Binani Cement kiln process diagram analysis

Page - 1/29
PLANT : Binani Cement - 20.06.2003

Kiln Feed
Kiln Feed Dividing Flap
O2 = 5.3%
K1
K2
C1
1.657 kg-Feed/kg-Clk
To Raw Mill/Baghouse
O2 = 3.2%
0.566 Nm3w/kg-clk
1.449 Nm3w/kg-clk
0.134 kg-Dust/kg-Clk
C2
KS Fan
844/82 kW/%
K3
K4
C3
ESP
0.884 Nm3/kg-Clk
Cooler ESP
CS Fan
1930/86.20 kW/%
C4
Kiln String
Calciner String
K5
C5
1.092 Nm3w/kg-clk
185 kW/%
Stack
0.020 kg-Dust/kg-Clk
K6
C6
Cal.
Calciner Firing
Kiln Firing
0.072 kg-Coal/kg-Clk
0.044 kg-Coal/kg-Clk
0.020 Nm3w/kg-clk
0.020 Nm3w/kg-clk
0.508 Nm /kg-Clk
3
T.A. Duct
Primary Air
0.020 Nm3w/kg-clk
KILN
KILN
1136 deg.C
3.56 %
Inlet O2
False Air a/c KS, Nm3w/kg-clk
0.030
False Air a/c CS, Nm3w/kg-clk
0.052
False Air a/c Cooler, Nm w/kg-clk
0.009
4.2 rpm
50 %
0.357 Nm3w/kg-clk
Cooler
Hot air to PA Fan
Clinker
1.889 Nm3w/kg-clk
251515 kg-Clk/hr
Page - 2/29
K6
C6
Cal.
Nm3w/kg-clk
kgw/kg-clk
Stoi.
0.479
0.613
Exc.
0.048
0.062
Tot.
0.528
0.675
Trpt. Air
0.020 Nm3w/kg-clk
0.026 kgw/kg-clk
Trpt. Air
0.020 Nm3w/kg-clk
Pri. Air
0.026 kgw/kg-clk
T.A.DUCT
0.025 kgd/kg-clk
Water Inj.
0.020 Nm3w/kg-clk
0.020 kg/kg-clk
0.025 kgw/kg-clk
0.508
Vent Air
0.650
KILN
KILN
1.092 Nm3w/kg-clk
#REF!
1.388 kgw/kg-clk
0.311
Nm3w/kg-clk
kgw/kg-clk
Stoi.
0.294
0.376
Exc.
0.063
0.081
0.819
Tot.
0.357
0.457
1.048
0.398
COOLAX COOLER
1284-3ME-IN
Ist 6 Row CIS
False Air
1.070
0.003 Nm3w/kg-clk
1.369
0.004 kgw/kg-clk
False Air
0.006 Nm3w/kg-clk
0.007 kgw/kg-clk
Excess Air Optimisation (vol%, d)

Optimised O2 - Kiln I/L
3.6
Optimised CO2 - Kiln I/L
20.7
Cooling Air
Optimised O2 - Cal. O/L
2.417 kgw/kg-clk
Optimised CO2 - Cal. O/L
1.889 Nm3w/kg-clk
1.4
39.3
Error Minimisation-1
0.00
Optimised Excess Air, Kiln
21.5
vol%, w
0.00
Optimised Excess Air, Cal.
10.1
vol%, w
0.00
10/04/2015 02:47:03 288628503.xls Pic-2S
LU001005-KCP#Ver.1.2D***
10/04/2015 02:47:03 288628503.xls Pic-2S
LU001005-KCP#Ver.1.2D***
kgd/kg-clk
0.602
0.061
0.663
0.026 kgd/kg-clk
0.025 kgd/kg-clk
0.638
1.349
kgd/kg-clk
0.391
0.369
0.079
0.448
1.029
1.344
0.007 kgd/kg-clk
3.491
0.065
20.703
0.000
1.416
0.027
39.347
0.000
10/04/2015 02:47:03 288628503.xls Pic-2S
2.374 kgd/kg-clk
LU001005-KCP#Ver.1.2D***
0.004
10/04/2015 02:47:03 288628503.xls Pic-2S
LU001005-KCP#Ver.1.2D***
kgd/kg-clk
kgd/kg-clk
10/04/2015 02:47:03 288628503.xls Pic-2S
LU001005-KCP#Ver.1.2D***
10/04/2015 02:47:03 288628503.xls Pic-2S
LU001005-KCP#Ver.1.2D***
Page - 3/29
Kiln Basic Calculations : SLC 6-Stage II-String
Site Conditions
Equipment Specifications
Clinker Production
tpd
Clinker Production
kg/hr
Plant Elevation
mts +MSL
6036
251515
402
Kiln Length
mts
68
Kiln Diameter
mts
4.55
Kiln Refractory Thickness
mm
220
Kiln Diameter, effective
mts
4.11
Barometric Pressure
mmWG
9827
Barometric Pressure
mmHG
723
Slope
deg.C
31.0
Cooler Area
Ambient Air Temperature

Relative Humidity
41
Pitot Constt. - S Type (L=01m)
S1
Pitot Constt. - S Type (L=03m)
S2
m2
97.03
0.01262
Burner Axial Area
5 mm withdrawn
m2
0.883
Burner Radial Area
X mm withdrawn
m2
Blocked
0.872
Burner - Coal Annulus
m2
0.03878
False Air Analysis
Raw Mix
A/c KS w.r.t. Mix - O2 Basis
mass%, w
5.52
Loss on Ignition (as LOI)
35.83
A/c CS w.r.t. Mix - O2 Basis
mass%, w
6.41
CaCO3
75.70
A/c Cooler ESP w.r.t. Mix
mass%, w
7.24
MgCO3
1.80
21.45
Sulphur (as pyrites)
0.04
10.10
Combined H2O
1.05
Carbon in Kiln Feed
0.20
Moisture in Kiln Feed
0.22
Moisture in Kiln Feed
kg/hr
917
Excess Air in Kiln
vol%, d
Excess Air in Calciner
vol%, d
Water Temp.
25
deg.C
Miscellaneous Data
Dust with Clinker, Kiln
2.00
Water In, Cooler
m /hr
5.0
Raw Mix - Clinker Ratio
kg/kg-clk
Water In, Cooler
tph
5.0
Raw Mix - Clinker Ratio
kg/hr
kcal/kg
Evaporation Heat
1.522
382896
539
Kiln Feed Rate
kg/kg-clk
Clinker Temperature, Kiln Outlet
deg.C
1450
Kiln Feed Rate
kg/hr
1.657
Clinker Temperature, Cooler Outlet
deg.C
140
Kiln Feed Temperature
deg.C
82
Silica (as SiO2)
20.87
Fine Coal Temperature
deg.C
73
Alumina (as Al2O3)
6.15
416689
Clinker Composition
Kiln Dust
mass%, w
6.70
Iron (as Fe2O3)
3.51
ESP I/L Dust Concn.
gm/m3-dg
9.0
Lime (as CaO)
65.23
yes/no
no
Magnesia (as MgO)
1.91
t/m3
1.3
Potassium Oxide (as K2O)
0.55
Sodium Oxide (as Na2O)
0.45
Sulphates (as SO3)
0.50
rpm
4.20
BH Dust Returned to Kiln

Clinker Density
Cooler Fans
kWh
Cooler ESP/Stack Radiations
31877
1.0
kcal/kg-Clk
Performance & Efficiency
CCR Data
Kiln Feed Residence Time in Kiln
min (d)
18.71
Kiln Speed
Clinker Residence Time in Cooler
min (d)
17.01
CFG Static Pressure
deg.C
2181
Kiln Feed Rate/Dosing Valve Position
tpd/m3
6.69
Kiln Feed Elevator Load
Theoretical Flame Temperature

Kiln Volumetric Loading
Burning Zone Loading
Mcal/hr-m2
Percent Filling
mmWG
tph/%
kW
4.95
Kiln Feed Diversion - Kiln/Calciner
16.56
Coal Screw Speed - Kiln/Calciner
735
415/78
92/71
%/% 40.5/59.5
rpm
629/673
Clinker Bed Thickness in Cooler
mm
565
KS Fan Load/Speed
kW/%
Clinker in Cooler
tons
71
CS Fan Load/Speed
kW/% 1930/86.20
Cooler Efficiency - Ref. : Amb. Temp.
Percent Primary Air (AA | RA)
% 6.79
P.A. Tip Velocity (AA | RA)

Flame Momentum (AA | RA)
73.11
0.00
Kiln String O2
Calciner String O2
3.65
m/sec
137
Kiln Inlet O2
%.m/sec
928
Cooler Grate-I Ch.I/II/III DP
Percent Coal Transport Air
C.T.A. Tip Velocity
m/sec
7.08
37
844/82
5.44
mmWG 676/123/84
Cooler Grate-I/II/III speed
spm 15.8/16.6/17.6
Cooler Grate-I/II/III load
amps
%.m/sec
260
Total Flame Momentum
%.m/sec
1188
Cooler ESP Fan Load
m /s/m
1.51
Cooler ESP Fan Speed
60
tpd/m2
62.2
Tert. Air Draft
mmWG
-38
Secondary Air Temperature
deg.C
1109
Hood Draft
mmWG
Tertiary Air Temperature
deg.C
905
Cooler Air
Cooler Loading
Burning Zone Temperature/Kiln Torque
69/56/55
Flame Momentum (CTA)
deg.C/%
kW
Dust Losses - PH
1136/50
185
-6
8.11
<<< ERRORS >>>
Hot air to PA Fan (Yes/No)
yes
Heat-1
0.00
Heat-2
0.00
Axial Air Contribution, %
100
Heat-3
0.00
Heat-4
0.00
Heat-5
0.00
Heat-6
0.00
Heat-7
0.00
Heat-8
0.00
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LU000211-KCP#Ver.2.2***
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Kiln Air Flow Calculations : SLC 6-Stage II-String
Flow Analysis
Kiln
Calciner
Total
Cooler
Primary
Coal Trpt. Air
False Air
String
String
PH Gas
Vent
Air
Kiln
Cal.
Kiln I/L
Cal. O/L
Cooler
Dry Bulb Temp.
deg.C
306
302
304
285
87
73
75
807
811
31
Wet Bulb Temp.
deg.C
30
34
34
22
Dew Point (F4)
deg.C
31
25
25
24
15
Dew Point, calc.
deg.C
58
31
25
25
24
16
0.110
0.110
0.030
0.021
0.021
0.020
0.012
0.012
0.012
1020
3305
2960
-66
-234
-6
9.75
50.86
50.19
0.40
0.255
0.255
Water Vapor
kg/kg-dg 0.110
Avg. Ps
mmWG
-575
-864
-753
-40
RMS Pd
mmWG
2.80
3.00
3.75
3.55
Duct Diameter
mts
O2, dry
vol %
5.3
3.2
4.0
21.0
21.0
21.0
21.0
3.6
1.4
21.0
CO2, dry
vol %
28.8
35.8
33.1
0.0
0.0
0.0
0.0
20.7
39.3
0.0
N2, dry
vol %
65.9
61.0
62.9
79.0
79.0
79.0
79.0
75.7
59.2
79.0
Density, dry - O2
kg/m3
0.60
0.59
0.59
0.66
1.14
1.43
1.39
0.34
0.33
1.22
Density, dry - CO2
kg/m3
0.83
0.81
0.82
0.92
1.57
1.98
1.92
0.47
0.46
1.69
Density, dry - N2
kg/m3
0.53
0.52
0.52
0.58
1.00
1.26
1.22
0.30
0.29
1.07
Density - H2O
kg/m3
0.34
0.33
0.33
0.37
0.64
0.81
0.78
0.19
0.19
0.69
Mass - O2, dry
kg
3.20
1.88
2.38
13.90
23.88
30.08
29.13
1.21
0.48
25.61
Mass - CO2, dry
kg 24.08
29.10
27.20
0.00
0.00
0.00
0.00
9.77
18.18
0.00
Mass - N2, dry
kg 34.96
31.58
32.87
46.01
79.03
99.55
96.38
22.73
17.40
84.74
Mass - H2O
kg
6.85
6.88
6.87
1.77
2.16
2.72
2.51
0.40
0.43
1.32
O2, wet
mass %
4.63
2.71
3.44
22.54
22.73
22.73
22.75
3.56
1.32
22.93
CO2, wet
mass % 34.85
41.91
39.24
0.00
0.00
0.00
0.00
28.64
49.82
0.00
N2, wet
mass % 50.61
45.47
47.42
74.59
75.21
75.21
75.29
66.62
47.67
75.88
H2O
mass %
9.91
9.91
9.91
2.87
2.06
2.06
1.96
1.19
1.19
1.19
Gas Density, dry
kg/Nm3
1.47
1.52
1.50
1.29
1.29
1.29
1.29
1.41
1.54
1.29
Gas Density, wet
kg/Nm3
1.36
1.40
1.38
1.27
1.28
1.28
1.28
1.40
1.53
1.28
Gas Density, dry
kg/m3
0.62
0.63
0.62
0.60
1.03
1.30
1.26
0.34
0.36
1.10
Gas Density, wet
kg/m3
0.57
0.57
0.57
0.59
1.02
1.28
1.24
0.33
0.36
1.10
m/s
15.2
21.2
22.1
13.1
13.7
27.9
28.2
6.16
7.07
11.04
12.60
0.13
0.051
0.051
Pitot Tube
Gas Velocity
S1/S2/L
Duct C.S. Area
Gas Flow Rate, wet
tph 193.68
310.38
504.06
###
6.31
6.57
6.42
10.69
19.89
2.84
Gas Flow Rate, wet
kNm /hr 142.27
222.22
364.44
###
4.94
5.14
5.03
7.64
13.03
2.21
Gas Flow Rate, wet
km /hr 336.90
539.90
876.81
###
6.21
5.13
5.18
32.01
55.75
2.59
30.8
50.0
10.0
0.1
0.1
0.1
0.1
0.2
0.0
Moisture, by diff.
tph
Gas Flow Rate, dry
tph 174.49
279.62
454.11
###
6.18
6.44
6.30
10.57
19.65
2.81
Gas Flow Rate, dry
kNm3/hr 118.40
183.96
302.29
###
4.78
4.98
4.87
7.48
12.74
2.17
Gas Flow Rate, dry
km3/hr 280.37
446.96
727.32
###
6.00
4.96
5.02
31.35
54.49
2.55
0.263
0.261
0.262
0.250
0.244
0.244
0.244
0.263
0.264
0.242
Mcal/hr 15548
24527
40075
24911
134
117
118
2268
4251
21
tph 12.98
20.81
33.79
5.10
kcal/kg/C
0.234
0.233
0.233
0.205
Heat Content, dust
Mcal/hr
927
1467
2394
298
Heat Content, total
Mcal/hr 16475
25994
42469
25209
134
117
118
2268
4251
21
Heat Cap., gas

