JOB AID

Kiln Heat Balance Calculation

Calciner _ Preheater
Pyroprocessing 1/18
PR PYR T09-04 v1. - Jan 2009

The following colour code is used:

Blue on yellow Cells to fill in

Data input is carried out on 4 input sheets (Input Sheet 1 to 4).

This tool is used for kiln audits' balance calculations and reporting of them. This version is the official release 1 as division
tool. Former versions distributed in CTEC area are replaced by this release - the changes and improvements compared to
the April 2008 version are documented in the next page _ revision.

A detailed training on the tool is provided in the process engineer training Pyroprocessing 2 (kiln audit training). To guide the
user comments are available for most input cells and important calculation cells.

This tool is using the updated Add IN Function thermodynamic.xla from January 2009 (1.5b). User should install the updated
add-in prior to using the tool. The add in file as well as an installation guide is attached below. The new add in version allows
the use of negative temperatures, an "Enthalpy_free" function without water evaporation is implemented.

There are no makros used for calculation to keep the tool transparent. The only makro used is to ensure the proper function
of the add ins - the makro is deleting any path to thermodynamic functions which might occure when copying from another
PC.
The add in function still have some logical checks which might cause error massages during data input (unlogical data as
long as the input is not completed). Just aknowledge and continue with further data input.

The cells are not protected to allow follow up with the formula auditing = take care not to modify. Input is done only on the
input pages and to be customised example pages at the back.

Summary layout of tool: 4 input sheets where data entry is processed into material balance, waste gas calculation and finally
heat balance sheets. Balanced figures of performance results are summarized in a final sheet.
The calculation and result sheets are created to be directly copied into the audit report.

Preheater and/or precalciner kilns are supported by the tool (still separate line calciners with separated preheater strings
need manipulation by user). For wet lines and long dry lines a separate version is in use within CTEC and available as
division tool soon.

Flow sheet example and example for cyclone speed calculations are added at the back, they are linked to the input sheets of
the heat balance but are not used for heat balance results, they can be customised for the specific application.

Source: CTEC Heat Balance Tool 2007 ; updated in 2008

Authors: Bernhard Koeck / Cenk Eskin

Any error to report ? Suggestions for improvement ?

Please contact your TC or the authors above.

All rights of reproduction, representation, adaptation and translation relating to this report belong to Lafarge SA. Lafarge SA reserves the right to exploit this report or not and to freely
distribute it to all of its current and future subsidiaries worldwide in any form, whether paper, electronic or digital, including via internet and/or intranet. This report along with its content
is of a confidential nature. In particular, it may not be reproduced, copied, transmitted, published, divulged and/or appropriated in whole or in part for personal use or for use by a third
party without prior consent from the Production & Process Department, except for reproduction by or for affiliated Lafarge companies.
Kiln Heat Balance Tool _ Calciner Preheater
Revisions
Version Date Who Comments
Division 1.0 Jan-09 DPC CTEC Kiln Heat Balance Tool v. 1.2.6 becomes the division tool version 1
For publication on Cement Portal's Pyroprocessing domain
CTEC 1_2_6 Nov-08 Bernhard Koeck Improvements / Correction since 1_1
All changes since the first CTEC release 1_1 are documented below.
CTEC 1_1 Apr-08 Cenk Eskin Official release within CTEC - spread out in CTEC area
Bernhard Koeck
CTEC test version 2007 Cenk Eskin Used by CTEC process engineers since begin 2007 - first use in kiln audit training -
Bernhard Koeck Sept 2007 - first sharing within the combustion COP

LIST OF MODIFICATIONS (VERSION 1.1 TO VERSION 1.2.6)

1) waste gas calculation: LHV as fired is corrected with 594kcal/KJ water instead of 596 before.
2) waste gas calculation and calciner waste gas calculation: correction of O88 - ambient air moisture was not considered in mass section
3) Change of clinker heat of formation. Dehydration of clay is considering the cristal water. C3S is without SO3 substraction.
4) False air tertiary air related to tertiary air input at the calciner
5) Correction of moisture - material balance N9 and O9
6) Material balance C42: Chlorine added to total
7) Material balance G68: corrected D45 (bypass dust) instead of D44
8) Input3: for a preheater kiln cells B36,B37,G31,G10,J10 "Not applicable for preheater kiln" sentance added
9) Input 3 C35: preheater false air in a preheater kiln is calculated using a separate equation and not linked to Waste Gas Calc. M115 "Tertiary air into calciner"
10) Input 3 I31: no value in case of preheater kiln
11) Heat value of CO in the exit gas considered as heat loss
12) Material balance: S, Cl and Fuel Ash is taken from as fired (was taken from input 2 before without considering wet/dry)
13) Material balance C37 and 38 --- correction of S2-/TOC and moisture calculation (dry --> dry+TOC/S-->wet+TOC/S).
Correction of all dependend calculations which had been C36 before to C 37 (calculated clinker analyse, CO2 raw mix,...)
14) A new input field (input 1 - kiln feed balanced dry) is created to avoid circular reference in the material balance - used to calculate the SO2 emissions and the S2- fuel ash part.
15) Material balance: Kiln feed S2- trapped is added to fuel ash.
16) Correction of material balance based on kiln feed
17) TOC and S flow in exit gas calculations (P54 and Q 54) are based on C37 material balance
18) heat capacity for gases from temperature 0C to -50C is added
19) enthalpy for H2Ov without heat of vaporization is replaced:
enthalpy_free(" "; )
20) enthalpy for kiln feed, filter dust and bypass dust are based on their chemical composition
21) enthalpy for coal (dry) is based on volatile content
22) enthalpy for oil is based on the density
23) material balance H68 corrected
24) Input 1 E25 deleted (bypass dust now by default not included in clinker weighing)
25) Calculation of secondary air is corrected by using blendtemperature_free. In version 1 vol % moisture had been used in I22 instead of mass %.
26) Corrction of bypass impact in waste gas calculation - N76 / N87 / N90.
27) Calculation of CO2 and CO2 fossil added, input fields for % fossil per fuel added.
28) Waste gas calc and calciner exit gas: Correction of cell D77 and O77 - use of calculated Oxygen in C117 instead of 20,95.
29) Sulfide considered in LOI check - input 1
30) Waste gas calculations Q31 - Sulfide oxydation into SO3 instead of SO2 is considered depending on the trapping coefficient, Fe2O3 oxidation from FeS2 is considered.
31) Waste gas calcualtion neutral combustion air - Oxidation into SO3 instead of SO2 is considered.
32) Heat Calculation Cooler - F23 and L10 - changed back from blendtemperature_free to blendtemperature considering recalculated energies in I21 and I22
(the blendtemperature_free function used before showed in some iteration cases an error).
33) Material balance - SO2 emissions not considered as output for the back calculation of kiln feed or clinker.
34) Waste gas calculation and calciner exit gas calculation (D100,...) - ambient moisture considered in the excess air of kiln and excess air of line. CO considered in the excess air as well.
35) blendtemperature_free replaced by blendtemperature with recalcualted enthalpy. (primary air and false air in heat calculation kiln)
36) Waste gas calculation g74 - ambient moisture considered in the bypass excess air.
37) Material balance D67 - decarbonatisation energy of bypass dust - taking CaO free in bypass dust as input figure
38) Waste gas calculation and calciner exit gas calculation - C63 is taking directly the decarbonatisation CO2 from the material balance - considering the bypass dust CO2 as well.
39) Change to the updated thermodynamic.xla (1.5b - Jan 2009). Improoved help and description of the add ins. Correction of blendtemperature_free, new Enthalpy_rawmix.
40) Material Balance T26 / X26 and AC26: Use of new Enthalpy_rawmix function. Chemical analyse is totalised to 100% to avoid missing Enthalpy out of analytics below 100%.

