Kiln Cooler Heat Mass Balance

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PLANT : Binani Cement - 20.06.2003 Kiln Feed

Kiln Feed Dividing Flap 1.657 kg-Feed/kg-Clk

O2 = 5.3% O2 = 3.2% To Raw Mill/Baghouse0.566 1.449

0.134 kg-Dust/kg-Clk

KS Fan844/82 kW/%

0.884 CS Fan Cooler ESP1930/86.20 kW/%

Kiln String Calciner String

1.092 185 kW/%

0.020 kg-Dust/kg-Clk Stack

Calciner Firing Kiln Firing

0.072 kg-Coal/kg-Clk 0.044 kg-Coal/kg-Clk

0.020 0.020

0.508 T.A. Duct

Primary Air0.020

KILN 1136 deg.C3.56 %

Inlet O2 4.2 rpm

0.030 50 %

0.052 0.357 0.009

Hot air to PA Fan Clinker 1.889 251515 kg-Clk/hr

Nm3w/kg-clk Nm3

w/kg-clk

Nm3/kg-Clk

Nm3w/kg-clk

Nm3w/kg-clk Nm3

w/kg-clk

Nm3/kg-Clk

Nm3w/kg-clk

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

False Air a/c CS, Nm3w/kg-clk Nm3

w/kg-clk

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

Nm3w/kg-clk

C1

C6

C5

C4

C3

C2

K1

K6

K5

K4

K3

K2

Cal.

KILN

Cooler

ESP

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04/22/2023 07:59:00 document.xls Pic-2S LU001005-KCP#Ver.1.2D***

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PLANT : Binani Cement - 20.06.2003

Stoi. 0.479 0.613

Exc. 0.048 0.062

Tot. 0.528 0.675 Trpt. Air0.020

0.026

Trpt. Air0.020

0.026 Pri. Air Water Inj.0.025 0.020 0.020

0.508 0.025

0.650 Vent Air KILN #REF! 1.092

1.388

0.311

0.398

Stoi. 0.294 0.376 False Air Exc. 0.063 0.081 0.819 1.070 0.003

Tot. 0.357 0.457 1.048 1.369 0.004

False Air0.006

0.007

Excess Air Optimisation (vol%, d) 3.6 Cooling Air

20.7 1.889

1.4 2.417

39.3Error Minimisation-1 0.00

Optimised Excess Air, Kiln 21.5 vol%, w Error Minimisation-2 0.00 Optimised Excess Air, Cal. 10.1 vol%, w Error Minimisation-3 0.00

Nm3w/kg-clk kgw/kg-clk

Nm3w/kg-clk

kgw/kg-clk

Nm3w/kg-clk

kgw/kg-clk

kgd/kg-clk Nm3w/kg-clk kg/kg-clk

kgw/kg-clk

Nm3w/kg-clk

kgw/kg-clk

Nm3w/kg-clk kgw/kg-clk

Nm3w/kg-clk

kgw/kg-clk

Nm3w/kg-clk

kgw/kg-clk

Optimised O2 - Kiln I/L Optimised CO2 - Kiln I/L Nm3

w/kg-clk

Optimised O2 - Cal. O/L kgw/kg-clk

Optimised CO2 - Cal. O/L

C6K6Cal.

KILN

T.A.DUCT

COOLAX COOLER 1284-3ME-IN Ist 6 Row CIS



0.602

0.061

0.663

0.026

0.025

0.638

1.349

0.369 0.391

0.079

0.448

1.029 1.344 0.004

0.007

3.491 0.065 2.374

20.703 0.0001.416 0.02739.347 0.000

kgd/kg-clk

kgd/kg-clk

kgd/kg-clk

kgd/kg-clk

kgd/kg-clk

kgd/kg-clk


kgd/kg-clk

kgd/kg-clk

04/22/2023 07:59:00 document.xls Kiln-CalcS LU000211-KCP#Ver.2.2***

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Kiln Basic Calculations : SLC 6-Stage II-StringSite Conditions Equipment Specifications

Clinker Production tpd 6036 Kiln Length mts 68Clinker Production kg/hr 251515 Kiln Diameter mts 4.55Plant Elevation mts +MSL 402 Kiln Refractory Thickness mm 220Barometric Pressure mmWG 9827 Kiln Diameter, effective mts 4.11Barometric Pressure mmHG 723 Slope % 4Ambient Air Temperature deg.C 31.0 Cooler Area 97.03Relative Humidity % 41 Burner Axial Area 5 mm withdrawn 0.01262Pitot Constt. - S Type (L=01m) S1 0.883 Burner Radial Are X mm withdrawn BlockedPitot Constt. - S Type (L=03m) S2 0.872 Burner - Coal Annulus 0.03878

False Air Analysis Raw Mixmass%, w 5.52 Loss on Ignition (as LOI) % 35.83mass%, w 6.41 % 75.70

A/c Cooler ESP w.r.t. Mix mass%, w 7.24 % 1.80Excess Air in Kiln vol%, d 21.45 Sulphur (as pyrites) % 0.04Excess Air in Calciner vol%, d 10.10 % 1.05Water Temp. deg.C 25 Carbon in Kiln Feed % 0.20

Miscellaneous Data Moisture in Kiln Feed % 0.22Dust with Clinker, Kiln % 2.00 Moisture in Kiln Feed kg/hr 917Water In, Cooler 5.0 Raw Mix - Clinker Ratio kg/kg-clk 1.522Water In, Cooler tph 5.0 Raw Mix - Clinker Ratio kg/hr 382896Evaporation Heat kcal/kg 539 Kiln Feed Rate kg/kg-clk 1.657Clinker Temperature, Kiln Outlet deg.C 1450 Kiln Feed Rate kg/hr 416689Clinker Temperature, Cooler Outlet deg.C 140 Clinker CompositionKiln Feed Temperature deg.C 82 % 20.87Fine Coal Temperature deg.C 73 % 6.15Kiln Dust mass%, w 6.70 % 3.51ESP I/L Dust Concn. 9.0 Lime (as CaO) % 65.23BH Dust Returned to Kiln yes/no no Magnesia (as MgO) % 1.91Clinker Density 1.3 % 0.55Cooler Fans kWh 31877 % 0.45Cooler ESP/Stack Radiations kcal/kg-Clk 1.0 Sulphates (as SO3) % 0.50

Performance & Efficiency CCR DataKiln Feed Residence Time in Kiln min (d) 18.71 Kiln Speed rpm 4.20Clinker Residence Time in Cooler min (d) 17.01 CFG Static Pressure mmWG 735Theoretical Flame Temperature deg.C 2181 Kiln Feed Rate/Dosing Valve Position tph/% 415/78Kiln Volumetric Loading 6.69 Kiln Feed Elevator Load kW 92/71Burning Zone Loading 4.95 Kiln Feed Diversion - Kiln/Calciner %/% 40.5/59.5Percent Filling % 16.56 Coal Screw Speed - Kiln/Calciner rpm 629/673Clinker Bed Thickness in Cooler mm 565 KS Fan Load/Speed kW/% 844/82Clinker in Cooler tons 71 CS Fan Load/Speed kW/% 1930/86.20Cooler Efficiency - Ref. : Amb. Temp. % 73.11 Kiln String O2 % 5.44Percent Primary Air (AA | RA) % 6.79 0.00 Calciner String O2 % 3P.A. Tip Velocity (AA | RA) m/sec 137 0 Kiln Inlet O2 % 3.65Flame Momentum (AA | RA) %.m/sec 928 0 Cooler Grate-I Ch.I/II/III DP mmWG 676/123/84

Percent Coal Transport Air % 7.08 Cooler Grate-I/II/III speed spm 15.8/16.6/17.6

C.T.A. Tip Velocity m/sec 37 Cooler Grate-I/II/III load amps 69/56/55Flame Momentum (CTA) %.m/sec 260 Burning Zone Temperature/Kiln Torque deg.C/% 1136/50Total Flame Momentum %.m/sec 1188 Cooler ESP Fan Load kW 185Cooler Air 1.51 Cooler ESP Fan Speed % 60Cooler Loading 62.2 Tert. Air Draft mmWG -38Secondary Air Temperature deg.C 1109 Hood Draft mmWG -6Tertiary Air Temperature deg.C 905 Dust Losses - PH % 8.11PLANT : Binani Cement - 20.06.2003 < < < E R R O R S > > >Hot air to PA Fan (Yes/No) yes Heat-1 0.00 Heat-2 0.00Axial Air Contribution, % 100 Heat-3 0.00 Heat-4 0.00

Heat-5 0.00 Heat-6 0.00Heat-7 0.00 Heat-8 0.00

m2

m2

m2

m2

A/c KS w.r.t. Mix - O2 BasisA/c CS w.r.t. Mix - O2 Basis CaCO3

MgCO3

Combined H2O

m3/hr

Silica (as SiO2)Alumina (as Al2O3)Iron (as Fe2O3)

gm/m3-dg

t/m3 Potassium Oxide (as K2O)Sodium Oxide (as Na2O)

tpd/m3

Mcal/hr-m2

m3/s/m2

tpd/m2


Page - 13/29

Kiln Air Flow Calculations : SLC 6-Stage II-String

Flow Analysis Kiln Calciner Total Cooler Primary Coal Trpt. Air False AirString 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 Water Vapor kg/kg-dg 0.110 0.110 0.110 0.030 0.021 0.021 0.020 0.012 0.012 0.012 Avg. Ps mmWG -575 -864 -753 -40 1020 3305 2960 -66 -234 -6RMS Pd mmWG - - - - 9.75 50.86 50.19 - - -Duct Diameter mts 2.80 3.00 3.75 0.40 0.255 0.255 - - -

vol % 5.3 3.2 4.0 21.0 21.0 21.0 21.0 3.6 1.4 21.0 vol % 28.8 35.8 33.1 0.0 0.0 0.0 0.0 20.7 39.3 0.0 vol % 65.9 61.0 62.9 79.0 79.0 79.0 79.0 75.7 59.2 79.0