Heat Content, gas
Dust, gas
Heat Cap., dust
kcal/kg/C
19.2
10/04/2015 02:47:03 288628503.xls Kiln-CalcS
LU000211-KCP#Ver.2.2***
Heat Cap - Coefficients

Gas/Mat
*T^0
*T^1
*T^2
*T^3
*T^4
0.2485
-3.340E-06
4.440E-08
###
5.597E-15
Not used in calc.
0.1244
0.000E+00
0.000E+00
###
0.000E+00
Not used in calc.
O2
0.2130
7.796E-05
-7.563E-08
###
-8.183E-15
CO2
0.1906
1.771E-04
-1.733E-07
###
-1.894E-14
N2+Ar
0.2465
-3.284E-06
4.366E-08
###
5.504E-15
H2O,steam
0.4445
2.910E-05
6.887E-08
###
6.472E-15
H2O, liq.
1.0000
Rawmeal
0.2060
1.014E-04
-3.673E-08
Clinker
0.1742
1.414E-04
-1.283E-07
###
23.5771
Sp. Gravity, dry - O2
kg/Nm3
1.429
-4042.90
Sp. Gravity, dry - CO2
kg/Nm
1.977
-37.58
Sp. Gravity, dry - N2
kg/Nm3
1.257
Rho H2O-Steam, kg/Nm3
0.804
Sp. Gravity - H2O
kg/Nm3
0.804
BURNER AXIAL/RADIAL ANNULUS

R/A Withd.
Area
A/A Withd.
Area
0.046850
0.005790
0.045465
0.005790
0.044088
10
0.008630
0.042722
15
0.010610
0.041365
20
0.012620
25
0.014690
30
0.016800
35
0.018950
40
0.021150
45
0.024520
50
0.028210
55
0.032110
60
0.035150
1930/86.20
5.8/16.6/17.6
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LU000211-KCP#Ver.2.2***
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Supporting Gas Analysis
Cooler-ESP Air Balancing
Ambient
ESP
False Air
To
KS
CS
Air
Stack
ESP
PA Fan
Fan I/L
Fan I/L
31
265
31
265
305
302
22
53
22
53
80
80
15
40
15
40
60
16
30
16
30
0.012
0.028
0.012
3.75
Mass
Temp.
Sp. Heat
kg/kg-clk
deg.C
kcal/kg/C kcal/kg-clk
Air (ESP I/L)
1.388
285
0.250
99
60
False Air
0.106
31
0.242
57
58
ESP Fan Pow.
0.028
0.110
0.110
1.495
100
-610
-910
6.00
9.07
17.51
Stack
1.470
265
0.250
97
4.20
2.80
3.00
To PA Fan
0.025
265
0.250
21.0
21.0
21.0
21.0
5.7
3.4
Radiations
0.0
0.0
0.0
0.0
24.9
34.6
1.495
100
79.0
79.0
79.0
79.0
69.4
62.0
1.22
0.69
1.22
0.69
0.60
0.59
1.69
0.95
1.69
0.95
0.83
0.81
1.07
0.61
1.07
0.61
0.53
0.51
Error1
0.0000
0.69
0.39
0.69
0.39
0.34
0.33
Error2
0.0000
25.62
14.48
25.62
14.48
3.43
1.99
0.00
0.00
0.00
0.00
20.73
28.02
84.79
47.93
84.79
47.93
36.74
31.92
1.32
1.77
1.32
1.77
6.70
6.81
22.93
22.57
22.93
22.57
5.07
2.89
0.00
0.00
0.00
0.00
30.67
40.76
75.88
74.68
75.88
74.68
54.35
46.44
1.19
2.75
1.19
2.75
9.91
9.91
1.29
1.29
1.29
1.29
1.45
1.51
1.28
1.27
1.28
1.27
1.34
1.39
1.10
0.62
1.10
0.62
0.61
0.62
1.10
0.61
1.10
0.61
0.56
0.57
S2
S2
S2
12.1
15.5
21.4
13.85
6.16
7.07
369.65
26.76
6.31
193.68
310.38
290.64
20.84
4.96
144.53
223.20
602.18
24.41
10.27
343.14
544.89
10.2
0.3
0.2
19.2
30.8
359.48
26.44
6.13
174.49
279.62
277.99
20.45
4.74
120.66
184.94
575.96
23.95
9.83
286.47
451.49
0.242
0.250
0.242
0.250
0.263
0.262
24450
200
417
15549
24526
12.98
20.81
0.234
0.233
925
1466
24450
200
417
16474
25992
10/04/2015 02:47:03 288628503.xls Kiln-CalcS
Const.
Heat
IN
TOTAL
OUT
TOTAL
ESP False Air Optimisation
7.24
LU000211-KCP#Ver.2.2***
10/04/2015 02:47:03 288628503.xls Kiln-CalcS
LU000211-KCP#Ver.2.2***
31.0
0.0296
-40
21.00
0.00
79.00
1.215
1.681
1.069
0.684
25.52
0.00
84.44
3.25
22.54
0.00
74.59
2.87
1.293
1.271
1.100
1.081
0.245
0.178
10/04/2015 02:47:03 288628503.xls Kiln-CalcS
LU000211-KCP#Ver.2.2***
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Kiln Heat & Mass Balance : SLC 6-Stage II-String
S.
Constriants
Amount
No.
kg/hr
Nm3/hr
Temp.
Cp
Heat
deg.C
kcal/kg/ oC
kcal/hr
kcal/kg-Clk
INPUT
1
Combustion of Coal
172787463
687.0
Cooling Air, Cooler
607797
475107
35
0.243
5167950
20.5
Fuel (Kiln+Cal.)
29207
73
0.262
559117
2.2
False Air (KS+CS+Cooler)
33423
22885
31
0.242
250376
1.0
Primary Air
6307
4938
87
0.244
134126
0.5
Kiln Feed, dry
415773
82
0.214
7298375
29.0
Combustibles in Kiln Feed
6442978
25.6
Free Water in Kiln Feed
917
82
1.000
75171
0.3
Water Injection, Cooler
5000
25
1.000
124999
0.5
12994
10172
73
0.244
231628
0.9
193072182
767.6
10
Coal Transport Air (Kiln+Cal.
TOTAL INPUT
1111418
OUTPUT
Preheater Exit Gases
504065
364436
304
0.262
40074502
159.3
Dust with PH Exit Gases
33794
304
0.233
2394225
9.5
Cooler Vent Air
349198
274761
285
0.250
24911420
99.0
Dust with Cooer Vent Air
5095
285
0.205
298061
1.2
Cold Clinker
246420
140
0.192
6610674
26.3
Total Radiations
11873278
47.2
Kiln String
2618130
10.4
Calciner String
3212876
12.8
Kiln
4437254
17.6
T.A. Duct
995312
4.0
Cooler + Hood
609706
2.4
Heat of Reaction excl. Comb
103329439
410.8
Evap. of Water, Kiln Feed
917
510611
2.0
Evap. of Water, Cooler Inj.
5000
3069969
12.2
0.00
193072182
767.6
10
Balance/Losses
TOTAL OUTPUT
1144488

Ref. Temp. - 0 deg.C
Mass Error =
-2.89 %
Heat Cap - Coeffici

Gas/Mat
*T^0
*T^1
0.2485 -3.340E-06
0.1244 0.000E+00
O2
0.2130 7.796E-05
CO2
0.1906 1.771E-04
N2+Ar
0.2465 -3.284E-06
H2O,steam
0.4445 2.910E-05
H2O, liq.
1.0000
Rawmeal
0.2060 1.014E-04
Coal 15.00-19.99%
0.237
Clinker
0.1742 1.414E-04
Coal < 14.99%
0.228
3.400E-04
Coal 15.00-19.99%
0.237
3.525E-04
Coal 20.00-24.99%
0.245
3.650E-04
Coal 25.00-29.99%
0.254
3.775E-04
Coal >= 30%
0.262
3.900E-04
3.525E-04
23.5771
-4042.90
-37.58
Rho H2O-Steam, kg/Nm3
0.804

*T^2
*T^3
*T^4
4.440E-08
-2.797E-11 5.597E-15 Not used in calc.
0.000E+00
0.000E+00 0.000E+00 Not used in calc.
-7.563E-08
4.074E-11 -8.183E-15
-1.733E-07
9.315E-11 -1.894E-14
4.366E-08
-2.750E-11 5.504E-15
6.887E-08
-3.726E-11 6.472E-15
-3.673E-08
0.000E+00
-1.283E-07
5.074E-11
0.000E+00
0.000E+00
0.000E+00
0.000E+00
0.000E+00
Sp. Gravity, dry - O2
kg/Nm3
1.429
Sp. Gravity, dry - CO2
kg/Nm3
1.977
Sp. Gravity, dry - N2
kg/Nm3
1.257
Sp. Gravity - H2O
kg/Nm3
0.804
Page - 5/29
Cooler Performance & Efficiency : SLC 6-Stage II-String
S.
Constriants
No.
Mass
Temp.
Cp
Heat
kg/kg-Clk
deg.C
kcal/kg/ C
kcal/hr
kcal/kg-Clk
INPUT
1
Clinker to Cooler
1.000
1450
0.264
96340716
383.0
Dust to Cooler
0.020
1450
0.264
1926814
7.7
Cooling Air
2.417
35
0.243
5167950
20.5
False Air, In
0.004
31
0.242
7714
0.0
Water Injection
0.020
25
1.000
124999
0.5
Power Consumption
1142273
TOTAL INPUT
4.5
3.461
416.3
OUTPUT
1
Secondary Air from Cooler
0.398
1109
0.266
29566604
117.6
Dust in Secondary Air
0.008
1109
0.242
513824
2.0
Tertiaruy Air from Cooler
0.650
905
0.262
38695835
153.9
Dust in Tertiary Air
0.012
905
0.235
662429
2.6
Evaporation of Injected Water
3069969
12.2
Cooler Vent/Excess Air
1.388
285
0.250
24911420
99.0
Dust in Vent/Excess Air
0.020
285
0.205
298061
1.2
Clinker from Cooler
0.980
140
0.192
6610674
26.3
Cooler Radiation
381650
1.5
TOTAL OUTPUT
3.456
416.3
1a
Cooler Vent/Excess Air, Amb.Tmp.
1.388
31
0.245
2653513
10.6
2a
Dust in Vent/Excess Air, Amb. Tmp.
0.020
31
3a
Clinker from Cooler, Amb.Tmp.
0.980
31
0.178
28189
0.1
0.178
1363271
5.4
1s
Cooler Vent/Excess Air, Std.
1.286
285
0.250
23076812
91.8
2s
Cooler Vent/Excess Air, Std.
1.286
Total Cooler Loss, Ref. - 0oC
31
0.245
2458094
9.8
kcal/kg-Clk
140
Total Cooler Loss, Ref. - Amb. Temp.
kcal/kg-Clk
112
Standard Cooler Loss
kcal/kg-Clk
Cooler Efficiency, Ref. - 0oC
66.31
Cooler Efficiency, Ref. - Amb. Temp.
73.11
105
VDZ Efficiency
S.
Constriants
No.
Mass
Temp.
Cp
kg/kg-Clk
deg.C
kcal/kg/ oC
kcal/hr
Heat
kcal/kg-Clk
1450
0.264
96340716
383
Clinker from Kiln
1.000
Clinker at Amb. Temperature
1.000
31
0.178
-1391460
-6
Clinker from Cooler
1.000
140
0.192
-6747366
-27
Power to Cooler Fans
1142273
Excess Air, Out
1.388
285
0.250
-24911420
-99
Excess Air, In
0.011
31
0.242
21291
Surface Losses
-381650
-2
Heat Absorption by Comb. Air
65463843
260
Max. Heat Release from Clinker
94949256
COOLER EFFICIENCY, %
378
68.95

Heat Error 0.00
10/04/2015 02:47:03 288628503.xls Cool-EffS
LU000211-KCP#Ver.2.2***
Mass Error 0.00
10/04/2015 02:47:03 288628503.xls Cool-EffS
LU000211-KCP#Ver.2.2***
117.55
117.55
2.04
2.04
153.85
153.85
2.63
2.63
276.08
276.08
0.00
10/04/2015 02:47:03 288628503.xls Cool-EffS
LU000211-KCP#Ver.2.2***
10/04/2015 02:47:03 288628503.xls Cool-EffS
LU000211-KCP#Ver.2.2***
Page - 6/29
Fuel Combustion Calculations : SLC 6-Stage II-String
Ultimate Analysis (ADB)
Air Requirement
Carbon (C)
65.06
Clinker Production
tpd
Hydrogen (H)
3.26
Clinker Production
kg/hr
251515
Nitrogen (N)
1.49
Unburnt Coal Consumption
kg/hr
2500
Sulphur (S)
0.52
Total Coal Consumption (ADB)
kg/hr
29207
Oxygen (O)
7.72
Coal Consumption (ADB)
11.61
Ash Content
19.90
Moisture (IM)
2.05
0.000007
HMB Error
Sp. Heat Consumption
6036
kcal/kg-Clk
687
Total O2 Requirement
kg/hr
58452
O2 in Coal
kg/hr
2256
Net O2 Requirement
kg/hr
56196
Proximate Analysis (ADB)
Description
Kiln
Cal.
Total
38.00
62.00
100.00
Fixed Carbon (FC)
55.09
Feed Ratio, %
Volatile Matter (VM)
22.97
Coal Consump., kg-Coal/kg-Clk
0.0441
0.0720
0.1161
Ash Content
19.90
Sp. Heat Consump., kcal/kg-Clk
261
426
687
Inher. Moisture (IM)
2.05
Lmin., kg/hr
92846
151486
244332
Lmin., kg/kg-Coal
3.179
5.187
8.365
112766
166783
279549
Calorific Value
GCV (calc.)
kcal/kg-Coal
6100
L, kg/hr
NCV
kcal/kg-Coal
5916
L, kg/kg-Coal
3.861
5.710
9.571
UHV
kcal/kg-Coal
5872
Sp. Air Consp., kg/kg-Clk
0.422
0.689
1.111
UHV (manual)
kcal/kg-Coal
6089
Ash Absorption, %
2.310
Value in calculations
kcal/kg-Coal
5916
Combustion of Coal :
Component
Wt. Fraction
Fuel
O2
CO2
H2O
SO2
kg/hr
kg/hr
kg/hr
kg/hr
kg/hr
0.6506
19002
50672
69674
0.0326
953
7628
8581
0.0149
435
0.0052
153
153
305
0.0772
2256
Ash
0.1990
5811
H2O
0.0205
598
598
Raw Mix
131145
4937
Total
1.0000
29207
58452
200819
14116
305
PH Outlet CO2 Calculations (DB) :

