Heat in=out Heat Input = Heat Output Heat Input Combustion heat of Fuel. Sensible heat of Raw Meal. Sensible heat of Fuel. Sensible heat of Air. i. Primary air. ii. Secondary air. iii. Tertiary air. iv. ByPass Quench air. Sensible heat of Cooing Water. i. ByPass Cond. Tower. ii. Clinker Crusher. iii. Cooler. Heat Output Clinker heat of formation. Heat loss with preheater exit gas. i. Exit gas. ii. Evaporation of water. iii. Dust. iv. CO. Heat loss with bypass exit gas. i. Bypass gas. ii. Evaporation of water from cond. Tower. Heat loss with bypass dust. Heat loss with clinker crusher water. Heat loss with clinker. Heat loss with cooler exit gas. i. Cooler exit gas. ii. Evaporation of water. Heat loss due to radiation & convection. i. Radiation from kiln. ii. Radiation from cooler. Heat Balance Q 1 Q 2 Q 3 Q 4 Q 5 Q 6 Q 7 Q 8 Q 9 Q 10 Q 11 Q 12 Q 13 Q 14 Q 15 Q 16
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Heat in=out
Heat Input = Heat Output
Heat Input
Combustion heat of Fuel.
Sensible heat of Raw Meal.
Sensible heat of Fuel.
Sensible heat of Air.i. Primary air.ii. Secondary air.iii. Tertiary air. iv. ByPass Quench air.
Sensible heat of Cooing Water.i. ByPass Cond. Tower.ii. Clinker Crusher. iii. Cooler.
Heat Output
Clinker heat of formation.
Heat loss with preheater exit gas.i. Exit gas.ii. Evaporation of water.iii. Dust.iv. CO.
Heat loss with bypass exit gas.
i. Bypass gas.
ii. Evaporation of water from cond. Tower.
Heat loss with bypass dust.
Heat loss with clinker crusher water.
Heat loss with clinker. Heat loss with cooler exit gas.
i. Cooler exit gas.
ii. Evaporation of water.Heat loss due to radiation & convection.
i. Radiation from kiln.
ii. Radiation from cooler.
Heat Balance
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q10
Q11
Q12
Q13
Q14
Q15
Q16
Heat in=out
iii. Radiation from preheater.Q17
1. Combustion Heat of Fuel
= F * Hc / P Where
Commbustion Heat
F Fuel Consumption (Main burner + Calciner)
Fuel Heat Content
P Clinker Production
Main burner 2240.45
Calciner burners 2810.29
F 5050.74 (Performance Test)
9500 (Fuel Analysis)P 38178.5 (Performance Test)
1256.8
Q1
Q1
Kcal / Kg ck
Kg f / hr
Hc
Kcal / Kg f
Kg ck
/ hr
Kg f / hr
Kg f / hr
Hc
Q1
Kcal / Kg ck
Q1
2. Sensible Heat of Raw Meal (Kiln Feed)
=Where
Sensible Heat of Raw Meal
M Kiln feed flow rate
Cp Specific Heat of Raw Meal
Kiln Feed Temperature
Ambient Temperature
P Clinker Production
M 67282.8 (Performance Test)Cp 0.22 (Table page )
83 (Thermometer)
30 (Assumption)P 38178.5 (Performance Test)
20.5
Q2
M * Cp * ( T2 - T
1 ) / P
Q2
Kcal / Kg ck
Kg raw
/ hr
Kcal / Kg raw
oC
T2
oCT
1oC
Kg ck
/ hr
T2
T1
Q2
Kcal / Kg ck
Q2
3. Sensible Heat of Fuel
=Where
Sensible Heat of Fuel
M Fuel flow rate (Main burner + Calciner )
Cp Specific Heat of Fuel
Fuel Temperature
Ambient Temperature
P Clinker Production
M 5050.7 (Performance Test)Cp 0.47 (Table page )
115 (Thermometer)
30 (Assumption)P 38178.5 (Performance Test)
5.2
Q3
M * Cp * ( T2 - T
1 ) / P
Q3
Kcal / Kg ck
Kg f / hr
Kcal / Kg f
oC
T2
oCT
1oC
Kg ck
/ hr
T2
T1
Q3
Kcal / Kg ck
Q3
4. Sensible Heat Of Airi. Primary Air.
ii. Secondary Air.iii. Tertiary Air.iv. ByPass Quench Air.
