.21
68.00
430.43
0.201
6.628
6.139
0.230
2.4
Riser pipe
2.60
7.5
20.20
98.21
52.00
250.89
0.052
6.124
5.565
0.060
2.5
Meal pipe
0.40
3.2
4.02
98.21 320.00
6550.17
0.268
19.928
6.618
0.278
2.7
Roof
4.83
13.01
98.21
70.00
454.46
0.060
6.693
6.193
0.069
2.8
Cyclone III B
4.83
3.7
56.14
98.21
80.00
579.70
0.331
7.029
6.416
0.377
2.9
Bottom
4.83
45.79
98.21
75.00
516.03
0.241
6.859
6.313
0.275
3.0
Riser pipe
2.60
7.5
20.20
98.21
60.00
337.77
0.069
6.372
5.890
0.080
3.1
Meal pipe
0.40
3.2
4.02
98.21 366.00
8597.45
0.352
23.663
6.443
0.364
3.2
Roof
4.83
13.01
98.21
87.00
672.31
0.089
7.271
6.539
0.101
3.3
Cyclone II
6.63
3.7
77.07
98.21 101.50
876.94
0.688
7.797
6.728
0.769
3.4
Bottom
6.63
6.5
77.90
98.21
99.00
840.42
0.667
7.704
6.701
0.747
3.5
Riser pipe
3.60
9.5
26.20
98.21 104.00
913.96
0.244
7.890
6.754
0.272
3.6
Meal pipe
0.40
3.2
4.02
98.21 366.00
8597.45
0.352
23.663
6.443
0.364
3.7
Roof
6.63
24.34
98.21
87.00
672.31
0.167
7.271
6.539
0.188
3.8
Cyclone I A
4.83
3.7
56.14
98.21
87.00
672.31
0.384
7.271
6.539
0.434
Page 1 of 1
Plant Operation Audit for two production lines (Line2 &3),
Annexure 4.1 A
CLINKER CONVERSION FACTOR - LINE 2
MEASUREMENTS TAKEN ON 27.11.2013
Sn
13170
Parameter
Unit
Value
Basis
Kiln feed rate
tph
351.00
CCR Indication
Loss on Ignition (LOI) of kiln feed
34.66
As provided by JKCL
Fuel Consumption (mixed coal)
9.42
Calculated based on data provided by JKCL during

process measurements
Ash content in Fuel (mixed coal )
5.0
Calculated based on data provided by JKCLduring

process measurements
Raw meal to clinker conversion factor

(On LOI basis) (CF 1)
1.52
Calculated
Dust loss from Preheater
9.00
As provided by JKCL during process measurements
Kiln feed to clinker conversion factor

(with return dust) (CF 2)
1.674
Calculated
Clinker produced
tph
209.69
Calculated
tpd
5033
Calculated
Page 1 of 1
Kiln 1 Heat Balance

Kiln feed rate
Clinker prouction
Tph
'tph
'tpd
165
98.2143
2357.14
KF to clinker conversion factor
1.68
oC
Raw meal temperature
60
Raw meal moisture
%
0.5
PH exit gas O2
%
6.0
Clinker temperature
oC
156.0
Natural Gas temperature to kil oC
75
Natural Gas temperature to PC oC
75
Kg/nm3
Atmosphere Gas density
1.293
Ambiant temperature
oC
23
Dust loss (assumed)
%
8.00
Cooler radiation
Kcal/kg clin
5
Drop in temp at two end of TA oC
96
Plant Operational Audit for two production lines ( Line 2&3),
Annexure 4.3 A
GAS FLOW MEASUREMENT - LINE 2

Pitot constant
Site pressure
S.N.
Location
Preheater
Exit (WHR
inlet)
0.836
9859
mmWG
Site elevation
Duct dia.
Date
Clinker
Production
Rate
tph
26.11.13
209.69
3.5
374
Duct
area
Temp.
Static
pressure
m2
oC
mmWG
9.625
315
-670
Cooler
exhaust
26.11.13
(WHR inlet)
209.69
2.80
6.16
418
-27
Tertiary air
209.69
2.18
3.73
930
-70
13170
26.11.13
RMS Avg
dynamic
pressure
Density
Velocity on
RMS Avg
No of
points
mmWG
Kg/ Nm3
mps
m3/ h
Nm3/ h
Nm3/kg
clinker
30
19.85
1.42
21.55
746746
308326
1.470
20
16.93
1.293
21.86
484669
182203
0.87
24
22.63
1.293
33.41
449173
96568
0.46
Dynamic Pressure, mmWG
10
10.0
13.0
13.0
12.0
17.0
25.0
24.0
23.0
26.0
27.0
27.0
27.0
26.0
26.0
24.0
20.0
23.0
19.0
20.0
14.0
16.0
18.0
20.0
21.0
16.0
17.0
16.0
15.0
26.0
25.0
15.0
18.0
18.0
17.0
18.0
19.0
18.0
17.0
16.0
17.0
18.0
15.0
17.0
16.0
15.0
15.0
17.0
17.0
18.0
18.0
25.0
27.0
24.0
23.0
24.0
24.0
28.0
24.0
23.0
24.0
23.0
24.0
23.0
24.0
26.0
28.0
24.0
27.0
10.0
12.0
13.0
25.0
22.0
23.0
Volume on
RMS
Average
Specific air
consp. on
RMS Avg.
Page 4 of 2
Plant Operational Audit for two production lines ( Line2 &3),
Annexure 4.3 A
GAS FLOW MEASUREMENT - LINE 2