0.60 0.59 0.59 0.66 1.14 1.43 1.39 0.34 0.33 1.22 0.83 0.81 0.82 0.92 1.57 1.98 1.92 0.47 0.46 1.69 0.53 0.52 0.52 0.58 1.00 1.26 1.22 0.30 0.29 1.07 0.34 0.33 0.33 0.37 0.64 0.81 0.78 0.19 0.19 0.69

kg 3.20 1.88 2.38 13.90 23.88 30.08 29.13 1.21 0.48 25.61 kg 24.08 29.10 27.20 0.00 0.00 0.00 0.00 9.77 18.18 0.00 kg 34.96 31.58 32.87 46.01 79.03 99.55 96.38 22.73 17.40 84.74 kg 6.85 6.88 6.87 1.77 2.16 2.72 2.51 0.40 0.43 1.32

mass % 4.63 2.71 3.44 22.54 22.73 22.73 22.75 3.56 1.32 22.93 mass % 34.85 41.91 39.24 0.00 0.00 0.00 0.00 28.64 49.82 0.00 mass % 50.61 45.47 47.42 74.59 75.21 75.21 75.29 66.62 47.67 75.88 mass % 9.91 9.91 9.91 2.87 2.06 2.06 1.96 1.19 1.19 1.19

Gas Density, dry 1.47 1.52 1.50 1.29 1.29 1.29 1.29 1.41 1.54 1.29 Gas Density, wet 1.36 1.40 1.38 1.27 1.28 1.28 1.28 1.40 1.53 1.28 Gas Density, dry 0.62 0.63 0.62 0.60 1.03 1.30 1.26 0.34 0.36 1.10 Gas Density, wet 0.57 0.57 0.57 0.59 1.02 1.28 1.24 0.33 0.36 1.10 Pitot Tube S1/S2/L - - - - L L L - - -Gas Velocity m/s 15.2 21.2 22.1 13.1 13.7 27.9 28.2 - - -Duct C.S. Area 6.16 7.07 11.04 12.60 0.13 0.051 0.051 - - -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 142.27 222.22 364.44 ### 4.94 5.14 5.03 7.64 13.03 2.21 Gas Flow Rate, wet 336.90 539.90 876.81 ### 6.21 5.13 5.18 32.01 55.75 2.59 Moisture, by diff. tph 19.2 30.8 50.0 10.0 0.1 0.1 0.1 0.1 0.2 0.0 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 118.40 183.96 302.29 ### 4.78 4.98 4.87 7.48 12.74 2.17 Gas Flow Rate, dry 280.37 446.96 727.32 ### 6.00 4.96 5.02 31.35 54.49 2.55 Heat Cap., gas kcal/kg/C 0.263 0.261 0.262 0.250 0.244 0.244 0.244 0.263 0.264 0.242 Heat Content, gas Mcal/hr 15548 24527 40075 24911 134 117 118 2268 4251 21 Dust, gas tph 12.98 20.81 33.79 5.10 - - - - - -Heat Cap., dust 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

3.552

O2, dryCO2, dryN2, dryDensity, dry - O2 kg/m3

Density, dry - CO2 kg/m3

Density, dry - N2 kg/m3

Density - H2O kg/m3

Mass - O2, dryMass - CO2, dryMass - N2, dryMass - H2OO2, wetCO2, wetN2, wetH2O

kg/Nm3

kg/Nm3

kg/m3

kg/m3

m2

kNm3/hr

km3/hr

kNm3/hr

km3/hr


Heat Cap - CoefficientsGas/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-15CO2 0.1906 1.771E-04 -1.733E-07 ### -1.894E-14N2+Ar 0.2465 -3.284E-06 4.366E-08 ### 5.504E-15H2O,steam 0.4445 2.910E-05 6.887E-08 ### 6.472E-15H2O, liq. 1.0000Rawmeal 0.2060 1.014E-04 -3.673E-08Clinker 0.1742 1.414E-04 -1.283E-07 ###

A 23.5771 1.429 B -4042.90 1.977 C -37.58 1.257

0.804 0.804

BURNER AXIAL/RADIAL ANNULUSR/A Withd. Area A/A Withd. Area

0 0.046850 0 0.005790

2 0.045465 5 0.005790

4 0.044088 10 0.008630

6 0.042722 15 0.010610

8 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

15.8/16.6/17.6

Sp. Gravity, dry - O2 kg/Nm3

Sp. Gravity, dry - CO2 kg/Nm3

Sp. Gravity, dry - N2 kg/Nm3

Rho H2O-Steam, kg/Nm3 Sp. Gravity - H2O kg/Nm3


Page - 14/29

Supporting Gas Analysis Cooler-ESP Air Balancing

Ambient ESP False Air To KS CS Const. Mass Temp. Sp. Heat Heat

Air Stack ESP PA Fan Fan I/L Fan I/L kg/kg-clk deg.C kcal/kg/C kcal/kg-clk

31 265 31 265 305 302 IN

22 53 22 53 80 80 Air (ESP I/L) 1.388 285 0.250 99

15 40 15 40 60 60 False Air 0.106 31 0.242 1

16 30 16 30 57 58 ESP Fan Pow. - - - 0

0.012 0.028 0.012 0.028 0.110 0.110 TOTAL 1.495 - - 100

0 3.75 0 - -610 -910 OUT

- 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 2

21.0 21.0 21.0 21.0 5.7 3.4 Radiations - - - 1

0.0 0.0 0.0 0.0 24.9 34.6 TOTAL 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 ESP False Air Optimisation 7.24

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


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 --

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Kiln Heat & Mass Balance : SLC 6-Stage II-String

S. Constriants Amount Temp. Cp Heat

No. kg/hr deg.C kcal/hr kcal/kg-Clk

I N P U T

1 Combustion of Coal - - - - 172787463 687.0

2 Cooling Air, Cooler 607797 475107 35 0.243 5167950 20.5

3 Fuel (Kiln+Cal.) 29207 - 73 0.262 559117 2.2

4 False Air (KS+CS+Cooler) 33423 22885 31 0.242 250376 1.0

5 Primary Air 6307 4938 87 0.244 134126 0.5

6 Kiln Feed, dry 415773 - 82 0.214 7298375 29.0

7 Combustibles in Kiln Feed - - - - 6442978 25.6

8 Free Water in Kiln Feed 917 - 82 1.000 75171 0.3

9 Water Injection, Cooler 5000 - 25 1.000 124999 0.5

10 Coal Transport Air (Kiln+Cal. 12994 10172 73 0.244 231628 0.9

TOTAL INPUT 1111418 193072182 767.6

O U T P U T

1 Preheater Exit Gases 504065 364436 304 0.262 40074502 159.3

2 Dust with PH Exit Gases 33794 - 304 0.233 2394225 9.5

3 Cooler Vent Air 349198 274761 285 0.250 24911420 99.0

4 Dust with Cooer Vent Air 5095 - 285 0.205 298061 1.2

5 Cold Clinker 246420 - 140 0.192 6610674 26.3

6 Total Radiations - - - - 11873278 47.2

a Kiln String - - - - 2618130 10.4

b Calciner String - - - - 3212876 12.8

c Kiln - - - - 4437254 17.6

d T.A. Duct - - - - 995312 4.0

e Cooler + Hood - - - - 609706 2.4

7 Heat of Reaction excl. Comb - - - - 103329439 410.8

8 Evap. of Water, Kiln Feed 917 - - - 510611 2.0

9 Evap. of Water, Cooler Inj. 5000 - - - 3069969 12.2

10 Balance/Losses - - - - 2 0.00

TOTAL OUTPUT 1144488 193072182 767.6


Ref. Temp. - 0 deg.C

Mass Error = -2.89 %

Nm3/hr kcal/kg/ oC


Heat Cap - Coefficients

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 3.525E-04

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

A 23.5771

B -4042.90

C -37.58

0.804 Rho H2O-Steam, kg/Nm3


Heat Cap - Coefficients

*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

1.429

1.977

1.257

0.804

Sp. Gravity, dry - O2 kg/Nm3

Sp. Gravity, dry - CO2 kg/Nm3

Sp. Gravity, dry - N2 kg/Nm3

Sp. Gravity - H2O kg/Nm3

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Cooler Performance & Efficiency : SLC 6-Stage II-String

S. Constriants Mass Temp. Cp HeatNo. kg/kg-Clk deg.C kcal/hr kcal/kg-Clk

INPUT

1 Clinker to Cooler 1.000 1450 0.264 96340716 383.0 2 Dust to Cooler 0.020 1450 0.264 1926814 7.73 Cooling Air 2.417 35 0.243 5167950 20.54 False Air, In 0.004 31 0.242 7714 0.05 Water Injection 0.020 25 1.000 124999 0.56 Power Consumption - - - 1142273 4.5

TOTAL INPUT 3.461 416.3

OUTPUT

1 Secondary Air from Cooler 0.398 1109 0.266 29566604 117.62 Dust in Secondary Air 0.008 1109 0.242 513824 2.03 Tertiaruy Air from Cooler 0.650 905 0.262 38695835 153.94 Dust in Tertiary Air 0.012 905 0.235 662429 2.65 Evaporation of Injected Water - - - 3069969 12.26 Cooler Vent/Excess Air 1.388 285 0.250 24911420 99.07 Dust in Vent/Excess Air 0.020 285 0.205 298061 1.28 Clinker from Cooler 0.980 140 0.192 6610674 26.39 Cooler Radiation - - - 381650 1.5

TOTAL OUTPUT 3.456 416.3

1a Cooler Vent/Excess Air, Amb.Tmp. 1.388 31 0.245 2653513 10.62a Dust in Vent/Excess Air, Amb. Tmp. 0.020 31 0.178 28189 0.13a Clinker from Cooler, Amb.Tmp. 0.980 31 0.178 1363271 5.41s Cooler Vent/Excess Air, Std. 1.286 285 0.250 23076812 91.82s Cooler Vent/Excess Air, Std. 1.286 31 0.245 2458094 9.81 kcal/kg-Clk 1402 Total Cooler Loss, Ref. - Amb. Temp. kcal/kg-Clk 1123 Standard Cooler Loss kcal/kg-Clk 1054 % 66.315 Cooler Efficiency, Ref. - Amb. Temp. % 73.11

VDZ EfficiencyS. Constriants Mass Temp. Cp Heat

No. kg/kg-Clk deg.C kcal/hr kcal/kg-Clk1 Clinker from Kiln 1.000 1450 0.264 96340716 3832 Clinker at Amb. Temperature 1.000 31 0.178 -1391460 -63 Clinker from Cooler 1.000 140 0.192 -6747366 -274 Power to Cooler Fans - - - 1142273 55 Excess Air, Out 1.388 285 0.250 -24911420 -996 Excess Air, In 0.011 31 0.242 21291 07 Surface Losses - - - -381650 -28 Heat Absorption by Comb. Air - - - 65463843 2609 Max. Heat Release from Clinker - - - 94949256 378