Description
CO2
CO2
Deg. of Calcination
Feed
/ Carbon in Coal
Rate
KS
CS
KS
CS
% / wt.%
tph
tph
tph
kNm3/hr
kNm3/hr
KF > KS (Deg. of Cal. - K6 Cyc.)
58.29
145.50
29.05
14.79
KF > CS (Deg. of Cal. - C6 Cyc.)
91.70
237.40
74.56
37.96
K6 Feed > Calciner
33.41
145.50
16.65
8.48
8.30
382.90
10.88
5.54
Coal Firing in Kiln
65.06
11.10
26.48
13.48
Coal Firing in Calciner
65.06
18.11
43.20
21.99
66.41
134.41
33.81
68.43
C6 Feed > Kiln
TOTAL
200.82
102.24
Page - 7/29
Coal Combustion Calculations : SLC 6-Stage II-String
Kiln Combustion Gases with Stoichiometric Air :
S
t
d
Comp.
CO2
D
R
Y
W
E
T
Mass Flow Rate
Vol. Flow Rate
Mass%
KS
CS
PH
KS
CS
PH
kg/hr
kg/hr
kg/hr
Nm /hr
Nm /hr
Nm /hr
m, %
37358
134413
200819
19019
68428
102235
34.23
KS
CS
Vol.%
PH
KS
CS
PH
m, %
m, %
vol., %
vol., %
vol., %
53.44
51.53
24.90
42.23
40.38
0.00
H2O
0.00
0.00
0.00
0.00
0.00
SO3
116
189
305
41
66
107
0.11
0.08
0.08
0.05
0.04
0.04
N2
71657
116913
188570
57325
93531
150856
65.66
46.48
48.39
75.05
57.73
59.58
O2
0.00
0.00
0.00
0.00
0.00
0.00
Total
109130
251515
389694
76384
162025
253198
100.00
100.00
100.00
100.00
100.00
100.00
CO2
37358
134413
200819
19019
68428
102235
32.31
51.29
49.37
22.52
39.06
37.26
H2O
6478
10570
17048
8062
13154
21216
5.60
4.03
4.19
9.55
7.51
7.73
SO3
116
189
305
41
66
107
0.10
0.07
0.08
0.05
0.04
0.04
N2
71657
116913
188570
57325
93531
150856
61.98
44.61
46.36
67.88
53.39
54.97
O2
0.00
0.00
0.00
0.00
0.00
0.00
Total
115609
262085
406742
84446
175179
274414
100.00
100.00
100.00
100.00
100.00
100.00
Kiln Combustion Gases incl. Excess Air :

S
t
d
Comp.
CO2
D
R
Y
W
E
T
Mass Flow Rate
Vol. Flow Rate
Mass%
Vol.%
KS
CS
PH
KS
CS
PH
KS
CS
PH
KS
CS
PH
kg/hr
kg/hr
kg/hr
Nm3/hr
Nm3/hr
Nm3/hr
m, %
m, %
m, %
vol., %
vol., %
vol., %
37358
134413
200819
19019
68428
102235
28.95
50.38
47.26
20.70
39.35
36.44
H2O
0.00
0.00
0.00
0.00
0.00
0.00
SO3
116
189
305
41
66
107
0.09
0.07
0.07
0.04
0.04
0.04
N2
86995
128693
215687
69596
102954
172550
67.41
48.23
50.76
75.76
59.20
61.50
O2
4582
3518
8100
3207
2463
5670
3.55
1.32
1.91
3.49
1.42
2.02
Total
129050
266813
424911
91862
173911
280562
100.00
100.00
100.00
100.00
100.00
100.00
CO2
37358
134413
200819
19019
68428
102235
27.52
48.43
45.39
18.98
36.54
33.82
H2O
6717
10754
17471
8359
13382
21742
4.95
3.87
3.95
8.34
7.15
7.19
SO3
116
189
305
41
66
107
0.09
0.07
0.07
0.04
0.04
0.04
N2
86995
128693
215687
69596
102954
172550
64.08
46.36
48.76
69.44
54.97
57.08
O2
4582
3518
8100
3207
2463
5670
3.37
1.27
1.83
3.20
1.31
1.88
Total
135767
277566
442382
100221
187294
302303
100.00
100.00
100.00
100.00
100.00
100.00
PH Outlet Gas Composition incl. False Air :

S
t
d
D
R
Y
W
E
T
Comp.
Mass Flow Rate
Vol. Flow Rate
Mass%
Vol.%
KS
CS
PH
KS
CS
PH
KS
CS
PH
KS
CS
PH
kg/hr
kg/hr
kg/hr
Nm3/hr
Nm3/hr
Nm3/hr
m, %
m, %
m, %
vol., %
vol., %
vol., %
CO2
66406
134413
200819
33807
68428
102235
38.67
46.47
42.98
28.84
35.76
32.62
H2O
0.00
0.00
0.00
0.00
0.00
0.00
SO3
116
189
305
41
66
107
0.07
0.07
0.07
0.03
0.03
0.03
N2
97446
145903
248114
77957
116723
198491
56.75
50.44
53.11
66.50
61.00
63.34
O2
7757
8747
17951
5430
6123
12566
4.52
3.02
3.84
5.30
3.20
4.01
Total
171725
289252
467189
117234
191340
313399
100.00
100.00
100.00
100.67
100.00
100.00
CO2
66406
134413
200819
33807
68428
102235
37.11
44.76
41.39
26.78
33.37
30.45
H2O
7230
11023
17978
8997
13717
22373
4.04
3.67
3.71
7.13
6.69
6.66
SO3
116
189
305
41
66
107
0.06
0.06
0.06
0.03
0.03
0.03
N2
97446
145903
248114
77957
116723
198491
54.45
48.59
51.14
61.76
56.92
59.11
O2
7757
8747
17951
5430
6123
12566
4.33
2.91
3.70
4.30
2.99
3.74
Total
178954
300275
485167
126231
205057
335772
100.00
100.00
100.00
100.00
100.00
100.00

FUEL : South African Coal
False air a/c KS w.r.t. gas, dry vol.%
11.52
False air a/c CS w.r.t. gas, dry vol.%
10.02
False air a/c PH w.r.t. gas, dry vol.%
11.70
w.r.t. mix
w.r.t. mix
w.r.t. mix
10.33
9.11
10.48
Page - 29/29
Unburnt Coal Combustion Calculations : SLC 6-Stage II-String
Ultimate Analysis (ADB)
Fuel-1
Fuel-2
Resultant Fuel
Carbon (C)
69.28
20.00
65.06
Hydrogen (H)
3.57
0.00
3.26
Nitrogen (N)
1.63
0.00
1.49
Sulphur (S)
0.57
0.00
0.52
Oxygen (O)
5.82
28.00
7.72
Ash Content
16.89
52.00
19.90
Moisture (IM)
2.24
0.00
2.05
Total
100.00
100.00
100.00
Fuel-1
Fuel-2
Resultant Fuel
Proximate Analysis (ADB)

Fixed Carbon (FC)
56.69
38.00
55.09
Volatile Matter (VM)
24.18
10.00
22.97
Ash Content
16.89
52.00
19.90
Inher. Moisture (IM)
2.24
0.00
2.05
Total
100.00
100.00
100.00
Fuel-1
Fuel-2
Resultant Fuel
Calorific Value
GCV (calc.)
kcal/kg-Coal
6613
611
6100
NCV
kcal/kg-Coal
6412
611
5916
UHV
kcal/kg-Coal
6260
1724
5872
UHV (manual)
kcal/kg-Coal
6500
1700
6089
26707
2500
29207
91.4
8.6
100.0
Fuel consumption
Fuel ratio
kg/hr
Page - 8/29
Preheater Draft & Temperature Measurements : SLC 6-Stage II-String
-575 mmWG
DP=85
306 deg.C
DT=9.30000000000001
-864 mmWG
DP=139
302 deg.C
DT=19.8
K-1
C-1
DP=105
-490 mmWG
DP=120
-725 mmWG
DT=139
315 deg.C
DT=115
322 deg.C
K-2
C-2
-385 mmWG
DP=81
-605 mmWG
DP=125
454 deg.C
DT=116
437 deg.C
DT=147
K-3
C-3
DP=84
-304 mmWG
DP=120
-480 mmWG
DT=90
570 deg.C
DT=137
584 deg.C
K-4
C-4
-220 mmWG
DP=80
-360 mmWG
DP=126
660 deg.C
DT=66
721 deg.C
DT=90
K-5
C-5
DP=74
-140 mmWG
DP=189
-234 mmWG
DT=81
726 deg.C
DT=69
811 deg.C
K-6
C-6/Cal.
Kiln I/L Draft
-66
mmWG
Cal. I/L Draft
-45
mmWG
Kiln I/L Temp
807
deg.C
Cal. I/L Temp
880
deg.C
Page - 9/29
Velocity Profiles : SLC 6-Stage II-String
S
Location
No.
Dimensions
Height
Dim-1
Dim-2
Ref.
Eff.
Thick.
Area
/ Dia.
Gas Characteristics
Vol.
Velo.
Ret.
Time
Flow, w
mts
mm
mm
mm
m2
km3/hr
m/sec
sec
336.90
18.40
K-1 Cyclone
5400
115
5.085
K-2 Cyclone
5400
179
6.212
0.00
K-3 Cyclone
5700
214
6.791
0.00
K-4 Cyclone
5700
214
6.791
0.00
K-5 Cyclone
5700
214
6.791
0.00
K-6 Cyclone
5700
214
6.791
0.00
Kiln Riser Duct
17.5
3100
3100
214
7.14
410.40
15.97
1.10
Smoke Chamber
4550
3100
214
11.01
410.40
10.35
Kiln (inlet)
68.0
4550
200
13.53
406.33
8.34
8.15
10
C-1 Cyclone
6300
115
7.009
539.90
21.40
11
C-2 Cyclone
6300
179
8.627
0.00
12
C-3 Cyclone
6600
214
9.308
0.00
13
C-4 Cyclone
6600
214
9.308
0.00
14
C-5 Cyclone
6600
214
9.308
0.00
15
C-6 Cyclone
6600
214
9.308
0.00
16
Calciner
26.5
6300
214
27.08
814.30
8.35
3.17
17
T.A. Duct
70.0
3000
214
5.20
581.87
31.11
2.25
18
Kiln Hood (throat)
5500
5480
300/214
24.75
862.93
9.68
10/04/2015 02:47:04 288628503.xls Vel-Prof
LU001007-KCP#Ver.1.1***
Page - 10/29
Heat of Reaction : Chemical Data
RAW MIX
Chemical Analysis
Unit
Value
Mineralogical Composition
Unit
Value
SiO2
13.02
Kaolinit
0.00
Al2O3
3.80
Montmorillonit
0.00
Fe2O3
2.30
Illit
100.00
CaO
43.10
Water of crystallisation
1.05
MgO
1.43
Carbon
0.20
SO3
0.20
Calculated Values :
Loss on ignition (LOI)
35.83
CaCO3
75.70
TOTAL
99.68
MgCO3
1.80
CO2
34.23
Sulphur in pyrites
0.04
K2O
0.38
CaSO4
0.34
Na2O
0.27
Silica-combined CaO
0.71
Sulphur, total
0.22
Fuel percent in clinker
11.61
Unit
Value
Sulphur, total
0.58
SiO2
47.66
Ash percent in coal
19.90
Al2O3
27.92
Net calorific value
kJ/kg
24722
Fe2O3
5.34
kcal/kg
5916
CaO
8.76
MgO
1.65
2.00
0.47
0.16
1)
FUEL : South African Coal
Heat consumption,
kJ per kg clinker
kcal per kg clinker
Ash Analysis
Sulphur
kJ/kg
2871
kcal/kg
687
K2O
2)
2)
Na2O
2)
RAW MIX ADJUSTMENT

Constituents
Unit
Raw Mix
Adjustment
Adjusted
Analysis
from Fuel
Raw Mix Analysis
SiO2
13.02
0.73
13.75
Al2O3
3.80
0.43
4.23
Fe2O3
2.30
0.08
2.38
CaO
43.10
0.13
43.23
MgO
1.43
0.03
1.46
SO3 (total)
0.30
0.08
0.38
K2O
0.38
0.01
0.39
Na2O
0.27
0.00
0.27
TOTAL
64.60
1.53
66.13
SULPHUR BALANCE AND RAW MIX/CLINKER RATIO

Adjusted raw mix, total
T:
66.13
Volatalised : U = 50% of sulphur in pyrites as SO3
U:
0.05
SO3 in clinker (calculated)

Raw mix / clinker ratio (loss of dust = 0 %) : F = 100 / (T - U)
0.49
%
F:
1.513
1) Carbon as CO2 is not included.