COOLING AIR FANS
Site pressure
S.N.
Fan No
9859
mmWG
Site elevation
374
Suction duct
dia.
Duct area
tph
m2
Fan outlet
Static
pressure
mmWC
Date
Temp.
oC
CF 1
26.11.13
209.69
0.71
0.396
+821
28
CF 2
26.11.13
209.69
0.71
0.396
+741
28
CF 3
26.11.13
209.69
0.63
0.312
+754
28
CF 4
26.11.13
209.69
0.90
0.636
+374
28
CF 5
26.11.13
209.69
0.9
0.636
+347
28
CF 6
26.11.13
209.69
0.9
0.636
+335
28
CF 7
26.11.13
209.69
0.9
0.636
+305
28
CF 8
26.11.13
209.69
1.12
0.985
+287
28
CF 9
26.11.13
209.69
1.12
0.985
+283
28
10
CF 10
26.11.13
209.69
1.12
0.985
+245
28
No of
values
Air Velocity, mps

1
10
9.4
9.3
9.6
10.2
10.3
13.0
12.6
12.4
12.2
11.0
9.9
16.6
12.2
13.3
13.4
12.3
12.6
9.2
11.2
10.2
10.7
11.1
9.0
8.8
9.7
9.3
8.6
9.3
8.6
9.9
9.8
11.2
12.7
12.4
11.8
10.9
15.7
16.6
16.8
15.7
14.7
17.3
17.3
15.8
16.9
16.0
16.7
16.4
16.4
17.3
17.7
17.3
17.1
17.2
17.8
17.4
17.0
17.1
17.5
15.4
16.7
16.3
17.2
24.3
21.6
21.8
24.5
23.8
24.0
25.8
25.7
26.7
25.9
26.2
24.2
25.0
26.1
24.9
23.9
24.1
21.5
21.5
22.7
22.0
20.8
22.8
23.5
21.6
20.6
23.4
14.5
14.8
13.6
15.5
13.0
14.0
12.0
14.8
14.9
15.0
14.0
15.8
15.7
15.4
13.8
13.0
13.2
13.2
12.9
14.3
13.7
14.1
12.6
12.0
12.0
13.7
12.3
12.5
13.9
11.7
10.9
11.0
10.0
12.3
11.6
10.0
13.6
12.4
12.5
10.0
13.1
11.0
11.0
Avg
velocity
Volume
Volume
Specific gas consp.
mps
m3/ h
Nm3/ h
Nm3/kg clinker
17
11.79
16802
14540
0.069
19
10.23
14581
12618
0.060
13
16.32
18314
15849
0.076
14
17.07
39088
33826
0.161
23.20
53124
45973
0.219
25.51
58421
50557
0.241
13
22.55
51650
44697
0.213
16
14.37
50949
44091
0.210
13
13.10
46476
40220
0.192
14
11.50
40803
35310
0.168
Total specific cooling air
13170
1.61
Page 2 of 2
Page 1 of 1
COOLER AIR & HEAT BALANCE
Plant capacity
Sp. heat capacity
Fuel firing in Kiln
Air density
Ambient temp.
Combustion air for kiln
Combustion air for PC
Primary air to kiln
Primary air to PC
Secondary air to kiln
Tertiary air to PC
Cooler vent air
Total Cooling air
t/d
Kcal/kgclk.
%
Kg/nm3
oC
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
2357
800
40
1.293
23
0.494
0.382
0.748
0.579
0.029
0.022
#REF!
#REF!
0.465
0.360
#REF!
#REF!
1.124
0.869
#REF!
#REF!
Flow
Temp
Heat balance
Sn
1
2
Item
Secondary air to kiln
Tertiary air to PC
(Draft)
kg/ kg clink 0C
0.46514271
1060
#REF!
883
Cp
Heat
Kcal/ kg 0 Kcal/ kg clinker