=
=Where
Sensible Heat of Air
M Air Flow rate
Cp Specific Heat Of Air
Air Temperature
Ambient Temperature
P Clinker Production
Asuming
=Therefore
= 0
Q4
Qprim
+ Qsecond
+ Qterti
+ Qquench
Q4
M * Cp * ( T2 - T
1 ) / P
Q4
Kcal / Kg ck
m3 / h
Kcal / m3 oCT
2oC
T1
oCKg
ck / hr
T2
T1
Q4
Kcal / Kg ck
Q4
5. Sensible Heat of Cooling Wateri. ByPass Cond. Tower
ii. Clinker Crusheriii. Cooler
=
=Where
Sensible Heat of Water
M Water Flow rate
Cp Specific Heat Of Water
Water Temperature
Ambient Temperature
P Clinker Production
Asuming
=Therefore
= 0
Q5
Qc.t
. + Qcrusher
+ Qcooler
Q5
M * Cp * ( T2 - T
1 ) / P
Q5
Kcal / Kg ck
m3 / h
Kcal / m3 oCT
2oC
T1
oCKg
ck / hr
T2
T1
Q5
Kcal / Kg ck
Q5
1. Clinker Heat of Formation
Lab. Analysis Raw Mix Clinker
Moisture 0.25
Titration 80.2
80.1
0.24
15.46 25.02
3.13 4.85
0.12 0.25
CaO 44.56 68.18
MgO 0.11 0.27
0.06 0.09
0.04 0.06
S 0 0.61
0.06
L.O.I. 35.95 0.21
Sum 99.49 99.54
LSF
SM
AM
Raw Mix To Clinker Factor (Ck Factor)= 100 / (100 - L.O.I.)= 1.5613 Kg / Kg Clinker
as follows ,
CaO == 70.0328 Kg / Kg Clinker
MgO = MgCO3 * Ck Factor * 40.3 / 84.30.17913 Kg / Kg Clinker
=
+
= 418.835
CaCO3
MgCO3
SiO2
Al2O
3
Fe2O
3
K2O
Na2O
Combined H2O
CaO & MgO calculated from CaCO3 & MgCO
3 in Raw Mix
CaCO3 * Ck Factor * 56 / 100
Q6
(7.646 * CaO) + (6.48 * MgO) + (2.22 * Al2O
3)
(11.6 * Ck Factor * H2O) - (5.116 * SiO
2) - (0.59
* Fe2O
3) - (10 * {K2O + Na2O}) - (32 * Ck Factor * S)
Q6
Kcal / Kg ck
Q6
2. Heat Loss With Preheater Exit Gas
=Where
Heat Loss With Preheater Exit Gas
M Preheater Exit Gas Flow rate
Cp Specific Heat of Exit Gas
Preheater Exit Gas Temperature
Ambient Temperature
P Clinker Production
M 83008.4 (Calculation)Cp 0.31 (Table page )
440 (Thermometer)
30 (Assumption)P 38178.5 (Performance Test)
276.3N.B.
Air Cp 0.31
ρ 1.293Sp.heat 0.237 Kcal / Kg
M
1.Process Flow Sheet 80985.2
2. Fuel Consumption 83008.4
3. Combustion Calculations 79353.803
Preheater Exit Gas CalculationProcess Update
I.D. Fan Flow Rate 65000 MKiln Feed 54 67.28 t / hFuel Consumption 3955 5050.74 Kg / h
i. Process Flow Sheet
M = 65000 * 67.28 / 54 = 80985.19
ii. Fuel Consumption
M = 65000*5050.7 / 3955 = 83008.37
iii. Combustion Calculations
M = 79353.8
Q7
M * Cp * ( T2 - T
1 ) / P
Q7
Kcal / Kg ck
m3 / h
Kcal / m3 oCT
2oC
T1 oC
Kg ck
/ h
T2
T1
Q7
Kcal / Kg ck
Q7
Kcal / m3 oC
Kg / m3
m3 / h
m3 / h
m3 / h
m3 / h
m3 / h
m3 / h
m3 / h
(See Mixing Chamber Balance)
AirPrimary Air = 3000Secondary Air 43600*67.28/54 = 54322Total 57322
Calculations Air = 0.26 * Hu
= 0.26 * 1256.7 * 38178.5 * 4.187 / 1000= 52230.8
Excess Air = 11 - 3.762 * CO 0.50%
2.50%
= 10% = 52230.8 * 0.1= 5223.1
Total Air = Min Air + Excess Air= 52230.8 + 5223.1= 57453.9