COOLER EFFICIENCY, % 68.95


Heat Error 0.00

kcal/kg/ oC

Total Cooler Loss, Ref. - 0oC

Cooler Efficiency, Ref. - 0oC

kcal/kg/ oC


Mass Error 0.00


117.55 117.552.04 2.04

153.85 153.852.63 2.63

276.08 276.080.00

04/22/2023 07:59:00 document.xls Coal-CalcS LU000211-KCP#Ver.2.2***

Page - 6/29Fuel Combustion Calculations : SLC 6-Stage II-String

Ultimate Analysis (ADB) Air RequirementCarbon (C) % 65.06 Clinker Production tpd 6036Hydrogen (H) % 3.26 Clinker Production kg/hr 251515Nitrogen (N) % 1.49 Unburnt Coal Consumption kg/hr 2500Sulphur (S) % 0.52 Total Coal Consumption (ADB) kg/hr 29207Oxygen (O) % 7.72 Coal Consumption (ADB) % 11.61Ash Content % 19.90 Sp. Heat Consumption kcal/kg-Clk 687Moisture (IM) % 2.05 kg/hr 58452HMB Error - 0.000007 kg/hr 2256

kg/hr 56196Proximate Analysis (ADB) Description Kiln Cal. Total

Fixed Carbon (FC) % 55.09 Feed Ratio, % 38.00 62.00 100.00Volatile Matter (VM) % 22.97 Coal Consump., kg-Coal/kg-Clk 0.0441 0.0720 0.1161Ash Content % 19.90 Sp. Heat Consump., kcal/kg-Clk 261 426 687Inher. Moisture (IM) % 2.05 Lmin., kg/hr 92846 151486 244332

Calorific Value Lmin., kg/kg-Coal 3.179 5.187 8.365GCV (calc.) kcal/kg-Coal 6100 L, kg/hr 112766 166783 279549NCV kcal/kg-Coal 5916 L, kg/kg-Coal 3.861 5.710 9.571UHV kcal/kg-Coal 5872 Sp. Air Consp., kg/kg-Clk 0.422 0.689 1.111UHV (manual) kcal/kg-Coal 6089 Ash Absorption, % - - 2.310Value in calculations kcal/kg-Coal 5916

Combustion of Coal :Component Wt. Fraction Fuel

kg/hr kg/hr kg/hr kg/hr kg/hrC 0.6506 19002 50672 69674 - -H 0.0326 953 7628 - 8581 -N 0.0149 435 - - - -S 0.0052 153 153 - - 305O 0.0772 2256 - - - -

Ash 0.1990 5811 - - - -0.0205 598 - - 598 -

Raw Mix - - - 131145 4937 -Total 1.0000 29207 58452 200819 14116 305

Description Deg. of Calcination Feed/ Carbon in Coal Rate KS CS KS CS

% / wt.% tph tph tphKF > 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 - 37.96K6 Feed > Calciner 33.41 145.50 - 16.65 - 8.48C6 Feed > Kiln 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

TOTAL - -66.41 134.41 33.81 68.43

200.82 102.24

Total O2 RequirementO2 in CoalNet O2 Requirement

O2 CO2 H2O SO2

H2O

PH Outlet CO2 Calculations (DB) :CO2 CO2

kNm3/hr kNm3/hr


2


Page - 7/29Coal Combustion Calculations : SLC 6-Stage II-String

Kiln Combustion Gases with Stoichiometric Air :Comp. Mass Flow Rate Vol. Flow Rate Mass% Vol.%

KS CS PH KS CS PH KS CS PH KS CS PHkg/hr kg/hr kg/hr m, % m, % m, % vol., % vol., % vol., %37358 134413 200819 19019 68428 102235 34.23 53.44 51.53 24.90 42.23 40.38

0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00116 189 305 41 66 107 0.11 0.08 0.08 0.05 0.04 0.04

71657 116913 188570 57325 93531 150856 65.66 46.48 48.39 75.05 57.73 59.580 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00

Total 109130 251515 389694 76384 162025 253198 100.00 100.00 100.00 100.00 100.00 100.0037358 134413 200819 19019 68428 102235 32.31 51.29 49.37 22.52 39.06 37.266478 10570 17048 8062 13154 21216 5.60 4.03 4.19 9.55 7.51 7.73116 189 305 41 66 107 0.10 0.07 0.08 0.05 0.04 0.04

71657 116913 188570 57325 93531 150856 61.98 44.61 46.36 67.88 53.39 54.970 0 0 0 0 0 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 :Comp. Mass Flow Rate Vol. Flow Rate Mass% Vol.%


0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00116 189 305 41 66 107 0.09 0.07 0.07 0.04 0.04 0.04

86995 128693 215687 69596 102954 172550 67.41 48.23 50.76 75.76 59.20 61.504582 3518 8100 3207 2463 5670 3.55 1.32 1.91 3.49 1.42 2.02

Total 129050 266813 424911 91862 173911 280562 100.00 100.00 100.00 100.00 100.00 100.0037358 134413 200819 19019 68428 102235 27.52 48.43 45.39 18.98 36.54 33.826717 10754 17471 8359 13382 21742 4.95 3.87 3.95 8.34 7.15 7.19116 189 305 41 66 107 0.09 0.07 0.07 0.04 0.04 0.04

86995 128693 215687 69596 102954 172550 64.08 46.36 48.76 69.44 54.97 57.084582 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 :Comp. Mass Flow Rate Vol. Flow Rate Mass% Vol.%


0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00116 189 305 41 66 107 0.07 0.07 0.07 0.03 0.03 0.03

97446 145903 248114 77957 116723 198491 56.75 50.44 53.11 66.50 61.00 63.347757 8747 17951 5430 6123 12566 4.52 3.02 3.84 5.30 3.20 4.01

Total 171725 289252 467189 117234 191340 313399 100.00 100.00 100.00 100.67 100.00 100.0066406 134413 200819 33807 68428 102235 37.11 44.76 41.39 26.78 33.37 30.457230 11023 17978 8997 13717 22373 4.04 3.67 3.71 7.13 6.69 6.66116 189 305 41 66 107 0.06 0.06 0.06 0.03 0.03 0.03

97446 145903 248114 77957 116723 198491 54.45 48.59 51.14 61.76 56.92 59.117757 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

PLANT : Binani Cement - 20.06.2003FUEL : 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.% 10.02False air a/c PH w.r.t. gas, dry vol.% 11.70

Std Nm3/hr Nm3/hr Nm3/hr

DRY

CO2

H2OSO3

N2

O2

WET

CO2

H2OSO3

N2

O2


DRY

CO2

H2OSO3

N2

O2

WET

CO2

H2OSO3

N2

O2


DRY

CO2

H2OSO3

N2

O2

WET

CO2

H2OSO3

N2

O2


w.r.t. mix 10.33w.r.t. mix 9.11w.r.t. mix 10.48

04/22/2023 07:59:00 document.xls Fuel Ratio LU000211-KCP#Ver.2.2***

Page - 29/29Unburnt 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

Proximate Analysis (ADB) Fuel-1 Fuel-2 Resultant Fuel

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

Calorific Value Fuel-1 Fuel-2 Resultant Fuel

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

Fuel consumption kg/hr 26707 2500 29207

Fuel ratio % 91.4 8.6 100.0

04/22/2023 07:59:00 document.xls Pyro-Pic LU000211-KCP#Ver.2.2D***

Page - 8/29

Preheater Draft & Temperature Measurements : SLC 6-Stage II-String

-575 mmWG DP=85 -864 mmWG DP=139306 deg.CDT=9.30000000000001 302 deg.C DT=19.8

K-1 C-1

DP=105 -490 mmWG DP=120 -725 mmWGDT=139 315 deg.C DT=115 322 deg.C

K-2 C-2

-385 mmWG DP=81 -605 mmWG DP=125454 deg.C DT=116 437 deg.C DT=147

K-3 C-3


K-4 C-4

-220 mmWG DP=80 -360 mmWG DP=126660 deg.C DT=66 721 deg.C DT=90

K-5 C-5


K-6 C-6/Cal.

Kiln I/L Draft -66 mmWG Cal. I/L Draft -45 mmWG Kiln I/L Tem 807 deg.C Cal. I/L Tem 880 deg.C


04/22/2023 07:59:01 document.xls Vel-Prof LU001007-KCP#Ver.1.1***

Page - 9/29Velocity Profiles : SLC 6-Stage II-String

S Location Dimensions Ref. Eff. Gas Characteristics

No. Height Dim-1 Dim-2 Thick. Area Vol. Velo. Ret.

/ Dia. Flow, w Time

mts mm mm mm m2 km3/hr m/sec sec

1 K-1 Cyclone - 5400 - 115 5.085 336.90 18.40 -

2 K-2 Cyclone - 5400 - 179 6.212 0.00 -

3 K-3 Cyclone - 5700 - 214 6.791 0.00 -

4 K-4 Cyclone - 5700 - 214 6.791 0.00 -

5 K-5 Cyclone - 5700 - 214 6.791 0.00 -

6 K-6 Cyclone - 5700 - 214 6.791 0.00 -

7 Kiln Riser Duct 17.5 3100 3100 214 7.14 410.40 15.97 1.10

8 Smoke Chamber - 4550 3100 214 11.01 410.40 10.35 -

9 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 -


04/22/2023 07:59:01 document.xls Heat-Rxn LU000303-RMD#Ver.1.3***

Page - 10/29Heat of Reaction : Chemical Data

RAW MIXChemical Analysis Unit Value Mineralogical Composition Unit ValueSiO2 % 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 % 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 : South African CoalFuel percent in clinker % 11.61 Ash Analysis Unit ValueSulphur, 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

Heat consumption, % 2.00 kJ per kg clinker kJ/kg 2871 % 0.47 kcal per kg clinker kcal/kg 687 % 0.16 RAW MIX ADJUSTMENT

Constituents Unit Raw Mix Adjustment AdjustedAnalysis 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 RATIOAdjusted raw mix, total % T : 66.13 Volatalised : U = 50% of sulphur in pyrites as SO3 % U : 0.05 SO3 in clinker (calculated) 0.49 Raw mix / clinker ratio (loss of dust = 0 %) : F = 100 / (T - U) % F: 1.513

1) Carbon as CO2 is not included.2) Calculated from analysis of solid fuel.


