kiln heat balance 1.xls

Kiln radiationHOLTECOMAN CEMENT COMPANY, OMANRADIATION CALCULATION FOR KILN 1 (From Kiln1 Outlet)Ambient temperature44oCII MethodS NLocation, mKiln Dia, mKiln Length, mTotal C. S, m2Clinker, tphAvg Temp, oCRadiation, Kcal/ hr/m2Radiation, Kcal/ kg clinkerHeat transfer coefficient (Radiation)Heat transfer coefficient (Convection)Radiation, Kcal/ kg clinker10 to 23.8223.8898.211902248.780.54712.5326.2480.57322 to 43.8223.8898.212052599.580.63213.3466.2520.66034 to 63.8223.8898.212253107.340.75514.4946.2400.78446 to 83.8223.8898.212202975.960.72314.2006.2450.75258 to 103.8223.8898.212152847.580.69213.9116.2480.721610 to 123.8223.8898.211902248.780.54712.5326.2480.573712 to 143.8223.8898.212002479.870.60313.0706.2520.630814 to 163.8223.8898.212052599.580.63213.3466.2520.660916 to 183.8223.8898.212403519.980.85615.4036.2200.8861018 to 203.8223.8898.212604115.411.00016.6816.1841.0321120 to 223.8223.8898.212824834.201.17518.1786.1331.2091222 to 243.8223.8898.213045624.981.36719.7736.0761.4051324 to 263.8223.8898.212935220.251.26918.9636.1051.3051426 to 283.8223.8898.212684368.801.06217.2146.1661.0951528 to 303.8223.8898.212704433.551.07817.3506.1621.1111630 to 323.8223.8898.212303241.770.78814.7926.2340.8171732 to 343.8223.8898.212152847.580.69213.9116.2480.7211834 to 363.8223.8898.211952362.960.57412.7996.2510.6011936 to 383.8223.8898.212253107.340.75514.4946.2400.7842038 to 403.8223.8898.212233054.430.74314.3766.2420.7712140 to 443.8447.7598.212072648.261.28813.4586.2521.3432244 to 483.8447.7598.212152847.581.38513.9116.2481.4412348 to 503.8223.8898.212102722.130.66213.6266.2510.6902450 to 524.2226.3998.212253107.340.83514.4946.2400.8672552 to 544.2226.3998.212363407.180.91515.1566.2260.9482654 to 564.2226.3998.212513840.871.03216.0966.2011.066Total >>22.60823.446

&L&10Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman&L&"Arial,Bold"&10(Draft)&R&"Arial,Bold"&10Page 1 of 1

PH radiationHOLTECOMAN CEMENT COMPANY, OMANRADIATION CALCULATION FOR PC AND PREHEATERAmbient temperature23oCII MethodS NLocationDiameter, mLength, mCyclone surface Area m2Clinker, tphAvg Temp, oCRadiation, Kcal/ hr/m2Radiation, Kcal/ kg clinkerHeat transfer coefficient (Radiation)Heat transfer coefficient (Convection)Radiation, Kcal/ kg clinker1.1Cyclone IV A5.063.7559.6198.2192.00740.920.4507.4496.6130.5061.2Bottom5.068.379.0198.2156.00293.580.2366.2475.7390.2741.3Riser pipe1.70210.6898.2142.00151.190.0165.8264.9870.0191.4Meal pipe0.408.310.4398.21260.004407.060.46815.7256.8300.4881.5Down commer duct2.4730232.7998.2142.00151.190.3585.8264.9870.4191.6Roof5.06-17.8498.2187.00672.310.1227.2716.5390.1381.7Cyclone IV B5.063.7559.616.0060.00337.773.3566.3725.8903.8761.8Bottom5.068.379.0198.2151.00240.460.1936.0935.5170.2251.9Riser pipe1.70210.6898.2142.00151.190.0165.8264.9870.0192.0Meal pipe0.4022.5198.21290.005410.220.13817.7356.7280.1442.1Roof5.06-17.8498.2187.00672.310.1227.2716.5390.1382.2Cyclone III A4.833.756.1498.2165.00395.030.2266.5316.0530.2602.3Bottom4.83545.7998.2168.00430.430.2016.6286.1390.2302.4Riser pipe2.607.520.2098.2152.00250.890.0526.1245.5650.0602.5Meal pipe0.403.24.0298.21320.006550.170.26819.9286.6180.2782.7Roof4.83-13.0198.2170.00454.460.0606.6936.1930.0692.8Cyclone III B4.833.756.1498.2180.00579.700.3317.0296.4160.3772.9Bottom4.83545.7998.2175.00516.030.2416.8596.3130.2753.0Riser pipe2.607.520.2098.2160.00337.770.0696.3725.8900.0803.1Meal pipe0.403.24.0298.21366.008597.450.35223.6636.4430.3643.2Roof4.83-13.0198.2187.00672.310.0897.2716.5390.1013.3Cyclone II6.633.777.0798.21101.50876.940.6887.7976.7280.7693.4Bottom6.636.577.9098.2199.00840.420.6677.7046.7010.7473.5Riser pipe3.609.526.2098.21104.00913.960.2447.8906.7540.2723.6Meal pipe0.403.24.0298.21366.008597.450.35223.6636.4430.3643.7Roof6.63-24.3498.2187.00672.310.1677.2716.5390.1883.8Cyclone I A4.833.756.1498.2187.00672.310.3847.2716.5390.4343.9Bottom4.834.743.0498.2164.00383.400.1686.4996.0230.1934.0Riser pipe2.808.823.2098.21114.001067.260.2528.2746.8390.2794.1Meal pipe0.6016.531.1098.21169.002066.270.65410.6577.0090.7024.2Roof4.83-12.1698.2190.00713.230.0887.3786.5850.1004.3Cyclone I B4.833.756.1498.2167.50424.480.2436.6126.1260.2794.4Bottom4.834.743.0498.2175.00516.030.2266.8596.3130.2584.5Riser pipe2.808.823.2098.21110.001004.940.2378.1196.8080.2644.6Meal pipe0.6016.531.1098.21135.671428.440.4529.1566.9540.4944.7Roof4.83-12.1698.2190.00713.230.0887.3786.5850.1004.8Flash Furnace (PC)(single duct)3.449.89926.6898.21147.801648.690.4489.6826.9880.4864.9Flash Furnace (PC) (double duct connecting to cyclone)4.51131.0098.21112.001035.930.3278.1966.8240.3635.0Bypass duct1.055.63318.5898.2169.00442.400.0846.6616.1660.096Total >>13.13614.726

