Heat Balance Calculation

SECTION : KILN DATE : 03-2-2009

Plant Capacity (TPD) 6000.000 Primary Air Heat Output ( Kcal/kg Clinker)
Ambient Temperature(oC) 25.000 Temperature(0C) 25.000 1). Heat for Clinkerisation 425.560
Volume (Nm3/kg) 0.032 2). Heat Carried by PH Exhaust Gas 178.297
Clinker Composition 3). Heat Carried by Cooler Exhaust Gas 109.074
% SiO2 20.650 PC Firing Air 4). Heat for Moisture Evaporation 8.215
% Al2O3 4.830 Temperature(0C) 25.000 5). Heat Carried by Clinker 18.286
% Fe2O3 3.640 Volume(Nm3/Kg) 0.058 6). Radiation Losses 48.135
% CaO 64.970 7). Heat Carried by PH Exhaust Gas Dust 10.986
% MgO 2.250 Radiation Losses(kcal/kg cli.)
% Na2O 0.110 Kiln Shell 19.908
PH Exhaust Gas Preheater 23.841 Total Heat Output (Kcal/kg Clinker) 798.553
Temperature(0C) 315.000 Cooler + Kiln Hood 4.386
Volume(Nm3/kg ) 1.759
Dust Load (gms/Nm3) 90.570 Specific Heat (kcal/kg oC)
Raw Meal PH Exhaust Gas 0.245 Heat Input ( Kcal/Kg Clinker )
Amount(kg/kg cli.) 1.600 Cooler Exhaust Gas 0.244 1). Heat from Cooling Air 17.835
Temperature(0C) 70.000 Primary Air 0.238 2). Heat from Primary Air 0.313
Moisture(%) 0.800 PC firing Air 0.238 3). Heat from PC firing Air 0.572
Raw Meal 0.213 4). Heat from Raw Meal 16.957
Clinker Clinker 0.192 5). Heat from Fuel 760.520
Temperature(0C) 120.000 Specific Heat of HFO 0.470 6). Sensible Heat of Fuel 2.358

Cooler Exhaust Gas

Temperature(0C) 311.000 Total Heat Input ( Kcal/Kg Clinker ) 798.553
Volume(Nm3/kg) 1.211

Cooling Air
Temperature(0C) 30.053
Volume ( Nm3/kg) 2.097
 Kiln Performance Report
Date: 31-01-2013
Sl.No. Description Units Parameters
1 Site Elevation m 275.000
2 Corresponding site Pressure mmwg 9982.466
3 Ambient Tempearature 0C 25.000
4 Kiln Lenth m 72.000
5 Kiln Diameter m 5.000
6 Brick Thickness mm 220.000
7 Effective Diameter m 4.560
8 Effective Cross Sectional Area m2 16.331
9 Effective Volume m3 1175.850
10 Kiln Fuel Kg/ hour 11417.000
11 PC Fuel Kg / hour 24417.000
12 Fuel Ratio for Kiln Firing % 31.861
13 Fuel Ratio for PC Firing % 68.139
14 Calorific Value of Fuel kcal / kg 5800.000
16 Kiln Feed TPH 445.000
17 Kiln Feed to Clinker Factor kg kf / kg clinker 1.770
18 Clinker production TPH 251.412
19 Specific Heat Consumtpion Kcal/kg clinker 826.678
20 Kiln Slope % 3.500
21 Kiln RPM RPM 3.950
22 Degree of Filling % 14.730
tpd/m3 5.132
23 Kiln Volumetric Loading tph/m3 0.214
kg/hr./m3 213.813
24 Burnig Zone Length m 24.000
25 Kiln Burning zone thermal load Gcal/hour/m2 4.055
26 Volumetric thermal Load Gcal/hour/m3 0.169
27 Material residence time in kiln Minutes 21.700
28 Cooler Area m2 139.000
29 Bed Height in Cooler mm 650.000
30 Clinker Density t/m3 1.600
31 Clinker Residence time in Cooler Minutes 34.499
32 Specific Cooler Capacity tpd/m2 43.409
33 Total Cooling Air m3/hour 560462.000
34 Specific Cooling Air m3/hr./kg clinker 2.229
35 Specific Cooling Air Nm3/hr/kg clinker 2.042
36 PC Exit O2 % 0.500
37 PH exit O2 % 3.500
38 False Air Leakage( at Kiln inlet to PH exit ) % 17.143
 Kiln Specific Heat Consumption
Date: 31-2-2013
Time: 8.00 AM to 11.30 AM

Description Parameters Units

Kiln Feed 460.00 TPH

Kiln feed to clinker factor 1.72 kg feed/kg clinker

Clinker production 267.44 TPH

Clinker production 267441.86 kg/hr.

HFO consumption for Kiln firing 11417.00 Liters/hr.

Density of HFO at 120 oC 1.00 kg/liter

HFO consumption for Kiln firing 11.42 t/hr.

HFO consumption for PC firing 24417.00 Liters/hr.

HFO consumption for PC firing 24.42 t/hr.

Total Fuel consumption (HFO) 35.83 t/hr.

% of Fuel consumption 13.40 %

Calorific Value of Fuel ( HFO) 5800.00 kcal/kg oil

Specific Heat Consumption 777.13 Kcal/kg Clinker

 False Air Measurements
Date: 03-2-2009
Time: 9.50 AM

% False air in terms of

Sl.No. Description CO2 O2 Remarks
CO2 O2 Average
Before fresh air damper 8.2 3.7 False air leakage through
Line-1 (441 FN1) 13.89 13.07 13.48
After fresh air damper 7.2 5.7 fresh air damper
Before fresh air damper 8 4.1 False air leakage through
Line-2 (441FN2) 9.59 9.03 9.31
After fresh air damper 7.3 5.5 fresh air damper
Avg. Kiln ID fans Inlet 7.25 5.6 11.74 11.05 11.40
Inlet 8.1 6.1
Raw Mill 80.00 55.21 67.60 Including False air from mill I/LFresh air dampr
Cyclone outlet 4.5 11.4
 DATA

Site elevation MSL (in metres) 275

Corresponding site Pressure 9982.4660323752
Volume in Nm3 871000 8710000
Pressure in mmWc 10333
Abs Temperature in Kelvin 273

Measuring point Static Pr mm Wc -70

Site Temperature in deg C 220
Corresponding temp in kelvin 493
Effective pressure in mmWc 9912.4660323752

V actual = 1639634.86499508
 PH Fan
Site elevation MSL (in metres) 275
Corresponding site Pressure 9982.47
Volume in Actual m3 840000
Site Pressure in mmWc -70
Site Temperature in Deg C 250
Effective site Pr in mm Wc 9912.47
Corresponding temperature in kelvin 523
Std Normal temperature in Kelvin 273
Std Normal absolute pressure 10333
V Normal / hour = 420625.43
V Normal / sec = 116.84
Clinker production in TPD 6700
Clinker in kg/hr 279166.666666667
Nm3/ kg Clinker 1.5067179631