0.26
128.1933322
0.25
#REF!
Page 1 of 1
(Draft)
Page 1 of 1
Page 1 of 1
(Draft)
Page 1 of 1
Page 1 of 1
Page 1 of 1
COOLER HEAT BALANCE
M
Kg/kg
clk
#REF!
Tertiary air
Cp
T
oC
Kcal/
kgoC
Kcal/kg
clk
883
0.25
#REF!
Secondary air
Cp
T
Kg/kg
clk
OC
0.47
1060
Kcal/ Kcal/kg
Kiln clk
kgoC
0.26
128
Cooler
M
Kg/kg
clk
1.00
Hot clinker
Cp
T
OC
Kcal/
kgoC
Kcal/kg
clk
1450
0.26
377
M
Kg/kg
clk
#REF!
Cooling air
Cp
T
OC
Kcal/
kgoC
Kcal/kg
clk
23
0.24
#REF!
#REF!
Recuperatuion Efficiency
:
%
(Draft)
Page 1 of 1
RADIATION CALCULATION FOR COOLER

Ambient temperature
SN
Location
oC
Cyclone
surface Area
m2
Clinker,
tph
II Method
Avg
Temp,
oC
Radiation,
Kcal/ hr/m2
Radiation,
Kcal/ kg
clinker
Heat transfer
coefficient
(Radiation)
Heat transfer
coefficient
(Convection)
1.1
Cooler
145.04
93.24
113.11
1319.99
2.053
7.521
7.991
1.2
Cooler roof
61.48
93.24
138.50
1757.03
1.159
8.518
8.021
Total >>
3.21
Page 1 of 1
RADIATION CALCULATION FOR COOLER

II Method
Radiation, Kcal/
kg clinker
2.347
1.299
3.646
Page 1 of 1
RADIATION CALCULATION FOR PC AND PREHEATER