2) Calculated from analysis of solid fuel.
10/04/2015 02:47:04 288628503.xls Heat-Rxn
LU000303-RMD#Ver.1.3***
Page - 11/29
Heat of Reaction : Calculations
Conv.
CALCULATIONS
Contributions to Heat of Reaction
Calc. Contributions
Factor
Raw Mix
Clinker
kJ/kg/%
kJ/kg
kJ/kg
A : DECOMPOSITION INTO OXIDES

Raw Mix
CaCO3
75.70
-17.78
-1345.95
-2036.91
MgCO3
1.80
-15.10
-27.18
-41.13
Water of crystallisation
1.05
-42.70
-44.84
-67.85
Silica-combined CaO
0.71
-17.00
-12.04
-18.21
0.65
-14.80
-9.62
-14.56
-1439.62
-2178.67
Alkali silicates :
(K2O + Na2O)rawmix
Heat of Decomposition :
B: HEAT OF FORMATION
Property
Component
C3S
CaO
43.23
-0.46
-19.89
-30.10
C2S
SiO2
13.75
21.43
294.62
445.87
C3A
Al2O3
4.23
1.21
5.11
7.74
C4AF
Fe2O3
2.38
2.46
5.86
8.87
0.33
59.60
19.45
29.44
305.16
461.82
SO3 in clinker from fuel and pyrites
Adj. Raw Mix
Heat of Formation :
C : HEAT OF COMBUSTION
Carbon
0.20
327.86
65.57
99.23
Sulphur in pyrites
0.04
129.14
5.17
7.82
70.74
107.05
Heat of Combustion :
A+B+C:
HEAT OF REACTION (kJ/kg clinker)

HEAT OF REACTION (kcal/kg clinker)
A+B:
HEAT OF REACTION excl. HEAT OF COMBUSTION (kJ/kg clinker)

HEAT OF REACTION excl. HEAT OF COMBUSTION (kcal/kg clinker)
10/04/2015 02:47:04 288628503.xls Heat-Rxn
-1610
-385.21
-1717
-410.83
LU000303-RMD#Ver.1.3***
-410.83
10/04/2015 02:47:04 288628503.xls Heat-Rxn
LU000303-RMD#Ver.1.3***
10/04/2015 02:47:04 288628503.xls Heat-Rxn
LU000303-RMD#Ver.1.3***
Page - 12/29
Mechanism of Volatile Matters in Kiln
LOI in kiln feed, %
35.83
Raw mix to clinker (calc.)
1.484
BH/ESP dust, kg/kg-clk
0.134
Kiln feed to clinker (calc.)
1.618
LOI in BH/ESP dust, %
35.30
M S/A input to system
1.71
LOI in K6 stage mat., %
14.95
M S/A C6 stage mat.
4.50
LOI in C6 stage mat., %
2.97
M S/A clinker
0.66
Excess SO3 in I/P, g/100 kg-clk
684
Fuel consumption, %
11.61
Ash content in fuel, %
19.90
K2O
Analysis
Na2O
SO3
Cl
Cl-free
K2O
Kiln Feed, %
0.380
0.270
0.005
0.200
0.373
Total input on clinker (LFKF), %
0.683
0.444
0.018
1.480
0.659
BH/ESP Dust, %
0.381
0.271
0.005
0.201
0.374
Lowest Stage, %
1.640
0.320
0.660
3.850
0.764
Clinker, %
0.550
0.450
0.007
0.500
0.541
Kiln Fuel (SO3 as Sulphur), %
0.470
0.160
0.044
2.000
0.412
Evaporation factor, E
0.69
-0.29
0.990
0.88
0.35
Circulation factor, K
2.65
0.80
40.730
2.87
1.28
Residual in clinker, R
0.82
1.03
0.397
0.34
0.83
Preheater valve, Vc
0.10
0.15
0.015
0.22
0.32
BH/ESP valve, Vf
1.00
0.99
0.998
1.00
1.00
Combined valve, Vx
0.10
0.12
0.015
0.26
0.37
Concept of Volatile Matter

e
d
V
E
b
a
K
Burning Zone
Back End
Legends
Evaporation Factor, E = d/b = (b-c)/b
Residual Component, R = c/a
Circulation Factor, K = b/a
Valve, V = e/d = (a-c)/(b-c)
10/04/2015 02:47:04 288628503.xls Alkali
LU010408-KCP#Ver.1.0**
K2O
Na2O
Cl
SO3
LOI
Kiln Feed, %
0.500
0.180
0.012
0.120
35.540
BH/ESP Dust, %
0.530
0.140
0.013
0.130
36.220
Lowest Stage, K6, %
1.400
0.210
0.015
0.930
17.760
Lowest Stage, C6, %
1.520
0.410
0.059
0.880
3.060
Clinker, %
0.710
0.210
0.019
0.043
0.230
Kiln Fuel (SO3 as Sulphur), %
0.570
0.120
0.005
1.780
UBC (SO3 as Sulphur), %
0.420
1.720
0.026
4.670
10/04/2015 02:47:04 288628503.xls Alkali
LU010408-KCP#Ver.1.0**
ASW
0.046
GVFW
0.086
GVCW
0.985
GVKA(1)
0.600
GVKA(2)
0.426
GVKA(3)
0.008
GVFA(1)
0.597
GVFA(2)
0.424
GVFA(3)
0.008
GVMA(1)
1.811
GVMA(2)
0.353
GVMA(3)
0.729
GVCA(1)
0.558
GVCA(2)
0.457
GVCA(3)
0.007
ALK(1)
0.055
ALK(2)
0.019
ALK(3)
0.005
ALC(1)
0.055
ALC(2)
0.019
ALC(3)
0.005
GVRA(1)
0.600
GVRA(2)
0.427
GVRA(3)
0.008
RA(1)
0.380
RA(2)
0.270
RA(3)
0.005
GVSRW
0.985
GVRW
0.939
GVFW
0.086
Calciner (SO3 as Sulphur), %
0.47
0.16
0.044
Kiln feed, %
0.38
0.27
0.005
10/04/2015 02:47:04 288628503.xls Alkali
LU010408-KCP#Ver.1.0**
10/04/2015 02:47:04 288628503.xls Alkali
LU010408-KCP#Ver.1.0**
ALK(4)
0.590
ALC(4)
0.590
GVKA(4)
0.316
GVKA(5)
0.590
GVFA(4)
0.315
GVFA(5)
0.586
GVMA(4)
4.251
GVMA(5)
0.844
GVCA(4)
0.508
GVCA(5)
0.549
ALK(4)
0.236
ALK(5)
0.049
ALC(4)
0.236
ALC(5)
0.049
GVRA(4)
0.316
GVRA(5)
0.590
RA(4)
0.200
RA(5)
0.373
GVKW
1.025
VP
11.61
VAS
19.90
2.00
0.41
0.20
0.37
10/04/2015 02:47:04 288628503.xls Alkali
LU010408-KCP#Ver.1.0**
10/04/2015 02:47:04 288628503.xls Alkali
LU010408-KCP#Ver.1.0**
Page - 15/29
Water Spray System
S.
Description
Kiln
Calciner
String
String
m3/hr
336905
539902
kg/hr
193683
310382
No.
A
Inlet Gas Conditions
Volume flow of gas, wet
Mass flow of gas, wet
Gas temperature
deg.C
305.7
302.2
Gas density, wet
kg/m3
0.575
0.575
Heat capacity of gas
kcal/kg/C
0.263
0.261
Heat content in gas (calc.)
kcal/hr
15547937
24527222
Heat content in gas (diff.)
kcal/hr
15547937
24527222
Error
kcal/hr
0.000
0.000
Water Injection
Volume flow of water
m3/hr
0.00
0.00
Mass flow of water
kg/hr
-2.51
1.49
Water pressure
Bar
14.1
15.8
Water temperature
25
25
Heat capacity of water
Heat content in water
kcal/hr
-63
37
Evaporation of water
kcal/hr
-1353
802
Compressed Air Injection
Volume flow of air
m3/hr
0.0
0.0
Mass flow of air
kg/hr
Air pressure
Bar
7.1
7.1
Air temperature
deg.C
60
60
Air density
kg/m3
8.434
8.434
Heat capacity of air
kcal/kg/C
0.242
0.242
Heat content in air
kcal/hr
Outlet Gas Conditions
Volume flow of gas, wet
m3/hr
343144
544887
Mass flow of gas, wet
kg/hr
193680
310384
Gas temperature
deg.C
305.0
302.0
Gas density, wet
kg/m3
0.564
0.570
Heat capacity of gas
kcal/kg/C
0.263
0.262
Heat content in gas
15549227
24526458
Water Balance
Water In, gas
kg/hr
19196
30757
Water In, spray
kg/hr
-3
Water In, total
kg/hr
19194
30759
Water Out, gas
kg/hr
19194
30759
Water Vapor, PH Exit
kg/kg-dg
0.1100
0.1100
Error
0.000
0.000
10/04/2015 02:47:04 288628503.xls H2O-SprS
deg.C
kcal/kg/C
kcal/hr
kg/hr
LU010522-KCP#Ver.2.3***
Page - 16/29
Cooler Air Flow Calculations : SLC 6-Stage II-String
Flow Analysis
COOLER FANS
FN1
FN2
FN3
FN4
FN5
FN6
FN7
FN8
FN9
FNA
FNB
FNC
FNH
Total
Dry Bulb Temp.
deg.C
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
Wet Bulb Temp.
deg.C
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
Dew Point (F4)
deg.C
22.0
22.0
22.0
22.0
22.0
22.0
22.0
22.0
22.0
22.0
22.0
22.0
22.0
22.0
Dew Point, calc.
deg.C
22.7
22.7
22.7
22.7
22.7
22.7
22.7
22.7
22.7
22.7
22.7
22.7
22.7
22.7
Water Vapor
Avg. Ps
kg/kg-dg 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181 0.0181
mmWG
660
685
866
827
795
788
645
625
640
655
570
515
565
651
tph
0.49
0.51
0.48
0.46
0.66
0.73
1.60
0.76
0.57
1.09
1.32
1.53
0.61
10.81
Gas Flow Rate, dry
tph
27.1
28.0
26.4
25.3
36.5
40.5
88.4
42.0
31.6
60.0
73.1
84.5
33.7
597.0
Gas Flow Rate, dry
kg/min
451
466
440
422
609
675
1474
700
527
1000
1218
1408
561
9950
Gas Flow Rate, dry
kNm /hr
20.9
21.6
20.4
19.6
28.2
31.3
68.4
32.5
24.5
46.4
56.5
65.3
26.0
461.7
Gas Flow Rate, dry
km3/hr
23.3
24.0
22.7
21.8
31.4
34.8
76.0
36.1
27.2
51.6
62.8
72.6
29.0
513.3
Gas Flow Rate, dry
m3/min
388
401
378
363
524
580
1267
602
453
860
1047
1211
483
8556
Moisture, by diff.
Sp. Heat, gas

Heat Content, gas
kcal/kg/C 0.243
Mcal/hr
Fan Speed
rpm
0.243
0.243
0.243
0.243
0.243
0.243
0.243
0.243
0.243
0.243
0.243
0.243
0.243
234
242
228
219
316
350
766
363
274
519
632
731
291
5168
2765
2757
1341
1342
1371
1365
1412
1475
1488
1475
1489
Fan Load
kW
70
69
89
84
104
107
188
90
75
120
144
122
68
1328
Fan Load
amps
108
106
138
130
160
165
291
139
116
185
222
188
105
2053
100
Fan Damper
100
100
100
100
100
100
100
100
100
100
100
100
Sp. Air Consmp.
kg/kg-Clk 0.110
0.113
0.107
0.102
0.148
0.164
0.358
0.170
0.128
0.243
0.296
0.342
0.136
2.417
Sp. Air Consmp.
Nm3/kg-Clk 0.086
0.088
0.084
0.080
0.116
0.128
0.280
0.133
0.100
0.190
0.231
0.267
0.107
1.889
Sp. Air Consmp.
m /kg-Clk 0.095
0.098
0.093
0.089
0.129
0.142
0.311
0.148
0.111
0.211
0.257
0.297
0.118
2.100
374
374
631
631
946
946
1439
507
507
1014
1014
1099
500
9982
399
412
389
373
539
597
1304
619
467
885
1078
1246
497
8804.61
Gas/Mat

*T^2
*T^3
*T^0
*T^1
0.2485
-3.340E-06
4.440E-08
-2.797E-11 5.597E-15 Not used in calc.
*T^4
0.1244
0.000E+00
0.000E+00
0.000E+00 0.000E+00 Not used in calc.
O2
0.2130
7.796E-05
-7.563E-08
4.074E-11 -8.183E-15
CO2
0.1906
1.771E-04
-1.733E-07
9.315E-11 -1.894E-14
N2+Ar
0.2465
-3.284E-06
4.366E-08
-2.750E-11 5.504E-15
H2O,steam
0.4445
2.910E-05
6.887E-08
-3.726E-11 6.472E-15
H2O, liq.
1.0000
Cooler Fans Flow : SLC 6-Stage II-String(with transmeter pezo pressure)

Kiln Output
6035
tpd
Sp. Air Consp.
1.87
Nm3/kg-Clk
Plant Elevation
402.00
Ambient Air
36.0
deg.C
Air Density
1.086
kg/m3
Barometric Press.
9827
I/L Dia
I/L Area
S.
Fan
Fan kW
Fan
Speed (rpm)
Damper
FACTOR
mts +MSL
mmWG
Ps
Ps
Flow (m3/min)
inlet
outlet
Fan
Fan
mmwg
mmwg
Inlet
Outlet
No.
471
m2
Rated
Run
amps
Rated
Run
FN1
0.45
0.159
90
58
85
2900
2663
100
40.56
143.63
660.00
413
398
FN2
0.45
0.159
90
56
82
2900
2616
100
40.56
153.50
685.00
427
411
FN3
0.56
0.246
132
90
132
1450
1376
100
62.81
59.13
866.00
411
388
FN4
0.56
0.246
132
92
134
1450
1407
100
62.81
53.88
827.00
392
372
FN5
0.71
0.396
180
117
171
1480
1411
100
100.97
43.13
795.00
564
537
FN6
0.71
0.396
190
117
172
1480
1394
100
100.97
52.88
788.00
624
595
FN7
0.90
0.636
225
202
296
1485
1492
100
162.24
98.13
645.00
1366
1319
FN8
0.56
0.246
90
1485
95
62.81
142.50
625.00
637
617
FN9
0.56
0.246
90
80
62.81
81.25
640.00
481
465
10
FNA
0.80
0.503
160
138
202
1485
1481
100
128.19
70.38
655.00
914
882
11
FNB
0.80
0.503
160
145
212
1485
1476
100
128.19
102.75
570.00
1104
1074
12
FNC
0.90
0.636
132
1485
100
162.24
84.88
515.00
1270
1242
13
FNH
0.56
0.246
90
76
112
1470
1496
62.81
187.63
565.00
731
712
9335
9012
1485
PLANT : Binani Cement, Sirohi (Rajasthan)

