project line b

8/10/2019 Project Line B

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Clinker factor= 1-(L.O.I +by pass+ Dust offilter)

=1-(0.35+0.02+0.01) = 0.62

Assume that : Clinker factor=0.58As safety factor

That mean each 1KG raw meal gives 0.58 KGclinker

X KG raw meal gives 1KG clinker X=1/0.58 =1.72

That means 1.72 KG raw meal gives 1KG clinker


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2 (L.S & Clay)Crushers will operate 6 d/w and 8 h/d Raw material required for crushers:

Lime stone :

Avg. Moisture =1.4166%

L.S/d=4500*1.72*1.1*0.7271*1.014166= 6278 ton/day L.S/h =6278*7/(6*8)=916 ton/h

Clay:

Avg. Moisture =17.34%

Clay/d=4500*1.72*1.1*0.2662*1.1734 = 2659 ton/day Clay/h=2659*7/(6*8)=388 ton/h

Sand:

Sand/d=9000*0.67/100 = 60.3 ton/day

So Sand needs per day = 65 ton/day to be in safe side


6/28

Impact crusher 1050 t/h

Working days = 6 days/week

Working shifts= (one shift)=8 hours/day Daily production = 1050 *8 =8400 t

Weekly production = 8400*6 = 50400 t

Roller crusher 400 t/h

Daily production=400*8 = 3200 t

Weekly production = 3200*6 = 19200 t


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5 Trucks with cap. 60 ton (3 for L.S & 2for Clay)

2 Loaders

2 BulldozerMaterial handling from crushers to plant by

belt conveyors as per flow sheet


8/28

Stock pile covers 4 days raw mill feeding (9,000t/d)

Selected longitudinal pile with max. capacity=3,5000 t

Reasons:

1- Different quality of quarry layers

2- Easy for extension

Stacker:

Slewing stacker 1900 t/h ( Operat. cap. 1450t/h)

Reclaimer:

Bridge scraper 500t/h

Raw Material open yard for Sand capacity 5,000 t


9/28

Raw Meal factor = 1.72 Moisture content of Mix = 5.65 %

Raw meal required =4,500*1.72*1.0565 = 8,177 ton/day

Safety factor (take over)= 1.1

We will operate the mill 22 h/d

Raw mill capacity =(8,177*1.1)/22= 409 ton/hour

Total raw meal = 9,000 t/d

Max. capacity of Raw mill = 409 t/h

Mill type: Atox roller mill 40 (3 rollers)

Capacity : Design cap. = 427 t/h working 355 day/year Mill Drive : 2152 KW

Air Separator :RAR 45

Separator drive : 163 KW

Hot gas generator: gas firing system


10/28

Air flow =120 Nm3/s (assumption)

Mill fan flow rate Q =120 x 60 x 60

= 432,000 Nm3/h

Mill fan power = 2,300 KW

Raw transportation by collecting air slidethen then to CF silo by using bucketelevator to reduce power consumption .

There is a sampler before bucketelevator for controlling quality


11/28

One Raw meal silo CF silo with bucket elevator

Capacity: 25,000 ton

=3.14*r*silo length*material density

Height: 52 m Active height:48m

Internal diameter: 20 m

Bulk density of raw material=1.42 ton/m Kiln feed tank capacity:100 ton

Bucket elevator capacity=(9000/24)*1.1=420t/hr


12/28

Preheater : In Line Calciner

5 stage Natural Gas for main burner & calciner

Kiln feed = 4500 x 1.72 / 24 = 323 t/h

Consider Gas lower calorific value = 9250 Kcal/Nm

Consider heat consumption = 800 kcal/kg clinker The production =4,500 x 1000/24 = 187,500 kg ck/hr

Total heat consumption = 187500 x 800

= 150,000,000 kcal / hr

Gas Req. for Kiln (Nm3/hr) = 150,000,000 / 9250

= 16,216 Nm/hr

Gas Req. for Main Burner = 16,216 x 0.4 = 6,487 Nm/hr

Gas Req. for preCalciner = 16,216 x 0.6 = 9,730 Nm/hr


13/28

The air required for combustion:

Lo = [ (Hu-1115) / 808 ] = [ ( 9250-1115 ) / 808 ]

= 10.07 Nm3 air/Nm3 gas

Assuming that excess air 8%

Total excess air= 10.07 x 1.08 = 10.87 Nm3air / Nm Gas

Req. air hourly= 10.87 x16,216 =176,327 NmAir/hr

Smoke gas (Vo) = (1.25 *9250 3025) / 808 = 10.56Nm3/Nm3 gas

Total smoke gas = 10.56 x16,216 = 171,344 Nm/hr ----1 Assuming that false air 0.5 % O

false air = 0.5/(21-0.5) = 2.5 %

Total false air = (2.5/100 )x 171344 = 4283 Nm/hr---- 2


14/28

Assuming that kiln decalcination about 15% and our L.O.I = 35%

Total volatized CO in kiln = (0.35/1.977) x 0.15 x 187,500=4,980 Nm3 CO2/hr ----3

