PLANT ALSALAM CEMENTS - 160 TPH - RAW MILL - BALL MILL
General Data Pressure in mmWG
Prod. t/h 160 Kiln gas 20
Water in % 2 Mill inlet 20
Water out % 0.5 Mill Outlet 200
T amb. o
C 35 Separator outlet 420
Rel. moist. % Cyclone outlet 560
Altitude m 42 Fan inlet 610
After fan 20
Mill Data
Diam. m 5
Length m 8
Filling % 28 False air in % Ambient air composition
Lining mm 75 Mill in 5 CO2
Mill kwh 2700 Mill out 10 O2
Before separator 2 H2O
Mat feed oC 25 Separator 2 N2
Gas out o
C 95 Cyclones 2
Mat out o
C 95 after cyclones 0
Circulationfactor 2.5 Fan 2
Mill O/L velocity m/s 2
Gas Data
O2 w% 4.55 Separator selected O-Sepa N 3000
CO2 w% 37.47 Nominal air flow 3000 m3/min
H 2O w% 5.3 Safety margin 30 % (the gaps between the
Amount t/h 60
Temp o
C 311
Dust kg/kg
For Heat Balance
1 kw = 860 Kcal
Radiation in 1 m2 600 Kcal
Ambient air composition in %
0
22.88
0.497
76.623
% (the gaps between the rotor vanes are slightly larger than the one for cement mill)
INPUT
Percentage of hot gas 66.512 % The flow at mill inlet 86747 kg/hr
The flow should be 86741 kg/hr
Mill inlet gas composition Mill inlet gas composition
wt% mol wt kg mole wt% mol wt
CO2 33.030 44 0.750676 CO2 33.00 44
O2 7.183 32 0.22446 O2 7.19 32
H 2O 5.612 18 0.311793 H2 O 5.61 18
N2 54.175 28 1.934831 N2 54.20 28
3.22176 kg mole
Density 1.384801 kg/Nm3 Density
Fan outlet gas composition Fan outlet gas composition
wt% mol wt kg mole wt% mol wt
CO2 24.211 44 0.550244 CO2 24.19 44
O2 12.412 32 0.387864 O2 12.44 32
H 2O 6.233 18 0.34625 H2 O 6.23 18
N2 57.145 28 2.040897 N2 57.14 28
3.325255 kg mole
Density 1.341701 kg/Nm3 Density
Separator outlet gas composition Separator outlet gas composition
wt% mol wt kg mole wt% mol wt
CO2 25.212 44 0.572994 CO2 25.21 44
O2 11.968 32 0.373998 O2 11.98 32
H 2O 6.468 18 0.359326 H2 O 6.47 18
N2 56.352 28 2.012588 N2 56.34 28
3.318906 kg mole
Density 1.344267 kg/Nm3 Density
Separator outlet gas temperature 84.50 deg C Separator outlet gas temperature
kg mole
0.75 3110.42
0.224688 1.38858
0.311833
1.935607
3.222128 kg mole
1.384643 kg/Nm3
kg mole
0.549773
0.388594
0.346333
2.04075
3.32545 kg mole
1.341622 kg/Nm3
composition
kg mole
0.572932
0.374375
0.359389
2.012214
3.31891 kg mole
1.344266 kg/Nm3
temperature 84.50 deg C
PLANT ALSALAM CEMENTS - 160 TPH - RAW MILL - BALL MILL
Mill O/L Return
Kiln gas Fan O/L Total gas Sep. Cyclone
Kiln gas used after
to mill at mill I/L false gas outlet outlet Fan inlet Fan outlet
air to sep.