Carbon 1)

Sulphur 2)

K2O 2)

Na2O 2)


Page - 11/29

Heat of Reaction : Calculations

CALCULATIONSConv. Calc. ContributionsFactor Raw Mix Clinker

Contributions to Heat of Reaction kJ/kg/% kJ/kg kJ/kgA : DECOMPOSITION INTO OXIDES

Raw MixCaCO3 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

Alkali silicates :(K2O + Na2O)rawmix 0.65 -14.80 -9.62 -14.56

Heat of Decomposition : -1439.62 -2178.67 B: HEAT OF FORMATIONProperty Component Adj. Raw MixC3S 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

SO3 in clinker from fuel and pyrites 0.33 59.60 19.45 29.44 Heat of Formation : 305.16 461.82

C : HEAT OF COMBUSTIONCarbon 0.20 327.86 65.57 99.23 Sulphur in pyrites 0.04 129.14 5.17 7.82

Heat of Combustion : 70.74 107.05

A + B + C : HEAT OF REACTION (kJ/kg clinker) -1610 HEAT OF REACTION (kcal/kg clinker) -385.21

A + B : HEAT OF REACTION excl. HEAT OF COMBUSTION (kJ/kg clinker) -1717 HEAT OF REACTION excl. HEAT OF COMBUSTION (kcal/kg clinker) -410.83


-410.83

04/22/2023 07:59:01 document.xls Alkali LU010408-KCP#Ver.1.0**

Page - 12/29

Mechanism of Volatile Matters in Kiln

LOI in kiln feed, % 35.83 Raw mix to clinker (calc.) 1.484BH/ESP dust, kg/kg-clk 0.134 Kiln feed to clinker (calc.) 1.618LOI in BH/ESP dust, % 35.30 M S/A input to system 1.71LOI in K6 stage mat., % 14.95 M S/A C6 stage mat. 4.50LOI in C6 stage mat., % 2.97 M S/A clinker 0.66Fuel consumption, % 11.61 Excess SO3 in I/P, g/100 kg-clk 684Ash content in fuel, % 19.90

Analysis Cl Cl-free

Kiln Feed, % 0.380 0.270 0.005 0.200 0.373Total input on clinker (LFKF), % 0.683 0.444 0.018 1.480 0.659BH/ESP Dust, % 0.381 0.271 0.005 0.201 0.374Lowest Stage, % 1.640 0.320 0.660 3.850 0.764Clinker, % 0.550 0.450 0.007 0.500 0.541

0.470 0.160 0.044 2.000 0.412Evaporation factor, E 0.69 -0.29 0.990 0.88 0.35Circulation factor, K 2.65 0.80 40.730 2.87 1.28Residual in clinker, R 0.82 1.03 0.397 0.34 0.83Preheater valve, Vc 0.10 0.15 0.015 0.22 0.32BH/ESP valve, Vf 1.00 0.99 0.998 1.00 1.00Combined valve, Vx 0.10 0.12 0.015 0.26 0.37

Concept of Volatile Matter

Burning Zone Back End

Legends

Evaporation Factor, E = d/b = (b-c)/b Residual Component, R = c/aCirculation Factor, K = b/a Valve, V = e/d = (a-c)/(b-c)


K2O Na2O SO3

K2O

Kiln Fuel (SO3 as Sulphur), %

cK

R

b

ed

a

VE


Cl LOIKiln Feed, % 0.500 0.180 0.012 0.120 35.540BH/ESP Dust, % 0.530 0.140 0.013 0.130 36.220Lowest Stage, K6, % 1.400 0.210 0.015 0.930 17.760Lowest Stage, C6, % 1.520 0.410 0.059 0.880 3.060Clinker, % 0.710 0.210 0.019 0.043 0.230

0.570 0.120 0.005 1.780 -0.420 1.720 0.026 4.670 -

K2O Na2O SO3

Kiln Fuel (SO3 as Sulphur), %UBC (SO3 as Sulphur), %


ASW 0.046 GVFW 0.086 GVCW 0.985GVKA(1) 0.600 GVKA(2) 0.426 GVKA(3) 0.008GVFA(1) 0.597 GVFA(2) 0.424 GVFA(3) 0.008GVMA(1) 1.811 GVMA(2) 0.353 GVMA(3) 0.729GVCA(1) 0.558 GVCA(2) 0.457 GVCA(3) 0.007ALK(1) 0.055 ALK(2) 0.019 ALK(3) 0.005

ALC(1) 0.055 ALC(2) 0.019 ALC(3) 0.005GVRA(1) 0.600 GVRA(2) 0.427 GVRA(3) 0.008RA(1) 0.380 RA(2) 0.270 RA(3) 0.005GVSRW 0.985 GVRW 0.939 GVFW 0.086

0.47 0.16 0.044Kiln feed, % 0.38 0.27 0.005Calciner (SO3 as Sulphur), %


ALK(4) 0.590 ALC(4) 0.590GVKA(4) 0.316 GVKA(5) 0.590GVFA(4) 0.315 GVFA(5) 0.586GVMA(4) 4.251 GVMA(5) 0.844GVCA(4) 0.508 GVCA(5) 0.549ALK(4) 0.236 ALK(5) 0.049

ALC(4) 0.236 ALC(5) 0.049GVRA(4) 0.316 GVRA(5) 0.590RA(4) 0.200 RA(5) 0.373GVKW 1.025 VP 11.61

2.00 0.41 VAS 19.900.20 0.37

04/22/2023 07:59:01 document.xls H2O-SprS LU010522-KCP#Ver.2.3***

Page - 15/29

Water Spray System

S. Description Kiln CalcinerNo. String StringA Inlet Gas Conditions1 Volume flow of gas, wet m3/hr 336905 5399022 Mass flow of gas, wet kg/hr 193683 3103823 Gas temperature deg.C 305.7 302.24 Gas density, wet kg/m3 0.575 0.5755 Heat capacity of gas kcal/kg/C 0.263 0.261 6 Heat content in gas (calc.) kcal/hr 15547937 245272227 Heat content in gas (diff.) kcal/hr 15547937 245272228 Error kcal/hr 0.000 0.000B Water Injection1 Volume flow of water m3/hr 0.00 0.002 Mass flow of water kg/hr -2.51 1.493 Water pressure Bar 14.1 15.84 Water temperature deg.C 25 255 Heat capacity of water kcal/kg/C 1 16 Heat content in water kcal/hr -63 377 Evaporation of water kcal/hr -1353 802C Compressed Air Injection1 Volume flow of air m3/hr 0.0 0.02 Mass flow of air kg/hr 0 03 Air pressure Bar 7.1 7.14 Air temperature deg.C 60 605 Air density kg/m3 8.434 8.4346 Heat capacity of air kcal/kg/C 0.242 0.2427 Heat content in air kcal/hr 0 0D Outlet Gas Conditions1 Volume flow of gas, wet m3/hr 343144 5448872 Mass flow of gas, wet kg/hr 193680 3103843 Gas temperature deg.C 305.0 302.04 Gas density, wet kg/m3 0.564 0.5705 Heat capacity of gas kcal/kg/C 0.263 0.262 6 Heat content in gas kcal/hr 15549227 24526458E Water Balance1 Water In, gas kg/hr 19196 307572 Water In, spray kg/hr -3 13 Water In, total kg/hr 19194 307594 Water Out, gas kg/hr 19194 307595 Water Vapor, PH Exit kg/kg-dg 0.1100 0.11006 Error kg/hr 0.000 0.000

04/22/2023 07:59:01 document.xls Clr-Flow LU000211-KCP#Ver.2.2***

Page - 16/29Cooler 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 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

Avg. Ps mmWG 660 685 866 827 795 788 645 625 640 655 570 515 565 651

Moisture, by diff. 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 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 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 388 401 378 363 524 580 1267 602 453 860 1047 1211 483 8556

Sp. Heat, gas kcal/kg/C 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 0.243

Heat Content, gas Mcal/hr 234 242 228 219 316 350 766 363 274 519 632 731 291 5168

Fan Speed rpm 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

Fan Damper % 100 100 100 100 100 100 100 100 100 100 100 100 100 -

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. 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. 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

kNm3/hr

km3/hr

m3/min

Nm3/kg-Clk

m3/kg-Clk


Heat Cap - CoefficientsGas/Mat *T^0 *T^1 *T^2 *T^3 *T^4

0.2485 -3.340E-06 4.440E-08 -2.797E-11 5.597E-15 Not used in calc.

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




c:\work\prdn\excel\document.xls : ClrF-IL04/22/2023 07:59:01

Prodn. Deptt. - Binani Cement Ltd.

Cooler Fans Flow : SLC 6-Stage II-String(with transmeter pezo pressure) Kiln Output = 6035 tpd Sp. Air Consp. = 1.87 Plant Elevation = 402.00 mts +MSL

Ambient Air = 36.0 deg.C Air Density = 1.086 Barometric Press. = 9827 mmWG

S. Fan I/L Dia I/L Area Fan kW Fan Damper FACTOR Ps Ps

inlet outlet Fan Fan

No. 471 m m2 Rated Run amps Rated Run % mmwg mmwg Inlet Outlet

1 FN1 0.45 0.159 90 58 85 2900 2663 100 40.56 143.63 660.00 413 398

2 FN2 0.45 0.159 90 56 82 2900 2616 100 40.56 153.50 685.00 427 411

3 FN3 0.56 0.246 132 90 132 1450 1376 100 62.81 59.13 866.00 411 388

4 FN4 0.56 0.246 132 92 134 1450 1407 100 62.81 53.88 827.00 392 372

5 FN5 0.71 0.396 180 117 171 1480 1411 100 100.97 43.13 795.00 564 537

6 FN6 0.71 0.396 190 117 172 1480 1394 100 100.97 52.88 788.00 624 595

7 FN7 0.90 0.636 225 202 296 1485 1492 100 162.24 98.13 645.00 1366 1319

8 FN8 0.56 0.246 90 - - 1485 - 95 62.81 142.50 625.00 637 617

9 FN9 0.56 0.246 90 0 1485 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

PLANT : Binani Cement, Sirohi (Rajasthan)Measured on : 20.02.2003 (10:30-11:30 hrs)

a) Kiln feed 415 tph b) Coal - Kiln/Cal. 521/525 rpm c) Gr. load - I/II/III 55/60/52 amps

d) DG - Kiln/Cal. 39.6/61.4 %/% e) Hood draft/ESP temp. -4/320 mmWG/deg.C f) Gr. DP-I/II/III 165/145/97mmWG

g)U.G.P.(CIS) 665 mm h) Fan outlet temp 45 deg.C I)U.G.P.(CFG) 760 mmWG

FN196 120 156 112

143.625159 172 164 170

Nm3/kg-Clk

kg/m3

Speed (rpm) Flow (m3/min)

c:\work\prdn\excel\document.xls : ClrF-IL04/22/2023 07:59:01

Prodn. Deptt. - Binani Cement Ltd.