Measured on :
20.02.2003 (10:30-11:30 hrs)
a) Kiln feed
d) DG - Kiln/Cal.
g)U.G.P.(CIS)
415
tph
b) Coal - Kiln/Cal.
39.6/61.4
%/%
e) Hood draft/ESP temp.
665
mm
h) Fan outlet temp
FN1
c:\work\prdn\excel\288628503.xls : ClrF-IL
521/525 rpm
-4/320
45
96
120
156
112
159
172
164
170
c) Gr. load - I/II/III
mmWG/deg.C
f) Gr. DP-I/II/III
deg.C
I)U.G.P.(CFG)
55/60/52 amps
165/145/97mmWG
760 mmWG
143.625
Prodn. Deptt. - Binani Cement Ltd.
FN2
FN3
FN4
FN5
FN6
FN7
FN8
FN9
FNA
FNB
FNC
FNH
c:\work\prdn\excel\288628503.xls : ClrF-IL
146
147
144
137
158
178
160
158
54
52
68
64
55
51
71
58
66
53
62
68
49
47
43
43
43
47
55
50
43
37
33
37
66
64
61
49
55
43
42
43
107
122
122
124
80
80
76
74
139
158
179
152
124
138
130
120
90
100
101
99
67
66
65
62
73
89
107
75
54
53
60
52
118
101
130
135
82
91
80
85
100
105
106
107
63
69
66
63
244
246
205
247
149
139
134
137
153.5
59.125
53.875
43.125
52.875
98.125
142.5
81.25
70.375
102.75
84.875
187.625
Prodn. Deptt. - Binani Cement Ltd.
Page - 17/29
Kiln Radiations : SLC 6-Stage II-String
Amb. Air
31.0
deg.C
Production
6036
tpd
Kiln Inlet
0.85
Kiln Diameter
4.55
mts
Rest Kiln
0.85
Wind Vel., m/s
5.00
Total Radiation
Sp. Radiation
*
4437254
17.64
Emissivity
kcal/hr
kcal/kg-clk
Inclusive of restriction due to kiln tyres and girth gea
5.00
Kiln
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
mts
m2
m2
deg.C
kcal/hr
14.3
1.00
14.3
200
48732
14.3
1.00
14.3
210
52653
14.3
1.00
14.3
183
42408
14.3
1.00
14.3
277
83349
14.3
1.00
14.3
220
56731
14.3
1.00
14.3
102
17214
14.3
1.00
14.3
232
61843
14.3
1.00
14.3
216
55081
14.3
1.00
14.3
230
60974
14.3
1.00
14.3
235
63160
10
14.3
1.00
14.3
239
64940
11
14.3
1.00
14.3
242
66294
12
14.3
1.00
14.3
227
59684
13
14.3
1.00
14.3
216
55081
14
14.3
1.00
14.3
215
54672
15
14.3
1.00
14.3
219
56316
16
14.3
1.00
14.3
222
57566
17
14.3
1.00
14.3
214
54265
18
14.3
1.00
14.3
190
44962
19
14.3
1.00
14.3
180
41335
20
14.3
1.00
14.3
177
40274
21
14.3
1.00
14.3
178
40626
22
14.3
1.00
14.3
201
49118
23
14.3
1.00
14.3
219
56316
24
14.3
1.00
14.3
212
53456
25
14.3
1.00
14.3
201
49118
26
14.3
1.00
14.3
195
46829
27
14.3
1.00
14.3
203
49892
28
14.3
1.00
14.3
251
70454
29
14.3
1.00
14.3
313
103567
30
14.3
1.00
14.3
319
107227
31
14.3
1.00
14.3
245
67664
32
14.3
1.00
14.3
346
124813
Page - 18/29
Kiln Radiations : SLC 6-Stage II-String
Kiln
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
mts
m2
m2
deg.C
kcal/hr
33
14.3
1.00
14.3
90
14045
34
14.3
1.00
14.3
336
118081
35
14.3
1.00
14.3
329
113523
36
14.3
1.00
14.3
332
115461
37
14.3
1.00
14.3
324
110344
38
14.3
1.00
14.3
317
105997
39
14.3
1.00
14.3
330
114167
40
14.3
1.00
14.3
328
112883
41
14.3
1.00
14.3
323
109716
42
14.3
1.00
14.3
321
108466
43
14.3
1.00
14.3
325
110975
44
14.3
1.00
14.3
319
107227
45
14.3
1.00
14.3
318
106611
46
14.3
1.00
14.3
304
98237
47
14.3
1.00
14.3
285
87594
48
14.3
1.00
14.3
113
20228
49
14.3
1.00
14.3
98
16144
50
14.3
1.00
14.3
128
24522
51
14.3
1.00
14.3
160
34483
52
14.3
1.00
14.3
165
36148
53
14.3
1.00
14.3
163
35478
54
14.3
1.00
14.3
129
24817
55
14.3
1.00
14.3
118
21635
56
14.3
1.00
14.3
240
65389
57
14.3
1.00
14.3
245
67664
58
14.3
1.00
14.3
256
72831
59
14.3
1.00
14.3
256
72831
60
14.3
1.00
14.3
85
12760
61
14.3
1.00
14.3
190
44962
62
14.3
1.00
14.3
177
40274
63
14.3
1.00
14.3
174
39224
64
14.3
1.00
14.3
184
42769
65
14.3
1.00
14.3
231
61408
66
14.3
1.00
14.3
249
69517
67
14.3
1.00
14.3
253
71399
68
14.3
1.00
14.3
256
72831
Total/Wt. Avg.
986.3
986.3
229
4437254
Page - 19/29
Kiln String Radiations : SLC 6-Stage II-String