Ambient temperature
SN
Location
oC
Cyclone
surface Area
m2
Clinker,
tph
II Method
Avg
Temp,
oC
Radiation,
Kcal/ hr/m2
Radiation,
Kcal/ kg
clinker
Heat transfer
coefficient
(Radiation)
Heat transfer
coefficient
(Convection)
763.56
0.461
6.210
7.736
Kiln String
1.1
Cyclone - 1A
126.61
209.69
75.33
1.2
Bottom
38.85
209.69
90.00
966.76
0.179
6.695
7.877
1.3
Riser pipe
16.21
209.69
128.00
1569.83
0.121
8.094
8.018
1.4
meal pipe
9.24
209.69
264.00
4846.82
0.213
15.000
7.619
1.5
Roof
9.69
209.69
84.33
886.35
0.041
6.504
7.830
2.1
Cyclone - 1 B
126.61
209.69
91.67
990.86
0.598
6.752
7.889
2.2
Bottom
38.85
209.69
97.33
1074.40
0.199
6.949
7.925
2.3
Riser pipe
16.21
209.69
125.67
1529.48
0.118
8.002
8.015
2.4
meal pipe
9.24
209.69
260.67
4740.74
0.209
14.791
7.634
2.5
Roof
9.69
209.69
91.00
981.20
0.045
6.730
7.884
3.1
Cyclone - 2
152.76
209.69
68.67
676.47
0.493
5.999
7.648
3.2
Bottom
51.19
209.69
80.00
826.48
0.202
6.361
7.788
3.3
Riser pipe
36.63
209.69
110.00
1270.02
0.222
7.405
7.981
3.4
Meal pipe
9.24
209.69
147.33
1921.85
0.085
8.888
8.016
3.5
Roof
22.39
209.69
112.00
1302.05
0.139
7.480
7.988
4.1
Cyclone - 3
151.13
209.69
68.67
676.47
0.488
5.999
7.648
4.2
Bottom
50.64
209.69
74.00
745.88
0.180
6.168
7.720
4.3
Riser pipe
36.92
209.69
178.00
2549.28
0.449
10.268
7.956
4.4
meal pipe
9.24
209.69
178.67
2563.92
0.113
10.300
7.954
4.5
Roof
15.10
209.69
82.67
863.15
0.062
6.449
7.815
5.1
Cyclone - 4
166.84
209.69
90.00
966.76
0.769
6.695
7.877
5.2
Bottom
53.75
209.69
105.00
1191.32
0.305
7.223
7.963
5.3
Riser pipe
38.80
209.69
135.33
1699.59
0.314
8.388
8.021
5.4
Meal pipe
10.81
209.69
158.33
2136.80
0.110
9.366
8.001
5.5
Roof
16.45
209.69
83.33
872.41
0.068
6.471
7.821
6.1
Cyclone - 5
166.84
209.69
96.67
1064.45
0.847
6.926
7.921
6.2
Bottom
53.75
209.69
131.67
1634.15
0.419
8.240
8.020
6.3
Riser pipe
38.80
209.69
116.67
1378.02
0.255
7.655
8.000
6.5
Meal pipe
10.81
209.69
165.67
2286.29
0.118
9.695
7.987
6.6
Roof
16.45
209.69
150.33
1979.39
0.155
9.016
8.012
6.1
Cyclone - 6
166.84
209.69
122.50
1475.44
1.174
7.878
8.011
6.2
Bottom
53.75
209.69
136.67
1723.67
0.442
8.443
8.021
6.3
Riser pipe
38.80
209.69
466.67
14940.49
2.765
32.124
6.687
6.5
Meal pipe
10.81
209.69
225.00
3696.67
0.191
12.690
7.790
6.6
Roof
16.45
209.69
101.33
1134.84
0.089
7.091
7.946
Calciner String
1.1
Cyclone - 1
148.64
209.69
83.33
872.41
0.618
6.471
7.821
1.2
Bottom
49.94
209.69
153.33
2037.74
0.485
9.146
8.009
1.3
Riser pipe
26.28
209.69
67.33
659.45
0.083
5.958
7.628
1.4
meal pipe
9.24
209.69
194.33
2920.98
0.129
11.067
7.906
1.5
Roof
20.87
209.69
100.00
1114.56
0.111
7.043
7.939
3.1
Cyclone - 2
145.34
209.69
97.00
1069.42
0.741
6.937
7.923
3.2
Bottom
48.93
209.69
74.00
745.88
0.174
6.168
7.720
3.3
Riser pipe
35.80
209.69
88.33
942.86
0.161
6.639
7.864
3.4
Meal pipe
9.24
209.69
155.33
2077.09
0.091
9.234
8.006
Page 1 of 1
3.5
Roof
13.67
209.69
107.33
1227.81
0.080
7.307
7.972
4.1
Cyclone - 3
141.69
209.69
112.33
1307.42
0.883
7.492
7.989
4.2
Bottom
48.36
209.69
78.00
799.31
0.184
6.296
7.767
4.3
Riser pipe
35.14
209.69
115.00
1350.69
0.226
7.592
7.996
4.4
meal pipe
9.24
209.69
156.33
2096.90
0.092
9.277
8.004
4.5
Roof
13.45
209.69
67.33
659.45
0.042
5.958
7.628
5.1
Cyclone - 4
151.13
209.69
95.67
1049.58
0.756
6.891
7.915
5.2
Bottom
50.64
209.69
125.00
1518.03
0.367
7.976
8.014
5.3
Riser pipe
36.92
209.69
138.00
1747.91
0.308
8.498
8.021
5.4
Meal pipe
9.24
209.69
193.67
2905.27
0.128
11.033
7.908
5.5
Roof
14.92
209.69
121.67
1461.35
0.104
7.846
8.010
6.1
Cyclone - 5
151.13
209.69
100.00
1114.56
0.803
7.043
7.939
6.2
Bottom
50.64
209.69
117.33
1389.02
0.335
7.680
8.001
6.3
Riser pipe
36.92
209.69
98.67
1094.41
0.193
6.996
7.932
6.5
Meal pipe
9.24
209.69
206.33
3211.98
0.141
11.682
7.863
6.6
Roof
14.92
209.69
98.33
1089.40
0.078
6.984
7.930
6.1
Cyclone - 6
151.13
209.69
101.00
1129.76
0.814
7.079
7.944
6.2
Bottom
50.64
209.69
136.67
1723.67
0.416
8.443
8.021
6.3
Riser pipe
36.92
209.69
154.67
2063.93
0.363
9.204
8.007
6.5
Meal pipe
9.24
209.69
181.67
2630.35
0.116
10.444
7.946
6.6
Roof
14.92
209.69
165.67
2286.29
0.163
9.695
7.987
PC
1.988
Riser ducts
3.128
Total >>
26.94
Page 1 of 1
ADIATION CALCULATION FOR PC AND PREHEATER

II Method
Radiation, Kcal/
kg clinker
0.545
0.209
0.137
0.226
0.048
0.697
0.231
0.134
0.221
0.053
0.587
0.238
0.254
0.094
0.159
0.581
0.213
0.491
0.124
0.073
0.897
0.351
0.353
0.122
0.080
0.982
0.472
0.291
0.130
0.173
1.332
0.496
2.882
0.204
0.103
0.726
0.539
0.099
0.140
0.128
0.859
0.206
0.188
0.101
Page 1 of 1
0.092
1.010
0.218
0.258
0.102
0.050
0.878
0.415
0.345
0.139
0.118
0.928
0.382
0.223
0.153
0.090
0.940
0.467
0.403
0.127
0.179
24.686
Page 1 of 1
RADIATION CALCULATION FOR KILN 1 (From Kiln Outlet)