FN2146 147 144 137

153.5158 178 160 158

FN354 52 68 64

59.12555 51 71 58

FN466 53 62 68

53.87549 47 43 43

FN543 47 55 50

43.12543 37 33 37

FN666 64 61 49

52.87555 43 42 43

FN7107 122 122 124

98.12580 80 76 74

FN8139 158 179 152

142.5124 138 130 120

FN990 100 101 99

81.2567 66 65 62

FNA73 89 107 75

70.37554 53 60 52

FNB118 101 130 135

102.7582 91 80 85

FNC100 105 106 107

84.87563 69 66 63

FNH244 246 205 247

187.625149 139 134 137

04/22/2023 07:59:01 document.xls Rad LU000211-KCP#Ver.2.2***

Page - 17/29Kiln Radiations : SLC 6-Stage II-String

Amb. Air 31.0 deg.C EmissivityProduction 6036 tpd Kiln Inlet 0.85Kiln Diameter 4.55 mts Rest Kiln 0.85Total Radiation 4437254 kcal/hrSp. Radiation 17.64 kcal/kg-clk Wind Vel., m/s 5.00

* Inclusive of restriction due to kiln tyres and girth gea 5.00 %

Kiln Surface Area Corr. Factor Corr. Area Temperature Radiationmts - deg.C kcal/hr0 14.3 1.00 14.3 200 487321 14.3 1.00 14.3 210 526532 14.3 1.00 14.3 183 424083 14.3 1.00 14.3 277 833494 14.3 1.00 14.3 220 567315 14.3 1.00 14.3 102 172146 14.3 1.00 14.3 232 618437 14.3 1.00 14.3 216 550818 14.3 1.00 14.3 230 609749 14.3 1.00 14.3 235 63160

10 14.3 1.00 14.3 239 6494011 14.3 1.00 14.3 242 6629412 14.3 1.00 14.3 227 5968413 14.3 1.00 14.3 216 5508114 14.3 1.00 14.3 215 5467215 14.3 1.00 14.3 219 5631616 14.3 1.00 14.3 222 5756617 14.3 1.00 14.3 214 5426518 14.3 1.00 14.3 190 4496219 14.3 1.00 14.3 180 4133520 14.3 1.00 14.3 177 4027421 14.3 1.00 14.3 178 4062622 14.3 1.00 14.3 201 4911823 14.3 1.00 14.3 219 5631624 14.3 1.00 14.3 212 5345625 14.3 1.00 14.3 201 4911826 14.3 1.00 14.3 195 4682927 14.3 1.00 14.3 203 4989228 14.3 1.00 14.3 251 7045429 14.3 1.00 14.3 313 10356730 14.3 1.00 14.3 319 10722731 14.3 1.00 14.3 245 6766432 14.3 1.00 14.3 346 124813

m2 m2

*


Page - 18/29Kiln Radiations : SLC 6-Stage II-String

Kiln Surface Area Corr. Factor Corr. Area Temperature Radiationmts - deg.C kcal/hr33 14.3 1.00 14.3 90 1404534 14.3 1.00 14.3 336 11808135 14.3 1.00 14.3 329 11352336 14.3 1.00 14.3 332 11546137 14.3 1.00 14.3 324 11034438 14.3 1.00 14.3 317 10599739 14.3 1.00 14.3 330 11416740 14.3 1.00 14.3 328 11288341 14.3 1.00 14.3 323 10971642 14.3 1.00 14.3 321 10846643 14.3 1.00 14.3 325 11097544 14.3 1.00 14.3 319 10722745 14.3 1.00 14.3 318 10661146 14.3 1.00 14.3 304 9823747 14.3 1.00 14.3 285 8759448 14.3 1.00 14.3 113 2022849 14.3 1.00 14.3 98 1614450 14.3 1.00 14.3 128 2452251 14.3 1.00 14.3 160 3448352 14.3 1.00 14.3 165 3614853 14.3 1.00 14.3 163 3547854 14.3 1.00 14.3 129 2481755 14.3 1.00 14.3 118 2163556 14.3 1.00 14.3 240 6538957 14.3 1.00 14.3 245 6766458 14.3 1.00 14.3 256 7283159 14.3 1.00 14.3 256 7283160 14.3 1.00 14.3 85 1276061 14.3 1.00 14.3 190 4496262 14.3 1.00 14.3 177 4027463 14.3 1.00 14.3 174 3922464 14.3 1.00 14.3 184 4276965 14.3 1.00 14.3 231 6140866 14.3 1.00 14.3 249 6951767 14.3 1.00 14.3 253 7139968 14.3 1.00 14.3 256 72831

Total/Wt. Avg. 986.3 986.3 229 4437254

Page - 19/29

m2 m2


Kiln String Radiations : SLC 6-Stage II-String

Amb. Air 31.00 deg.C EmissivityProduction 6036 tpd Preheater 0.75Total Radiation 2618130 kcal/hr Riser Duct 0.75Sp. Radiation 10.41 kcal/kg-clk** Exclusive of amount as per FLS norm 5.00 %

KS Surface Area Corr. Factor Corr. Area Temperature RadiationCyclone-1 - deg.C kcal/hr

Roof 27.4 1.20 32.9 65.0 15536Vertical Inlet 51.5 1.01 52.0 70.0 27622Conical Inlet 25.0 1.00 25.0 67.0 12762

Cylindrical Part 122.6 1.00 122.6 56.0 38720Conical Part 53.7 1.00 53.7 58.0 19331

Material Pipes 11.1 1.01 11.2 175.0 28619Riser Cylindrical 97.6 1.01 98.6 75.0 57314

Riser Rest 79.1 1.01 79.9 65.0 35751Total/Wt. Avg. 468.0 475.9 67.2 235656











Page - 20/29Kiln String Radiations : SLC 6-Stage II-String

m2 m2

m2 m2

m2 m2

**















Material Pipes 54.8 1.01 55.3 103.0 57059Total/Wt. Avg. 315.0 322.0 89.4 265350

Kiln Surface Area Corr. Factor Corr. Area Temperature RadiationRiser Duct - deg.C kcal/hr

Rectangular Pipe 199.6 1.20 239.5 130.0 330299Smoke Chamber 101.0 1.20 121.2 160.0 239268

Rest 183.0 1.15 210.5 96.0 179676Total/Wt. Avg. 483.6 571.2 123.8 749243

Page - 21/29Calciner String Radiations : SLC 6-Stage II-String

m2 m2

m2 m2

m2 m2

m2 m2


Amb. Air 31.00 deg.C EmissivityProduction 6036 tpd Preheater 0.75Total Radiation 3212876 kcal/hr Calciner 0.75Sp. Radiation 12.77 kcal/kg-clk*** Exclusive of amount as per FLS nor 5.00 %

CS Surface Area Corr. Factor Corr. Area Temperature RadiationCyclone-1 - deg.C kcal/hr















Page - 22/29Calciner String Radiations : SLC 6-Stage II-String

CS Surface Area Corr. Factor Corr. Area Temperature Radiation

m2 m2

m2 m2

m2 m2

***


Cyclone-4 - deg.C kcal/hrRoof 39.2 1.20 47.0 83.0 34207

Vertical Inlet 70.1 1.01 70.8 85.0 52369Conical Inlet 45.1 1.00 45.1 82.0 32194












Material Pipes 31.1 1.01 31.4 175.0 76140Total/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 49272Cal.-C6 Duct 121.3 1.20 145.6 100.0 135579

Cylindrical Part 357.0 1.00 357.0 85.0 241101Bottom Cone 51.3 1.00 51.3 115.0 63260

Bend Area 67.3 1.10 74.0 125.0 101967Total/Wt. Avg. 628.1 662.2 97.2 591179

Page - 23/29Cooler.Hood.TAD Radiations : SLC 6-Stage II-String

Amb. Air 31.00 deg.C EmissivityProduction 6036 tpd Cooler 0.75

m2 m2

m2 m2

m2 m2

m2 m2

****


Total Radiation 1605018 kcal/hr Kiln Hood 0.75Sp. Radiation 6.38 kcal/kg-clk**** Exclusive of amount as per FLS no 5.00 %

Grate Surface Area Corr. Factor Corr. Area Temperature RadiationCooler - deg.C kcal/hr

Front-Kiln End 14.6 1.30 19.0 100.0 19852Grate1-L/Side 33.3 1.10 36.6 102.0 38060Grate1-Roof 42.8 1.50 64.2 112.0 75007

Grate1-R/Side 33.3 1.10 36.6 115.0 46023Grate2-L/Side 22.3 1.10 24.5 95.0 23256Grate2-Roof 28.6 1.50 42.9 95.0 39360

Grate2-R/Side 22.3 1.10 24.5 96.0 23656Grate3-L/Side 23.3 1.10 25.6 98.0 25492Grate3-Roof 29.9 1.50 44.8 92.0 38928

Grate3-R/Side 23.3 1.10 25.6 110.0 30646Back 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 RadiationHood - deg.C kcal/hr

Right Side 13.8 1.50 20.7 106.0 23636Left Side 27.5 1.50 41.3 95.0 37932Kiln Side 12.0 1.50 18.0 150.0 35405

Burner Side 18.0 1.50 27.0 115.0 34510Roof 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 RadiationSettling Chamb. - deg.C kcal/hr

Connecting Duct 57.0 1.10 62.7 133.0 95945Tert. Pipe 582.8 1.00 582.8 143.4 899367

Total/Wt. Avg. 639.8 645.5 142.4 995312

m2 m2

m2 m2

m2 m2

****


Wt. Avg. Dia. <= 3.05 >3.052859 4.55 39811 487323002 4.55 43473 526532616 4.55 33962 424083960 4.55 72754 833493145 4.55 47307 567311458 4.55 11897 172143316 4.55 52142 618433088 4.55 45752 550813288 4.55 51318 609743359 4.55 53393 631603416 4.55 55086 649403459 4.55 56376 662943245 4.55 50096 596843088 4.55 45752 550813073 4.55 45368 546723130 4.55 46915 563163173 4.55 48095 575663059 4.55 44985 542652716 4.55 36314 449622573 4.55 32977 413352530 4.55 32007 402742544 4.55 32329 406262873 4.55 40169 491183130 4.55 46915 563163030 4.55 44226 534562873 4.55 40169 491182787 4.55 38042 468292902 4.55 40892 498923588 4.55 60350 704544474 4.55 92386 1035674560 4.55 95958 1072273502 4.55 57683 676644946 4.55 113176 124813