Amb. Air
Production
Total Radiation
Sp. Radiation
**
31.00
deg.C
6036
tpd
Preheater
0.75
kcal/hr
Riser Duct
0.75
2618130**
10.41
Emissivity
kcal/kg-clk
Exclusive of amount as per FLS norms
5.00
KS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-1
m2
m2
deg.C
kcal/hr
Roof
27.4
1.20
32.9
65.0
15536
Vertical Inlet
51.5
1.01
52.0
70.0
27622
Conical Inlet
25.0
1.00
25.0
67.0
12762
Cylindrical Part
122.6
1.00
122.6
56.0
38720
Conical Part
53.7
1.00
53.7
58.0
19331
Material Pipes
11.1
1.01
11.2
175.0
28619
Riser Cylindrical
97.6
1.01
98.6
75.0
57314
Riser Rest
79.1
1.01
79.9
65.0
35751
Total/Wt. Avg.
468.0
475.9
67.2
235656
KS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-2
deg.C
kcal/hr
Roof
26.4
1.20
31.7
75.0
19714
Vertical Inlet
47.7
1.01
48.2
70.0
25703
Conical Inlet
29.7
1.00
29.7
66.0
14560
Cylindrical Part
56.3
1.00
56.3
85.0
42203
Conical Part
53.2
1.00
53.2
65.0
24402
Material Pipes
13.4
1.01
13.5
85.0
11055
Riser Cylindrical
55.9
1.01
56.5
65.0
25803
Riser Rest
86.7
1.01
87.6
71.0
46301
Total/Wt. Avg.
369.3
376.6
71.7
209742
KS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-3
deg.C
kcal/hr
Roof
29.4
1.20
35.3
90.0
29941
Vertical Inlet
52.9
1.01
53.4
90.0
44254
Conical Inlet
33.2
1.00
33.2
70.0
18121
Cylindrical Part
63.2
1.00
63.2
76.0
38643
Conical Part
59.2
1.00
59.2
60.0
22826
Material Pipes
11.3
1.01
11.4
70.0
6662
Riser Cylindrical
48.5
1.01
49.0
120.0
64730
Riser Rest
96.9
1.01
97.9
90.0
78294
Total/Wt. Avg.
394.6
402.6
84.8
303471
Page - 20/29
Kiln String Radiations : SLC 6-Stage II-String
KS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-4
deg.C
kcal/hr
Roof
29.4
1.20
35.3
98.0
34441
Vertical Inlet
52.9
1.01
53.4
75.0
32213
Conical Inlet
33.2
1.00
33.2
70.0
18121
Cylindrical Part
63.2
1.00
63.2
76.0
38643
Conical Part
59.2
1.00
59.2
125.0
82517
Material Pipes
8.3
1.01
8.4
162.0
19313
Riser Cylindrical
41.0
1.01
41.4
100.0
41384
Riser Rest
97.0
1.01
98.0
110.0
108700
Total/Wt. Avg.
384.2
392.1
97.6
375334
KS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-5
deg.C
kcal/hr
Roof
29.4
1.20
35.3
100.0
35585
Vertical Inlet
52.9
1.01
53.4
60.0
20732
Conical Inlet
33.2
1.00
33.2
75.0
20601
Cylindrical Part
63.2
1.00
63.2
80.0
42352
Conical Part
59.2
1.00
59.2
80.0
39825
Material Pipes
67.4
1.01
68.1
150.0
124992
Riser Cylindrical
62.2
1.01
62.8
80.0
42113
Riser Rest
96.9
1.10
106.6
130.0
153133
Total/Wt. Avg.
464.4
481.8
99.9
479334
KS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-6
deg.C
kcal/hr
Roof
27.3
1.20
32.8
70.0
17896
Vertical Inlet
69.2
1.01
69.9
75.0
41469
Conical Inlet
33.2
1.01
33.5
115.0
42339
Cylindrical Part
63.2
1.00
63.2
98.0
59666
Conical Part
67.3
1.00
67.3
82.0
46920
Material Pipes
54.8
1.01
55.3
103.0
57059
Total/Wt. Avg.
315.0
322.0
89.4
265350
Kiln
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Riser Duct
deg.C
kcal/hr
Rectangular Pipe
199.6
1.20
239.5
130.0
330299
Smoke Chamber
101.0
1.20
121.2
160.0
239268
Rest
183.0
1.15
210.5
96.0
179676
Total/Wt. Avg.
483.6
571.2
123.8
749243
Page - 21/29
Calciner String Radiations : SLC 6-Stage II-String
Amb. Air
31.00
Production
6036
Total Radiation
Sp. Radiation
***
deg.C
***
3212876
12.77
Emissivity
tpd
Preheater
0.75
kcal/hr
Calciner
0.75
kcal/kg-clk
Exclusive of amount as per FLS norm
5.00
CS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-1
m2
m2
deg.C
kcal/hr
Roof
37.0
1.20
44.4
70.0
23806
Vertical Inlet
69.4
1.01
70.1
75.0
41582
Conical Inlet
34.6
1.00
34.6
75.0
21416
Cylindrical Part
168.1
1.00
168.1
86.0
120752
Conical Part
73.0
1.01
73.7
90.0
59944
Material Pipes
7.7
1.01
7.8
205.0
25842
Riser Cylindrical
109.7
1.01
110.8
92.0
91317
Riser Rest
108.4
1.10
119.2
78.0
73611
Total/Wt. Avg.
607.9
628.7
84.5
458270
CS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-2
deg.C
kcal/hr
Roof
35.8
1.20
43.0
72.0
24340
Vertical Inlet
64.1
1.01
64.7
75.0
38588
Conical Inlet
41.0
1.00
41.0
75.0
25117
Cylindrical Part
78.3
1.00
78.3
72.0
42789
Conical Part
65.8
1.01
66.5
70.0
34774
Material Pipes
11.3
1.01
11.4
98.0
11914
Riser Cylindrical
50.1
1.01
50.6
78.0
32851
Riser Rest
118.0
1.10
129.8
65.0
56424
Total/Wt. Avg.
464.4
485.3
71.7
266797
CS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-3
deg.C
kcal/hr
Roof
39.2
1.20
47.0
83.0
34207
Vertical Inlet
70.1
1.01
70.8
85.0
52369
Conical Inlet
45.1
1.00
45.1
82.0
32194
Cylindrical Part
86.5
1.00
86.5
75.0
50680
Conical Part
72.3
1.01
73.0
80.0
48520
Material Pipes
12.2
1.01
12.3
125.0
18735
Riser Cylindrical
47.2
1.01
47.7
80.0
32485
Riser Rest
132.3
1.10
145.5
86.0
105389
Total/Wt. Avg.
504.9
528.0
83.0
374579
Page - 22/29
Calciner String Radiations : SLC 6-Stage II-String
CS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-4
m2
m2
deg.C
kcal/hr
Roof
39.2
1.20
47.0
83.0
34207
Vertical Inlet
70.1
1.01
70.8
85.0
52369
Conical Inlet
45.1
1.00
45.1
82.0
32194
Cylindrical Part
86.5
1.00
86.5
75.0
50680
Conical Part
72.3
1.01
73.0
80.0
48520
Material Pipes
10.5
1.01
10.6
125.0
16264
Riser Cylindrical
47.2
1.01
47.7
80.0
32485
Riser Rest
132.3
1.10
145.5
86.0
105389
Total/Wt. Avg.
503.2
526.3
82.9
372108
CS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-5
m2
m2
deg.C
kcal/hr
Roof
39.2
1.20
47.0
92.0
40716
Vertical Inlet
70.1
1.01
70.8
85.0
52369
Conical Inlet
45.1
1.00
45.1
90.0
37726
Cylindrical Part
86.5
1.00
86.5
85.0
63243
Conical Part
72.3
1.01
73.0
85.0
53915
Material Pipes
107.4
1.01
108.5
152.0
198686
Riser Cylindrical
83.0
1.01
83.8
90.0
67656
Riser Rest
132.3
1.10
145.5
95.0
124604
Total/Wt. Avg.
635.9
660.3
99.7
638915
CS
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cyclone-6
deg.C
kcal/hr
Roof
36.4
1.20
43.7
145.0
77845
Vertical Inlet
90.7
1.01
91.6
95.0
80483
Conical Inlet
45.1
1.01
45.6
85.0
34574
Cylindrical Part
86.5
1.00
86.5
93.0
73606
Conical Part
72.3
1.00
72.3
175.0
168377
Material Pipes
31.1
1.01
31.4
175.0
76140
Total/Wt. Avg.
362.1
371.0
121.6
511027
Calciner
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
deg.C
kcal/hr
Roof
31.2
1.10
34.3
125.0
49272
Cal.-C6 Duct
121.3
1.20
145.6
100.0
135579
Cylindrical Part
357.0
1.00
357.0
85.0
241101
Bottom Cone
51.3
1.00
51.3
115.0
63260
Bend Area
67.3
1.10
74.0
125.0
101967
Total/Wt. Avg.
628.1
662.2
97.2
591179
Page - 23/29
Cooler.Hood.TAD Radiations : SLC 6-Stage II-String
Amb. Air
31.00
Production
6036
deg.C
tpd
****
Emissivity
Cooler
0.75
Total Radiation
Sp. Radiation
****
1605018**** kcal/hr
6.38
Kiln Hood
0.75
kcal/kg-clk
Exclusive of amount as per FLS nor
5.00
Grate
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Cooler
m2
m2
deg.C
kcal/hr
Front-Kiln End
14.6
1.30
19.0
100.0
19852
Grate1-L/Side
33.3
1.10
36.6
102.0
38060
Grate1-Roof
42.8
1.50
64.2
112.0
75007
Grate1-R/Side
33.3
1.10
36.6
115.0
46023
Grate2-L/Side
22.3
1.10
24.5
95.0
23256
Grate2-Roof
28.6
1.50
42.9
95.0
39360
Grate2-R/Side
22.3
1.10
24.5
96.0
23656
Grate3-L/Side
23.3
1.10
25.6
98.0
25492
Grate3-Roof
29.9
1.50
44.9
92.0
38928
Grate3-R/Side
23.3
1.10
25.6
110.0
30646
Back End
13.4
1.10
14.7
122.0
21371
Total/Wt. Avg.
287.1
359.3
103.1
381650
Kiln
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Hood
deg.C
kcal/hr
Right Side
13.8
1.50
20.7
106.0
23636
Left Side
27.5
1.50
41.3
95.0
37932
Kiln Side
12.0
1.50
18.0
150.0
35405
Burner Side
18.0
1.50
27.0
115.0
34510
Roof
53.5
1.50
80.3
115.0
96572
Total/Wt. Avg.
124.8
187.2
113.0
228056
TA Duct &
Surface Area
Corr. Factor
Corr. Area
Temperature
Radiation
Settling Chamb.
deg.C
kcal/hr
Connecting Duct
57.0
1.10
62.7
133.0
95945
Tert. Pipe
582.8
1.00
582.8
143.4
899367
Total/Wt. Avg.
639.8
645.5
142.4
995312
Wt. Avg.
Dia.
<= 3.05
>3.05
2859
4.55
39811
48732
3002
4.55
43473
52653
2616
4.55
33962
42408
3960
4.55
72754
83349
3145
4.55
47307
56731
1458
4.55
11897
17214
3316
4.55
52142
61843
3088
4.55
45752
55081
3288
4.55
51318
60974
3359
4.55
53393
63160
3416
4.55
55086
64940
3459
4.55
56376
66294
3245
4.55
50096
59684
3088
4.55
45752
55081
3073
4.55
45368
54672
3130
4.55
46915
56316
3173
4.55
48095
57566
3059
4.55
44985
54265
2716
4.55
36314
44962
2573
4.55
32977
41335
2530
4.55
32007
40274
2544
4.55
32329
40626
2873
4.55
40169
49118
3130
4.55
46915
56316
3030
4.55
44226
53456
2873
4.55
40169
49118
2787
4.55
38042
46829
2902
4.55
40892
49892
3588
4.55
60350
70454
4474
4.55
92386
103567
4560
4.55
95958
107227
3502
4.55
57683
67664
4946
4.55
113176
124813
1286
4.55
9369
14045
4803
4.55
106575
118081
4703
4.55
102113
113523
4746
4.55
104010
115461
4631
4.55
99004
110344
4531
4.55
94758
105997
4717
4.55
102743
114167
4689
4.55
101486
112883
4617
4.55
98390
109716
4588
4.55
97169
108466
4646
4.55
99621
110975
4560
4.55
95958
107227
4546
4.55
95357
106611
4345
4.55
87194
98237
4074
4.55
76860
87594
1615
4.55
14375
20228
1401
4.55
11034
16144
1830
4.55
18006
24522
2287
4.55
26762
34483
2359
4.55
28260
36148
2330
4.55
27656
35478
1844
4.55
18258
24817
1687
4.55
15552
21635
3431
4.55
55514
65389
3502
4.55
57683
67664
3659
4.55
62627
72831
3659
4.55
62627
72831
1215
4.55
8371
12760
2716
4.55
36314
44962
2530
4.55
32007
40274
2487
4.55
31050
39224
2630
4.55
34293
42769
3302
4.55
51729
61408
3559
4.55
59453
69517
3616
4.55
61255
71399
3659
4.55
62627
72831
3794136
4437254
15.09
17.64
225563
2137
6.470
9795
15536
3641
8.138
18344
27622
1675
5.642
7988
12762
6866
12.494
25143
38720
3115
8.269
12085
19331
1962
3.778
22258
28619
7393
11.203
40379
57314
5193
10.086
23799
35751
159792
235656
31981
2376
6.351
12977
19714
3372
7.832
16991
25703
1960
6.149
9168
14560
4786
8.467
29830
42203
3458
8.230
15848
24402
1150
4.151
7171
11055
3670
8.479
16819
25803
6217
10.559
31865
46301
140668
209742
26990
3175
6.702
20923
29941
4809
8.248
31686
44254
2324
6.502
11709
18121
4803
8.970
26624
38643
3552
8.682
14527
22826
799
3.812
4025
6662
5878
7.897
49710
64730
8808
11.163
58041
78294
217244
303471
34148
3457
6.702
24639
34441
4007
8.248
21886
32213
2324
6.502
11709
18121
4803
8.970
26624
38643
7400
8.682
64659
82517
1358
3.267
14516
19313
4141
7.261
30044
41384
10777
11.169
84851
108700
278928
375334
38268
3528
6.702
25597
35585
3206
8.248
13111
20732
2490
6.502
13600
20601
5056
8.970
29622
42352
4736
8.682
27747
39825
10211
9.310
102863
124992
5026
8.944
29444
42113
13857
11.650
124894
153133
366878
479334
48109
2293
6.458
11553
17896
5242
9.433
28629
41469
3856
6.534
31501
42339
6194
8.970
44138
59666
5519
9.257
33173
46920
5701
8.395
42444
57059
191438
265350
28804
31138
17.463
280652
330299
19392
12.422
205300
239268
20203
16.369
141331
179676
627284
749243
7.88
10.41
70733
3108
7.519
15659
23806
5257
9.447
28712
41582
2595
6.637
14173
21416
14457
14.630
91165
120752
6636
9.689
43725
59944
1594
3.147
20488
25842
10193
11.877
68572
91317
9301
12.322
53040
73611
335533
458270
53141
3093
7.396
16118
24340
4856
9.079
26519
38588
3075
7.225
16795
25117
5638
9.985
29378
42789
4652
9.199
23438
34774
1118
3.812
7971
11914
3947
8.027
22508
32851
8437
12.856
38667
56424
181394
266797
34816
3904
7.739
23762
34207
6018
9.495
37514
52369
3698
7.578
22230
32194
6488
10.495
35432
50680
5842
9.642
34226
48520
1540
3.961
13458
18735
3814
7.791
22344
32485
12516
13.612
78924
105389
267890
374579
43820
3904
7.739
23762
34207
6018
9.495
37514
52369
3698
7.578
22230
32194
6488
10.495
35432
50680
5842
9.642
34226
48520
1326
3.675
11583
16264
3814
7.791
22344
32485
12516
13.612
78924
105389
266015
372108
43605
4328
7.739
29113
40716
6018
9.495
37514
52369
4059
7.578
26746
37726
7353
10.495
45832
63243
6207
9.642
38691
53915
16488
11.752
167799
198686
7545
10.331
49715
67656
13825
13.612
95799
124604
491209
638915
65822
6334
7.458
62155
77845
8703
10.800
60303
80483
3872
7.616
24135
34574
8045
10.495
54663
73606
12653
9.595
143544
168377
5497
6.324
62363
76140
407164
511027
45102
4290
6.610
37485
49272
14556
13.614
105608
135579
30345
21.320
189156
241101
5900
8.082
48192
63260
9254
9.709
80857
101967
461298
591179
9.58
12.77
64344
1898
4.916
13771
19852
3736
6.829
27582
38060
7190
9.041
57471
75007
4212
6.829
34411
46023
2330
5.589
16148
23256
4076
7.391
28240
39360
2355
5.589
16474
23656
2512
5.713
17900
25492
4126
7.557
27758
38928
2819
5.713
22198
30646
1798
4.332
15411
21371
277362
381650
37053
2194
5.134
16744
23636
3919
7.247
27154
37932
2700
4.787
27199
35405
3105
5.863
25364
34510
9229
10.108
75389
96572
171850
228056
21147
8339
8.935
76522
95945
83569
27.240
813103
899367
889625
995312
5.32
6.38
91908
CCR Mimic - PR_W103 Preheater, Calciner & Kiln Feed
10/04/2015 02:47:04 288628503.xls Aux-Pag
Page - 24/29
LU010519-KCP#Ver.1.2*
CCR Mimic - PR_W104 Kiln & Kiln Auxiliaries
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Page - 25/29
LU010519-KCP#Ver.1.2*
CCR Mimic - PR_W105 Cooler
10/04/2015 02:47:04 288628503.xls Aux-Pag
Page - 26/29
LU010519-KCP#Ver.1.2*
CCR Mimic - PR_W109 Cooler Parameters
10/04/2015 02:47:04 288628503.xls Aux-Pag
Page - 27/29
LU010519-KCP#Ver.1.2*
CCR Mimic - Kiln Shell Scanner
10/04/2015 02:47:04 288628503.xls Aux-Pag
Page - 28/29
LU010519-KCP#Ver.1.2*
Give command to Printer for Pages 1 to 5
10/04/2015 02:47:04 288628503.xls Aux-Pag
LU010519-KCP#Ver.1.2*
sheet 1 of 5
PROCESS, EFFICIENCY & PERFORMANCE MONITORING
Section : KILN & COOLER - 6 Stage II String SLC
Time :
Date :
Site Conditions & Constants :

Plant Elevation
mts +MSL
Ambient Air DBT / WBT
deg.C
Pitot Constant (S-Type : L=01m)
0.883
(P.S. No. 601)
Pitot Constant (S-Type : L=02m)
0.847
(P.S. No. V422)
Pitot Constant (L-Type : L=01/02m)
1.000
Process Parameters :
Clinker Prodn., tpd
Kiln Feed Temp., deg.C
Kiln/Cal. Coal Feed Rate, tph
Kiln I/L O2, %
Burner Axial/Radial Area, m2
Cal. O/L O2, %
Water in Cooler (3rd Gr.), m3/hr
KF Residue +90/+212 m, %
Water Spray (ESP I/L), m3/hr
ESP I/L Temp./Draft, deg.C/mmWG
Clinker Temp. (Cooler O/L), deg.C
Sec./Tert. Air Temp., deg.C
Raw Mix / Clinker / Coal Parameters :

Raw Mix
Clinker
Coal (ADB)
Coal Ash
S/A, %
SiO2, %
Carbon, %
SiO2, %
F/C, %
Al2O3, %
Hydrogen, %
Al2O3, %
M/LOI, %
Fe2O3, %
Nitrogen, %
Fe2O3, %
K/N, %
CaO, %
Sulphur, %
CaO, %
SO3, %
MgO, %
Oxygen, %
MgO, %
CC/MC, %
S, %
Ash, %
S, %
S(pyr.), %
K2O, %
Moisture, %
K2O, %
C/F H2O, %
Na2O, %
VM, %
Na2O, %
CCR Parameters :
Kiln Speed, rpm
ESP Fan Load/Speed, kW/%
CFG Gr.I Static Pressure, mmWG
KS/CS O2, %/%
KF Rate / Dosing Valve, tph/%
KS/CS CO, %/%
KF Elev. Load, kW/kW
Kiln Inlet O2/CO, %/%
KS/CS Diversion, %/%
Gr.1 Chb.1/2/3 DP, mmWG
Coal Screw Speed, rpm/rpm
Gr.1/2/3 Speed, spm
KS Fan Load/Speed, kW/%
Gr.1/2/3 Load, amps
CS Fan Load/Speed, kW/%
BZ Temp./Kiln Torque, deg.C/%
sheet 2 of 5
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
Flow Measurement & Gas Analysis :

Flow/Gas Analysis
Tapping Location
Dry Bulb Temperature
deg.C
Wet Bulb Temperature
deg.C
Static Pressure
"WG
Dynamic Pressure
"WG
O2, dry - OPTIFUEL250
vol.%, d
O2, dry - ORSAT
vol.%, d
CO2, dry - ORSAT
vol.%, d
Time Period
KS Fan
CS Fan
PA Fan
Cooler
CTA
CTA
Inlet
Inlet
Outlet
ESP Stack
Kiln
Cal.
hh.mm - hh.mm
sheet 3 of 5
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
Flow Measurement & Gas Analysis :