PR PYR T09-04 v1
 KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 1

Plant Name Rawang, Malaysia Kiln Feed Preheater dust Bypass Dust Clinker Clinker t/d
Name of the Kiln RK3# Flowrate wet, kg/h 280000 41720 199540 4789
Kiln Type Precalciner H2O, % 0.21 0
Date of measurement March 13, 2012 Temperatures,C 69 445
Date of report Crystall Water, % 1 0.4 0
Ambient temperature, C 30
Altitude above sea level, m. 40 Kiln Feed Preheater dust Bypass Dust Clinker Hot meal
Atmospheric pressure, hPa 1008 Err:511 SiO2 ,% 6.81 12.11 22.48
Ambiente relative humidity, % 50% Al2O3 ,% 0.99 3.94 5.34
Fe2O3 ,% 0.41 1.84 4.74
SO2 trapping % of S-2 50% CaO, % 50.38 44.93 65.69
TOC burnt in calciner 0% MgO, % 0.48 0.48 0.64
Ratio hot meal/kk 1.19 LOI ,% 40.3 34.9
Kiln inlet dust g/kgck 150 CO2 ,% 39.3
K2O ,% 0.18 0.91 0.52 1.3
Is there a by-pass in the kiln? No Na2O ,% 0.03 0.04 0.07 0.27
Volume ratio of gas extraction at the by-pass, % 0.00% SO3 ,% 0.06 0.28 0.6
TiO ,% 0.116
P2O5 ,% 0.033
Non Carbonated CaO in Kiln Feed / Total CaO, % 0 TOC ,%
Non Carbonated MgO in Kiln Feed / Total MgO, % 0 Cl- , % 0.6
S-2 ,% free lime: 1.71
Kiln feed dry - back calculated, kg/h: 308680 305338 LOI check 0.00 34.50
Total 99.64 64.65 0.00 99.91 2.17
 KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 2

KILN FUELS on Burner PRECALCINER FUELS OTHERS

Choose Fuel Type Coal AF-sol. Gas Coal Coal Coal Coal Coal AF-sol. AF-sol.

Name of Fuel Servo Coal Servo Coal Bottom feed Rice husk Wood TOC SNCR S-2
Flowrate, kg/h fired 8625 8075 71250 1040 6917 0 0 0.00
Analyse (dry / wet) dry dry dry dry dry dry wet dry
Carbon, % 56.80 56.80 12.90 41.20 45.90 100
Hydrogen, % 5.90 5.90 1.05 5.90 8.30
Sulphur, % 0.50 0.50 0.14 0.06 0.10 100
Oxygen, % 15.50 15.50 5.13 34.51 42.30
Nitrogen, % 0.50 0.50 0.26 0.91 0.30
Ash, % 19.50 19.50 79.29 16.47 2.50
Cl-, %
Total, % 98.70 0.00 0.00 0.00 0.00 0.00 98.70 98.77 99.05 99.40 100.00 0.00 100.00
LHV [kJ/kg] 24144 24144 5279 16089 16747.2 33830 13120
H2O, % 13.81 13.81 2.05 18.36 48.30 0.00 100 0
Temperatures,C 60 60 70 30 30
volatiles,% 40 40 11 68 79
fossil carbon, % 100% 100% 100% 100% 100% 100%
oil density, kg/dm

Ash 1 Ash 2 Ash 3 Ash 4 Ash 5 Ash 6 Ash 7 Ash 8 Ash 9 Ash 10
SiO2, % 51.78 51.78 36.13 94.44 32.48
Al2O3, % 16.45 16.45 13.35 0.15 6.96
Fe2O3, % 7.98 7.98 12.42 0.11 21.53
CaO, % 7 7 6.1 0.52 24.18
MgO, % 4.47 4.47 0.55 0.67 0.96
K2O, % 2.66 2.66 1.47 2.13 2.05
Na2O, % 2.84 2.84 0.24 0.49 0.76
TiO, % 0.73 0.73 0.379 0.01 0.28
P2O5, % 0.36 0.36 0.162 0.97 0.906
Total, % 94.27 0 0 0 0 0 94.27 70.801 99.49 90.106
 KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 3
Preheater Exit Gas Nm3/h C l/h Wall Losses kJ/kgck Kiln Physical Properties
Gas Flowrate Err:511 462 Kiln 97.3 Kiln Length, m. 74
Preheater Water Injection Err:511 0 0 Preheater 115 Kiln Diameter, m. 4.7
Tertiary Air Duct 11.4 Kiln Speed, rpm 3.0
Preheater Exit Static Pressure, hPa -84.93 Kiln Slope, % 4.0
Refractory thickness, mm. 230
Nm3/h C Main burner Nm/h C Clinker Density, t/m3 1.4
Precalciner Exit Gas Err:511 914 Transport air 1 2846 30
Transport air 2
Precalciner Exit Static Pressure,hPa -8.8 Transport air 3
Transport air 4
Gas measurements O2 [%] CO [%]
Kiln inlet,% (dry) 5.2 0.0274
Preheater outlet, % (dry) 3.65 0.08
Calciner Outlet, % (dry) 1.3 0.15 Precalciner burners Nm/h C
Transport air 1 2835 30
Main burner Nm/h C % Transport air 2 1240 30
Primary air 1 7283 30 Err:511 Transport air 3 3455 30
Primary air 2 Err:511 Transport air 4 3455 30
Precalciner burners
Primary air 1 By-Pass Nm/h C
Primary air 2 ## Extracted kiln inlet gas Err:511
Primary air 3

False air Nm/h C % Preheater false air assessment for preca kiln Err:511
Kiln hood sealing Err:511 30 4.0
Kiln inlet sealing Err:511 30 4.0
Airlift 6813 65 Err:511
Preheater false air Err:511 30 Err:511
Tertiary air false air 24997 30 Err:511
False air calciner 6700
 KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 4 - COOLER