&L&"Arial,Italic"&10Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman&L&10 (Draft)&R&10Page 1 of 1

2_1Plant Operation Audit for two production lines (Line2 &3),Annexure 4.1 ACLINKER CONVERSION FACTOR - LINE 2MEASUREMENTS TAKEN ON 27.11.2013SnParameterUnitValueBasis1Kiln feed ratetph351.00CCR Indication2Loss on Ignition (LOI) of kiln feed%34.66As provided by JKCL3Fuel Consumption (mixed coal)%9.42Calculated based on data provided by JKCL during process measurements0.09415584424Ash content in Fuel (mixed coal )%5.0Calculated based on data provided by JKCLduring process measurements5Raw meal to clinker conversion factor (On LOI basis) (CF 1)-1.52Calculated6Dust loss from Preheater%9.00As provided by JKCL during process measurements7Kiln feed to clinker conversion factor (with return dust) (CF 2)-1.674Calculated8Clinker producedtph209.69Calculatedtpd5033Calculatedtpd5033

&L13170&RPage 1 of 1

HEAT BALANCEKiln 1 Heat BalanceKiln feed rateTph165Clinker prouction'tph98.2142857143'tpd2357.1428571429KF to clinker conversion factor1.68Raw meal temperatureoC60Raw meal moisture%0.5PH exit gas O2%6.0Clinker temperatureoC156.0Natural Gas temperature to kilnoC75Natural Gas temperature to PCoC75Atmosphere Gas densityKg/nm31.293Ambiant temperatureoC23Dust loss (assumed)%8.00Cooler radiationKcal/kg clinker5Drop in temp at two end of TADoC96KILN, PREHEATER AND COOLERClinker production2357tpdS. N.StreamFlow, Kg/ Kg clinkerTemp, oCHeat, Kcal/ kg clk% HeatSp. heat Kcal/KgoCMass balance, tph1Sensible Heat of kiln feed1.676021.060.000.210.02Sensible Heat of kiln feed moisture0.01600.500.001.000.83Sensible Heat of fuel (Nat. gas)0.08753.100.000.527.94Sensible Heat of Primary air to Kiln0.03230.160.000.242.95Sensible Heat of Primary air to precalciner0.00230.000.000.240.06Sensible Heat of Cooling air0.00230.000.000.240.07Sensible Heat of false air0.00230.000.000.240.08Quench air in bypass0.00230.000.000.240.09Sensible heat of kiln feed conveying air0.27603.840.000.2426.410Calorific value from fuel (by balance)0.000.000.0Total Heat Input >>0.000.000.000.0Heat Output1Sensible Heat of Clinker1.0015630.400.000.1998.22Sensible Heat of PH exhaust gas2.03315159.790.000.25199.33Sensible Heat of dust0.133159.910.000.2313.20.0004Cooler exhaust air, Fan1.1200.000.000.00110.35Heat of Formation for Clinker--401.070.006Evaporation of Moisture in kiln feed0.013155.690.000.460.87Bypass gas0.003440.000.000.240.08Bypass Dust0.033442.720.000.243.39Preheater,precalciner & T A Duct radiation losses22.900.000.010Kiln and cooler radiation losses27.610.000.012Other losses by difference0.000.000.0Total Heat Output >>0.000.000.000.0Air liftBlower capacitym3/min95pressurebar1Airm3/h5700nm3/h10204Kg/h13194