1286 4.55 9369 140454803 4.55 106575 1180814703 4.55 102113 1135234746 4.55 104010 1154614631 4.55 99004 1103444531 4.55 94758 1059974717 4.55 102743 1141674689 4.55 101486 1128834617 4.55 98390 1097164588 4.55 97169 1084664646 4.55 99621 1109754560 4.55 95958 1072274546 4.55 95357 1066114345 4.55 87194 982374074 4.55 76860 875941615 4.55 14375 202281401 4.55 11034 161441830 4.55 18006 245222287 4.55 26762 344832359 4.55 28260 361482330 4.55 27656 354781844 4.55 18258 248171687 4.55 15552 216353431 4.55 55514 653893502 4.55 57683 676643659 4.55 62627 728313659 4.55 62627 728311215 4.55 8371 127602716 4.55 36314 449622530 4.55 32007 402742487 4.55 31050 392242630 4.55 34293 427693302 4.55 51729 614083559 4.55 59453 695173616 4.55 61255 713993659 4.55 62627 72831

225563 3794136 443725415.09 17.64


2137 6.470 9795 155363641 8.138 18344 276221675 5.642 7988 127626866 12.494 25143 387203115 8.269 12085 193311962 3.778 22258 286197393 11.203 40379 573145193 10.086 23799 35751

31981 159792 235656

2376 6.351 12977 197143372 7.832 16991 257031960 6.149 9168 145604786 8.467 29830 422033458 8.230 15848 244021150 4.151 7171 110553670 8.479 16819 258036217 10.559 31865 46301

26990 140668 209742

3175 6.702 20923 299414809 8.248 31686 442542324 6.502 11709 181214803 8.970 26624 386433552 8.682 14527 22826799 3.812 4025 6662

5878 7.897 49710 647308808 11.163 58041 78294

34148 217244 303471


3457 6.702 24639 344414007 8.248 21886 322132324 6.502 11709 181214803 8.970 26624 386437400 8.682 64659 825171358 3.267 14516 193134141 7.261 30044 41384

10777 11.169 84851 10870038268 278928 375334

3528 6.702 25597 355853206 8.248 13111 207322490 6.502 13600 206015056 8.970 29622 423524736 8.682 27747 39825

10211 9.310 102863 1249925026 8.944 29444 42113

13857 11.650 124894 15313348109 366878 479334

2293 6.458 11553 178965242 9.433 28629 414693856 6.534 31501 423396194 8.970 44138 596665519 9.257 33173 469205701 8.395 42444 57059

28804 191438 265350

31138 17.463 280652 33029919392 12.422 205300 23926820203 16.369 141331 17967670733 627284 749243

7.88 10.41


3108 7.519 15659 238065257 9.447 28712 415822595 6.637 14173 21416

14457 14.630 91165 1207526636 9.689 43725 599441594 3.147 20488 25842

10193 11.877 68572 913179301 12.322 53040 73611

53141 335533 458270

3093 7.396 16118 243404856 9.079 26519 385883075 7.225 16795 251175638 9.985 29378 427894652 9.199 23438 347741118 3.812 7971 119143947 8.027 22508 328518437 12.856 38667 56424

34816 181394 266797

3904 7.739 23762 342076018 9.495 37514 523693698 7.578 22230 321946488 10.495 35432 506805842 9.642 34226 485201540 3.961 13458 187353814 7.791 22344 32485

12516 13.612 78924 10538943820 267890 374579


3904 7.739 23762 342076018 9.495 37514 523693698 7.578 22230 321946488 10.495 35432 506805842 9.642 34226 485201326 3.675 11583 162643814 7.791 22344 32485

12516 13.612 78924 10538943605 266015 372108

4328 7.739 29113 407166018 9.495 37514 523694059 7.578 26746 377267353 10.495 45832 632436207 9.642 38691 53915

16488 11.752 167799 1986867545 10.331 49715 67656

13825 13.612 95799 12460465822 491209 638915

6334 7.458 62155 778458703 10.800 60303 804833872 7.616 24135 345748045 10.495 54663 73606

12653 9.595 143544 1683775497 6.324 62363 76140

45102 407164 511027

4290 6.610 37485 4927214556 13.614 105608 13557930345 21.320 189156 2411015900 8.082 48192 632609254 9.709 80857 101967

64344 461298 5911799.58 12.77


1898 4.916 13771 198523736 6.829 27582 380607190 9.041 57471 750074212 6.829 34411 460232330 5.589 16148 232564076 7.391 28240 393602355 5.589 16474 236562512 5.713 17900 254924126 7.557 27758 389282819 5.713 22198 306461798 4.332 15411 21371

37053 277362 381650

2194 5.134 16744 236363919 7.247 27154 379322700 4.787 27199 354053105 5.863 25364 345109229 10.108 75389 96572

21147 171850 228056

8339 8.935 76522 9594583569 27.240 813103 89936791908 889625 995312

5.32 6.38

04/22/2023 07:59:01 document.xls Aux-Pag LU010519-KCP#Ver.1.2*

CCR Mimic - PR_W103 Preheater, Calciner & Kiln Feed Page - 24/29


CCR Mimic - PR_W104 Kiln & Kiln Auxiliaries Page - 25/29


CCR Mimic - PR_W105 Cooler Page - 26/29


CCR Mimic - PR_W109 Cooler Parameters Page - 27/29


CCR Mimic - Kiln Shell Scanner Page - 28/29


Give command to Printer for Pages 1 to 5

04/22/2023 07:59:01 document.xls Mon-Form LU990611-RMP#Ver.1.3*

sheet 1 of 5PROCESS, 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 µm, % :

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


Flow Measurement & Gas Analysis :

Flow/Gas Analysis Tapping Location

KS Fan CS Fan PA Fan Cooler CTA CTA

Inlet Inlet Outlet ESP Stack Kiln Cal.

Dry Bulb Temperature deg.C

Wet Bulb Temperature deg.C

Static Pressure "WG

Dynamic Pressure "WG

vol.%, d

vol.%, d

vol.%, d

Time Period hh.mm - hh.mm

sheet 3 of 5

O2, dry - OPTIFUEL250

O2, dry - ORSAT

CO2, dry - ORSAT


Flow Measurement & Gas Analysis :


471FN1 471FN2 471FN3 471FN4 471FN5 471FN6 471FN7

Dry Bulb Temperature deg.CWet Bulb Temperature deg.C

Static Pressure "WG


Fan Load ampsFan Speed rpmTime Period hh.mm - hh.mm


471FN8 471FN9 471FNA 471FNB 471FNC 471FNH

Dry Bulb Temperature deg.CWet Bulb Temperature deg.C

Static Pressure "WG


Fan Load ampsFan Speed rpmTime Period hh.mm - hh.mm


Radiations sheet 4 of 5

Kiln Inlet 0.85 Preheater 0.75 Preheater 0.75 Cooler 0.75Rest Kiln 0.85 Riser Duct 0.75 Riser Duct 0.75 Kiln Hood 0.75

Kiln Kiln String Cal. String CoolerLength Temp. Area Temp. Area Temp. Area Temp.

mts deg.C deg.C deg.C deg.C0 Cyclone-1 Cyclone-1 Front-Kiln/S1 Roof Roof Gr.1-L/Side2 Vert. Inlet Vert. Inlet Gr.1-Roof3 Con. Inlet Con. Inlet Gr.1-R/Side4 Cyl. Part Cyl. Part Gr.2-L/Side5 Con. Part Con. Part Gr.2-Roof6 Mat. Pipes Mat. Pipes Gr.2-R/Side7 Riser Cyl. Riser Cyl. Gr.3-L/Side8 Riser Rest Riser Rest Gr.3-Roof9 Cyclone-2 Cyclone-2 Gr.3-R/Side

10 Roof Roof Back End11 Vert. Inlet Vert. Inlet Hood12 Con. Inlet Con. Inlet Right Side13 Cyl. Part Cyl. Part Left Side14 Con. Part Con. Part Kiln Side15 Mat. Pipes Mat. Pipes Burner Side16 Riser Cyl. Riser Cyl. Roof17 Riser Rest Riser Rest TAD18 Cyclone-3 Cyclone-3 Conn. Duct19 Roof Roof Tert. Pipe20 Vert. Inlet Vert. Inlet21 Con. Inlet Con. Inlet22 Cyl. Part Cyl. Part23 Con. Part Con. Part24 Mat. Pipes Mat. Pipes25 Riser Cyl. Riser Cyl.26 Riser Rest Riser Rest27 Cyclone-4 Cyclone-428 Roof Roof29 Vert. Inlet Vert. Inlet30 Con. Inlet Con. Inlet31 Cyl. Part Cyl. Part32 Con. Part Con. Part33 Mat. Pipes Mat. Pipes34 Riser Cyl. Riser Cyl.35 Riser Rest Riser Rest36 Cyclone-5 Cyclone-537 Roof Roof38 Vert. Inlet Vert. Inlet39 Con. Inlet Con. Inlet40 Cyl. Part Cyl. Part41 Con. Part Con. Part42 Mat. Pipes Mat. Pipes43 Riser Cyl. Riser Cyl.44 Riser Rest Riser Rest45 Cyclone-6 Cyclone-646 Roof Roof47 Vert. Inlet Vert. Inlet48 Con. Inlet Con. Inlet49 Cyl. Part Cyl. Part50 Con. Part Con. Part51 Mat. Pipes Mat. Pipes52 Kiln Riser Duct Calciner53 Rect. Pipe Roof54 Smk. Chmb. Cyl. Part55 Rest Con.Part56 Kiln (contd.) Bend.57 63 Rest58 6459 6560 6661 6762 68


sheet 5 of 5PH 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 deg.C

K-6 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


Kiln String Fan Calciner String Fan Cooler ESP Fan PA Fan

2800 3000 4200 400

0.97 2716 8 2.83 2910 15 3.87 4074 3 372

0.92 2576 9 3.00 2760 17 4.12 3864 3 300

0.85 2380 11 3.32 2550 21 4.58 3570 3 100

0.77 2156 11 3.32 2310 24 4.90 3234 3 28

0.66 1848 11 3.32 1980 23 4.80 2772 3 372

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 9 3.00 450 10 3.16 630 28

0.08 224 9 3.00 240 17 4.12 336

0.03 84 9 3.00 90 11 3.32 12610 3.1559028 4.1171451

9.9597224 16.95088416.950884


PA Fan

400

10.00

11.00

10.00

8.00

10.00

11.00

10.00

9.00

9.875

04/22/2023 07:59:01 document.xls Cooler-Pic

Coolax Cooler : 1284-3ME-INF.L. Smidth & Co. A/S

Grate-I (CFG) Grate-II (RFT) 1 M 700-800 mmWG 37 M471FN2 2 F 471FN1 38 F 450-550 mmWG