Ambient temperature
oC
II Method
SN
Location, m
Kiln Dia,
m
Kiln
Length,
m
Total C. S,
m2
Clinker,
tph
0 to 2
4.27
26.83
209.69
2 to 4
4.27
26.83
209.69
4 to 6
4.27
26.83
6 to 8
4.27
26.83
8 to 10
4.27
10 to 12
4.27
12 to 14
4.27
14 to 16
4.27
Avg
Temp,
oC
Radiation, Kcal/
hr/m2
Radiation,
Kcal/ kg
clinker
Heat transfer
coefficient
(Radiation)
Heat transfer
coefficient
(Convection)
Radiation, Kcal/
kg clinker
364
9418.04
1.205
22.304
7.148
1.179
280
5703.77
0.730
16.032
7.545
0.726
209.69
281
5740.67
0.735
16.098
7.540
0.731
209.69
291
6118.62
0.783
16.770
7.494
0.777
26.83
209.69
246
4540.15
0.581
13.899
7.700
0.585
26.83
209.69
204
3325.53
0.425
11.561
7.872
0.436
26.83
209.69
165
2388.36
0.306
9.665
7.988
0.320
26.83
209.69
347
8558.33
1.095
20.913
7.228
1.074
16 to 18
4.27
26.83
209.69
318
7223.53
0.924
18.686
7.366
0.911
10
18 to 20
4.27
26.83
209.69
351
8755.29
1.120
21.235
7.209
1.098
11
20 to 22
4.27
26.83
209.69
201
3247.30
0.415
11.406
7.883
0.427
12
22 to 24
4.27
26.83
209.69
225
3904.14
0.500
12.690
7.790
0.507
13
24 to 26
4.27
26.83
209.69
257
4897.79
0.627
14.564
7.651
0.628
14
26 to 28
4.27
26.83
209.69
327
7620.71
0.975
19.358
7.323
0.960
15
28 to 30
4.27
26.83
209.69
215
3621.73
0.463
12.142
7.830
0.472
16
30 to 32
4.27
26.83
209.69
318
7223.53
0.924
18.686
7.366
0.911
17
32 to 34
4.27
26.83
209.69
309
6841.09
0.875
18.030
7.408
0.865
18
34 to 36
4.27
26.83
209.69
305
6675.73
0.854
17.745
7.427
0.845
19
36 to 38
4.27
26.83
209.69
307
6758.06
0.865
17.887
7.418
0.855
20
38 to 40
4.27
26.83
209.69
257
4886.69
0.625
14.544
7.653
0.627
21
40 to 42
4.27
26.83
209.69
260
4987.13
0.638
14.729
7.639
0.639
22
42 to 44
4.27
26.83
209.69
215
3621.73
0.463
12.142
7.830
0.472
23
44 to 46
4.27
26.83
209.69
228
3991.38
0.511
12.858
7.778
0.518
24
46 to 48
4.27
26.83
209.69
221
3789.64
0.485
12.469
7.806
0.493
25
48 to 50
4.27
26.83
209.69
212
3539.47
0.453
11.982
7.842
0.462
26
50 to 52
4.27
26.83
209.69
218
3695.80
0.473
12.287
7.820
0.481
27
52 to 54
4.27
26.83
209.69
209
3449.38
0.441
11.805
7.855
0.451
28
54 to 56
4.27
26.83
209.69
209
3449.38
0.441
11.805
7.855
0.451
28
56 to 58
4.27
26.83
209.69
222
3827.58
0.490
12.542
7.801
0.498
28
58 to 60
4.27
26.83
209.69
285
5889.90
0.754
16.364
7.522
0.749
Total >>
20.18
20.15
Page 1 of 1
HEAT BALANCE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Kiln feed temperature

Kiln feed moisture
Fine Coal moisture
PH exit gas CO2
O2
N2
Clinker temperature
Temperature of Coal fired in kiln
Temperature of Coal fired in PC
Gas density
Ambiant temperature
Dust loss
Cooler radiation
Kiln radiation
PH radiation
C
%
%
%
%
%
o
C
o
C
o
C
Kg/nm3
o
C
%
Kcal/kg clinker
Kcal/kg clinker
Kcal/kg clinker
o
60
0.2
0.5
18
4.0
78.0
130
50
50
1.293
28
9.00
3.21
20.2
26.94
C
Primary air temp
%
%
%
%
%
o
C
o
C
o
C
Kg/nm3
o
C
%
Kcal/kg clinker
Kcal/kg clinker
Kcal/kg clinker
o
Deg C
50
KILN, PREHEATER AND COOLER -Kiln 2