Flowrate, Temperature, Grate Area, Nm3/s/m Cum. Area, Flowrate, Temperature

Cooler fans Nm3/h C m2 2
m2 Nm3/h C
Fan # 1 34342 30 7.1 1.35 7.09 Secondary air Err:511
Fan # 2 58918 30 9.3 1.76 16.38 Tertiary air Err:511 901
Fan # 3 95217 30 15.6 1.70 31.93 Mill take off #1
Fan # 4 28311 30 7.2 1.10 39.11 Mill take off #2
Fan # 5 40356 30 12.1 0.93 51.16 Exhaust air measured 360
Fan # 6 39295 30 13.6 0.80 64.78 Exhaust air calculated Err:511
Fan # 7 28235 30 15.1 0.52 79.87 Hot clinker temperature, C 1450
Fan # 8 28489 30 21.2 0.37 101.03 Cold clinker temperature, C 227
Fan # 9
Fan # 10
Fan # 11 litres/h or Temperature
Exhaust air water
Fan # 12 kg/h C
injection
Fan # 13
Fan # 14
Total 353164 101.03 0.97
kJ/kgck
Wall losses of cooler
Air leakage leaving cooler 24.00
False air entering cooler Cooling air: 1.77Nm/kgcl
 KILN AUDIT HEAT BALANCE TOOL - MATERIAL BALANCE CALCULATIONS

Kiln Fuels Precalciner Fuels

Kiln Feed Servo Coal 0 0 0 0 0 Servo Coal Bottom feed Rice husk Wood Preheater dBypass Dust
Flowrate, [t/h] 280 8.625 0 0 0 0 0 8.075 71.25 1.04 6.917 41.72 0
H2O, [%] 0.21
Sulphur, [%] 0.43 0.00 0.00 0.00 0.00 0.00 0.43 0.14 0.05 0.05
Ash, [%] 16.81 0.00 0.00 0.00 0.00 0.00 16.81 77.66 13.45 1.29
Cl, [%] 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0 0

Kiln Feed Ash 1 Ash 2 Ash 3 Ash 4 Ash 5 Ash 6 Ash 7 Ash 8 Ash 9 Ash 10 Dust 1 Bypass Dust
SiO2 6.81 51.78 0 0 0 0 0 51.78 36.13 94.44 32.48 12.11 0
Al2O3 0.99 16.45 0 0 0 0 0 16.45 13.35 0.15 6.96 3.94 0
Fe2O3 0.41 7.98 0 0 0 0 0 7.98 12.42 0.11 21.53 1.84 0
CaO 50.38 7 0 0 0 0 0 7 6.1 0.52 24.18 44.93 0
MgO 0.48 4.47 0 0 0 0 0 4.47 0.55 0.67 0.96 0.48 0
LOI 40.30 0.4 0
CO2 39.30 0 0
K2O 0.18 2.66 0 0 0 0 0 2.66 1.47 2.13 2.05 0.91 0
Na2O 0.03 2.84 0 0 0 0 0 2.84 0.24 0.49 0.76 0.04 0
SO3 0.06 0 0
TiO 0 0.73 0 0 0 0 0 0.73 0.379 0.01 0.28 0 0
P2O5 0 0.36 0 0 0 0 0 0.36 0.162 0.97 0.906 0 0
Cl 0 0 0
 KILN AUDIT HEAT BALANCE TOOL - MATERIAL BALANCE RESULTS

Material Balance Based Material Balance Elemental Balance Based on

on Clinker Weighing Based on Kiln Feed Clinker Weighing
t/h kg/kgck t/h kg/kgck Clinker Measured Calculated
Kiln Feed (dry) 305.34 1.53 279.41 1.52 SiO2 22.48 18.72
Kiln Feed (dry + TOC + S )-2
305.34 1.53 279.41 1.52 Al2O3 5.34 4.63
Kiln Feed (wet+TOC+S-2) 305.98 1.53 280.00 1.52 Fe2O3 4.74 3.81
Total Fuel Ash 58.37 0.29 58.37 0.32 CaO 65.69 69.50
Total Fuel SO3 0.43 0.00 0.43 0.00 MgO 0.64 0.85
Total Fuel Cl 0.00 0.00 0.00 0.00 LOI 0.00 0.00
364.14 1.82 338.22 1.84 CO2 0.00 0.00
Clinker 199.54 1.00 184.06 1.00 K2O 0.52 0.53
Preheater Dust 41.72 0.21 41.72 0.23 Na2O 0.07 0.14
Bypass Dust 0.00 0.00 0.00 0.00 SO3 0.28 0.31
SO2 in preheater exit 0.00 0.00 0.00 0.00 TiO 0.12 0.12
Dehydration+Decarbonation 122.88 0.62 112.44 0.61 P2O5 0.03 0.05
364.14 1.82 338.22 1.84 Cl 0.00 0.00
99.91 98.66
Kiln feed wet / clinker 1.53 1.52
Raw mix dry / clinker 1.32 1.29

Factor kiln feed / clinker for production: 1.40

KILN AUDIT HEAT BALANCE TOOL - THEORETICAL HEAT OF CLINKER FORMATION CALCULATION
Clinker Bypass
Ash Corr. Clinker Compounds gr/kgck Al+F 0.022 Metakaolin 0.047
SiO2 116.51 Kaolin 0.054 SiO2 0.091 Clinker Phases Based on average clinker analysis by plant Lab
Al2O3 14.03 C3S, [%] 46.9 58.30
Fe2O3 11.74 CaCO3 Cal. 0.256 C2S, [%] 29.1 17.50
CaO 638.89 0.00 MgCO3 Cal. 0.002 all Nm/kgck C3A, [%] 6.1 6.50
MgO 4.24 0.00 CO2=> 0.258 0.3063 <=CO2 C4AF, [%] 14.4 13.30
Delta 0.0483 Free lime 1.7
kcal/kgck kcal/kgck Sulphur / Alkali 53 %
1.45 % crystal water / kg cl LSF 0 fCaO 90.8
Dehydration clay 19.5 S/R 2.23
CaCO3 Decarbonisation 482.6 0.00 Clinkerisation 113.98 108.429
MgCO3 Decarbonisation 2.7 0.00 Crystallization 3.38 3.38
Glas formation 5.0
Total Endothermic 509.8 0.00 Total Exothermic 117.36 111.81

Theoretical Heat Clinker, [kcal / kgck] 410.24 398.01

Theoretical Heat Clinker, [kJ/kgck] 1717.69

For comparison: Perray's heat for clinker formation which is based on clinker analysis
410.24 [kcal / kgck]
Clinker
199.54

Clinker
22.48
5.34
4.74
65.69
0.64
0
0
0.52
0.07
0.28
0.116
0.033
0
ker analysis by plant Lab
 KILN AUDIT HEAT BALANCE TOOL - FUEL SUMMARY

Kiln Specific Heat Consumption, (SHC), kJ/kgck 3866

SHC including TOC and S , kJ/kgck
-2
3866

Neutral Waste Gases

Main Burner Fuels Flowrate, kg/h LHV, (kJ/kg - as fired) Nm/kgck Nm/MJ Ratio over kiln SHC, %
Servo Coal 8625 20466 0.23
0.00
0.00
0.00
0.00
0.00
Preheater / Precalciner Fuels
Servo Coal 8075 20466 0.21
Bottom feed 71250 5120 0.47
Rice husk 1040 12678 0.02
Wood 6917 7457 0.07
TOC 33830 0.00
S-2 13120 0.00
 02/10/2017
Date: 3/13/2012
Kiln: RK3#
Comment:

PRIMARY FIRING SECONDARY FIRING

Water Inj. TOC S-2
Type of fuel Servo Coal 0 0 0 0 0 Type of fuel Servo Coal Bottom feed Rice husk Wood SNCR feed TOC feed S-2
Type of analyse (dry / wet) dry 0 0 0 0 0 Type of analyse (dry / wet) dry dry dry dry wet dry dry
Carbone 56.80% 0.00% 0.00% 0.00% 0.00% 0.00% Carbone 56.80% 12.90% 41.20% 45.90% 100.00%
Hydrogen 5.90% 0.00% 0.00% 0.00% 0.00% 0.00% Hydrogen 5.90% 1.05% 5.90% 8.30% 0.00%
Sulphur 0.50% 0.00% 0.00% 0.00% 0.00% 0.00% Sulphur 0.50% 0.14% 0.06% 0.10% 0.00% 100.00%
Oxygen 15.50% 0.00% 0.00% 0.00% 0.00% 0.00% Oxygen 15.50% 5.13% 34.51% 42.30% 0.00%
Nitrogen 0.50% 0.00% 0.00% 0.00% 0.00% 0.00% Nitrogen 0.50% 0.26% 0.91% 0.30% 0.00%
Ash 19.50% 0.00% 0.00% 0.00% 0.00% 0.00% Ash 19.50% 79.29% 16.47% 2.50% 0.00%
LHV [kJ/kg] 24,144 0 0 0 0 0 LHV [kJ/kg] 24,144 5,279 16,089 16,747 33,830 13120
LHV (kcal/kg) 5,766 0 0 0 0 0 LHV (kcal/kg) 5,766 1,261 3,843 4,000 0 8,080 3,134
H2O 13.81% 0.00% 0.00% 0.00% 0.00% 0.00% H2O 13.81% 2.05% 18.36% 48.30% 100.00%
Total 98.70% 0.00% 0.00% 0.00% 0.00% 0.00% Total 98.70% 98.77% 99.05% 99.40% 0.00% 100.00% 100.00%
LHV calculated (kcal/kg) 5,738 0 0 0 0 0 LHV calculated (kcal/kg) 5,738 1,163 3,786 4,576 0 8,080 2,245
Analyses as fired Analyses as fired
Carbone 48.96% 0.00% 0.00% 0.00% 0.00% 0.00% Carbone 48.96% 12.64% 33.64% 23.73% 0.00% 100.00% 0.00%
Hydrogen 5.09% 0.00% 0.00% 0.00% 0.00% 0.00% Hydrogen 5.09% 1.03% 4.82% 4.29% 0.00% 0.00% 0.00%
Sulphur 0.43% 0.00% 0.00% 0.00% 0.00% 0.00% Sulphur 0.43% 0.14% 0.05% 0.05% 0.00% 0.00% 100.00%
Oxygen 13.36% 0.00% 0.00% 0.00% 0.00% 0.00% Oxygen 13.36% 5.02% 28.17% 21.87% 0.00% 0.00% 0.00%
Nitrogen 0.43% 0.00% 0.00% 0.00% 0.00% 0.00% Nitrogen 0.43% 0.25% 0.74% 0.16% 0.00% 0.00% 0.00%
Ash 16.81% 0.00% 0.00% 0.00% 0.00% 0.00% Ash 16.81% 77.66% 13.45% 1.29% 0.00% 0.00% 0.00%
H2O 13.81% 0.00% 0.00% 0.00% 0.00% 0.00% H2O 13.81% 2.05% 18.36% 48.30% 100.00% 0.00% 0.00%
LHV [kJ/kg] 20,465 0 0 0 0 0 LHV [kJ/kg] 20,465 5,120 12,677 7,453 0 33,830 13,120
LHV (kcal/kg) 4,888 0 0 0 0 0 LHV (kcal/kg) 4,888 1,223 3,028 1,780 0 8,080 3,134
Neutral combustion air Total Neutral combustion air Total
Nm / kg fuel Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Nm / kg fuel Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Nm / kgck Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Nm / kgck Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Nm / h Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Nm / h Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511

Neutral waste gases Neutral waste gases

Volume Volume
Flowrate (Nm/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (Nm/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 0.91 0.00 0.00 0.00 0.00 0.00 CO2 0.91 0.24 0.63 0.44 0.00 1.87 0.00
H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.003 0.00 0.00 0.00 0.00 0.00 SO2 0.00 0.00 0.00 0.00 0.00 0.00 0.70
N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Mass Mass
Flowrate (kg/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (kg/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 1.79 0.00 0.00 0.00 0.00 0.00 CO2 1.79 0.46 1.23 0.87 0.00 3.66 0.00
H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.01 0.00 0.00 0.000 0.00 0.00 SO2 0.01 0.00 0.00 0.00 0.00 0.00 2.00
N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Fuel feed rate (kg/h) 8,625.0 0.0 0.0 0.0 0.0 0.0 Fuel feed rate (kg/h) 8075 71250 1040 6917 0 0.0 0.0
Total (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Total (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
kJ/kgck 885 0 0 0 0 0 kJ/kgck 828 1,828 66 258 0 0 0
Nm/MJ Err:511 Nm/MJ Err:511 Err:511 Err:511 Err:511
% 22.9% 0.0% 0.0% 0.0% 0.0% 0.0% % 21.4% 47.3% 1.7% 6.7% 0.0%

heat cons. including TOC&S: 3,865.4 923 kcal/kgck Kiln excess air avail. (Nm/kgck) Err:511
Kiln production (kg.ck/h) 199,540 Neutral combustion air preca (Nm/kgck) Err:511
kJ/kgck total fuel consumption 3,865 which 22.9% in kiln Ratio "raw mix / clinker" (dry) 1.3211
decarbonatisation Nm CO2 / kg cli 0.31
%H2O in raw mix (cristall water) 0.00%
Ratio "hot meal / ck" 1.19 (in real mass)

