20 25 30
25
5.773503
Kiln feed to clinker factor =
Raw Meal to Clinker Factor x (100) / Top Stage Cyclone Efficiency
Raw meal to clinker factor 1.55
top cyclone efficiency 92 %
Kiln feed to clinker factor 1.68
Raw meal to clinker factor = 100 – ash absorbtion / 100 – LOI
Ash absorbtion = % of ash in fuel x specific fuel consumption
Specific fuel consumption = kg coal kg clinker = Specific heat consumption NCV of coal
Thermal loading of kiln Thermal Loading =
=Clinker (tpd) x Heat consumption x %firing in kiln x 103 πx (D2 /4) x 24
Thermal Loading : (kcal/hr/m2)) p= 2850 TPD
Heat consmp. 890 kcal/kg
Heat consumption : (kcal/kg Firing % in kiln 40
3.4
D : Effective Diameter of the Kiln (m) (ID of kiln) sp. Thermal load 2275992440352.00 kcal/hr/m2
Specific thermal loading for precalciner kilns of modern design : 4.0 to 5.0 M kcal/hr/m2
There are two principa There are two principal metric brick configurations
metric brick configurations, ISO and VDZ. Both ar , ISO and VDZ.Both are described
by a three digit code,eg 418 wh e described by a three digit code,eg 418
where the ere the first digit gives kiln diameter in first digit gives kiln diameter in M
and the last two the last two give brick thickness in cm
With considerable varia With considerable variation, installed brick tion,
installed brick thickness is related to internal kiln diame thickness
is related to internal kiln diameter:
< 4.2 M Dia 180 mm
4.2-4.7 M 200 mm
4.7-5.2 M 225 mm
> 5.2 M 250 mm
and brick and brick specific gravities specific gravities are approximately:
Magnesite 3.05 70% 70%Alumina 2.7
Spinel 2.95 40% 40% Alumina 2.25
Dolomite 2.80
Then brick weight in tonnes per meter of length, W = ρ π ((R 2 – (R – t)2)
where
ρ = brick specific specific gravity, gravity, g/cm 2 2.7
R = inside radius o radius of kiln shell, M 3.6
t = brick thickness, M 0.2
W = 79.3676448 t/m of length
Material balance
DATA CONSIDERED:
Basis 3000 ton of cement per day
GYPSUM 5 % in cement
CLAY
a CLAY ANALYSIS
Sio2 55 %
Al2o3 17 %
Fe2o3 7%
Cao 6.5 %
Mgo 1.1 %
LOI 13.4 %
b COAL ANALYSIS
C 85 %
O2 6.78 %
H 5.31 %
N 2.12 %
S 0.79 %
1 Limestone wastage during crushin 3%
2 kiln Caco3 conversion 97 %
By Reverse Calculation:
1 cement grinding stage:
It is assumed that gypsum added 5%
so total gypsum required 150 tons
clinker required is 2850 tons
2 Rotary kiln stage:
asume following reaction
conversion of reaction 97 % due to crushing losses
so total clinker required 2938.1443299 tons
According to the following reactions we can obtain the amount of Lime and SiO2
by
stoichiometry.
Molecular Weight of CaO = 56
Molecular Weight of SiO2= 60
Molecular Weight of 2CaO.SiO2= 172
2CaO = 2CaO.SiO2
112 172
Amount of CaO Required = 1913.21 tons
Amount of SiO2 1024.93 tons
Limestone Requirement:
Limestone required for 1913.21026133 ton of Cao
By Stoichiometry,
CaCO3 = CaO
100 56
therefore Limestone required= 3416.45 tons
crushing losses 3%
TOTAL Limestone required to crushing 3522.11 tons
PREHEATER AND PRECALCINER:
suppose PH DOC 94 %
100 56 44
Entering:
Limestone entering = 3416.45 tons
Exit:
Limestone reacted 94 %
3211.46 tons
Limestone unreacted 204.99 tons
Lime formed 1798.42 tons
CO2 formed 1413.04 tons
ROTARY KILN:
Calcination reaction:
100 56 44
Assume calcination occur in kiln is = 97 %
Limestone entering = 204.99 tons
Lime formed = 114.79 tons
CO2 formed = 90.19 tons
Hence total lime = 1913.21 tons
Combustion Reaction:
Amount of Coal required =
assume coal contains carbon 85 %
total coal
Amount of Coal required = 495.18 tons 20.6327 t/hr
pc head
Carbon entering = 582.57 tons
12.3796 8.25306
CO2 from combustion = 2136.09 tons
By the following reaction,
12 32 44
Where C is carbon from coal 85 %
Oxygen requirement 1553.52 tons
Assuming excess oxygen 12 %
Total Oxygen 1739.94 tons
Excess Oxygen 186.42 ton
Total air required 7564.96 tons
N2 Present 5825.02 tons
Clinkerisation reaction:
By considering the following reaction occurring in kiln,
Lime present = 1913.21 tons
SiO2 present 1024.93 tons
Clinker formed (stoichiometry) = 2938.14 tons
Conversion formed = 2850.00 tons
prepared by Irfan Ahmed Abro
J.Manager Process
Material balance
DATA CONSIDERED:
Basis 3300 ton of cement per day
GYPSUM 5 % in cement
CLAY
a CLAY ANALYSIS
Sio2 55 %
Al2o3 17 %
Fe2o3 7%
Cao 6.5 %
Mgo 1.1 %
LOI 13.4 %
b COAL ANALYSIS
C 85 %
O2 6.78 %
H 5.31 %
N 2.12 %
S 0.79 %
1 Limestone wastage during crushin 3%
2 kiln Caco3 conversion 97 %
By Reverse Calculation:
1 cement grinding stage:
It is assumed that gypsum added 5%
so total gypsum required 165 tons
clinker required is 3135 tons
2 Rotary kiln stage:
asume following reaction
conversion of reaction 97 % due to crushing losses
so total clinker required 3231.95876289 tons
According to the following reactions we can obtain the amount of Lime and SiO2
by
stoichiometry.