Clinker production
S.
N.
Stream
5033
Gas flow, Nm3/kg
Flow, Kg/ Kg clinker
clinker
tpd
Temp, oC
Heat,
Kcal/ kg clk
% Heat
Mass flow
tph
Sp. heat
Kcal/KgoC
Sensible Heat of kiln feed
1.671
60
21.24
2.78
350.30
0.21
Sensible Heat of kiln feed moisture
0.003
60
0.20
0.03
0.70
1.00
Sensible Heat of Fuel
0.094
50
1.31
0.17
19.64
0.28
Sensible Heat of fine fuel moisture
0.0005
50
0.01
0.001
0.10
0.28
Sensible Heat of Primary air to Kiln
0.022
0.029
50
0.35
0.05
6.09
0.24
Sensible heat of coal conveying air to kiln
0.009
0.012
50
0.15
0.02
2.58
0.24
Sensible Heat of Cooler air
1.610
2.082
28
13.86
1.82
436.62
0.24
Sensible Heat of false air
0.305
0.394
28
2.62
0.34
82.66
0.24
Sensible heat of coal conveying air to PC
0.014
0.017
50
0.21
0.03
3.66
0.24
723
94.77
0.00
763
100.00
902.4
10
Heat from Fuel
11
Calcination Gases
0.278
12
Combustion Gases only
0.024
Total Heat Input >>
2.26
4.30
Heat Output
Heat loss through Clinker
Heat loss through PH exhaust gas
Heat loss through PH return dust
Heat loss through Cooler exhaust air
Heat of Formation for Clinker
Evaporation of Moisture in kiln feed
0.003
Evaporation of Moisture in fine fuel
0.0005
Preheater radiation losses
Kiln and cooler radiation losses

Total Heat Output >>
1.426
0.87
2.30
1.000
130
25.09
3.29
209.69
0.193
2.025
315
157.0
20.57
424.69
0.25
0.151
315
11.11
1.46
31.59
0.23
1.124
418
115.8
15.18
235.59
0.25
401.1
52.57
315
2.27
0.30
0.70
0.46
315
0.32
0.04
0.10
0.46
26.94
3.53
0.00
23.39
3.07
0.00
763.0
100.00
902
4.30
Cooler 2 Heat Balance -Kiln 2

Data
Clinker Production
Specific Heat Consumption
% of fuel to Kiln
% of fuel to PC
Clinker temperature
Cooler Exhaust Temperature
Secondary
Tertiary Air Temperature
Primary air to kiln
Primary air to PC
Secondary Air Quantity
Tertiary quantity
Density of air
Ambient Air Temperature
Sn
Description
tpd
kcal/kg clinker
%
%
Deg C
Deg C
Deg C
Deg C
kg/kg clinker
kg/kg clinker
kg/kg clinker
kg/kg clinker
kg/nm3
Deg C
5033
723
31.1
68.9
130
418
1140
930
0.029
0.017
0.363
0.595
1.293
28
Flow
Temperature
kg/kg clinker
Deg C
Cp
Heat
kcal/kg oC kcal/kg clinker
HEAT INPUT
1
Hot Clinker
1.00
1450
0.264
383
Cooling Air
2.08
28
0.238
13.9
Total
3.08
397.1
HEAT OUTPUT
3
Heat loss through Cooler Exhaust air
1.12
418
0.247
115.8
Secondary air
0.363
1140
0.263
109.0
Tertiary Air
0.595
930
0.258
143.1
Heat loss through Clinker
1.00
130
0.193
25.1
Cooler Radiation losses

Total
3.2
3.08
396.2
% of Heat Recuperation Efficiency
64
Total Cooler losses
144
Plant Operational Audit for production lines ( Line 2& 3),
Annexure 4.7 A
COOLER HEAT BALANCE LINE 2

Secondary air
Mass
Temp.
Heat flow
0.36
1140
109.00
Kg/ kg clk
0
C
Kcal/ kg clk.
Tertiary Air
Mass
Temp.
Heat flow
0.60
930
143.09
Kg/ kg clk
0
C
Kcal/ kg clk.
Cooler exhaust
Mass
Temp.
Heat flow
1.12
418
115.82
Kg/ kg clk
C
Kcal/ kg clk.
Clinker
Mass
Temp.
Heat flow
Clinker
Mass
Temp.
Heat flow
1.00
1450
383.24
Kg/ kg clk
C
Kcal/ kg clk.
Kg/ kg clk
0
C
Kcal/ kg clk.
Total cooling air
Heat recuperation efficiency

63.6 %
Total Cooler losses
144.1 kcal/kg clinker
13170
1.00
130
25.09
Cooler radiation losses

3.21
Mass
Temp.
Heat flow
2.08
28
13.86
Kcal/ kg clk.
Kg/ kg clk
C
Kcal/ kg clk.
Page 1 of 1
Plant Operational Audit for two production lines ( Line2& 3),