BY-PASS Extra
POINT Air
Neutral Including Including Including By-pass for Neutral Including Including Incl.H2O Including Including
KILN EXIT kiln 0.00% 5.20% 0.03% 0.00% extracted calciner Neutral decarbo Excluding 1.30% 0.15%
Volume waste gases CO2hotmeal O2 dry CO dry extraction bypass Volume kiln total Bypass O2 dry CO dry
Flowrate (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 0.039 0.039 0.039 Err:511 Err:511 CO2 0.140 0.179 0.486 0.486 0.486 Err:511
H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.0001 0.0001 0.0001 0.0001 0.00000 SO2 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
O2 Err:511 Err:511 Err:511 Err:511 O2 0.000 0.000 Err:511 Err:511
CO Err:511 Err:511 CO Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 ppm Err:511 Err:511 Err:511 Err:511 Err:511 SO2 ppm Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%O2 Err:511 Err:511 Err:511 %O2 Err:511 Err:511 Err:511 Err:511 Err:511
%CO Err:511 Err:511 %CO Err:511
Mass Mass
Flowrate (kg/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (kg/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 0.078 0.078 0.078 Err:511 Err:511 CO2 0.274 0.352 0.953 0.953 0.953 Err:511
H2O Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.000 0.000 0.000 0.000 0.000 SO2 0.0000 0.000 0.000 0.0000 0.0000 0.0000
N2 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
O2 Err:511 Err:511 Err:511 O2 0.000 0.000 0.000 Err:511 Err:511
CO Err:511 Err:511 CO Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%O2 Err:511 Err:511 Err:511 %O2 Err:511 Err:511 Err:511 Err:511 Err:511
%CO Err:511 Err:511 %CO Err:511
CO2 decarbo kiln (Nm/kgck) 0.000 CO2 decarbo calciner (Nm/kgck) 0.306 CO2 decarbo total: 0.306
Neutral air calciner (Nm/kgck) Err:511
Excess air kiln (Nm/kgck) Err:511 Excess air (Nm/kgck) Err:511 /neutral air
(Nm/h) Err:511 (Nm/h) Err:511 Err:511
Total combustion air kiln (Nm/kgck) Err:511 Total combustion air (Nm/kgck) Err:511
(Nm/h) Err:511 (Nm/h) Err:511 PC Exit Gas
Density
Total kiln exit gas (wet) (Nm/kgck) Err:511 Err:511 Total calciner exit gas (wet) (Nm/kgck) Err:511 Err:511 Am/h kg/Nm
(Nm/h) Err:511 Err:511 (Nm/h) Err:511 Err:511 Am/h Err:511

Secondary air Tertiary air

Primary air kiln (% total kiln air) Err:511 Err:511 (Nm/kgck) Primary air preca including transport air 0.055 (Nm/kgck)
including transport air 10,129 (Nm/h) 10,985 (Nm/h)
Kiln hood inleak.(%total kiln air) 4.0% Err:511 (Nm/kgck) Kiln inlet inleakage (% kiln exit gas) 4.0% Err:511 (Nm/kgck)
Err:511 (Nm/h) Err:511 (Nm/h)
Secondary air flow Err:511 (Nm/kgck) false air kiln inlet / calciner 6,700 0.0335772276 (Nm/kgck)
Err:511 (Nm/h) Tertiary air into calciner Err:511 (Nm/kgck)
Air from the cooler(secondary + tertiary air) Err:511 (Nm/kgck) Err:511 (Nm/h)
Air Composition False air into tertiary air: 24997 (Nm/h)
%O2 air Err:511 %N2 air Err:511 %H2O air Err:511 Tertiary air from cooler Err:511 (Nm/h)
 KILN AUDIT HEAT BALANCE TOOL - COOLER HEAT CALCULATIONS SUPPORT SHEET
kg/h kcal/h kJ/h TC kg/h kcal/h kJ/h TC
Fan # 1 Err:511 Err:511 Err:511 30 Secondary air, TC measured Err:511 Err:511 Err:511 0
Fan # 2 Err:511 Err:511 Err:511 30 Secondary air, TC calculated Err:511 Err:511 Err:511 Err:511
Fan # 3 Err:511 Err:511 Err:511 30 Tertiary Air Err:511 Err:511 Err:511 901
Fan # 4 Err:511 Err:511 Err:511 30 Mill take off #1 Err:511 Err:511 Err:511 0
Fan # 5 Err:511 Err:511 Err:511 30 Mill take off #2 Err:511 Err:511 Err:511 0
Fan # 6 Err:511 Err:511 Err:511 30 Exhaust air measured Err:511 0 360
Fan # 7 Err:511 Err:511 Err:511 30 Exhaust air calculated Err:511 Err:511 Err:511
Fan # 8 Err:511 Err:511 Err:511 30 Wall losses 1143769 4788960
Fan # 9 Err:511 Err:511 Err:511 Vaporisation Heat Err:511 Err:511
Fan # 10 Err:511 Err:511 Err:511 Cold clinker 199540 Err:511 Err:511
Fan # 11 Err:511 Err:511 Err:511
Fan # 12 Err:511 Err:511 Err:511 Energy recalculations for TC kcal/h
Fan # 13 Err:511 Err:511 Err:511 Total Cooling Fans Err:511
Fan # 14 Err:511 Err:511 Err:511 Secondary Air Err:511
Total Cooling fans Err:511 Err:511 Err:511 Err:511
kg/h kcal/h kJ/h TC
Air leakage leaving cooler Err:511 Err:511 Err:511
False air entering cooler Err:511 Err:511 Err:511
Hot clinker 199540 Err:511 Err:511
Exhaust air water inj. 0 Err:511 Err:511 Water injection volume, Nm3/h Err:511
 KILN AUDIT HEAT BALANCE TOOL - KILN HEAT CALCULATIONS SUPPORT SHEET
Fuel sensible heat calculations
PRIMARY FIRING SECONDARY FIRING
1 3 2 1 1 1 1 1 3 3
Servo Coal Servo Coal Bottom feed Rice husk Wood Total
kg/h, wet 8625.00 0.00 0.00 0.00 0.00 0.00 8075.00 71250.00 1040.00 6917.00 95907
kg/h dry 7433.89 0.00 0.00 0.00 0.00 0.00 6959.84 69789.38 849.06 3576.09 88608
kg/h,H2O 1191.11 0.00 0.00 0.00 0.00 0.00 1115.16 1460.63 190.94 3340.91 7299
enthalpy fuel Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
C 60.00 0.00 0.00 0.00 0.00 0.00 60.00 70.00 30.00 30.00
kcal/h, fuel Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
kJ/h, fuel Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
enthalpy H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
kcal/h, H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
kJ/h, H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511

Humidity calculations False air heat calculations

Absolute humidity, kgH2O/kg dry air Err:511 kg/h C kcal/h kJ/h
Air moisture by mass, % Err:511 Kiln hood sealing Err:511 30 Err:511 Err:511
Air moisture by volume, % Err:511 Kiln inlet sealing Err:511 30 Err:511 Err:511
Airlift Err:511 65 Err:511 Err:511
Wet molecular weight, g/gmole wet air Err:511 Preheater false air Err:511 30 Err:511 Err:511
TA duct false air Err:511 30 Err:511 Err:511
Total Err:511 Err:511 Err:511 Err:511
Recalculated energy for mixed TC Err:511