Molecular Weight of CaO = 56
Molecular Weight of SiO2= 60
Molecular Weight of 2CaO.SiO2= 172
2CaO = 2CaO.SiO2
112 172
Amount of CaO Required = 2104.53 tons
Amount of SiO2 1127.43 tons
Limestone Requirement:
Limestone required for 2104.53128746 ton of Cao
By Stoichiometry,
CaCO3 = CaO
100 56
therefore Limestone required= 3758.09 tons
crushing losses 3%
TOTAL Limestone required to crushing 3874.32 tons
PREHEATER AND PRECALCINER:
suppose PH DOC 94 %
100 56 44
Entering:
Limestone entering = 3758.09 tons
Exit:
Limestone reacted 94 %
3532.61 tons
Limestone unreacted 225.49 tons
Lime formed 1978.26 tons
CO2 formed 1554.35 tons
ROTARY KILN:
Calcination reaction:
100 56 44
Assume calcination occur in kiln is = 97 %
Limestone entering = 225.49 tons
Lime formed = 126.27 tons
CO2 formed = 99.21 tons
Hence total lime = 2104.53 tons
Combustion Reaction:
Amount of Coal required =
assume coal contains carbon 85 %
total coal
Amount of Coal required = 544.70 tons 22.6959 t/hr
pc head
Carbon entering = 640.83 tons
13.6176 9.07837026
CO2 from combustion = 2349.70 tons
By the following reaction,
12 32 44
Where C is carbon from coal 85 %
Oxygen requirement 1708.87 tons
Assuming excess oxygen 12 %
Total Oxygen 1913.93 tons
Excess Oxygen 205.06 ton
Total air required 8321.45 tons
N2 Present 6407.52 tons
Clinkerisation reaction:
By considering the following reaction occurring in kiln,
Lime present = 2104.53 tons
SiO2 present 1127.43 tons
Clinker formed (stoichiometry) = 3231.96 tons
Conversion formed = 3135.00 tons
prepared by Irfan Ahmed Abro
J.Manager Process
crusher capacity
The nominal capacity, or rating, ofthe crusher will Ье governed bythe required raw
material throughput and the possibIe working time of the crushing plant. The
quarrying operations, of which the crushing plant usually forms part, are in most
cases conducted оп а si ngle-srlift basis with five or six working days per week. For
ап 8-houг shift the effective crushing time per shift сап Ье put at 7 or at most
7.5 houгs. The crusher should therefore, in ап effective time of 35 to 45 houгs, Ье
аЫе to produce sufficient raw material to feed the kiln plant for а whole (7 -day)
week. Currently we run crusher 10 hrs per day or 70 hrs per week.
The requisite crusher throughput capacity сап Ье calculated from the following
formula:
where:
crusher =
capacity 501.3613 t/hr
kiln =
capacity 2850 t/day
raw
material/c =
li. Factor 1.68
Moisture =
in material 4.5 %
kiln =
rhs/week 168 hrs/week
crusher =
hrs/week 70 hrs/week
crusher capacity
The nominal capacity, or rating, ofthe crusher will Ье governed bythe required raw
material throughput and the possibIe working time of the crushing plant. The
quarrying operations, of which the crushing plant usually forms part, are in most
cases conducted оп а si ngle-srlift basis with five or six working days per week. For
ап 8-houг shift the effective crushing time per shift сап Ье put at 7 or at most
7.5 houгs. The crusher should therefore, in ап effective time of 35 to 45 houгs, Ье
аЫе to produce sufficient raw material to feed the kiln plant for а whole (7 -day)
week. Currently we run crusher 10 hrs per day or 70 hrs per week.
The requisite crusher throughput capacity сап Ье calculated from the following
formula:
where:
crusher =
capacity 1759.162 t/hr
=
kiln capacity
raw 10000 t/day
material/cli. =
Factor 1.68
Moisture in =
material 4.5 %
=
kiln rhs/week 168 hrs/week
crusher =
hrs/week 70 hrs/week