Flow/Gas Analysis
Tapping Location
deg.C
deg.C
Static Pressure
"WG
Dynamic Pressure
"WG
471FN1
471FN2
471FN3
471FN8
471FN9
471FNA
471FN5
471FN6
471FNC
471FNH
471FN7
amps
Fan Load
rpm
Fan Speed
hh.mm - hh.mm
Time Period
Flow/Gas Analysis
Tapping Location
deg.C
deg.C
Static Pressure
"WG
Dynamic Pressure
"WG
471FNB
amps
Fan Load
rpm
Fan Speed
Time Period
471FN4
hh.mm - hh.mm
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
Radiations
Kiln Inlet
Rest Kiln
0.85
0.85
Kiln
Length
Temp.
mts
deg.C
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
sheet 4 of 5
Preheater 0.75
Riser Duct 0.75
Kiln String
Area
Temp.
deg.C
Cyclone-1
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-2
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-3
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-4
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-5
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-6
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Kiln Riser Duct
Rect. Pipe
Smk. Chmb.
Rest
Kiln (contd.)
63
64
65
66
67
68
10/04/2015 02:47:04 288628503.xls Mon-Form
Preheater 0.75
Riser Duct 0.75
Cal. String
Area
Temp.
deg.C
Cyclone-1
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-2
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-3
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-4
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-5
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Riser Cyl.
Riser Rest
Cyclone-6
Roof
Vert. Inlet
Con. Inlet
Cyl. Part
Con. Part
Mat. Pipes
Calciner
Roof
Cyl. Part
Con.Part
Bend.
Rest
Cooler
0.75
Kiln Hood 0.75
Cooler
Area
Temp.
deg.C
Front-Kiln/S
Gr.1-L/Side
Gr.1-Roof
Gr.1-R/Side
Gr.2-L/Side
Gr.2-Roof
Gr.2-R/Side
Gr.3-L/Side
Gr.3-Roof
Gr.3-R/Side
Back End
Hood
Right Side
Left Side
Kiln Side
Burner Side
Roof
TAD
Conn. Duct
Tert. Pipe
LU990611-RMP#Ver.1.3*
sheet 5 of 5
PH Temperature & Draft Profile
mmWG
mmWG
deg.C
deg.C
K-1
C-1
mmWG
mmWG
deg.C
deg.C
mmWG
deg.C
K-2
C-2
mmWG
deg.C
mmWG
mmWG
deg.C
deg.C
K-3
C-3
mmWG
mmWG
deg.C
deg.C
mmWG
deg.C
K-4
C-4
mmWG
deg.C
mmWG
mmWG
deg.C
deg.C
K-5
C-5
mmWG
mmWG
deg.C
deg.C
mmWG
mmWG
deg.C
K-6
deg.C
mmWG
C-6/Cal.
deg.C
mmWG
mmWG
deg.C
deg.C
Kiln I/L Draft
mmWG
Cal. I/L Draft
mmWG
Kiln I/L Temp.
deg.C
Cal. I/L Temp.
deg.C
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
Kiln String Fan
Calciner String Fan
Cooler ESP Fan
PA Fan
2800
3000
4200
400
0.97
2716
2.83
2910
15
3.87
4074
372
0.92
2576
3.00
2760
17
4.12
3864
300
0.85
2380
11
3.32
2550
21
4.58
3570
100
0.77
2156
11
3.32
2310
24
4.90
3234
28
0.66
1848
11
3.32
1980
23
4.80
2772
372
0.34
952
11
3.32
1020
22
4.69
1428
300
0.23
644
12
3.46
690
13
3.61
966
100
0.15
420
3.00
450
10
3.16
630
28
0.08
224
3.00
240
17
4.12
336
0.03
84
3.00
90
11
3.32
126
10 3.1559028
9.9597224
16.950884
10/04/2015 02:47:04 288628503.xls Mon-Form
4.1171451
16.950884
LU990611-RMP#Ver.1.3*
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
PA Fan
400
10.00
11.00
10.00
8.00
10.00
11.00
10.00
9.00
9.875
10/04/2015 02:47:04 288628503.xls Mon-Form
LU990611-RMP#Ver.1.3*
Coolax Cooler : 1284-3ME-IN

F.L. Smidth & Co. A/S
Grate-I (CFG)
471FN2
450-600 mmWG
471FNH
7.12
262.08
308.68
m2
m3/min
m3/min
471FN4
450-600 mmWG
471FN7
35.64
990.10
1164.80
m2
m3/min
m3/min
471FN6
Fan
471FN1
471FN2
471FN3
471FN4
471FN5
471FN6
471FNH
471FN7
471FN8
471FN9
471FNA
471FNB
471FNC
Grate-II (RFT)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
Vol. Flow,
design
Density
m3/min
kg/m3
374
700-800 mmWG
Grate Area =
Min. Flow =
Nor. Flow =
471FN1
3.56
273.73
320.33
m2
m3/min
m3/min
600-700 mmWG
450-550 mmWG
471FN3
7.13
436.81
512.53
471FN9
7.09
349.45
407.70
m2
m3/min
m3/min
471FNA
11.81
693.07
815.40
500-600 mmWG
4665
471FN5
10.69
646.48
762.97
m2
m3/min
m3/min
Speed
Grate
Plates
mmWG
kW
rpm
nos.
1.04
45
1000
83
2900
36
374
1.04
45
1000
83
2900
36
631
631
1.04
1.04
45
45
900
900
122
122
1450
1450
72
72
946
1.04
45
800
165
1480
108
946
1.04
45
800
165
1480
108
500
1439
1.04
1.04
45
45
300
700
90
225
1470
1485
Press. Fan
Press. Fan
507
1.04
45
700
76
1485
72
507
1.04
45
700
76
1485
72
1014
1014
1.04
1.04
45
45
600
600
136
136
1485
1485
120
168
1099
1.04
45
500
123
1485
9982
Fan
Vol. flow,
design
1602
Miscellaneous Fans
Density Temp. D.P.
Power,
min.
m3/min
kg/m3
Cooler
Vent Fan
12370
Primary
176
144
1008
Speed
Grate
Plates
mmWG
kW
rpm
nos.
0.56
320
150
455
590
nil
1.04
45
160
75
2980
nil
m2
m3/min
m3/min
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
450-550 mmWG
471FN8
7.09
349.45
407.70
Air Fan
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
Grate
I
II
III
Total
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
m3/min
400-500 mmWG
471FNB
16.54
693.07
815.40
471FNC
14.18
739.67
873.63
Cooler Grates
Length Area Power Plates
Rows
mts
m2
kW
nos.
nos.
11.88
7.26
8.30
27.44
43.01
26.28
30.05
99.33
60
45
45
432
264
312
1008
36
22
26
84
Length of one grate plate, eff = 330.0

Width of one grate plate, eff. = 298.0
Area of one grate plate, eff. = ###
Width of cooler, eff.
= 3.62
mm
mm
Mass flow rate, normal

Grate area
Specific load
t/24h
= 4750
= 99.33
= 47.82
cm2
mts
m2
t/d/m2
1. Depending upon the particle size distribution of the clinker, the expected air load for normal operation corresponds to about :
a) ~90 kg/m2/min for 1st/2nd part of Grate-I
c) ~45 kg/m2/min for 1st Sealing Air Fan
e) ~55 kg/m2/min for Grate-II
b) ~80 kg/m2/min for 3rd part of Grate-I
d) ~35 kg/m2/min for 2nd Sealing Air Fan
f) ~50 kg/m2/min for Grate-III
2. Minimum air flow rates are about 85% of the normal flow rates.
m2
m3/min
m3/min
300-400 mmWG
Norms :
10/04/2015 02:47:04 288628503.xls Cooler-Pic
m2
m3/min
Grate-III (RFT)
Total
m3/min
m3/min
400-500 mmWG
Cooler Fans
Temp. D.P.
Power,
min.
o
m2
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
m2
m3/min
m3/min
Coolax Cooler : 1284-3ME-IN

Grate-II (RFT)
11
471FN1
471FN2
Grate Area =
723 mm WG
3.6 m2
Min. Flow =
244 m3/min
Nor. Flow =
287 m3/min
Nor. Pr. =
723 mm WG
3.6 m2
CIS
244.29 m3/min
287.4 m3/min
471FN4
765 mm WG
6.5 m2
498 m3/min
586 m3/min
471FN9
615 mm WG
13 m2
425 m3/min
500 m3/min
471FNH
530 mm WG
21.38 m2
431 m3/min
507 m3/min
471FN6
680 mm WG
10.69 m2
646.48 m3/min
762.97 m3/min
Fan
471FN1
471FN2
471FN3
471FN4
471FN9
471FN5
471FN6
471FNH
471FN7
471FN8
471FNA
471FNB
471FNC
Total
Fan
Cooler
Vent Fan
Primary
Air Fan
471FNA
1
2
3
4
5
6
7
8
9
10
11
1
2
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
Grate-I (CFG)
Vol. Flow,
design
Density
m3/min
kg/m3
373
525 mm WG
7.09 m2
532 m3/min
626 m3/min
471FN3
765 mm WG
6.5 m2
498 m3/min
586 m3/min
471FN7
375 mm WG
11.81 m2
1065 m3/min
1253 m3/min
1
6
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
471FN5
680 mm WG
10.69 m2
646.48 m3/min
762.97 m3/min
Speed
Grate
Plates
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
mmWG
kW
rpm
nos.
1.04
45
1000
83
2900
27
373
631
1.04
1.04
45
45
1000
900
83
122
2900
1450
27
60
631
1.04
45
900
122
1450
60
500
946
1.04
1.04
45
45
800
800
76
165
1485
1480
Press. Fan
108
946
1.04
45
800
165
1480
108
507
1.04
45
700
90
1470
Press. Fan
1439
507
1.04
1.04
45
45
700
700
225
76
1485
1485
72
72
Grate
1014
1.04
45
600
136
1485
120
1446
1.04
45
500
136
1485
168
1099
10413
1.04
45
500
123
1602
1485
144
822
CIS
I
II
III
Total
Speed
Grate
Plates
Vol. flow,
design
Miscellaneous Fans
Density Temp.
D.P.
Power,
min.
m3/min
kg/m3
mmWG
kW
rpm
nos.
12370
0.56
320
150
455
590
nil
176
1.04
45
160
75
2980
nil
471FN8
450 mm WG
7.09 m2
532 m3/min
626 m3/min
Grate-III (RFT)
Cooler Fans
Temp.
D.P.
Power,
min.
o
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
471FNB
300 mm WG
16.54 m2
693.07 m3/min
815.40 m3/min
471FNC
300 mm WG
14.18 m2
739.67 m3/min
873.63 m3/min
Cooler Grates
Length Area Power Plates
Rows
mts
m2
kW
nos.
nos.
2.4
9.57
7.26
8.58
27.81
6.48
34.64
26.28
31.06
98.46
60
45
45
-
54
348
264
312
924
6
29
22
26
83

= 3.62
mm

Grate area
Specific load
t/24h
= 6100
= 98.46
= 61.95
mm
cm2
mts
m2
t/d/m2
Norms :
10/04/2015 02:47:05 288628503.xls Cooler-Pic (2)
10/04/2015 02:47:05 288628503.xls Cooler-Pic (2)
Coolax Cooler : 1284-3ME-IN (Modify with CIS )

Grate-II (RFT)
11
471FN1
471FN2
Grate Area =
723 mm WG
3.24 m2
Min. Flow =
244 m3/min
Nor. Flow =
287 m3/min
Nor. Pr. =
723 mm WG
3.24 m2
CIS
244.29 m3/min
471FNA
287.4 m3/min
471FN4
765 mm WG
6.5 m2
498 m3/min
586 m3/min
471FN9
615 mm WG
13 m2
425 m3/min
500 m3/min
471FNH
530 mm WG
21.38 m2
431 m3/min
507 m3/min
471FN6
680 mm WG
10.69 m2
646.48 m3/min
762.97 m3/min
Fan
471FN1
471FN2
471FN3
471FN4
471FN9
471FN5
471FN6
471FNH
471FN7
471FN8
471FNA
471FNB
471FNC
1
2
3
4
5
6
7
8
9
10
11
1
2
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Density
m3/min
kg/m3
373
471FN3
765 mm WG
6.5 m2
498 m3/min
586 m3/min
471FN7
375 mm WG
11.81 m2
1065 m3/min
1253 m3/min
471FN5
680 mm WG
10.69 m2
646.48 m3/min
762.97 m3/min
Cooler Fans
Temp.
D.P.
Power,
min.
Speed
Grate
Plates
rpm
nos.
1.04
45
1000
83
2900
27
373
1.04
45
1000
83
2900
27
631
631
1.04
1.04
45
45
900
900
122
122
1450
1450
66
66
500
1.04
45
800
76
1485
Press. Fan
946
946
1.04
1.04
45
45
800
800
165
165
1480
1480
108
108
507
1.04
45
700
90
1470
Press. Fan
1439
1.04
45
700
225
1485
72
507
1014
1.04
1.04
45
45
700
600
76
136
1485
1485
72
120
1446
1.04
45
500
136
1485
168
1099
1.04
45
500
123
1485
1602
Miscellaneous Fans
Density Temp.
D.P.
Power,
min.
m3/min
kg/m3
12370
176
144
978
Speed
Grate
Plates
mmWG
kW
rpm
nos.
0.56
320
150
455
590
nil
1.04
45
160
75
2980
nil
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
Grate
CIS
I
II
III
Total
471FN8
450 mm WG
7.09 m2
532 m3/min
626 m3/min
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
Cooler Grates
Area
Plates
471FNB
300 mm WG
16.54 m2
693.07 m3/min
815.40 m3/min
471FNC
300 mm WG
14.18 m2
739.67 m3/min
873.63 m3/min
Rows
m2
nos.
nos.
6.48
34.22
25.96
30.68
97.35
54
348
264
312
978
6
29
22
26
83

= 3.62
mm

Grate area
Specific load
t/24h
Norms :
Note :
First 07 rows+1(Zero) Row = Total Eight Rows of CFG replaced with CIS (06 Rows) in the month of Jun -2001
10/04/2015 02:47:05 288628503.xls Cooler-Pic (3)
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
Grate-III (RFT)
kW
Vol. flow,
design
Air Fan
532 m3/min
626 m3/min
mmWG
Fan
Primary
525 mm WG
7.09 m2
10413
Vent Fan
Grate-I (CFG)
Vol. Flow,
design
Total
Cooler
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
1
6
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
= 6100
= 97.35
= 62.66
mm
cm2
mts
m2
t/d/m2
10/04/2015 02:47:05 288628503.xls Cooler-Pic (3)
Coolax Cooler : 1284-3ME-IN ( Modify With CIS )