Gas composition
CO2 % wt 37.47 37.47 24.19 33.00 27.51 24.19 25.21 24.70 24.70 25.21
O2 % wt 4.55 4.55 12.44 7.19 10.96 12.44 11.97 12.20 12.20 11.98
H 2O % wt 5.3 5.3 6.23 5.61 7.01 6.23 6.47 6.35 6.35 6.47
N2 % wt 52.68 52.68 57.14 54.20 54.52 57.14 56.35 56.75 56.75 56.34
Temp. o
C 311 311 82.5 218.6 89 82.5 84.50 83.51 83.51 82.54
Press. mmWG -20 -20 -20 -20 -200 -20 -420 -560 -610 -20
Density kg/Nm3 1.4076 1.4076 1.3416 1.3846 1.3502 1.3416 1.3443 1.3430 1.3430 1.3417
Density kg/m3 0.6534 0.6534 1.0229 0.7636 0.9933 1.0229 0.9795 0.9674 0.9624 1.0229
H 2O kg/kg dry 0.056 0.056 0.066 0.059 0.075 0.066 0.069 0.068 0.068 0.069
Dew pt. o
F 108 108 112 110 118 112 115 114 114 115
Dew pt. o
C 42.22 42.22 44.44 43.33 47.78 44.44 46.11 45.56 45.56 46.11
Mass flow kg/hr 60000 57697 29050 86747 103287 121343 229214 233799 233799 238475
Vol. flow m3/hr 91821 88297 28400 113598 103982 118629 234000 241680 242930 233126
Vol. flow m3/sec 25.51 24.53 7.89 31.56 28.88 32.95 65.00 67.13 67.48 64.76
Plant
Altitude 42 m Barom. 10282 mmWG T amb 35
1 kw = 860 Kcal Radiation in 1 m2 600 kcal/hr
Mill dia 5m eff. C.S.A 18.47453 m2 C.S.A 13.30166
eff. Dia 4.85 m Max. filling 28 % Velocity 2
Heat of evaporation at 0 deg C 597 kcal/kg water so for 1 deg c, heat of evaporation
Heat of evaporation at 100 deg C 539 kcal/kg water
Heat of evaporation 25 deg C 582.5 kcal/kg water
wt% mol wt kg mole
CO2 33.00 44 0.75
O2 7.19 32 0.224688 Mill inlet gas composition
H 2O 5.61 18 0.311833
N2 54.20 28 1.935607
3.222128 kg mole
Density 1.384643 kg/Nm3
False air at ball mill inlet 5 % of the mill inlet air Ambient air composition
wt% (wet)
wt% mol wt kg mole false air =
CO2 31.35 44 0.7125 hot gas =
O2 7.9745 32 0.249203 Mill outlet gas composition only
H 2O 5.3572 18 0.297622 and without addition of moisture
N2 55.3183 28 1.975654
3.234979 kg mole
Density 1.379143 kg/Nm3
Mill outlet temperature 95 o
C
Mill outlet pressure 200 mmWG
Density at mill outlet 0.9980797 kg/m3
Mill outlet flow 95772 m3/hr
95588 kg/hr (Assumption)
% of moi. Evaporated per kg of air 2.57 %
`
wt% mol wt kg mole
CO2 30.56 44 0.694614
O2 7.77 32 0.242947 Mill outlet gas composition with
H 2O 7.73 18 0.42961 moisture included in the mill ven
N2 53.93 28 1.92606
3.293231 kg mole
Density 1.354748 kg/Nm3
Mill outlet gas density 0.9804 kg/m3
Mill outlet flow 93897 kg/hr
Mill outlet false air 10 %
false air =
wt% mol wt kg mole hot gas =
CO2 27.51 44 0.625153
O2 10.96 32 0.342572
H 2O 7.01 18 0.38941 Mill outlet gas composition with
N2 54.52 28 1.947199
3.304334 kg mole
Density 1.350196 kg/Nm3
Mill outlet temperature 89 C
o
Mill outlet pressure 200 mmWG
Mill outlet gas density 0.9933 kg/m3
Mill outlet flow 103982 m3/hr
103287 kg/hr
Mill inlet hot gas temperature 219 o
C
HEAT BALANCE
Flow Temp. Cp
IN kg/h o
C Kcal/kgoC
Feed 160000 25 0.208502
Moi. In feed 3265 25 0.443993
Return material 238800 89 0.214696
Moi. In return materia 1200 89 0.446693
Grinding heat 1350 kw
False air (inlet+outle 14085 35 0.237805
Total
Flow Temp. Cp
OUT kg/h o
C Kcal/kgoC
Raw meal 398800 89 0.214696
Moi. In product 804 89 0.446693
Moi. Evaporated 2461 89 0.446693
Radiation loss 126 m2
Total gas 100826 89 0.2474
Total
o
C
m2 (Velocity calculation)
m/s at mill outlet (Assumption)
eg c, heat of evaporation 0.58 kcal/kg water
Mill inlet gas composition
air composition CO2 0 H 2O 0.497
O2 22.88 N2 76.623
5%
95 %
Mill outlet gas composition only with false air
and without addition of moisture evaporated
Mill outlet gas composition with flase air and
moisture included in the mill vent gases.