&L&"Arial,Italic"&10Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman

2_3_ Page 1 of 2Plant Operational Audit for two production lines ( Line 2&3),Annexure 4.3 AGAS FLOW MEASUREMENT - LINE 2Pitot constant0.836Site pressure9859mmWGSite elevation374mDesign SpecifcationsS.N.LocationDateClinker Production RateDuct dia.Duct areaTemp.Static pressureDynamic Pressure, mmWGRMS Avg dynamic pressureDensityVelocity on RMS AvgVolume on RMS AverageSpecific air consp. on RMS Avg.PowerSpecific powerSpeedFan outlet PressureFan inlet pressureTotal head developed by fanEfficiencyVolumePressureKWspeedType of controltphmm2oCmmWG12345678910No of pointsmmWGKg/ Nm3mpsm3/ hNm3/ hNm3/kg clinkerKWkW/t of clirpmmmWCmmWCmmWC%m3/hr1Preheater Exit (WHR inlet)26.11.13209.693.59.625315-67010.013.013.012.017.025.024.023.026.027.03019.851.4221.557467463083261.47018939.03873.00-98-84074286.6830,0006602700993SPRS27.027.026.026.024.020.023.019.020.014.016.018.020.021.016.017.016.015.026.025.02Cooler exhaust (WHR inlet)26.11.13209.692.806.16418-2715.018.018.017.018.019.018.017.016.017.02016.931.29321.864846691822030.872881.37747-6-13012463486000120465991SPRS18.015.017.016.015.015.017.017.018.018.03Tertiary air26.11.13209.692.183.73930-7025.027.024.023.024.024.028.024.023.024.02422.631.29333.41449173965680.4623.024.023.024.026.028.024.027.010.012.013.025.022.023.04Cooler vent ESP stack26.11.13209.693.187.9454571429150-64.05.04.06.06.05.06.05.06.05.0235.661.2939.882825111738640.832881.37747-6-13012437486000120465991SPRS5.07.06.08.08.09.08.06.05.04.05.05.04.05Preheater Exit (WHR outlet)26.11.13209.693.28.0457142857197-77029.030.031.028.027.030.028.029.032.028.02329.291.4223.536815383482211.66118939.03873.00-98-84074279.1830,0006602700993SPRS29.030.029.028.028.029.033.031.029.030.028.030.028.0

&L13170&RPage &P of 2

2_3_ page 2 of 2Plant Operational Audit for two production lines ( Line2 &3),Annexure 4.3 AGAS FLOW MEASUREMENT - LINE 2COOLING AIR FANSDesign temp15Site pressure9859mmWGSite elevation374mDesign SpecificationsS.N.Fan NoDateSuction duct dia.Duct areaFan outlet Static pressureTemp.Air Velocity, mpsNo of valuesAvg velocityVolumeVolumeSpecific gas consp.PowerFan inlet PressureTotal Head developed by fanEfficiencyDesign , KWDesign PressureDesign capacityNm3/hrNm3/kg clinktphmm2mmWCoC12345678910mpsm3/ hNm3/ hNm3/kg clinkerkWmmWCmmWC%KWmmWC1CF 126.11.13209.690.710.396+821289.49.39.610.210.313.012.612.412.211.01711.7916802145400.06952-208410.82110.00100019800197300.09409273079.916.612.213.313.412.312.62CF 226.11.13209.690.710.396+741289.211.210.210.711.19.08.89.79.38.61910.2314581126180.06042-317720.82110.00100019440193720.09238195389.38.69.99.811.212.712.411.810.93CF 326.11.13209.690.630.312+7542815.716.616.815.714.717.317.315.816.916.01316.3218314158490.07652-147680.82110.00100019440193720.092381953816.716.416.44CF 426.11.13209.690.900.636+3742817.317.717.317.117.217.817.417.017.117.51417.0739088338260.16150-163900.9268238040367960.175478381215.416.716.317.25CF 526.11.13209.690.90.636+3472824.321.621.824.523.8523.2053124459730.21973-233700.8265830300292420.13945555546CF 626.11.13209.690.90.636+3352824.025.825.726.725.926.224.225.026.1925.5158421505570.24182-433780.82658303007CF 726.11.13209.690.90.636+3052824.923.924.121.521.522.722.020.822.823.51322.5551650446970.21365-343390.826583030021.620.623.48CF 826.11.13209.691.120.985+2872814.514.813.615.513.014.012.014.814.915.01614.3750949440910.21057-163030.826583030014.015.815.715.413.813.09CF 926.11.13209.691.120.985+2832813.213.212.914.313.714.112.612.012.013.71313.1046476402200.19251-112940.826583030012.312.513.910CF 1026.11.13209.691.120.985+2452811.710.911.010.012.311.610.013.612.412.51411.5040803353100.16838-925410.013.111.011.0Total specific cooling air1.61561BLOWERS2.681245120.59379057481Main firing -Primary air (BLOWER) fan - Kiln26.11.13209.690.5 X 0.5x 41.00+1748281.251.121.421.491.551.611.741.691.711.55101.51544747140.0221.66015665772Kiln Coal conveying blower26.11.13209.690.5 X 0.50.25+3500282.642.712.672.672.651.942.532.642.542.58102.56230119920.0093PC Coal conveying blower26.11.13209.690.5 x 0.50.25+3045283.394.274.063.883.953.213.313.253.563.51103.64327528340.014