Grate-II (RFT)
11
471FN1
471FN2
Grate Area =
1000 mm WG
3.24 m2
Op. Flow =
373 m3/min
Nor. Pr. =
1000 mm WG
3.24 m2
373 m3/min
CIS
471FNA
471FN4
900 mm WG
6.5 m2
631 m3/min
471FN9
800 mm WG
13 m2
500 m3/min
471FNH
700 mm WG
21.38 m2
507 m3/min
471FN6
800 mm WG
10.69 m2
946 m3/min
Fan
471FN1
471FN2
471FN3
471FN4
471FN9
471FN5
471FN6
471FNH
471FN7
471FN8
471FNA
471FNB
471FNC
1
2
3
4
5
6
7
8
9
10
11
1
2
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
532 m3/min
626 m3/min
471FN3
900 mm WG
6.5 m2
631 m3/min
471FN7
375 mm WG
11.81 m2
1065 m3/min
1253 m3/min
m3/min
373
kg/m3
1.04
471FN5
800 mm WG
10.69 m2
946 m3/min
Grate
Plates
C
45
mmWG
1000
kW
83
rpm
2900
nos.
27
373
1.04
45
631
1.04
45
1000
83
2900
27
900
122
1450
66
631
500
1.04
1.04
45
45
900
800
122
76
1450
1485
66
Press. Fan
946
946
1.04
45
800
165
1480
108
1.04
45
800
165
1480
108
507
1439
1.04
1.04
45
45
700
700
90
225
1470
1485
Press. Fan
72
507
1.04
45
700
76
1485
72
1014
1446
1.04
1.04
45
45
600
500
136
136
1485
1485
120
168
1099
1.04
45
500
123
1485
Vol. flow,
design
1602
Miscellaneous Fans
Density Temp.
D.P.
Power,
min.
144
978
Speed
Grate
Plates
m3/min
kg/m3
mmWG
kW
rpm
nos.
12370
0.56
320
150
455
590
nil
176
1.04
45
160
75
2980
nil
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
471FN8
450 mm WG
7.09 m2
532 m3/min
626 m3/min
Grate-III (RFT)
Speed
Fan
Air Fan
525 mm WG
7.09 m2
Cooler Fans
Temp.
D.P.
Power,
min.
Density
10413
Primary
Grate-I (CFG)
Vol. Flow,
Operating
Total
Cooler
Vent Fan
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
1
6
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
Grate
CIS
I
II
III
Total
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
M
F
Cooler Grates
Area
Plates
471FNB
300 mm WG
16.54 m2
693.07 m3/min
815.40 m3/min
471FNC
300 mm WG
14.18 m2
739.67 m3/min
873.63 m3/min
Rows
m2
nos.
nos.
6.48
34.22
25.96
30.68
97.35
54
348
264
312
978
6
29
22
26
83

= 3.62
mm

Grate area
Specific load
t/24h
= 6100
= 97.35
= 62.66
mm
cm2
mts
m2
t/d/m2
Norms :
10/04/2015 02:47:05 288628503.xls Cooler-Pic Op.
Original
Option 1
Option 2
Option 3
0.769824
0.805332
0.693876
0.616116
1100
1100
1100
1100
23.814967
22.764936
26.421624
29.756297
10/04/2015 02:47:06 288628503.xls Cooler-Pic Op.
10/04/2015 02:47:06 288628503.xls Cooler-Pic Op.
10/04/2015 02:47:06 288628503.xls Cooler-Pic Op.
Flow
6
400
60
0
0
0
0
0
0
0
0
0
0
300
120
400
100
400
100
400
100
400
80
0
0
300
120
300
120
300
120
300
120
400
100
400
100
300
120
300
120
300
120
300
120
300
120
400
100
300
120
300
120
300
120
300
120
300
120
400
100
300
120
300
120
300
120
300
120
300
120
400
100
300
120
300
120
300
120
300
120
300
120
400
100
300
120
300
120
300
120
300
120
300
120
400
100
300
120
300
120
300
120
300
120
400
100
400
100
300
120
400
100
400
100
400
100
400
80
0
0
400
80
400
100
0
0
0
0
0
0
0
0
300
120
Dp(mmWG)
Flow (Kg/Min-m2)
Total Area of CIS

Blocked Area
Eff. Area
Kg/Min-m2)
7.92
1.44
6.48
Kiln Performance & Efficiency

S.
Constraint
Symbol
Unit
Formula
DoF
3.2 x TPDclk
NO.
1
Degree of Filling
Deff3 x n x S
mts
Burning Zone
BZL
Gcal/
kg/hr
kcal/kg
Coalkiln x NCVcoal
hr-m2
Loading
rpm %
C.S. Areakiln
m2
kcal/kg-clk
TPDclk x Sp. Heat Consp.

C.S. Areakiln x 24 x 1000
m2
Volumetric Loading
VL
TPDclk
tpd/m3
C.S. Areakiln x L
m2
Burner Tip
BTV
m/sec
Velocity
5
Combustion Air,
mts
4 x Ps0.5
mmWG
Lmin
kg/sec
Minimum
1.41 x Coal
Mcal/sec
kg-air/
0.11594xC + 0.34783x(H-O/8)
kg-coal
+ 0.04348xS
C, H, O, S - %
Percent Primary Air
%PA
Primary Air x 100

Lmin
Flame Momentum or
10/04/2015 02:47:06 288628503.xls Kln-Forml
FM or
%.m/sec
%PA x Tip Velocity
LU001016-KCP#Ver.1.2*
Relative Impulse
RI
Feed Residence
RT-K
%.m/sec
min
(decimal)
Time, Kiln
m/sec
mts
19 x L
Deff x n x S
mts
Clinker Residence
RT-C
min
(decimal)
Time, Cooler
rpm %
m2 mmWG
1.55 x A x Ps
TPDclk
10 Combustion Air
CAR
kg-air/
kg-coal
Requirement
kcal
10.478 x (100 - m) x GCV

100 x 7000
11 Sulphur-Alkali
SO3/80
(K2O/94)-(Na20/62)-(Cl/71)
Ratio
gms/kg-clk
12 Theoretical Flame
TFT
deg.C
kcal/kg-coal
Hv
Temperature
1.11 x A x s
Comb. Air Sp. Heatcomb. gas
kg/kg-fuel
0.29
Hv
Vxs
Nm3/kg-fuel
13 True CO2 in Kiln
T-CO2
100 x (CO2 + CO)

100 + (1.89 x CO) - (4.78 x O2)
Exit Gas
14 Kiln Feed Ratio,
0.38
KFR-S
kg-feed/
kg-clk
Dust to Silo
dec.
1 - Ash Abs.
(1 - LOI) * (1 - D/L)
Dust to Kiln
10/04/2015 02:47:06 288628503.xls Kln-Forml
KFR-K
1 - Ash Abs.
LU001016-KCP#Ver.1.2*
1 - LOI
dec.
15 Ash Absorption
AA
tons
Coal Consp. x Ashcoal

Clinker Prodn.
tons
kcal/kg-clk
Sp. Heat Consp. x Ashcoal

NCVcoal
kcal/kg-coal
16 Excess Air in Kiln
EAK
189 x (2xO2 - CO)

N2 - [1.89 x (2xO2 - CO)]
O2, N2, CO - Kiln exit gas
79 x O2
0.21 x ( 100 - CO2 ) - O2
17 Major Pluging
Problems, if
18 Radiation
kcal/hr/m2
4*10-8 (T4 - t4)

T=Shell Temp. and t=Amb. Air Temp.
T & t - deg.K
19 Convection
Forced Convection
(if amb. air vel. is
more than 3.0 m/s)
10/04/2015 02:47:06 288628503.xls Kln-Forml
kcal/hr/m2
80.33 x ((T+t)/2)-0.724 x (T-t)1.333
kcal/hr/m2
28.03 x ((T+t)/2)-0.351 x
v0.805 x D-0.195 x (T-t)
v=amb. air vel., m/sec
LU001016-KCP#Ver.1.2*
D=Shell dia., mts
10/04/2015 02:47:06 288628503.xls Kln-Forml
LU001016-KCP#Ver.1.2*
Coal Combustion Analysis

S.
Constraint
Symbol
Unit
Formula
UA
wt.%
C+H+N+S+O+Ash = 100
NO.
1
Ultimate Analysis
O - Determined by difference
Proximate Analysis
PA
wt.%
VM+FC+Ash+m = 100
FC - Determined by difference
3
4
Gross Calorific Value

Net Calorific Value
GCV
NCV
kcal/
80.8*C + 22.45*S + 339.53*H - 35.89*O
kg-coal
C, S, H, O - Ultimate Analysis (wt.%)
kcal/
GCV - 52.53*H - 6*m
kg-coal
5
6
Useful Heat Value

Methods of Expressing
Solid Fuel Analysis
Conversion from "As
UHV
kcal/
8900 - 138*(Ash + m)
kg-coal
Ash, m - Proximate Analysis (wt.%)
ARB, r
"As Received Basis"
AA, a/ADB
"As Analysed" or "Air Dry Basis"
DB, d
"Dry Basis"
AFB, f
"As Fired Basis"
CB, c
"Combustible Basis (moist. & ash free)"
Yd
wt.%
where Y - C, S, N, Ash
Received" to "Dry
Basis"
8
Conversion from "As
Hd
wt.%
((Hr - 0.1119 * mr) * 100) / (100 - mr)
Od
wt.%
100 - (Yd + Hd)
Yc
wt.%
(Yr * 100) / (100 - (Ashr + mr))

Received" to
"Combustible Basis"
9
Conversion from "As

Analysed / Air Dry
10/04/2015 02:47:06 288628503.xls Comb-Forml
(Yr * 100) / (100 - mr)
Hc
wt.%
((Hr-0.1119*mr)*100)/(100-(Ashr+mr))
Oc
wt.%
100 - (Yc + Hc)
Yd
wt.%
(Ya * 100) / (100 - ma)

LU981125-KCP#Ver.1.1*
Basis" to "Dry Basis"

10 Conversion from "Dry
Hd
wt.%
((Ha - 0.1119 * ma) * 100) / (100 - ma)
Od
wt.%
100 - (Yd + Hd)
Yr
wt.%
(Yd * (100 - mr)) / 100

Basis" to "As Received

Basis"
11 Conversion from "Dry
Hr
wt.%
(Hd * ((100 - mr) / 100) + 0.1119 * mr
Or
wt.%
100 - (Yr + Hr)
Yf
wt.%
(Yd * (100 - mf)) / 100

Basis" to "As Fired

Basis"
12 Conversion from
Hf
wt.%
(Hd * ((100 - mf) / 100) + 0.1119 * mf
Of
wt.%
100 - (Yf + Hf)
Yf
wt.%
(Yc * 100) / ((100 - (Ashf + mf)) / 100)

"Combustible Basis"
to "As Fired Basis"
13 Ash Absorption
Hf
wt.%
(Hc*(100-(Ashf+mf))/100) + 0.1119*mf
Of
wt.%
100 - (Yf + Hf)
AA
tons
Coal Consp. x Ashcoal

Clinker Prodn.
tons
kcal/kg-clk
Sp. Heat Consp. x Ashcoal

NCVcoal
kcal/kg-coal
14 Effect of Coal Ash on
(LOI free Coal Ash x Ash Absorption)

+ ((100-LOI free Coal Ash) x Theoretical
Clinker Composition
Clinker)
15 Theoretical Fuel
Consumption
kg-coal/
(K1*V) / ((K2*W) - (K3*V))
100 kg-clk
K1 = (400 * m)/(100 - n)
K2 = (b/3) + c + (a*d/7) - (e/8) + (f/8)
K3 = (b/3) - ((m*g) / (2500-25*n))
10/04/2015 02:47:06 288628503.xls Comb-Forml
LU981125-KCP#Ver.1.1*
V = (a*s) - q - (t/2)
W=p+t
where,
a = constant, 0.266
b = %FC in dry coal
c = %H in dry coal
d = %N in dry coal
e = %O in dry coal
f = %S in dry coal
g = %Ash in dry coal
m = %True CO2 in exit gas
q = %O2 in exit gas
s = %N2 in exit gas
t = %CO in exit gas
16 True CO2 in Exit Gas
T-CO2
100xCO2 + CO
100 + 1.89xCO - 4.78xO2
17 Standard Coal Factor
SCF
((100-mf)/100) * (NCVf/7000)
%
18 Combustion Air,
Lmin
kg/sec
Minimum
kcal-kg-coal
1.41 x Coal
Mcal/sec
kg-air/
0.11594xC + 0.34783x(H-O/8)
kg-coal
+ 0.04348xS
C, H, O, S - %
kg-air/
10.478 x SCF
kg-coal
19 Combustion Air,
Lmin * 1.10
Incl. Extra
20 Theoretical Flame
10/04/2015 02:47:06 288628503.xls Comb-Forml
TFT
deg.C
kcal/kg-coal
LU981125-KCP#Ver.1.1*
Temperature
Hv
1.11 x A x s
Comb. Air Sp. Heatcomb. gas
kg/kg-fuel
10/04/2015 02:47:06 288628503.xls Comb-Forml
0.29
LU981125-KCP#Ver.1.1*

Binani Cement kiln process diagram analysis

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Binani Cement kiln process diagram analysis

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Page - 1/29

PLANT : Binani Cement - 20.06.2003

False Air a/c CS, Nm3w/kg-clk

False Air a/c Cooler, Nm w/kg-clk

Hot air to PA Fan

PLANT : Binani Cement - 20.06.2003

Excess Air Optimisation (vol%, d)

Optimised O2 - Cal. O/L

Optimised CO2 - Cal. O/L

Optimised Excess Air, Kiln

Optimised Excess Air, Cal.

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10/04/2015 02:47:03 288628503.xls Pic-2S

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10/04/2015 02:47:03 288628503.xls Pic-2S

Kiln Refractory Thickness

Kiln Diameter, effective

Ambient Air Temperature

Pitot Constt. - S Type (L=01m)

Pitot Constt. - S Type (L=03m)

Burner Axial Area

Burner Radial Area

Burner - Coal Annulus

False Air Analysis

A/c KS w.r.t. Mix - O2 Basis

Loss on Ignition (as LOI)

A/c CS w.r.t. Mix - O2 Basis

A/c Cooler ESP w.r.t. Mix

Sulphur (as pyrites)

Carbon in Kiln Feed

Moisture in Kiln Feed

Moisture in Kiln Feed

Excess Air in Kiln

Excess Air in Calciner

Water In, Cooler

Raw Mix - Clinker Ratio

Water In, Cooler

Raw Mix - Clinker Ratio

Kiln Feed Rate

Clinker Temperature, Kiln Outlet

Kiln Feed Rate

Clinker Temperature, Cooler Outlet

Kiln Feed Temperature

Silica (as SiO2)

Fine Coal Temperature

Alumina (as Al2O3)

Iron (as Fe2O3)

ESP I/L Dust Concn.

Lime (as CaO)

Magnesia (as MgO)

Potassium Oxide (as K2O)

Sodium Oxide (as Na2O)

Sulphates (as SO3)

BH Dust Returned to Kiln

Cooler ESP/Stack Radiations

Performance & Efficiency

Kiln Feed Residence Time in Kiln

Clinker Residence Time in Cooler

CFG Static Pressure

Kiln Feed Rate/Dosing Valve Position

Kiln Feed Elevator Load