10 %
90 %
Mill outlet gas composition with mill outlet false air
Heat Cp Inlet hot gas Outlet hot gas
Kcal/h
CO2 0.219737 0.206161
834008 O2 0.224557 0.22067
36244 H 2O 0.452862 0.446693
4562975 N2 0.248809 0.245958
47707
1161000 Avg 0.2489 0.2474
117228
6759162
Heat False air
Kcal/h Mill Inlet 4695 kg/hr
mill outlet 9390 kg/hr
7620245
31964
1531549
75398
2219607
11478764
Altitude 42 m Barometric pressure 10282 mmWG Ambient temperature
separator selected O-Sepa N 3000 Ambient air composition wt% CO2 0
Nominal air flow 3000 m /min
3
O2 22.88
safety margin 30 % (the gaps between the rotor vanes are slightly larger than the one for cement mill)
Nominal air flow 234000 m3/hr wt% mol wt kg mole
Temp. (assumption) 85 C
o
CO2 25.21 44 0.572932
Press. (assumption) 420 mmWG O2 11.98 32 0.374375
assuming density 1.3443 kg/Nm 3
H2O 6.47 18 0.359389
0.979548 kg/m 3
N2 56.342 28 2.012214
sep. outlet flow 229214 kg/hr 3.31891 kg mole
False air at cyclones 2% Density 1.344266 kg/Nm3
Total flow at cyclone outlet 233799 kg/hr wt% mol wt kg mole
Temperature at cyclone outlet 83.51 Co
CO2 24.70482 44 0.5614732
Pressure at cyclone outlet 560 mmWG O2 12.198 32 0.3811875
Density at cyclone outlet 0.967388 kg/m3 H 2O 6.34956 18 0.3527533
Total flow at cycone outlet 241680.1 m3/hr N2 56.74762 28 2.0267007
3.3221147
Density 1.3429691
False air at fan 2%
Total flow at fan outlet 238475 kg/hr
Temperature at fan outlet 82.5398 oC wt% mol wt kg mole
Pressure at fan outlet 20 mmWG CO2 24.21072 44 0.5502437
Density at fan outlet 1.022941 kg/m3 O2 12.41164 32 0.3878638
Total flow at fan outlet 233126.3 m3/hr H 2O 6.232509 18 0.3462505
N2 57.14513 28 2.0408974
3.3252554
Density 1.3417006
35 o
C
H 2O 0.497
N2 76.623
ger than the one for cement mill)
sep. outlet gas composition
cyclone outlet gas composition
kg mole
kg/Nm3
fan outlet gas composition
kg mole
kg/Nm3
Mill outlet gas composition
wt% mol wt kg mole
CO2 27.51 44 0.625153
O2 10.96 32 0.342572
H 2O 7.01 18 0.38941 Mill outlet gas composition with mill outlet
N2 54.52 28 1.947199
3.304334 kg mole
Density 1.350196 kg/Nm3
Fan outlet gas composition
wt% mol wt kg mole
CO2 24.21072 44 0.550244
O2 12.41164 32 0.387864 fan outlet gas composition
H 2O 6.232509 18 0.34625
N2 57.14513 28 2.040897
3.325255 kg mole
Density 1.341701 kg/Nm3
Separator outlet nominal flow 229214 kg/hr
Mill outlet flow 103287 kg/hr
Leakage in the separator 2%
Flow from fan outlet 121343 kg/hr
Fan outlet gas temperature 82.5398 oC
Fan outlet gas density 1.022941 kg/m3
Fan out let gas volume to the separator 118621.7 m3/hr 32.95047 m3/sec
wt% mol wt kg mole
CO2 0 44 0
O2 22.88 32 0.715 Ambient air composition
H 2O 0.497 18 0.027611
N2 76.623 28 2.736536
3.479147 kg mole
Density 1.282354 kg/Nm3
Separator outlet gas compostition Percentage of mill air 0.450613
% of fan outlet air 0.529387
wt% mol wt kg mole % of leakage air 0.02
CO2 25.21173 44 0.572994
O2 11.96792 32 0.373998 separator outlet gas composition
H 2O 6.467865 18 0.359326
N2 56.35248 28 2.012588
3.318906 kg mole
Density 1.344267 kg/Nm3
Separator outlet gas temperature 84.50 deg C
t gas composition with mill outlet false air
gas composition
air composition
45.06132 %
52.93868 %
2%
outlet gas composition
Mill input gas quantity 86741 kg/hr
Heat thru hot gas 4719602 kcal/hr
wt% mol wt kg mole
CO2 37.47 44 0.851591
O2 4.55 32 0.142188 Kiln inlet gas composition
H 2O 5.3 18 0.294444
N2 52.68 28 1.881429
3.169651 kg mole
Density 1.407567 kg/Nm3
wt% mol wt kg mole
CO2 24.21072 44 0.550244
O2 12.41164 32 0.387864 Fan outlet gas composition
H 2O 6.232509 18 0.34625
N2 57.14513 28 2.040897
3.325255 kg mole
Density 1.3417 kg/Nm3
Percentage of hot gas 66.512 %
Percentage of fan outlet air 33.488 %
Temperature of mill inlet hot gas 218.5731 o
C
Specific heat of mill inlet hot gas
Cp % kcal/kgoC
CO2 0.219737 33.02973 0.072579
O2 0.224557 7.182706 0.016129
H 2O 0.452862 5.612279 0.025416
N2 0.248809 54.17528 0.134793
Average 0.248917 kcal/kgoC
Mill input flow 86747.06 kg/hr The flow should be 86741
gas composition
t gas composition
kg/hr