3 M Grate Area = 3.56 39 M 471FN8 4 F Min. Flow = 273.73 40 F 7.09

450-600 mmWG 5 M Nor. Flow = 320.33 41 M 349.45471FNH 6 F 42 F 407.70

7.12 7 M 43 M262.08 8 F 600-700 mmWG 450-550 mmWG 44 F308.68 9 M 471FN9 45 M

10 F 7.09 46 F 11 M 349.45 47 M471FN4 12 F 471FN3 407.70 48 F

13 M 7.13 49 M 14 F 436.81 50 F 15 M 512.53 51 M

16 F 400-500 mmWG 52 F

450-600 mmWG 17 M 471FNA 53 M471FN7 18 F 11.81 54 F

35.64 19 M 693.07 55 M990.10 20 F 500-600 mmWG 815.40 56 F

1164.80 21 M 4665 57 M 22 F 58 F

23 M24 F Grate-III (RFT)25 M 59 M

471FN6 26 F 471FN5 60 F 27 M 10.69 61 M 28 F 646.48 62 F 29 M 762.97 63 M

30 F 64 F 400-500 mmWG

31 M 65 M 471FNB32 F 66 F 16.5433 M 67 M 693.0734 F 68 F 815.4035 M 69 M36 F 70 F

71 M 72 F 73 M 74 F

75 MC o o l e r F a n s 76 F

Fan Vol. Flow, Density Temp. D.P. Power, Speed Grate 77 M 300-400 mmWG

design min. Plates 78 F 471FNC mmWG kW rpm nos. 79 M 14.18

471FN1 374 1.04 45 1000 83 2900 36 80 F 739.67471FN2 374 1.04 45 1000 83 2900 36 81 M 873.63471FN3 631 1.04 45 900 122 1450 72 82 F471FN4 631 1.04 45 900 122 1450 72 83 M471FN5 946 1.04 45 800 165 1480 108 84 F471FN6 946 1.04 45 800 165 1480 108471FNH 500 1.04 45 300 90 1470 Press. Fan471FN7 1439 1.04 45 700 225 1485 Press. Fan C o o l e r G r a t e s471FN8 507 1.04 45 700 76 1485 72 Grate Length Area Power Plates Rows471FN9 507 1.04 45 700 76 1485 72 mts kW nos. nos.471FNA 1014 1.04 45 600 136 1485 120 I 11.88 43.01 60 432 36471FNB 1014 1.04 45 600 136 1485 168 II 7.26 26.28 45 264 22471FNC 1099 1.04 45 500 123 1485 144 III 8.30 30.05 45 312 26

Total 9982 1602 1008 Total 27.44 99.33 1008 84

M i s c e l l a n e o u s F a n s Length of one grate plate, eff= 330.0 mmFan Vol. flow, Density Temp. D.P. Power, Speed Grate Width of one grate plate, eff. = 298.0 mm

design min. Plates Area of one grate plate, eff. = ###mmWG kW rpm nos. Width of cooler, eff. = 3.62 mts

Cooler 12370 0.56 320 150 455 590 nilVent Fan Mass flow rate, normal = 4750 t/24hPrimary 176 1.04 45 160 75 2980 nil Grate area = 99.33Air Fan Specific load = 47.82

Norms :

1. Depending upon the particle size distribution of the clinker, the expected air load for normal operation corresponds to about :

2. Minimum air flow rates are about 85% of the normal flow rates.

m2

m3/min m2

m3/min m3/minm3/min

m2

m3/minm3/min

m2

m3/minm3/min

m2

m3/minm3/min

m2

m2 m3/minm3/min m3/minm3/min

m2

m3/minm3/min

m2

m3/minm3/min

m3/min kg/m3 oC m2

m3/minm3/min

m2

cm2

m3/min kg/m3 oC

m2

t/d/m2

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-IIb) ~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

04/22/2023 07:59:01 document.xls Cooler-Pic (2)

Coolax Cooler : 1284-3ME-INF.L. Smidth & Co. A/S

Grate-II (RFT) 1 11 1 M

471FN1 6 F471FN2 Nor. Pr. = 723 mm WG 3 M

723 mm WGC I S Grate Area = 3.6 4 F

3.6 Min. Flow = 244 5 M244.29 Nor. Flow = 287 6 F

287.4 471FNA 1 M1 F 525 mm WG 2 F2 Grate-I (CFG) M 7.09 3 M

471FN4 3 F 532 4 F 471FN8765 mm WG 4 M 626 5 M 450 mm WG6.5 5 F 471FN3 6 F 7.09

498 6 M 765 mm WG 1 M 532586 7 F 6.5 2 F 626

471FN9 8 M 498 3 M615 mm WG 9 F 586 4 F

13 10 M 471FN7 5 M425 11 F 375 mm WG 6 F500 1 M 11.81 7 M

471FNH 2 F 1065 8 F530 mm WG 2 M 1253 9 M

21.38 4 F 10 F431 5 M507 6 F Grate-III (RFT)

7 M 1 M471FN6 8 F 471FN5 2 F

680 mm WG 9 M 680 mm WG 3 M10.69 10 F 10.69 4 F

646.48 11 M 646.48 5 M762.97 12 F 762.97 6 F

13 M 7 M 471FNB14 F 8 F 300 mm WG15 M 9 M 16.5416 F 10 F 693.0717 M 11 M 815.4018 F 12 F

13 M 14 F 1 M 2 F


Fan Vol. Flow, Density Temp. D.P. Power, Speed Grate 5 Mdesign min. Plates 6 F 471FNC

mmWG kW rpm nos. 7 M 300 mm WG471FN1 373 1.04 45 1000 83 2900 27 8 F 14.18471FN2 373 1.04 45 1000 83 2900 27 9 M 739.67471FN3 631 1.04 45 900 122 1450 60 10 F 873.63471FN4 631 1.04 45 900 122 1450 60 11 M471FN9 500 1.04 45 800 76 1485 Press. Fan 12 F471FN5 946 1.04 45 800 165 1480 108471FN6 946 1.04 45 800 165 1480 108471FNH 507 1.04 45 700 90 1470 Press. Fan C o o l e r G r a t e s471FN7 1439 1.04 45 700 225 1485 72 Grate Length Area Power Plates Rows471FN8 507 1.04 45 700 76 1485 72 mts kW nos. nos.471FNA 1014 1.04 45 600 136 1485 120 CIS 2.4 6.48 - 54 6471FNB 1446 1.04 45 500 136 1485 168 I 9.57 34.64 60 348 29471FNC 1099 1.04 45 500 123 1485 144 II 7.26 26.28 45 264 22

Total 10413 1602 822 III 8.58 31.06 45 312 26Total 27.81 98.46 - 924 83




Norms :



m2


m2

m3/minm3/min

m2 m2

m3/min m3/minm3/min m2 m3/min

m3/minm3/min

m2

m3/minm3/min m2

m3/minm3/min

m2

m3/minm3/min

m2 m2

m3/min m3/minm3/min m3/min

m2

m3/minm3/min

m3/min kg/m3 oCm2

m3/minm3/min

m2

cm2

m3/min kg/m3 oC

m2

t/d/m2




Coolax Cooler : 1284-3ME-IN (Modify with CIS )F.L. Smidth & Co. A/S




3.24 Min. Flow = 244 5 M244.29 Nor. Flow = 287 6 F

287.4 471FNA 1 M1 F 525 mm WG 2 F2 Grate-I (CFG) M 7.09 3 M


498 6 M 765 mm WG 1 M 532586 7 F 6.5 2 F 626

471FN9 8 M 498 3 M615 mm WG 9 F 586 4 F

13 10 M 471FN7 5 M425 11 F 375 mm WG 6 F500 1 M 11.81 7 M

471FNH 2 F 1065 8 F530 mm WG 2 M 1253 9 M

21.38 4 F 10 F431 5 M507 6 F Grate-III (RFT)

7 M 1 M471FN6 8 F 471FN5 2 F

680 mm WG 9 M 680 mm WG 3 M10.69 10 F 10.69 4 F

646.48 11 M 646.48 5 M762.97 12 F 762.97 6 F

13 M 7 M 471FNB14 F 8 F 300 mm WG15 M 9 M 16.5416 F 10 F 693.0717 M 11 M 815.4018 F 12 F

13 M 14 F 1 M 2 F


Fan Vol. Flow, Density Temp. D.P. Power, Speed Grate 5 Mdesign min. Plates 6 F 471FNC

mmWG kW rpm nos. 7 M 300 mm WG471FN1 373 1.04 45 1000 83 2900 27 8 F 14.18471FN2 373 1.04 45 1000 83 2900 27 9 M 739.67471FN3 631 1.04 45 900 122 1450 66 10 F 873.63471FN4 631 1.04 45 900 122 1450 66 11 M471FN9 500 1.04 45 800 76 1485 Press. Fan 12 F471FN5 946 1.04 45 800 165 1480 108471FN6 946 1.04 45 800 165 1480 108471FNH 507 1.04 45 700 90 1470 Press. Fan C o o l e r G r a t e s471FN7 1439 1.04 45 700 225 1485 72 Grate Area Plates Rows471FN8 507 1.04 45 700 76 1485 72 nos. nos.471FNA 1014 1.04 45 600 136 1485 120 CIS 6.48 54 6471FNB 1446 1.04 45 500 136 1485 168 I 34.22 348 29471FNC 1099 1.04 45 500 123 1485 144 II 25.96 264 22

Total 10413 1602 978 III 30.68 312 26Total 97.35 978 83




Norms :1. Minimum air flow rates are about 85% of the normal flow rates.Note :First 07 rows+1(Zero) Row = Total Eight Rows of CFG replaced with CIS (06 Rows) in the month of Jun -2001

m2


m2

m3/minm3/min

m2 m2

m3/min m3/minm3/min m2 m3/min

m3/minm3/min

m2

m3/minm3/min m2

m3/minm3/min

m2

m3/minm3/min

m2 m2

m3/min m3/minm3/min m3/min

m2

m3/minm3/min

m3/min kg/m3 oCm2

m3/minm3/min

m2

cm2

m3/min kg/m3 oC

m2

t/d/m2


04/22/2023 07:59:01 document.xls Cooler-Pic Op.