Primary air heat calculations Water inputs

Main burner kg/h C kcal/h kJ/h kg/h C kcal/h kJ/h
Primary 1 Err:511 30 Err:511 Err:511 Kiln feed total H2O 643 69 Err:511 Err:511
Primary 2 Err:511 0 Err:511 Err:511
Transport 1 Err:511 30 Err:511 Err:511 Preheater 0 0 Err:511 Err:511
Transport 2 Err:511 0 Err:511 Err:511 Cooler 0 0 Err:511 Err:511
Transport 3 Err:511 0 Err:511 Err:511 Total injected water 0 Err:511 Err:511 Err:511
Transport 4 Err:511 0 Err:511 Err:511
Preca burners By-Pass
Primary 1 Err:511 0 Err:511 Err:511 Gas Composition kg/h C kcal/h kJ/h
Primary 2 Err:511 0 Err:511 Err:511 CO2 0 Err:511
Primary 3 Err:511 0 Err:511 Err:511 H2O 0 Err:511
Transport 1 Err:511 30 Err:511 Err:511 SO2 0 Err:511
Transport 2 Err:511 30 Err:511 Err:511 N2 0 Err:511
Transport 3 Err:511 30 Err:511 Err:511 O2 0 Err:511
Transport 4 Err:511 30 Err:511 Err:511 Total By-Pass Gas 0 0 Err:511 Err:511
Total primary air Err:511 Err:511 Err:511 Err:511 By-pass Dust 0 0 Err:511 Err:511
Recalculated energy for mixed TC Err:511
 02/10/2017
Date: 3/13/2012
Kiln: RK3#
Comment:

PRIMARY FIRING SECONDARY FIRING

Water Inj. TOC S-2
Type of fuel Servo Coal 0 0 0 0 0 Type of fuel Servo Coal Bottom feed Rice husk Wood SNCR feed TOC feed S-2
Type of analyse (dry / wet) dry 0 0 0 0 0 Type of analyse (dry / wet) dry dry dry dry wet dry dry
Carbone 56.80% 0.00% 0.00% 0.00% 0.00% 0.00% Carbone 56.80% 12.90% 41.20% 45.90% 100.00%
Hydrogen 5.90% 0.00% 0.00% 0.00% 0.00% 0.00% Hydrogen 5.90% 1.05% 5.90% 8.30% 0.00%
Sulphur 0.50% 0.00% 0.00% 0.00% 0.00% 0.00% Sulphur 0.50% 0.14% 0.06% 0.10% 0.00% 100.00%
Oxygen 15.50% 0.00% 0.00% 0.00% 0.00% 0.00% Oxygen 15.50% 5.13% 34.51% 42.30% 0.00%
Nitrogen 0.50% 0.00% 0.00% 0.00% 0.00% 0.00% Nitrogen 0.50% 0.26% 0.91% 0.30% 0.00%
Ash 19.50% 0.00% 0.00% 0.00% 0.00% 0.00% Ash 19.50% 79.29% 16.47% 2.50% 0.00%
LHV [kJ/kg] 24,144 0 0 0 0 0 LHV [kJ/kg] 24,144 5,279 16,089 16,747 33,830 13120
LHV (kcal/kg) 5,766 0 0 0 0 0 LHV (kcal/kg) 5,766 1,261 3,843 4,000 0 8,080 3,134
H2O 13.81% 0.00% 0.00% 0.00% 0.00% 0.00% H2O 13.81% 2.05% 18.36% 48.30% 100.00%
Total 98.70% 0.00% 0.00% 0.00% 0.00% 0.00% Total 98.70% 98.77% 99.05% 99.40% 0.00% 100.00% 100.00%
LHV calculated (kcal/kg) 5,738 0 0 0 0 0 LHV calculated (kcal/kg) 5,738 1,163 3,786 4,576 0 8,080 2,245
Analyses as fired Analyses as fired
Carbone 48.96% 0.00% 0.00% 0.00% 0.00% 0.00% Carbone 48.96% 12.64% 33.64% 23.73% 0.00% 100.00% 0.00%
Hydrogen 5.09% 0.00% 0.00% 0.00% 0.00% 0.00% Hydrogen 5.09% 1.03% 4.82% 4.29% 0.00% 0.00% 0.00%
Sulphur 0.43% 0.00% 0.00% 0.00% 0.00% 0.00% Sulphur 0.43% 0.14% 0.05% 0.05% 0.00% 0.00% 100.00%
Oxygen 13.36% 0.00% 0.00% 0.00% 0.00% 0.00% Oxygen 13.36% 5.02% 28.17% 21.87% 0.00% 0.00% 0.00%
Nitrogen 0.43% 0.00% 0.00% 0.00% 0.00% 0.00% Nitrogen 0.43% 0.25% 0.74% 0.16% 0.00% 0.00% 0.00%
Ash 16.81% 0.00% 0.00% 0.00% 0.00% 0.00% Ash 16.81% 77.66% 13.45% 1.29% 0.00% 0.00% 0.00%
H2O 13.81% 0.00% 0.00% 0.00% 0.00% 0.00% H2O 13.81% 2.05% 18.36% 48.30% 100.00% 0.00% 0.00%
LHV [kJ/kg] 20,466 0 0 0 0 0 LHV [kJ/kg] 20,466 5,120 12,678 7,457 0 33,830 13,120
LHV (kcal/kg) 4,888 0 0 0 0 0 LHV (kcal/kg) 4,888 1,223 3,028 1,781 0 8,080 3,134
Neutral combustion air Total Neutral combustion air Total
Nm / kg fuel Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Nm / kg fuel Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Nm / kgck Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Nm / kgck Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Nm / h Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Nm / h Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511

Neutral waste gases Neutral waste gases

Volume Volume
Flowrate (Nm/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (Nm/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 0.91 0.00 0.00 0.00 0.00 0.00 CO2 0.91 0.24 0.63 0.44 0.00 1.87 0.00
H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.003 0.00 0.00 0.00 0.00 0.00 SO2 0.00 0.00 0.00 0.00 0.00 0.00 0.70
N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Mass Mass
Flowrate (kg/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (kg/kg fuel) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 1.79 0.00 0.00 0.00 0.00 0.00 CO2 1.79 0.46 1.23 0.87 0.00 3.66 0.00
H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.01 0.00 0.00 0.000 0.00 0.00 SO2 0.01 0.00 0.00 0.00 0.00 0.00 2.00
N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
Fuel feed rate (kg/h) 8,625.0 0.0 0.0 0.0 0.0 0.0 Fuel feed rate (kg/h) 8075 71250 1040 6917 0 0.0 0.0
Total (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Total (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
kJ/kgck 885 0 0 0 0 0 kJ/kgck 828 1,828 66 258 0 0 0
Nm/MJ Err:511 Nm/MJ Err:511 Err:511 Err:511 Err:511
% 22.9% 0.0% 0.0% 0.0% 0.0% 0.0% % 21.4% 47.3% 1.7% 6.7% 0.0%

heat cons. including TOC&S: 3,865.7 923 kcal/kgck Kiln excess air avail. (Nm/kgck) Err:511
Kiln production (kg.ck/h) 199,540 Neutral combustion air preca (Nm/kgck) Err:511
kJ/kgck total fuel consumption 3,866 which 22.9% in kiln Ratio "raw mix / clinker" (dry) 1.3211
decarbonatisation Nm CO2 / kg cli 0.31
%H2O in raw mix (cristall water) 1.09% %H2O (moisture) in kiln feed: 0.21%
Ratio "hot meal / ck" 1.19 (in real mass) kg/h kiln feed (moist) 305,980