Cooler heat balanceCOOLER AIR & HEAT BALANCEPlant capacityt/d2357Sp. heat capacityKcal/kgclk.800Fuel firing in Kiln%40Air densityKg/nm31.293Ambient temp.oC23Combustion air for kilnKg/kg clinker0.494Nm3/kg clinker0.382Combustion air for PCKg/kg clinker0.748Nm3/kg clinker0.579Primary air to kilnKg/kg clinker0.029Nm3/kg clinker0.022Primary air to PCKg/kg clinker0.000Nm3/kg clinker0.000Secondary air to kilnKg/kg clinker0.465Nm3/kg clinker0.360Tertiary air to PCKg/kg clinker0.000Nm3/kg clinker0.000Cooler vent airKg/kg clinker1.124Nm3/kg clinker0.869Total Cooling airKg/kg clinker0.000Nm3/kg clinker0.000Heat balanceSnItemFlowTempCpHeatkg/ kg clinker0CKcal/ kg 0CKcal/ kg clinker1Secondary air to kiln0.465142714710600.26128.19333217542Tertiary air to PC08830.2503Cooler vent air1.1235082612480.2466.87121169754Clinker leaving the cooler11560.1929.70333333335Total Heat output >>006Hot Clinker114500.263777Cooling air0230.2408Total Heat Input >>009Cooler heat recuperation efficiency0

&L&10Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman&R&10Page 1 of 1&L&"Times New Roman,Regular"&10 (Draft)&R&"Times New Roman,Regular"&10Page 1 of 1

cooler diagramCOOLER HEAT BALANCETertiary airMTCpHKg/kg clkoCKcal/ kgoCKcal/kgclk0.008830.250Secondary airCooler vent airMTCpHMTCpHKg/kg clkOCKcal/ kgoCKcal/kgclkKg/kg clkOCKcal/ kgoCKcal/kgclk0.4710600.261281.122480.2467Hot clinkerMTCpHKg/kg clkOCKcal/ kgoCKcal/kgclk1.0014500.26377Cooled clinkerMTCpHCooling airKg/kg clkOCKcal/ kgoCKcal/kgclkMTCpH1.00156.33333333330.1930Kg/kg clkOCKcal/ kgoCKcal/kgclk0.00230.240Recuperatuion Efficiency :0.00%

&L&10Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman&R&10Page 1 of 1&L&"Times New Roman,Regular"&10 (Draft)&R&"Times New Roman,Regular"&10Page 1 of 1KilnCooler

Cooler RadiationRADIATION CALCULATION FOR COOLERAmbient temperature0oCII MethodS NLocationCyclone surface Area m2Clinker, tphAvg Temp, oCRadiation, Kcal/ hr/m2Radiation, Kcal/ kg clinkerHeat transfer coefficient (Radiation)Heat transfer coefficient (Convection)Radiation, Kcal/ kg clinker1.1Cooler145.0493.24113.111319.992.0537.5217.9912.3471.2Cooler roof61.4893.24138.501757.031.1598.5188.0211.299Total >>3.213.646