J K Lakshmi Cement Ltd, Sirohi Rajasthan
Annexure 4.4A
KILN SHELL TEMPERATURE LINE 2
S.N.
13170
Location (From kiln outlet), m
Average temperature, oC
0 to 2
364
2 to 4
280
4 to 6
281
6 to 8
291
8 to 10
246
10 to 12
204
12 to 14
165
14 to 16
347
16 to 18
318
10
18 to 20
351
11
20 to 22
201
12
22 to 24
225
13
24 to 26
257
14
26 to 28
327
15
28 to 30
215
16
30 to 32
318
17
32 to 34
309
18
34 to 36
305
19
36 to 38
307
20
38 to 40
257
21
40 to 42
260
22
42 to 44
215
23
44 to 46
228
24
46 to 48
221
25
48 to 50
212
26
50 to 52
218
27
52 to 54
209
28
54 to 56
209
29
56 to 58
222
30
58 to 60
285
Page 1 of 1
Plant Operational Audit for two production lines ( Line 2& 3),
J K Lakshmi Cement Ltd, Sirohi Rajasthan
Annexure 4.5A
CHEMICAL ANALYSIS OF CLINKER LINE 2
13170
Component
Unit
Value
SiO2
20.94
Al2O3
5.71
Fe2O3
3.75
CaO
63.87
MgO
3.02
SO3
1.45
K2O
0.73
Na2O
0.31
Cl
0.00
Free CaO
1.89
Page 1 of 1
Heat loss by
Radiation
Heat loss through Cooler Vent
6.60%
15.18%
Sensible heat of Kiln Feed
Heat loss through Preheater exhaust gas
2.78%
20.57%
Heat loss through clinker

Heat input by Fuel
3.29%
Heat Balance of Kiln 2
94.77%
Specific Heat Consumption

Kcal/ kg clinker
763.0
Heat of Formation
52.57%
Estimation of Phase Density
Kiln
Pipe line size
Dia
CSA
Volume
Coal tpt
Velocity at tpt line
Coal to air ratio
power cons
sp power
kg of air required for 4
kg ratio
Extra air going
% Extra air going
% reduction in power
for 20% speed red
kw saving
annual cost saving
kW
mm
m2
m3/sec
kg/sec
m3/hr
Nm3/kg clinker
TPH
kg/sec
m/sec
PC
141.2
0.0157
0.6393
0.7224
2301
0.009
6
1.67
40.82
2.31
110
18.33
179.2
0.0252
0.9098
1.0280
3275
0.014
13.4
3.72
36.07
3.62
110
8.21
0.42
0.93
0.31
0.42
0.10
0.09
0.512
0.512
53.7
8.59
0.0
0.00
32.13610586
321.3610586
Kiln 2 - Energy Saving Proposals,

Power cost
3.880
present level
Increasing Gas residence time in existing precalciner
Reduction of preheater calciner exit temperature
Reduce pressure drop across duct from WHR outlet to ph fan inlet
Arresting of false air
Reduce bypass in pyro section
Reduce pressure drop across Top stage cyclone
Reduce false air across CT system -Pyro
Replacement of existing cooling fans
Upgradation of heat exchanger in cooler vent system
Installation of Precalciner
10
Increasing kiln inlet area

Reduction of dust accumulation inside Tertiary Air Duct (TAD) & Improving Tertiary
air flow.
11
70.0
278.0
471 FN2,3,4,5,6,7
7
Reduce pressure drop across cyclone & cyclone outlet bend in Raw mill circuit
Reduce false air in GCT and VRM circuit
Reduce damper loss in Kiln/raw mill Bag House Fan
10
Reduce false air in coal mill circuit
11
Reduce pressure drop in coal mill bag hose to Fan duct
115.0
12
47.0
13
Reduce damper loss in coal mill booster fan

Reduce speed of kiln & PC coal conveying blowers by 20 % by installing VFD and
reduce pipe dia /size to maintain 35 m/s transportation velocity
14
Installation of automation system
15
Reduce pressure drop across damper in Sepax fan Slag HPGR roller press
80.0
16
Reduce pressure drop across damper in bag house fan in Slag VRM
113.0
17
Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF1)
64.0
18
Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF3)
303.0
19
Avoid damper loss by installing VFD in Auxilary bag filter fan (221BF1)
440.0
Long term energy saving proposals

