Академический Документы
Профессиональный Документы
Культура Документы
Pyroprocessing
1/18
This tool is used for kiln audits' balance calculations and reporting of them. This version is the official release 1 as division
tool. Former versions distributed in CTEC area are replaced by this release - the changes and improvements compared to
the April 2008 version are documented in the next page _ revision.
A detailed training on the tool is provided in the process engineer training Pyroprocessing 2 (kiln audit training). To guide the
user comments are available for most input cells and important calculation cells.
This tool is using the updated Add IN Function thermodynamic.xla from January 2009 (1.5b). User should install the updated
add-in prior to using the tool. The add in file as well as an installation guide is attached below. The new add in version allows
the use of negative temperatures, an "Enthalpy_free" function without water evaporation is implemented.
There are no makros used for calculation to keep the tool transparent. The only makro used is to ensure the proper function
of the add ins - the makro is deleting any path to thermodynamic functions which might occure when copying from another
PC.
The add in function still have some logical checks which might cause error massages during data input (unlogical data as
long as the input is not completed). Just aknowledge and continue with further data input.
The cells are not protected to allow follow up with the formula auditing = take care not to modify. Input is done only on the
input pages and to be customised example pages at the back.
Summary layout of tool: 4 input sheets where data entry is processed into material balance, waste gas calculation and finally
heat balance sheets. Balanced figures of performance results are summarized in a final sheet.
The calculation and result sheets are created to be directly copied into the audit report.
Preheater and/or precalciner kilns are supported by the tool (still separate line calciners with separated preheater strings
need manipulation by user). For wet lines and long dry lines a separate version is in use within CTEC and available as
division tool soon.
Flow sheet example and example for cyclone speed calculations are added at the back, they are linked to the input sheets of
the heat balance but are not used for heat balance results, they can be customised for the specific application.
Source:
Authors:
All rights of reproduction, representation, adaptation and translation relating to this report belong to Lafarge SA. Lafarge SA reserves the right to exploit this report or not and to freely
distribute it to all of its current and future subsidiaries worldwide in any form, whether paper, electronic or digital, including via internet and/or intranet. This report along with its content
is of a confidential nature. In particular, it may not be reproduced, copied, transmitted, published, divulged and/or appropriated in whole or in part for personal use or for use by a third
party without prior consent from the Production & Process Department, except for reproduction by or for affiliated Lafarge companies.
Revisions
Version
Division 1.0
Date
Jan-09
Who
DPC
CTEC 1_2_6
Nov-08
Bernhard Koeck
CTEC 1_1
Apr-08
2007
Cenk Eskin
Bernhard Koeck
Cenk Eskin
Bernhard Koeck
Comments
CTEC Kiln Heat Balance Tool v. 1.2.6 becomes the division tool version 1
For publication on Cement Portal's Pyroprocessing domain
Improvements / Correction since 1_1
All changes since the first CTEC release 1_1 are documented below.
Official release within CTEC - spread out in CTEC area
Used by CTEC process engineers since begin 2007 - first use in kiln audit training Sept 2007 - first sharing within the combustion COP
PR PYR T09-04 v1
50%
1.19
Kiln Feed
Flowrate wet, kg/h
H2O, %
Temperatures,C
Crystall Water, %
41720
0.21
69
445
0.4
Kiln Feed
40
1008
Err:511
50%
150
199540
Clinker t/d
4789
No
0.00%
0
0
308680
305338
Clinker
SiO2 ,%
Al2O3 ,%
Fe2O3 ,%
6.81
12.11
22.48
0.99
3.94
5.34
0.41
1.84
4.74
CaO, %
MgO, %
LOI ,%
CO2 ,%
K2O ,%
Na2O ,%
SO3 ,%
50.38
44.93
65.69
0.48
0.48
0.64
40.3
34.9
TOC ,%
Cl- , %
S-2 ,%
LOI check
Total
Hot meal
39.3
0.18
0.91
0.52
1.3
0.03
0.04
0.07
0.27
0.28
0.6
0.06
TiO ,%
P2O5 ,%
Non Carbonated CaO in Kiln Feed / Total CaO, %
Non Carbonated MgO in Kiln Feed / Total MgO, %
Clinker
30
0%
280000
0.116
0.033
0.6
free lime:
0.00
34.50
99.64
64.65
0.00
1.71
99.91
2.17
AF-sol.