&L&409 Process&CPage 1 of 1&R&409.07.2002

PH radiation (2)RADIATION CALCULATION FOR PC AND PREHEATERAmbient temperature0oCII MethodS NLocationCyclone surface Area m2Clinker, tphAvg Temp, oCRadiation, Kcal/ hr/m2Radiation, Kcal/ kg clinkerHeat transfer coefficient (Radiation)Heat transfer coefficient (Convection)Radiation, Kcal/ kg clinkerKiln String1.1Cyclone - 1A126.61209.6975.33763.560.4616.2107.7360.5451.2Bottom38.85209.6990.00966.760.1796.6957.8770.2091.3Riser pipe16.21209.69128.001569.830.1218.0948.0180.1371.4meal pipe9.24209.69264.004846.820.21315.0007.6190.2261.5Roof9.69209.6984.33886.350.0416.5047.8300.0482.1Cyclone - 1 B126.61209.6991.67990.860.5986.7527.8890.6972.2Bottom38.85209.6997.331074.400.1996.9497.9250.2312.3Riser pipe16.21209.69125.671529.480.1188.0028.0150.1342.4meal pipe9.24209.69260.674740.740.20914.7917.6340.2212.5Roof9.69209.6991.00981.200.0456.7307.8840.0533.1Cyclone - 2152.76209.6968.67676.470.4935.9997.6480.5873.2Bottom51.19209.6980.00826.480.2026.3617.7880.2383.3Riser pipe36.63209.69110.001270.020.2227.4057.9810.2543.4Meal pipe9.24209.69147.331921.850.0858.8888.0160.0943.5Roof22.39209.69112.001302.050.1397.4807.9880.1594.1Cyclone - 3151.13209.6968.67676.470.4885.9997.6480.5814.2Bottom50.64209.6974.00745.880.1806.1687.7200.2134.3Riser pipe36.92209.69178.002549.280.44910.2687.9560.4914.4meal pipe9.24209.69178.672563.920.11310.3007.9540.1244.5Roof15.10209.6982.67863.150.0626.4497.8150.0735.1Cyclone - 4166.84209.6990.00966.760.7696.6957.8770.8975.2Bottom53.75209.69105.001191.320.3057.2237.9630.3515.3Riser pipe38.80209.69135.331699.590.3148.3888.0210.3535.4Meal pipe10.81209.69158.332136.800.1109.3668.0010.1225.5Roof16.45209.6983.33872.410.0686.4717.8210.0806.1Cyclone - 5166.84209.6996.671064.450.8476.9267.9210.9826.2Bottom53.75209.69131.671634.150.4198.2408.0200.4726.3Riser pipe38.80209.69116.671378.020.2557.6558.0000.2916.5Meal pipe10.81209.69165.672286.290.1189.6957.9870.1306.6Roof16.45209.69150.331979.390.1559.0168.0120.1736.1Cyclone - 6166.84209.69122.501475.441.1747.8788.0111.3326.2Bottom53.75209.69136.671723.670.4428.4438.0210.4966.3Riser pipe38.80209.69466.6714940.492.76532.1246.6872.8826.5Meal pipe10.81209.69225.003696.670.19112.6907.7900.2046.6Roof16.45209.69101.331134.840.0897.0917.9460.103Calciner String1.1Cyclone - 1148.64209.6983.33872.410.6186.4717.8210.7261.2Bottom49.94209.69153.332037.740.4859.1468.0090.5391.3Riser pipe26.28209.6967.33659.450.0835.9587.6280.0991.4meal pipe9.24209.69194.332920.980.12911.0677.9060.1401.5Roof20.87209.69100.001114.560.1117.0437.9390.1283.1Cyclone - 2145.34209.6997.001069.420.7416.9377.9230.8593.2Bottom48.93209.6974.00745.880.1746.1687.7200.2063.3Riser pipe35.80209.6988.33942.860.1616.6397.8640.1883.4Meal pipe9.24209.69155.332077.090.0919.2348.0060.1013.5Roof13.67209.69107.331227.810.0807.3077.9720.0924.1Cyclone - 3141.69209.69112.331307.420.8837.4927.9891.0104.2Bottom48.36209.6978.00799.310.1846.2967.7670.2184.3Riser pipe35.14209.69115.001350.690.2267.5927.9960.2584.4meal pipe9.24209.69156.332096.900.0929.2778.0040.1024.5Roof13.45209.6967.33659.450.0425.9587.6280.0505.1Cyclone - 4151.13209.6995.671049.580.7566.8917.9150.8785.2Bottom50.64209.69125.001518.030.3677.9768.0140.4155.3Riser pipe36.92209.69138.001747.910.3088.4988.0210.3455.4Meal pipe9.24209.69193.672905.270.12811.0337.9080.1395.5Roof14.92209.69121.671461.350.1047.8468.0100.1186.1Cyclone - 5151.13209.69100.001114.560.8037.0437.9390.9286.2Bottom50.64209.69117.331389.020.3357.6808.0010.3826.3Riser pipe36.92209.6998.671094.410.1936.9967.9320.2236.5Meal pipe9.24209.69206.333211.980.14111.6827.8630.1536.6Roof14.92209.6998.331089.400.0786.9847.9300.0906.1Cyclone - 6151.13209.69101.001129.760.8147.0797.9440.9406.2Bottom50.64209.69136.671723.670.4168.4438.0210.4676.3Riser pipe36.92209.69154.672063.930.3639.2048.0070.4036.5Meal pipe9.24209.69181.672630.350.11610.4447.9460.1276.6Roof14.92209.69165.672286.290.1639.6957.9870.179PC1.988Riser ducts3.128Total >>26.9424.686