Installation of new clinker cooler
160.0
40.0
INR
new one
Coal cost
861.6
present power fan head
INR/ mio kcal
saving power Running hrs savings in Lakhs
10.19
40
1893.0
1893.0
742.0
742.0
77
94.65
7920
7920
23.5
29.1
40.76
90
2075.1
830.0
235
8000
7.3
2075.1
830.00
92.1
8000
1.43
75.0
8000
23.3
8000
45.0
0.0
8000
3.06
130
20.0
8000
6.2
1580.0
903.0
52.5
7000
14.3
1580.0
903.0
145
7000
39.4
803.0
294.0
27.3
8000
8.5
380.0
893.0
39
5000
7.6
40
380.0
893.0
31.9
5000
6.2
20
60.0
141.0
11.5
5000
2.2
67.0
8000
20.8
109
8000
33.8
20
20
400.0
464.0
25.9
7000
7.0
20
1435.0
686.0
97.3
7000
26.4
10
22.0
351.0
3.4
5000
0.7
10
45.0
496.0
13.3
5000
2.6
10
55.0
515.0
23.0
5000
4.5
157.0
417
Thermal savings
Electrical savings
investement Lakhs
payback, months
kcal/kg
MTOE/ year
KW
10
1171
101
5.1
0.5
3.6
424
40.00
20
20.0
2.2
0.1
40
2.40
235
0.13
1.1
92.1
2.5
1.3
2.5
2.3
0.6
2.0
1.5
5.9
77
40
77.3
20
16.8
20
6.1
0.0
25
39.4
25
48.5
16.2
20
11.5
50
17.7
0.0
0.0
36.6
18.6
10.8
600
45.9
826
Electrical savings
kW/ t of clinker
0.68
6.6
39895
1.6
0.6
0.5
59996
0.11
False air %
43376
11890
Primary air_kiln _ PC
Primary air to kiln

Air required for kiln firing
% primary air to kiln
Primary air to precalciner

Air required for PC firing
% primary air toPC
Savings from Recommended action
The O2 at PH exit may be reduced to 3.5%

by identifying the leakages in the Cyclones,
riser ducts, meal chutes, PC, kiln seals, etc. 29.314989 Kcal/ kg clinker
Primary air to PC may be reduced to
maximum 6 % i.e. 0.045 Kg/ kg clinker.
From 0.06kg /kg clinker
Primary air to kiln may be reduced to
maximum 6 % i.e. 0.04 Kg/ kg clinker.
From 0.025kg /kg clinker
Temperature drop across the T A Duct may
be reduced to 50 Deg C from 96
3.1788 Kcal/ kg clinker

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Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

Down commer duct

Plant Operation Audit for two production lines (Line2 &3),

Kiln feed rate

Loss on Ignition (LOI) of kiln feed

Fuel Consumption (mixed coal)

Calculated based on data provided by JKCL during

Ash content in Fuel (mixed coal )

Calculated based on data provided by JKCLduring

Raw meal to clinker conversion factor

Dust loss from Preheater

As provided by JKCL during process measurements

Kiln feed to clinker conversion factor

Kiln 1 Heat Balance

Plant Operational Audit for two production lines ( Line 2&3),

GAS FLOW MEASUREMENT - LINE 2

Dynamic Pressure, mmWG

Plant Operational Audit for two production lines ( Line2 &3),

GAS FLOW MEASUREMENT - LINE 2

Air Velocity, mps

Specific gas consp.

Total specific cooling air

COOLER AIR & HEAT BALANCE

Kcal/ kg 0 Kcal/ kg clinker

COOLER HEAT BALANCE

RADIATION CALCULATION FOR COOLER

RADIATION CALCULATION FOR COOLER

RADIATION CALCULATION FOR PC AND PREHEATER

ADIATION CALCULATION FOR PC AND PREHEATER

RADIATION CALCULATION FOR KILN 1 (From Kiln Outlet)

Kiln feed temperature

KILN, PREHEATER AND COOLER -Kiln 2

Sensible Heat of kiln feed

Sensible Heat of kiln feed moisture

Sensible Heat of Fuel

Sensible Heat of fine fuel moisture

Sensible Heat of Primary air to Kiln

Sensible heat of coal conveying air to kiln

Sensible Heat of Cooler air

Sensible Heat of false air

Sensible heat of coal conveying air to PC

Heat from Fuel

Combustion Gases only

Total Heat Input >>

Heat loss through Clinker

Heat loss through PH exhaust gas

Heat loss through PH return dust

Heat loss through Cooler exhaust air

Heat of Formation for Clinker

Evaporation of Moisture in kiln feed

Evaporation of Moisture in fine fuel

Preheater radiation losses

Kiln and cooler radiation losses

Cooler 2 Heat Balance -Kiln 2

kcal/kg oC kcal/kg clinker

Heat loss through Cooler Exhaust air

Heat loss through Clinker

Cooler Radiation losses

% of Heat Recuperation Efficiency

Total Cooler losses

Plant Operational Audit for production lines ( Line 2& 3),

COOLER HEAT BALANCE LINE 2