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UNIT-3 : HEAT BALANCE CALCULATION

: 9/8/2008
: KILN
: PROCESS DEPT

Date

Section
Calculations by

PLANT CAPACITY TPD :

AMB. TEMPERATURE (OC) :

DOSING AIR :
TEMPERATURE (OC) :

34

VOLUME (NM /KG) :

3500
29

PRIMARY AIR :
TEMPERATURE (OC) :

33

CLINKER COMPOSITION :
% SiO2 :

22.38

% Al2O3 :

5.47

RADIATION LOSSES (kcal/Kg CLINKER):

% Fe2O3 :

4.20
64.89
1.19

KILN SHELL:
PREHEATER :
COOLER SIDE :

% CaO :
% MgO :

VOLUME (NM /KG) :

0.056

TEMPERATURE (OC) :

295

BYPASS :

VOLUME (NM3/KG) :

1.56

VOLUME AT KILN INLET (NM3/KG) :

DUST LOAD (gms/NM ) :

50

% BYPASS CONSIDERED :

RAW MEAL :
AMOUNT (Kg/Kg of CLINKER) :

GAS TEMP. AT KILN INLET ( C) :

DUST LOAD (gms/NM3) :

1.6

TEMPERATURE ( C) :

60

MOISTURE (%) :

0.5

204

TEMPERATURE (OC) :
VOLUME (NM /KG) :
3

239
0.970

TEMPERATURE (OC) :
VOLUME (NM /KG) :
3

3.18
4.95

6. HEAT CARRIED BY CLINKER :

7. RADIATION LOSSES :
8. HEAT CARRIED BY BYPASS GAS :
HEAT CARRIED BY BYPASS DUST :
DECARBONISATION LOSS :

35.97
70.405
0.00
0.00
0.00

TOTAL HEAT OUTPUT (KCAL/Kg CLINKER) :

743.12

5.20
0.38

SP. HEAT OF RAW MEAL (KCAL/Kg) :

0.320
0.311
0.214

3. HEAT FROM PRIMARY AIR :

4. HEAT FROM RAW MEAL :
5. HEAT FROM FUEL :

0.23
13.71
723.61

SP. HEAT OF KILN DUST (KCAL/Kg) :

0.231

SP. HEAT OF CLINKER (KCAL/Kg) :

0.195
0.209
0.323

TOTAL HEAT INPUT (KCAL/Kg CLINKER) :

743.12

SP. HEAT OF COOLER EXH. GAS (KCAL/NM3) :

SP. HEAT OF DUST AT KILN INLET (KCAL/Kg) :

COOLING AIR :

68.04

4. HEAT CARRIED BY PH EXHAUST GAS DUST :

1. HEAT FROM COOLING AIR :

2. HEAT FROM DOSING AIR :

SP. HEAT OF DOSING AIR (KCAL/NM3) :

COOLER EXHAUST GAS :

3. HEAT CARRIED BY COOLER EXHAUST GAS :

0.310
0.352

SP. HEAT OF PH. EXHAUST GAS (KCAL/NM3) :

TEMPERATURE (OC) :

151.21

HEAT INPUT (KCAL/Kg CLINKER) :

SP. HEAT OF AMBIENT AIR (KCAL/NM3) :

CLINKER :

409.37

2. HEAT CARRIED BY PH EXHAUST GAS :

0.00
0

1. HEAT FOR CLINKERISATION :

5. HEAT FOR MOISTURE EVAPORATION :

29.655
29.994
10.756

PH EXHAUST GAS :

HEAT OUTPUT (KCAL/Kg CLINKER) :

0.088

SP. HEAT OF GAS AT KILN INLET(KCAL/NM3) :

29
1.86

Calculation by: B.Ravindran

UNIT-3 : HEAT BALANCE CALCULATION

Note: Raw Meal to Clinker Factor = 1.60 kg / kg clinker.

Calculation by: B.Ravindran

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Page :3/4

UNIT-3 : HEAT BALANCE CALCULATION

PH EXHAUST GAS :

RAW MEAL :

CLK. TEMPERATURE (OC) :

TEMPERATURE ( C) :

295

Kg/Kg of CLINKER :

1.6

COOLER EXHAUST GAS :

VOLUME (NM /KG) :

1.56

TEMPERATURE ( C) :

60

TEMPERATURE ( C) :

DUST LOAD (gms/NM3) :

50

MOISTURE (%) :

0.5

VOLUME (NM3/KG) :

HEAT OUTPUT KCAL/ Kg CLINKER

204

COOLING AIR :
TEMPERATURE (OC) :

29

239

VOLUME (NM /KG) :

1.86

0.97

DATE:

9/8/2008

HEAT INPUT KCAL/ Kg CLINKER

Clinkerisation
55.09%

409.37

20.35%

PH Exhaust gas
151.21

Sensible heat cooling air

5.20

0.70%

Sensible heat dosing air

Cooler Exhaust gas
9.16%

0.43%

0.67%

0.38

0.05%

68.04
PH Exhaust dust

PLANT CAPACITY

Sensible heat primary air

3.18

3500 TPD

0.23

0.03%

Moisture

AMB. TEMP.

4.95

29 OC

Sensible heat raw meal

13.71

1.84%

FUEL
723.61

97.37%

Exit clinker
4.84%

35.97
Radiation losses

9.47%

70.405

0.00%

By pass losses
0.00
743.12

TOTAL HEAT INPUT (KCAL/Kg CLINKER) :

Calculation by: B.Ravindran

743.12

UNIT-3 : HEAT BALANCE CALCULATION

Calculation by: B.Ravindran

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