&L&409 Process&CPage 1 of 1&R&409.07.2002

Kiln radiation (2)RADIATION CALCULATION FOR KILN 1 (From Kiln Outlet)Ambient temperature0oCII MethodS NLocation, mKiln Dia, mKiln Length, mTotal C. S, m2Clinker, tphAvg Temp, oCRadiation, Kcal/ hr/m2Radiation, Kcal/ kg clinkerHeat transfer coefficient (Radiation)Heat transfer coefficient (Convection)Radiation, Kcal/ kg clinker10 to 24.27226.83209.693649418.041.20522.3047.1481.17922 to 44.27226.83209.692805703.770.73016.0327.5450.72634 to 64.27226.83209.692815740.670.73516.0987.5400.73146 to 84.27226.83209.692916118.620.78316.7707.4940.77758 to 104.27226.83209.692464540.150.58113.8997.7000.585610 to 124.27226.83209.692043325.530.42511.5617.8720.436712 to 144.27226.83209.691652388.360.3069.6657.9880.320814 to 164.27226.83209.693478558.331.09520.9137.2281.074916 to 184.27226.83209.693187223.530.92418.6867.3660.9111018 to 204.27226.83209.693518755.291.12021.2357.2091.0981120 to 224.27226.83209.692013247.300.41511.4067.8830.4271222 to 244.27226.83209.692253904.140.50012.6907.7900.5071324 to 264.27226.83209.692574897.790.62714.5647.6510.6281426 to 284.27226.83209.693277620.710.97519.3587.3230.9601528 to 304.27226.83209.692153621.730.46312.1427.8300.4721630 to 324.27226.83209.693187223.530.92418.6867.3660.9111732 to 344.27226.83209.693096841.090.87518.0307.4080.8651834 to 364.27226.83209.693056675.730.85417.7457.4270.8451936 to 384.27226.83209.693076758.060.86517.8877.4180.8552038 to 404.27226.83209.692574886.690.62514.5447.6530.6272140 to 424.27226.83209.692604987.130.63814.7297.6390.6392242 to 444.27226.83209.692153621.730.46312.1427.8300.4722344 to 464.27226.83209.692283991.380.51112.8587.7780.5182446 to 484.27226.83209.692213789.640.48512.4697.8060.4932548 to 504.27226.83209.692123539.470.45311.9827.8420.4622650 to 524.27226.83209.692183695.800.47312.2877.8200.4812752 to 544.27226.83209.692093449.380.44111.8057.8550.4512854 to 564.27226.83209.692093449.380.44111.8057.8550.4512856 to 584.27226.83209.692223827.580.49012.5427.8010.4982858 to 604.27226.83209.692855889.900.75416.3647.5220.749Total >>20.1820.15Existing25.6231 to 550.0240.00209.693006472.930.00017.3927.4510.0008.228

&R&"Arial,Bold"Page 1 of 1

HEAT BALANCE (2)HEAT BALANCE1Kiln feed temperatureoC60oCPrimary air tempDeg C502Kiln feed moisture%0.2%3Fine Coal moisture%0.5%4PH exit gas CO2%18%5O2%4.0%6N2%78.0%7Clinker temperatureoC130oC8Temperature of Coal fired in kilnoC50oC9Temperature of Coal fired in PCoC50oC10Gas densityKg/nm31.293Kg/nm311Ambiant temperatureoC28oC12Dust loss%9.00%13Cooler radiationKcal/kg clinker3.21Kcal/kg clinker14Kiln radiationKcal/kg clinker20.2Kcal/kg clinker15PH radiationKcal/kg clinker26.94Kcal/kg clinkerKILN, PREHEATER AND COOLER -Kiln 2Clinker production5033tpdS. N.StreamGas flow, Nm3/kg clinkerFlow, Kg/ Kg clinkerTemp, oCHeat, Kcal/ kg clk% HeatMass flow tphSp. heat Kcal/KgoC1Sensible Heat of kiln feed1.6716021.242.78350.300.212Sensible Heat of kiln feed moisture0.003600.200.030.701.003Sensible Heat of Fuel0.094501.310.1719.640.28From graph4Sensible Heat of fine fuel moisture0.0005500.010.0010.100.28From graph5Sensible Heat of Primary air to Kiln0.0220.029500.350.056.090.246Sensible heat of coal conveying air to kiln0.0090.012500.150.022.580.247Sensible Heat of Cooler air1.6102.0822813.861.82436.620.248Sensible Heat of false air0.3050.394282.620.3482.660.241.2939Sensible heat of coal conveying air to PC0.0140.017500.210.033.660.240.30486356550.03010Heat from Fuel72394.770.0011Calcination Gases0.27812Combustion Gases only0.024Total Heat Input >>2.264.30763100.00902.4Heat Output1Heat loss through Clinker1.00013025.093.29209.690.1932Heat loss through PH exhaust gas1.4262.025315157.020.57424.690.253Heat loss through PH return dust0.15131511.111.4631.590.234Heat loss through Cooler exhaust air0.871.124418115.815.18235.590.255Heat of Formation for Clinker401.152.576Evaporation of Moisture in kiln feed0.0033152.270.300.700.467Evaporation of Moisture in fine fuel0.00053150.320.040.100.468Preheater radiation losses26.943.530.009Kiln and cooler radiation losses23.393.070.00Total Heat Output >>2.304.30763.0100.00902-0.030.000FuelQuantity fired, tphCalorific Value, Kcal/kgtotal heat, kcal/hr% Thermal Substitution rateAsh content, %combustion air requirementKiln coal6.00078004680000031.116.251480PC coal13.300780010374000068.916.29.2%0.00700000.08Density at nozzle1.258150540000100.0velocity204Specific heat718momemntum1864% m/sAverage CV value of final fuel (fine coal ), kcal/kg clinker78000.310880829Average fuel ash %16.200GAS BALANCEGAS INPUTNm3/kg clinker1Sensible Heat of Primary air to Kiln0.022PH exhaust1.47Nm3/kg clinker2Sensible heat of coal conveying air to kiln0.0093Sensible Heat of Cooler air1.6104Sensible Heat of false air0.3055Sensible heat of coal conveying air to PC0.0146Calcination Gases0.2787combustion gases only0.024Total2.263Coal conveying air to PC0.014Nm3/kg clinkerGAS OUTPUTNm3/kg clinker1Preheater Exhaust1.4702Heat loss through Cooler exhaust air0.869Cooler Exhaust0.87Nm3/kg clinkerTotal2.339Primary air0.0225Nm3/kg clinkercoal conveying air to kiln0.0094974688Nm3/kg clinker0.764Secondary + Tertiary air0.741(With out calicnation and combustion gases)Tertiary Air0.461Nm3/kg clinkerSecondary air0.281Nm3/kg clinkerCooling air1.61Nm3/kg clinkerPetcoke, %Turkish coal, %Italian (imported coal), %AFR (RDF)80020Combustion gasesAverageCoal ultimate analysis%Carbon 81.287.2168.3275.25Hydrogen (H2)3.93.864.313.84Oxygen (O2)Sulphur2.54.661.210.28Nitrogen (N2)2.42.483.122.38Coal ash10Water (H2O)0Total100.098.2176.9681.75Theritical air requirement8.3Nm3/kg coal0.78Theoritical air requirement160799Nm3/hr4001Nm3/hr(secondary air +Tertiary air+Primary air)0.77Nm3/kg clinker0.16Nm3/kg clinkerSecondary air + Teritary air0.744% primary air consumptionTheoritical gas volume8.59Nm3/kg coal0.02Nm3/kg clinker165702Nm3/hr(secondary +Tertiary +combustion gases)0.790Nm3/kg clinkerBy balance0.744Increase in gas volume (Only combustion gases)0.024Nm3/kg clinker0.9588Calcination gasesRaw meal analysis%Al2o33.49Cao45.02Mgo0.29Theoritical calcination gases0.278Nm3/kg clinkerTotal PH gases1.068Nm3/kg clinker