BY-PASS Extra
POINT Air
Neutral Including Including Including By-pass for Neutral Including Including Incl.H2O Including Including
KILN EXIT kiln 0.00% 5.20% 0.03% 0.00% extracted calciner Neutral decarbo Excluding 3.65% 0.08%
Volume waste gases CO2hotmeal O2 dry CO dry extraction bypass Volume kiln total Bypass O2 dry CO dry
Flowrate (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (Nm/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 0.039 0.039 0.039 Err:511 Err:511 CO2 0.140 0.179 0.486 0.486 0.486 Err:511
H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.0001 0.0001 0.0001 0.0001 0.00000 SO2 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
O2 Err:511 Err:511 Err:511 Err:511 O2 0.000 0.000 Err:511 Err:511
CO Err:511 Err:511 CO Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 ppm Err:511 Err:511 Err:511 Err:511 Err:511 SO2 ppm Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%O2 Err:511 Err:511 Err:511 %O2 Err:511 Err:511 Err:511 Err:511 Err:511
%CO Err:511 Err:511 %CO Err:511
Mass Mass
Flowrate (kg/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Flowrate (kg/kgck) Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
CO2 0.078 0.078 0.078 Err:511 Err:511 CO2 0.274 0.352 0.953 0.9533 0.953 Err:511
H2O Err:511 Err:511 Err:511 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
SO2 0.000 0.000 0.000 0.000 0.000 SO2 0.0000 0.000 0.000 0.0000 0.0000 0.0000
N2 Err:511 Err:511 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
O2 Err:511 Err:511 Err:511 O2 0.000 0.000 0.000 Err:511 Err:511
CO Err:511 Err:511 CO Err:511
% CO2 Err:511 Err:511 Err:511 Err:511 Err:511 % CO2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%H2O Err:511 Err:511 Err:511 Err:511 Err:511 %H2O Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%N2 Err:511 Err:511 Err:511 Err:511 Err:511 %N2 Err:511 Err:511 Err:511 Err:511 Err:511 Err:511
%O2 Err:511 Err:511 Err:511 %O2 Err:511 Err:511 Err:511 Err:511 Err:511
%CO Err:511 Err:511 %CO Err:511
CO2 decarbo kiln (Nm/kgck) 0.000 CO2 decarbo calciner (Nm/kgck) 0.306 CO2 decarbo total: 0.306
Neutral air calciner (Nm/kgck) Err:511
Excess air kiln (Nm/kgck) Err:511 Excess air line (Nm/kgck) Err:511 /neutral air
(Nm/h) Err:511 (Nm/h) Err:511 Err:511
Total combustion air kiln (Nm/kgck) Err:511 Total combustion air line (Nm/kgck) Err:511
(Nm/h) Err:511 (Nm/h) Err:511 PH Exit Gas
Density
Total kiln exit gas (wet) (Nm/kgck) Err:511 Err:511 Total preheater exit gas (wet) (Nm/kgck) Err:511 Err:511 Am/h kg/Nm
(Nm/h) Err:511 Err:511 (Nm/h) Err:511 Err:511 Am/h Err:511

Secondary air Tertiary air

Primary air kiln (% total kiln air) Err:511 Err:511 (Nm/kgck) Primary air preca including transport air 0.055 (Nm/kgck)
including transport air 10,129 (Nm/h) 10,985 (Nm/h)
Kiln hood inleak.(%total kiln air) 4.0% Err:511 (Nm/kgck) Kiln inlet inleakage (% kiln exit gas) 4.0% Err:511 (Nm/kgck)
Err:511 (Nm/h) Err:511 (Nm/h)
Secondary air flow Err:511 (Nm/kgck) air lift / PH / calciner (Nm/h) Err:511 Err:511 (Nm/kgck) Err:511
Err:511 (Nm/h) Tertiary air into calciner Err:511 (Nm/kgck)
Air from the cooler(secondary + tertiary air) Err:511 (Nm/kgck) Err:511 (Nm/h)
Air Composition False air into tertiary air: 24997 (Nm/h)
%O2 air Err:511 %N2 air Err:511 %H2O air Err:511 Tertiary air from cooler Err:511 (Nm/h)

False air assesment along preheater (calciner exit till preheater exit): Err:511 (Nm/h)

CO2 out of decarbonatisation: 0.601 kg/kg cl

CO2 out of combustion: 0.352 kg/kg cl
Total CO2: 0.953 kg/kg cl

CO2 out of fossil combustion kiln: 0.078 kg/kg cl

CO2 out of fossil combustion calciner: 0.274 kg/kg cl
Total fossil CO2 out of combustion: 0.352 kg/kg cl

Total fossil CO2: 0.953 kg/kg cl

 Date: #VALUE!
Kiln: RK3#
Comment:

KILN AUDIT HEAT BALANCE TOOL - COOLER BALANCE AND PERFORMANCE SHEET
Cooler input Cooler output
kg/h TC Nm3/kgck kJ/kgck % kg/h TC Nm3/kgck kJ/kgck %
Cooling fans Err:511 Err:511 1.77 Err:511 Err:511 Secondary air Err:511 Err:511 Err:511 Err:511 Err:511
Hot Clinker 199540 1450 Err:511 Err:511 Tertiary air Err:511 901 Err:511 Err:511 Err:511
Exhaust air water injection 0 0 Err:511 Err:511 Err:511 Mill take off #1 Err:511 0 0.00 Err:511 Err:511
False air Err:511 0.00 0.00 Err:511 Mill take off #2 Err:511 0 0.00 Err:511 Err:511
Exhaust air Err:511 360 Err:511 Err:511 Err:511
Cold clinker 199540 227 Err:511 Err:511
Wall losses 24.00 Err:511
Vap. Heat Err:511 Err:511
Air leakage Err:511 0.00 0.00 Err:511
Total Err:511 Err:511 Err:511 Err:511 Total Err:511 Err:511 Err:511 Err:511 Err:511
Out - In Err:511 Err:511 Err:511
Cooler Load, tday/m2 47.40
Recovery Efficiency, Err:511 Air Load, Nm3/kgck 1.77
Cooling Efficiency, Err:511 Average Blowing Density, Nm3/s/m2 0.97

B lo w in g D e n sity, N m 3/s/m 2
Recovery Factor, k Err:511 Err:511 Cooler Loss, kJ/kgck Err:511

Err:511 Nm3/kgck Err:511 Nm3/kgck 0.00 Nm3/kgck 0.00 Nm3/kgck

Err:511 C 901 C 0 C 0 C
Secondary air Tertiary air
Mill take off #1
Mill take off #2
BLOWING DENSITY OF THE COOLER
2.00
Hot Clinker Exhaust air 1.80