Assuming that firing in kiln 40% --- Preheater 60%

Kiln smoke gases=0.4 x 171,344 = 68,535 Nm3 / hr ------4

Total kiln gases = (2)+(3)+(4)=77,800 Nm/hr

Depending on CL content we have 20% By pass + safety factor15%

By pass=0.35 x 77800.347 = 27,230 Nm3 / hr

Total kiln gas without by pass = total kiln gases by pass gases= 77800.347-27230.12= 50,570 Nm/hr -------5


15/28

Total smoke gases in preheater (60%) =0.60 x 171,344=102,806 Nm/hr --------6

Considering decalcination in preheater is about 85 % and our

L.O.I=35%

Volatized CO2 = (0.35/1.977) x 187500 x 0.85=28215.1 Nm/hr ---------------7

Assuming O2 after ID fan is 5% so

Total false air in preheater =[(5-2)/ [(21-5) x(102,806+28,215) ]=24,566 Nm/hr -------------8

Total gases after preheater = 5+ 6 + 7+8 =206158.29 Nm/hr

Taking 15% Safety factor = 206158.29*1.15=237082.03 Nm/hr

So ID fans capacities are 237082.03 Nm/hr


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Kiln production/h =(4500 x 1000)/24=187500kg/h

Burner Fuel = 800 kcal x 0.4=320 Kcal/Kg clinker Total thermal load = 187500 x 320= 6 x 107Kcal/h Assume burning zone thermal load in case of in line calciner = 4.1 x

106Kcal/h/m Active cross section = (6 x 107 )/ 4.1 x 106 =14.63m

Active cross section = 3.14 x (D-0.44)/4 So Kiln Diameter (D)=4.75m

Assume Volumetric load =4.2TPD/m 4.2=4500/[(D-0.44) x (3.14/4) x L] So kiln length (L) = 74m

Speed rotation of Kiln : 4.0 rpm

Kiln Slope = 4 % Filling Degree = ( 3.2 x prod. t/d ) / ( Diam x slope % x RPM )

= ( 3.2 x 4,500 ) / ( 4.75 x 4 x 4.0 ) = 8.2 % Retention time = ( 23 x kiln L ) / ( Kiln D x RPM x slope% )

= ( 23 x 74 ) / ( 4.75 x 4 x 4 ) = 22.5 Min


17/28

we will use Duoflex burner ( multi channel) due to :- Good controlling system- low primary air consumption

- adjustable swirling- good air nozzle area- central fuel

injection

- suitable foralternative fuels


18/28

ID fan gas temp. 290 C

Bag house filter before final fan

Reasons:

1- reduce power consumption2- Pollution control

Dust emission ~ 25 mg/m3


19/28

Bypass fan for volatile gases fromkiln inlet

quenching air fan for cooling

condition tower

Bag House Filter


20/28

Assume specific load for cross section 46 TPD/m Cross section area = TPD/sp. load=4500/46

=98 mModule dimension(F.L sys) =1.3Width*4.2Length

=5.46 mNo. of modules =98/5.46=17.8 ~ 20 module Kiln D.= 4.75 m then cooler width must be larger

So we need 4 module in width and 5 module inlength

Cooler Width=4*1.3=5.2m

Cooler length = 5*4.2=21m


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Cooler has 7 cooling fans

Total prod./h =4500*1000/24=187500Kg/h

From F.Ls system cooling rate =1.8

Nm/Kg CkCooling air req.=1.8*187500=337500

Nm/h

Cooler crusher : Hammer crusherPan conveyor cap. =4500*1.6/24=300 t/h


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2 clinker silo each one 20000 tons

Each silo have 6 automatic discharge gatesys. For feeding cement mills

1 off-standard silo 700 tonMaterial handling from silos to cement mills

in flow sheet


23/28

Two tube mills closed circuits with max cap. 130t/h

Separator:- high eff. Sep. fls sepax- one dyn. Sep. with 4 cyclones

Filling degree 30 %

Speed 74 % from critical speed

Length / diam. = 3.5 Bulk weight balls charge = 4.5 t/m Using bucket elevator for cement trans to silos


24/28

Ass. Blaine 3500 cm/gm from fig 22

Sp. Power consumption = 43 Kw.h/t

The power req. for 130 t = 43 * 130 =

5600 KwAss. Gear box eff. = 95 %

The mill motor power = 5600/ 0.95 = 5895

Kw From fig. 10- Di = 4.54 m

- Dn = Di + Lining thickness = 4.54 +0.26 = 4.8 m


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Total Mill length = 3.5 * 4.54 =15.9 m

Compartment length- Com. 1 = 0.35 * 15.9 = 5.565 m

- Com. 2 = 0.65 * 15.9 = 10.335 m Balls charge

- Com. 1 = 121.618 t

- Com. 2 = 225.852 t


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3 cement silos

Capacity : 15 000 t x 3

Having bulk dischargeDischarge rate 260 ton/hr

Cement production / day = 5 720 ton


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Use 3 machines

Type : ventomatic

Capacity : 120 t/h for each one

Running hour : 24 hrTotal packing = 8,640 t / day


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project line b

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