&R

Cooler HBCooler 2 Heat Balance -Kiln 2DataClinker Productiontpd5033Specific Heat Consumptionkcal/kg clinker723% of fuel to Kiln%31.1% of fuel to PC%68.9Clinker temperatureDeg C130Cooler Exhaust TemperatureDeg C418SecondaryDeg C1140Tertiary Air TemperatureDeg C930Primary air to kilnkg/kg clinker0.029Primary air to PCkg/kg clinker0.017Secondary Air Quantitykg/kg clinker0.363Tertiary quantitykg/kg clinker0.595Density of airkg/nm31.293Ambient Air TemperatureDeg C28SnDescriptionFlowTemperatureCpHeatkg/kg clinkerDeg Ckcal/kg oCkcal/kg clinkerHEAT INPUT1Hot Clinker1.0014500.2643832Cooling Air2.08280.23813.9Total3.08397.1HEAT OUTPUT3Heat loss through Cooler Exhaust air1.124180.247115.84Secondary air0.36311400.263109.05Tertiary Air0.5959300.258143.16Heat loss through Clinker1.001300.19325.17Cooler Radiation losses3.2Total3.08396.20.87% of Heat Recuperation Efficiency64Total Cooler losses1440.959

Annexure 2_7Plant Operational Audit for production lines ( Line 2& 3),Annexure 4.7 ACOOLER HEAT BALANCE LINE 2Secondary airTertiary AirMass0.36Kg/ kg clkMass0.60Kg/ kg clkTemp.11400CTemp.9300CHeat flow109.00Kcal/ kg clk.Heat flow143.09Kcal/ kg clk.Cooler exhaustMass1.12Kg/ kg clkTemp.4180CHeat flow115.82Kcal/ kg clk.ClinkerMass1.00Kg/ kg clkTemp.1300CClinkerHeat flow25.09Kcal/ kg clk.Mass1.00Kg/ kg clkTemp.14500CHeat flow383.24Kcal/ kg clk.Total cooling airCooler radiation lossesHeat recuperation efficiency3.21Kcal/ kg clk.63.6%Mass2.08Kg/ kg clkTotal Cooler lossesTemp.280C144.1kcal/kg clinkerHeat flow13.86Kcal/ kg clk.


2_4Plant Operational Audit for two production lines ( Line2& 3),J K Lakshmi Cement Ltd, Sirohi RajasthanAnnexure 4.4AKILN SHELL TEMPERATURE LINE 2S.N.Location (From kiln outlet), mAverage temperature, oC10 to 236422 to 428034 to 628146 to 829158 to 10246610 to 12204712 to 14165814 to 16347916 to 183181018 to 203511120 to 222011222 to 242251324 to 262571426 to 283271528 to 302151630 to 323181732 to 343091834 to 363051936 to 383072038 to 402572140 to 422602242 to 442152344 to 462282446 to 482212548 to 502122650 to 522182752 to 542092854 to 562092956 to 582223058 to 60285


2_5Plant Operational Audit for two production lines ( Line 2& 3),J K Lakshmi Cement Ltd, Sirohi RajasthanAnnexure 4.5ACHEMICAL ANALYSIS OF CLINKER LINE 2ComponentUnitValueSiO2%20.94401.06972Al2O3%5.71Fe2O3%3.75CaO%63.87MgO%3.02SO3%1.45K2O%0.73Na2O%0.31Cl%0.00Free CaO%1.89H20%0.00


