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Material out = Material in + Generation - Consumption - Accumulation

Accumulation = 0 (Steady State)


Generation & Consumption = 0 (No Chemical Reaction)
Material out = Material in
Dry Basis 100 kg/day
85%
85
15%
15

L/S
Clay

M2

Loss

kg/day
kg/day
1%

0.01

Clay
M1
M3

Component
%

IN
M1
15

=
=
=
=

Loss
M2
15*0.01
0.15
14.85

M3
SiO2
50

+
+
+

OUT
M3
M3

kg/day

Al2O3
13

CaCO3
6

Fe2O3
10

MgCO3
2

M5

Loss

1%

0.01

Inert
19

Crusher
M4
M6

Component
%

IN
M4
85

=
=
=
=

Loss
M5
85*0.01
0.85
84.15

M6
SiO2
6

+
+
+
kg/day

Al2O3
2

CaCO3
48

Fe2O3
1

OUT
M6
M6

MgCO3
1.5

Inert
0

M8
Raw Mill
M3
M6
Loss

M3
14.85

IN
+
+

M6
84.15
M8

OUT
M8
M8
98.505

+
+
+
kg/day

Loss
M7
0.495

Composition of M7 & M8
SiO2
Al2O3
CaCO3
Fe2O3
MgCO3
12.474000 3.613500 41.283000 2.326500 1.559250

Component
kg/day

Component
%

=
=
=
=

Concentration of Composition in Mixture


SiO2
Al2O3
CaCO3
Fe2O3
12.60
3.6500
41.70
2.35

M7
0.5%
0.005

MgCO3
1.58

Inert
2.822

Inert
2.85

Exhaust Gases
Kiln
M8
M9
IN
M8
98.505

=
=
kg/day

OUT
M9

+
+

Component
kg/day

SiO2
12.4

Analysis of M8
Al2O3
CaCO3
3.60
41.08

Component
Mwt

SiO2
60.06

Mwt of Component
Al2O3
CaCO3
101.94
100.09

Component
kmol/day

Exhaust Gases
Exhaust Gases

Fe2O3
2.31

MgCO3
1.55

Fe2O3
159.68

MgCO3
84.31

Moles of Component
SiO2
Al2O3
CaCO3
Fe2O3
MgCO3
0.206654 0.035270 0.410396 0.014497 0.018402

Inert
2.81

Component
%

C2S
20

Component
Mwt

C2S
172.22

Analysis of M9
C3S
C3A
60
12

C3S
228.30

C3A
270.18

C4AF
8

C4AF
485.95

Reaction In Kiln
CaCO3 -------------- CaO + CO2
MgCO3 ------------- MgO + CO2
CaO + Al2O3 ------------- CaO.Al2O3
4CaO + 2Al2O3 + CaO.Al2O3 ----------------- 5CaO.3Al2O3
5CaO + 3Al2O3 --------------- 5CaO.3Al2O3
2CaO + SiO2 -------------- 2CaO.SiO2
4CaO + 5CaO.3Al2O3 -------------- 3(3CaO.Al2O3)
CaO + 2CaO.SiO2 -------------- 3CaO.SiO2
4CaO + Al2O3 + Fe2O3 -------------- 4CaO.Al2O3.Fe2O3

1
2
3
4
5
6
7
8
9

3 + 4 ------------- 5

Moles of Components By the Reaction


CaCO3
1
0.410396
X1

MgCO3
1
0.018402
X2

CO2
Weigh of CO2

----------------------

Y1

----------------------

Y2

=
=

Y1

CaO
1
X1
=

MgO
1
X2
=

CO2
1
Y1

0.410396 kmol/day

CO2
1
Y2

0.018402 kmol/day

+
Y2
kmol/day * Mwt

=
=

0.428798 kmol/day
18.871412 kg/day

2CaO
2
Y3

SiO2
1
0.206654

----------------------

Y3
X3

=
=

0.413308
0.206654

kmol/day
kmol/day

4CaO
4
Z4

Al2O3
1
Y4

Z4
Y4
X4

=
=
=

0.057988
0.014497
0.014497

kmol/day
kmol/day
kmol/day

5CaO
5
Z5

3Al2O3
3
Y5

Fe2O3
1
0.014497

----------------------

2Ca.SiO2
1
X3

----------

4CaO.Al2O3.Fe2O3
1
X4

5CaO.3Al2O3
1
X5

3(3CaO.3Al2O3)
3
X6

Y5 = Total moles of Al2O3 - Y4


Y5
X5
Z5

4CaO
4
Y6
Y6
X6

=
=
=

0.020773
0.006924
0.034622

kmol/day
kmol/day
kmol/day

5CaO.3Al2O3
----------1
X5 =
0.006924
=
=

0.027698
0.020773

kmol/day
kmol/day

CaO
1
Z7

2CaO.SiO2
1
Y7

-----------

3CaO.SiO2
1
X7

From outlet % Analysis

Weigh Ratio
Mwt
Mole Ratio

C3S
3CaO.SiO2
60%
3
228.3
0.013141
2.263
X7
X7
X7

2CaO.SiO2 Excess
2CaO.SiO2 Excess

Inerts in
MgO
CaO Excess

----------------------------

Amount of Inerts

=
=

weigh ratio / mwt


Divided by 0.005806

=
=
=

SiO2 kmol/day *2.263 / (2.263+1)


0.143321 kmol/day
Y7
=
Z7
=
0.143321

=
=

SiO2 kmol/day* (1/2.263+1)


0.063332 kmol/day

The amount of CaO excess


The amount of CaO excess
The amount of CaO excess

Amount of Inerts

C2S
2CaO.SiO2
20%
1
172.22
0.005807
1

Inert in

=
=
=

Outlet
Reactant
CaCo3
Y3+Z4+Z5+Y6+Z7
-0.266540 kmol/day

MgO

CaO Excess

Analysis of inlet
Moles of component * Mwt
CaO Excess * Mwt

2.807393
########

+
kg/day

0.7419596

-14.94755

% Analysis of the clinker

Component
C2S
C3S
C3A
C4AF
Inert
Sum

kmol/day
0.063332
0.143321
0.020773
0.014497
-

Mwt
177.22
228.3
270.3
485.95
-

=
=
=

M9
45.205618
64.077029

kg/day
kmol/day * Mwt
11.223780
32.720270
5.614988
7.044776
-11.398197
45.205618

%
24.8
72.4
12
15.6
-25.2
100.0

Check
M8
98.505
98.505

+
+

Exhaust Gases
18.871412

M9
Cement Mill
M10
5%

0.05

M10

M11

From the Mill:


Balance:
M9

M11

M.B of CaSO4:
0.0*M9 + M10 = 0.05M11
M.B of Clinker:
0.0 + M9 = 0.95M11 = 60.285304 kg/day
M11 = M9 / 0.95 = 60.285304 / 0.95
M11

47.584861

kg/day

M10

2.379243

kg/day

Real Quantities
Converted Balance
Annual Production
Working Days
1000000

ton/year

100
X

kg/day
kg/day

1000000
300

ton/year
day/year

3333333.3

kg/day

------------63.1
------------- 3333333.3

kg/day
kg/day

Basis

5282620.2

kg/day

M``
=
X*M / 100
M`` : Real quantities
X : the amount of clay and lime stone which produce 1000000 ton/day

M2
0.15

Clay

Loss

M1

15

M``

X*M / 100

M1``
M2``
M3``

=
=
=

792393
7923.93
784469.1

kg/day
kg/day
kg/day

M5
0.85

Loss

Crusher
M4

85

5%

0.05
14.85
M3

5%

0.05
84.15
M6