Coolax Cooler : 1284-3ME-IN ( Modify With CIS )F.L. Smidth & Co. A/S




3.24 Op. Flow = 373 5 M373 6 F

471FNA 1 M1 F 525 mm WG 2 F2 Grate-I (CFG) M 7.09 3 M


631 6 M 900 mm WG 1 M 5327 F 6.5 2 F 626

471FN9 8 M 631 3 M800 mm WG 9 F 4 F

13 10 M 471FN7 5 M500 11 F 375 mm WG 6 F

1 M 11.81 7 M471FNH 2 F 1065 8 F

700 mm WG 2 M 1253 9 M21.38 4 F 10 F

507 5 M6 F Grate-III (RFT)7 M 1 M

471FN6 8 F 471FN5 2 F800 mm WG 9 M 800 mm WG 3 M

10.69 10 F 10.69 4 F946 11 M 946 5 M

12 F 6 F13 M 7 M 471FNB14 F 8 F 300 mm WG15 M 9 M 16.5416 F 10 F 693.0717 M 11 M 815.4018 F 12 F

13 M 14 F 1 M 2 F


Fan Vol. Flow, Density Temp. D.P. Power, Speed Grate 5 MOperating min. Plates 6 F 471FNC

mmWG kW rpm nos. 7 M 300 mm WG471FN1 373 1.04 45 1000 83 2900 27 8 F 14.18471FN2 373 1.04 45 1000 83 2900 27 9 M 739.67471FN3 631 1.04 45 900 122 1450 66 10 F 873.63471FN4 631 1.04 45 900 122 1450 66 11 M471FN9 500 1.04 45 800 76 1485 Press. Fan 12 F471FN5 946 1.04 45 800 165 1480 108471FN6 946 1.04 45 800 165 1480 108471FNH 507 1.04 45 700 90 1470 Press. Fan C o o l e r G r a t e s471FN7 1439 1.04 45 700 225 1485 72 Grate Area Plates Rows471FN8 507 1.04 45 700 76 1485 72 nos. nos.471FNA 1014 1.04 45 600 136 1485 120 CIS 6.48 54 6471FNB 1446 1.04 45 500 136 1485 168 I 34.22 348 29471FNC 1099 1.04 45 500 123 1485 144 II 25.96 264 22

Total 10413 1602 978 III 30.68 312 26Total 97.35 978 83




Norms :



m2

m2 m3/minm3/min

m2

m3/minm3/min

m2 m2

m3/min m3/minm2 m3/minm3/min

m2

m3/minm2

m3/minm3/min

m2

m3/min

m2 m2

m3/min m3/min

m2

m3/minm3/min

m3/min kg/m3 oCm2

m3/minm3/min

m2

cm2

m3/min kg/m3 oC

m2

t/d/m2



Original 0.769824 1100 23.814967Option 1 0.805332 1100 22.764936Option 2 0.693876 1100 26.421624Option 3 0.616116 1100 29.756297


Flow6 5 4 3 2 1

A400 0 0 0 0 060 0 0 0 0 0

B300 400 400 400 400 0 300 Dp(mmWG)120 100 100 100 80 0 120

C300 300 300 300 400 400120 120 120 120 100 100

D300 300 300 300 300 400120 120 120 120 120 100 Total Area of CIS

E300 300 300 300 300 400 Blocked Area120 120 120 120 120 100 Eff. Area

F300 300 300 300 300 400120 120 120 120 120 100

G300 300 300 300 300 400120 120 120 120 120 100

H300 300 300 300 300 400120 120 120 120 120 100

I300 300 300 300 400 400120 120 120 120 100 100

J300 400 400 400 400 0120 100 100 100 80 0

K400 400 0 0 0 080 100 0 0 0 0

Flow (Kg/Min-m2)

7.92

1.446.48

Flow (Kg/Min-m2)

04/22/2023 07:59:01 document.xls Kln-Forml LU001016-KCP#Ver.1.2*

Kiln Performance & EfficiencyS. Constraint Symbol Unit Formula

NO.

1 Degree of Filling DoF %

mts rpm %

2 Burning Zone BZL Gcal/ kg/hr kcal/kg

Loading

kcal/kg-clk

3 Volumetric Loading VL

4 Burner Tip BTV m/secVelocity mmWG

5 Combustion Air, Lmin kg/sec 1.41 x CoalMinimum Mcal/sec

kg-air/ 0.11594xC + 0.34783x(H-O/8)kg-coal + 0.04348xS

C, H, O, S - %

6 Percent Primary Air %PA % Primary Air x 100Lmin

7 Flame Momentum or FM or %.m/sec %PA x Tip Velocity

3.2 x TPDclk

Deff3 x n x S

hr-m2 Coalkiln x NCVcoal

C.S. Areakiln

m2

TPDclk x Sp. Heat Consp.C.S. Areakiln x 24 x 1000

m2

tpd/m3 TPDclk

C.S. Areakiln x L m2 mts

4 x Ps0.5


Relative Impulse RI %.m/sec m/sec

8 Feed Residence RT-K min mts

Time, Kiln (decimal) 19 x L

mts rpm %

9 Clinker Residence RT-C minTime, Cooler (decimal) 1.55 x A x Ps

10 Combustion Air CAR kg-air/ % kcal

Requirement kg-coal 10.478 x (100 - m) x GCV100 x 7000

11 Sulphur-Alkali Q - SO3/80Ratio (K2O/94)-(Na20/62)-(Cl/71)

gms/kg-clk

12 Theoretical Flame TFT deg.C kcal/kg-coal

Temperature Hv1.11 x A x s

kg/kg-fuel 0.29

HvV x s

Nm3/kg-fuel 0.38

13 True CO2 in Kiln T-CO2 % 100 x (CO2 + CO)Exit Gas 100 + (1.89 x CO) - (4.78 x O2)

14 Kiln Feed Ratio, KFR-S kg-feed/ dec.

Dust to Silo kg-clk 1 - Ash Abs.(1 - LOI) * (1 - D/L)

Dust to Kiln KFR-K 1 - Ash Abs.

Deff x n x S

m2 mmWG

TPDclk

Comb. Air Sp. Heatcomb. gas


1 - LOI dec.

15 Ash Absorption AA % tons %

Clinker Prodn.tons

kcal/kg-clk %

kcal/kg-coal

16 Excess Air in Kiln EAK %

O2, N2, CO - Kiln exit gas

0.21 x ( 100 - CO2 ) - O2

17 Major Pluging

Problems, if

18 Radiation kcal/hr/m2T=Shell Temp. and t=Amb. Air Temp.

T & t - deg.K19 Convection kcal/hr/m2

Forced Convection kcal/hr/m2(if amb. air vel. is

more than 3.0 m/s) v=amb. air vel., m/sec

Coal Consp. x Ashcoal

Sp. Heat Consp. x Ashcoal

NCVcoal

189 x (2xO2 - CO)N2 - [1.89 x (2xO2 - CO)]

79 x O2

4*10-8 (T4 - t4)

80.33 x ((T+t)/2)-0.724 x (T-t)1.333

28.03 x ((T+t)/2)-0.351 xv0.805 x D-0.195 x (T-t)


D=Shell dia., mts

04/22/2023 07:59:01 document.xls Comb-Forml LU981125-KCP#Ver.1.1*

Coal Combustion AnalysisS. Constraint Symbol Unit Formula

NO.

1 Ultimate Analysis UA wt.% C+H+N+S+O+Ash = 100O - Determined by difference

2 Proximate Analysis PA wt.% VM+FC+Ash+m = 100FC - Determined by difference

3 Gross Calorific Value GCV kcal/ 80.8*C + 22.45*S + 339.53*H - 35.89*Okg-coal C, S, H, O - Ultimate Analysis (wt.%)

4 Net Calorific Value NCV kcal/ GCV - 52.53*H - 6*mkg-coal

5 Useful Heat Value UHV kcal/ 8900 - 138*(Ash + m)kg-coal Ash, m - Proximate Analysis (wt.%)

6 Methods of Expressing ARB, r "As Received Basis"Solid Fuel Analysis 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)"

7 Conversion from "As Yd wt.% (Yr * 100) / (100 - mr)Received" to "Dry where Y - C, S, N, AshBasis" Hd wt.% ((Hr - 0.1119 * mr) * 100) / (100 - mr)

Od wt.% 100 - (Yd + Hd)8 Conversion from "As Yc wt.% (Yr * 100) / (100 - (Ashr + mr))

Received" to where Y - C, S, N, Ash"Combustible Basis" Hc wt.% ((Hr-0.1119*mr)*100)/(100-(Ashr+mr))

Oc wt.% 100 - (Yc + Hc)9 Conversion from "As Yd wt.% (Ya * 100) / (100 - ma)

Analysed / Air Dry where Y - C, S, N, Ash


Basis" to "Dry Basis" Hd wt.% ((Ha - 0.1119 * ma) * 100) / (100 - ma)Od wt.% 100 - (Yd + Hd)

10 Conversion from "Dry Yr wt.% (Yd * (100 - mr)) / 100Basis" to "As Received where Y - C, S, N, AshBasis" Hr wt.% (Hd * ((100 - mr) / 100) + 0.1119 * mr

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

Basis" to "As Fired where Y - C, S, N, AshBasis" Hf wt.% (Hd * ((100 - mf) / 100) + 0.1119 * mf

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

"Combustible Basis" where Y - C, S, N, Ashto "As Fired Basis" Hf wt.% (Hc*(100-(Ashf+mf))/100) + 0.1119*mf

Of wt.% 100 - (Yf + Hf)13 Ash Absorption AA % tons %

Clinker Prodn.tons

kcal/kg-clk %

kcal/kg-coal

14 Effect of Coal Ash on % (LOI free Coal Ash x Ash Absorption)Clinker Composition + ((100-LOI free Coal Ash) x Theoretical

Clinker)15 Theoretical Fuel kg-coal/

Consumption 100 kg-clk

Coal Consp. x Ashcoal

Sp. Heat Consp. x Ashcoal

NCVcoal

(K1*V) / ((K2*W) - (K3*V))K1 = (400 * m)/(100 - n)

K2 = (b/3) + c + (a*d/7) - (e/8) + (f/8)K3 = (b/3) - ((m*g) / (2500-25*n))


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 + CO100 + 1.89xCO - 4.78xO2

17 Standard Coal Factor SCF - % kcal-kg-coal

18 Combustion Air, Lmin kg/sec 1.41 x CoalMinimum Mcal/sec

kg-air/ 0.11594xC + 0.34783x(H-O/8)kg-coal + 0.04348xS

C, H, O, S - %

kg-air/ 10.478 x SCFkg-coal

19 Combustion Air, L Lmin * 1.10Incl. Extra

20 Theoretical Flame TFT deg.C kcal/kg-coal

((100-mf)/100) * (NCVf/7000)


Temperature Hv1.11 x A x s

kg/kg-fuel 0.29

Comb. Air Sp. Heatcomb. gas

Documents

Kiln Cooler Heat Mass Balance