Sankey DiagramHeat loss by RadiationHeat loss through Cooler Vent6.60%15.18%Sensible heat of Kiln FeedHeat loss through Preheater exhaust gas2.78%20.57%Heat loss through clinkerHeat input by Fuel3.29%94.77%Specific Heat ConsumptionKcal/ kg clinker763.0Heat of Formation52.57%

Heat Balance of Kiln 2

coal conveyingEstimation of Phase DensityKilnPCPipe line sizeDiamm141.2179.232.1361058601CSAm20.01570.0252321.3610586011Volumem3/sec0.63930.9098kg/sec0.72241.0280m3/hr23013275Nm3/kg clinker0.0090.014Coal tptTPH613.4kg/sec1.673.72Velocity at tpt linem/sec40.8236.07Coal to air ratio2.313.62power conskW110110sp power18.338.21kg of air required for 4 kg ratio0.420.93Extra air going0.310.10% Extra air going0.420.09% reduction in power for 20% speed red0.5120.512kw saving53.70.0annual cost saving8.590.00

savings with coalKiln 2 - Energy Saving Proposals,Power cost3.880INRCoal cost861.6INR/ mio kcalThermal savingsElectrical savingspresent levelnew onepresent powerfan headsaving powerRunning hrssavings in Lakhsinvestement Lakhspayback, monthskcal/kgMTOE/ yearKWkW/ t of clinker1Increasing Gas residence time in existing precalciner001011711010.682Reduction of preheater calciner exit temperature10.195.10.53.64243Reduce pressure drop across duct from WHR outlet to ph fan inlet70.0401893.0742.077792023.540.0020776.64Arresting of false air1893.0742.094.65792029.120.085398950.11False air %4Reduce bypass in pyro section40.762.20.1405Reduce pressure drop across Top stage cyclone278.0902075.1830.023580007.32.4042351.66Reduce false air across CT system -Pyro2075.1830.0092.180001.430.131.192.10.6599967Replacement of existing cooling fans75.0800023.32.51.30.58Upgradation of heat exchanger in cooler vent system2.59Installation of Precalciner800045.02.30.610Increasing kiln inlet area0.02.011Reduction of dust accumulation inside Tertiary Air Duct (TAD) & Improving Tertiary air flow.80003.061.55.9471 FN2,3,4,5,6,720.080006.24077.37Reduce pressure drop across cyclone & cyclone outlet bend in Raw mill circuit160.01301580.0903.052.5700014.32016.88Reduce false air in GCT and VRM circuit1580.0903.0145700039.4206.1433769Reduce damper loss in Kiln/raw mill Bag House Fan40.020803.0294.027.380008.500.010Reduce false air in coal mill circuit380.0893.03950007.62539.41189011Reduce pressure drop in coal mill bag hose to Fan duct115.040380.0893.031.950006.22548.512Reduce damper loss in coal mill booster fan47.02060.0141.011.550002.2316.213Reduce speed of kiln & PC coal conveying blowers by 20 % by installing VFD and reduce pipe dia /size to maintain 35 m/s transportation velocity67.0800020.82011.514Installation of automation system109800033.85017.715Reduce pressure drop across damper in Sepax fan Slag HPGR roller press80.020400.0464.025.970007.000.016Reduce pressure drop across damper in bag house fan in Slag VRM113.0201435.0686.097.3700026.400.017Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF1)64.01022.0351.03.450000.7236.618Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF3)303.01045.0496.013.350002.6418.619Avoid damper loss by installing VFD in Auxilary bag filter fan (221BF1)440.01055.0515.023.050004.5410.8Long term energy saving proposalsInstallation of new clinker cooler157.060045.9417826

Primary air_kiln _ PCPrimary air to kiln0.04Kcal/ kg clinkerAir required for kiln firing0.500264336% primary air to kiln8.00Primary air to precalciner0.06Kcal/ kg clinkerAir required for PC firing0.750396504% primary air toPC8.00Savings from Recommended actionThe O2 at PH exit may be reduced to 3.5% by identifying the leakages in the Cyclones, riser ducts, meal chutes, PC, kiln seals, etc.29.3149888778Kcal/ kg clinkerPrimary air to PC may be reduced to maximum 6 % i.e. 0.045 Kg/ kg clinker. From 0.06kg /kg clinker3.1788Kcal/ kg clinkerPrimary air to kiln may be reduced to maximum 6 % i.e. 0.04 Kg/ kg clinker. From 0.025kg /kg clinker3.7332Kcal/ kg clinkerTemperature drop across the T A Duct may be reduced to 50 Deg C from 965.87328Kcal/ kg clinkerGas quantity at kiln inlet0.5843968948Kg/ kg clinkerBy pass gas as measured0.27Kg/ kg clinkerQuench air as measured0.20Kg/ kg clinkerBy pass gas0.074757Kg/ kg clinker12.7921624272%

&C&"Times New Roman,Regular"&12&A&C&"Times New Roman,Regular"&12Page &P

kiln heat balance 1.xls

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