199540 kg/h Err:511 Nm3/kgck 1.60

1450 C 360 C 1.40

1.20
1.00
0.80
0.60

Cold 0.40

Cooling fans Clinker 0.20

0.00
0.00 20.00 40.00 60.00 80.00 100.00 120.00
1.77 Nm3/kgck 199540 kg/h Cumulative Surface Area, m2
Err:511 C 227 C
 Date: #VALUE!
Kiln: RK3#
Comment:

KILN AUDIT HEAT BALANCE TOOL - KILN SYSTEM HEAT BALANCE

System In System Out

kg/h TC Nm3/kgck kJ/kgck heat% content kg/h TC Nm3/kgck kJ/kgck heat %
Kiln Feed 305338 69 Err:511 Err:511 Preheater Exit Gas Err:511 462 Err:511 Err:511 Err:511
H2O 643 69 Err:511 Err:511 Gas Composition
Total Fuel 95907 Err:511 Err:511 CO2 Err:511 Err:511 Err:511 Err:511
Sensible Heat 88608 Err:511 Err:511 H2O Err:511 Err:511 Err:511 Err:511
Combustion 88608 Err:511 3865.67 Err:511 SO2 (ppm) Err:511 0 Err:511 Err:511
H2O 7299 Err:511 Err:511 Err:511 N2 Err:511 Err:511 Err:511 Err:511
TOC Combustion 0 69 Err:511 0.00 Err:511 O2 Err:511 Err:511 Err:511 Err:511
S-2 Combustion 0 69 Err:511 0.00 Err:511 CO Err:511 Err:511 Err:511 Err:511
Total False Air Err:511 Err:511 Err:511 Err:511 Err:511 Heat Loss CO Preheater Exit Err:511 Err:511 Err:511
Total Primary Air Err:511 Err:511 0.11 Err:511 Err:511 Cooler Exhaust Air Err:511 360 Err:511 Err:511 Err:511
Total Cooling Air of Cooler Err:511 Err:511 1.77 Err:511 Err:511 Cooler Exhaust Inj. Water Vap. Err:511 Err:511
Total Water Injection 0 Err:511 Err:511 Err:511 Err:511 Cooler Mill Take Off #1 Err:511 0 0.00 Err:511 Err:511
Cooler Mill Take Off #2 Err:511 0 0 Err:511 Err:511
Clinker 199540 227 Err:511 Err:511
Clinker Formation Heat 1717.69 Err:511
Preheater Dust 41720 445 Err:511 Err:511
By-Pass Gas 0 0 Err:511 Err:511 Err:511
By-Pass Dust 0 0 0.00 Err:511
Heat Consumption (fuels only, no TOC,S2-): 3866 kJ/kgck By-Pass Decarbonisation Heat 0.00 Err:511
Water Vaporization Heat 643 Err:511 Err:511
Wall Losses 248.10
Tertiary Air Duct 11.40 Err:511
Preheater 115.40 Err:511
Kiln 97.30 Err:511
Cooler 24.00 Err:511
Total Heat In Err:511
Total Heat Out Err:511
 Date: 12/30/1899
Kiln: RK3#
Comment:

KILN AUDIT HEAT BALANCE TOOL - RESULTS SUMMARY TABLE

Main Parameter Unit Audit Result Comments Levers

Lafarge Unit
standard
Kiln&Preheater
Clinker Production [t/d] 4789 Load is high due to upraded kiln from 4000 tpd to 5000 tpd 4.5 Tpd kk / m3 internal volume 4.9

Clinkerisation Factor [-] 1.53

Preheater Exit Dust [g/Nm] Err:511 80 gr/Nm3 (normal practice) Err:511
Top Cyclone Efficiency [%] 86.37 92% (Normal practice) 86%
Specific Heat Consumption [kJ/kgck] 3866 Very high SPC due to low PF. Quartz in material streams to be confirmed 3331 (Corrected value from 3866
normal practice in the 5
stages PC kiln with feed
only in the top, Kj/kgkk )
% Heat Input on Main Burner: [%] 22.9 Too low. High high load at FF due to dual feed system. 1260 Normal practice kj/kgkk to 885
the main burner
AF Substitution Rate [%] 8.40 Not including SBE and Kimberly Clark in shale stream
Thermal Load (Burning Zone) [MW/m2] 3.47 5 MW/m2. ((can be pushed to 3.5
maximum 6MW/m2 in day
to day operation)
Specific Preheater Gas Flow [Nm3/kgck] Err:511 Due to high heat consumption 1.6 Nm3/kgkk Err:511
Specific Preheater Gas Flow [Am3/kgck] Err:511 4 Normal practice, Am3/kgkk Err:511

Preheater Exit Gas Oxygen (wet) [%] Err:511 4 Normal practice, %O2 Err:511
False air Preheater and Calciner [Nm3/kgck] Err:511 High. Will repair on shut down 0.08 Lafarge target in normal PH Err:511
kiln with 1.6 Nm3/kgkk
waste gas, Nm3/kgkk
Preheater Exit Gas Temperature [C] 462 High due to dual feed system 360 degC, assumed 30deg C is 462
the effect of bottom feed to
the heat transfer.
Calcination Degree [%] 100.00 - 92 % 100.0
Kiln Residence Time [min.] 28
CO2 total [kg/kg cl] 0.953
CO2 fossil total [kg/kg cl] 0.953
Kiln Loading [%] 6.28
Burning zone filling degree [%] 17 High filling. To be optimized 14 % filling degree 16.8
(Fuller Formula)
Cooler
Secondary Air Volume [Nm3/kgck] Err:511 Low. 0.31 Nm3/kgkk Err:511
Secondary Air Temperature [C] Err:511 1200 C Err:511
Tertiary Air Volume [Nm3/kgck] Err:511 High 0.47 Nm3/kgkk Err:511
Tertiary Air Temperature [C] 901 850 C, normal practice. 901
Cooling Air [Nm3/kgck] 1.77 2.00 Nm3/kgkk 1.77
Clinker Exit Temperature [C] 227 125 C. Good practice 227.0
Recovery Efficiency [%] Err:511 72 % Err:511
K Factor [-] 1.20 1.5 1.20
Cooler Load [t/d/m2] 47.4
 Gas Speed - Stage 1 Exit
Preheater exit gas: Err:511 Nm/h Absolute Pressure:
Temperature: 462 C
Pressure: -84.93 hPa
Flow in actual: Err:511 Am/h

Number of cyclones: 4
Diameter of stage exit: 1.7 m
Area per stage: 2.27 m
Total area: 9.08 m

Gas Speed: Err:511 m/s

1008 hPa
 Calciner Residence Time
Calciner exit gas: Err:511 Nm/h Absolute Pressure: 1008 hPa
Temperature: 914 C
Pressure: -8.8 hPa
Flow in actual: Err:511 Am/h

Calciner Volume: 740 m

gas volume: Err:511 Am/s

residence time: Err:511 sec