Name of Fuel
Flowrate, kg/h fired
Servo Coal
dry
Gas
Coal
PRECALCINER FUELS
Coal
Coal
Coal
Coal
AF-sol.
8625
8075
dry
71250
dry
OTHERS
AF-sol.
Rice husk
1040
dry
Wood
TOC
6917
dry
56.80
56.80
12.90
41.20
45.90
5.90
5.90
1.05
5.90
8.30
0.50
0.50
0.14
0.06
0.10
Oxygen, %
Nitrogen, %
15.50
15.50
5.13
34.51
42.30
0.50
0.50
0.26
0.91
0.30
Ash, %
19.50
19.50
79.29
16.47
2.50
98.70
0.00
0.00
0.00
0.00
0.00
98.70
98.77
99.05
5279
16089
16747.2
99.40 100.00
33830
13.81
13.81
2.05
18.36
48.30
0.00
Temperatures,C
60
60
70
30
30
volatiles,%
fossil carbon, %
40
40
11
68
79
100%
100%
100%
100%
100%
Ash 1
Ash 2
Ash 3
Ash 4
Ash 5
Ash 6
Ash 7
Ash 8
Ash 9
Ash 10
SiO2, %
51.78
51.78
36.13
94.44
Al2O3, %
16.45
16.45
13.35
0.15
6.96
Fe2O3, %
7.98
7.98
12.42
0.11
21.53
32.48
CaO, %
6.1
0.52
24.18
MgO, %
K2O, %
4.47
4.47
0.55
0.67
0.96
2.66
2.66
1.47
2.13
2.05
Na2O, %
2.84
2.84
0.24
0.49
0.76
TiO, %
P2O5, %
0.73
0.73
0.379
0.01
0.28
0.36
0.36
0.162
0.97
0.906
Total, %
94.27
94.27
70.801
99.49
90.106
0.00
dry
100
24144
0
wet
100
24144
LHV [kJ/kg]
H2O, %
S-2
0
dry
Hydrogen, %
Sulphur, %
Cl-, %
Total, %
SNCR
100%
0.00
100.00
13120
100
Nm3/h
Err:511
462
Err:511
kJ/kgck
Kiln
97.3
Err:511
115
Kiln Diameter, m.
4.7
11.4
3.0
Nm/h
Transport air 1
914
2846
30
Transport air 2
Precalciner Exit Static Pressure,hPa
Transport air 3
-8.8
Transport air 4
Gas measurements
Kiln inlet,% (dry)
Preheater outlet, % (dry)
Calciner Outlet, % (dry)
Main burner
Primary air 1
O2 [%]
CO [%]
5.2
0.0274
3.65
0.08
1.3
0.15
Nm/h
7283
Precalciner burners
30
Primary air 2
Nm/h
Transport air 1
2835
30
1240
30
Err:511
Transport air 2
Transport air 3
3455
30
Err:511
Transport air 4
3455
30
Precalciner burners
By-Pass
Primary air 1
Primary air 2
Primary air 3
False air
Nm/h
Err:511
30
Err:511
30
4.0
6813
65
Err:511
Err:511
30
Err:511
24997
30
Err:511
6700
Nm/h
Err:511
4.0
74
Main burner
Kiln Length, m.
Preheater
-84.93
Nm3/h
Wall Losses
l/h
Gas Flowrate
Err:511
Kiln Slope, %
4.0
230
1.4
Fan # 1
Fan # 2
Fan # 3
Fan # 4
Fan # 5
Fan # 6
Fan # 7
Fan # 8
Fan # 9
Fan # 10
Fan # 11
Fan # 12
Fan # 13
Fan # 14
Total
Air leakage leaving cooler
False air entering cooler
Cum. Area,
m2
34342
30
7.1
1.35
7.09
58918
30
9.3
1.76
16.38
95217
30
15.6
1.70
31.93
28311
30
7.2
1.10
39.11
40356
30
12.1
0.93
51.16
39295
30
13.6
0.80
64.78
28235
30
15.1
0.52
79.87
28489
30
21.2
0.37
101.03
Flowrate,
Nm3/h
Secondary air
Tertiary air
Mill take off #1
Mill take off #2
Exhaust air measured
Exhaust air calculated
Hot clinker temperature, C
Cold clinker temperature, C
353164
101.03
Err:511
Err:511
Cooling air:
1.77Nm/kgcl
901
360
Err:511
1450
227
litres/h or
kg/h
0.97
Temperature
C
kJ/kgck
24.00
Temperature
C
Flowrate, [t/h]
H2O, [%]
0
0
Kiln Fuels
0
0
0
0
0
0
0.00
0.00
0.00
0.00
0.00
0.00
Precalciner Fuels
0 Servo Coal Bottom feed Rice husk Wood
Preheater dBypass Dust
0
8.075
71.25
1.04
6.917
41.72
0
0.21
Sulphur, [%]
Ash, [%]
Cl, [%]
0.43
16.81
0.00
0
Kiln Feed
Ash 1
0.00
0.00
0.00
Ash 2
0.00
0.00
0.00
Ash 3
Ash 4
Ash 5
0.00
0.00
0.00
Ash 6
0.43
16.81
0.00
Ash 7
0.14
77.66
0.00
Ash 8
0.05
13.45
0.00
Ash 9
0.05
1.29
0.00
Ash 10
0
Dust 1
0
Bypass Dust
SiO2
6.81
51.78
51.78
36.13
94.44
32.48
12.11
Al2O3
0.99
16.45
16.45
13.35
0.15
6.96
3.94
Fe2O3
0.41
7.98
7.98
12.42
0.11
21.53
1.84
CaO
50.38
6.1
0.52
24.18
44.93
MgO
0.48
4.47
4.47
0.55
0.67
0.96
0.48
LOI
CO2
40.30
0.4
39.30
K2O
0.18
2.66
2.66
1.47
2.13
2.05
0.91
Na2O
0.03
2.84
2.84
0.24
0.49
0.76
0.04
SO3
0.06
TiO
P2O5
0.73
0.73
0.379
0.01
0.28
0.36
0.36
0.162
0.97
0.906
Cl
t/h
Kiln Feed (dry)
kg/kgck
305.34
1.53
Material Balance
Based on Kiln Feed
t/h
kg/kgck
279.41
1.52
Clinker
SiO2
Measured
Calculated
22.48
18.72
5.34
4.63
305.34
1.53
279.41
1.52
Al2O3
305.98
1.53
280.00
1.52
Fe2O3
4.74
3.81
58.37
0.29
58.37
0.32
CaO
65.69
69.50
0.43
0.00
0.43
0.00
MgO
0.64
0.85
0.00
0.00
0.00
0.00
0.00
0.00
364.14
1.82
338.22
1.84
LOI
CO2
0.00
0.00
-2
Clinker
Preheater Dust
Bypass Dust
SO2 in preheater exit
Dehydration+Decarbonation
199.54
1.00
184.06
1.00
K2O
0.52
0.53
41.72
0.21
41.72
0.23
Na2O
0.07
0.14
0.00
0.00
0.00
0.00
SO3
0.28
0.31
0.00
0.12
0.12
0.03
0.05
0.00
99.91
0.00
98.66
0.00
0.00
0.00
122.88
0.62
112.44
0.61
TiO
P2O5
364.14
1.82
338.22
1.84
Cl
1.53
1.52
1.32
1.29
1.40
KILN AUDIT HEAT BALANCE TOOL - THEORETICAL HEAT OF CLINKER FORMATION CALCULATION
Ash Corr. Clinker Compounds
SiO2
Clinker
gr/kgck
Bypass
116.51
Al+F
0.022 Metakaolin
0.047
Kaolin
0.054 SiO2
0.091
Al2O3
14.03
Fe2O3
11.74
CaCO3 Cal.
CaO
638.89
MgO
4.24
46.9
58.30
C2S, [%]
29.1
17.50
0.00
MgCO3 Cal.
0.002
C3A, [%]
6.1
6.50
0.00
CO2=>
0.258
C4AF, [%]
14.4
13.30
Delta
all Nm/kgck
0.3063
<=CO2
Free lime
0.0483
Sulphur / Alkali
kcal/kgck
482.6
0.00
Clinkerisation
113.98
108.429
MgCO3 Decarbonisation
2.7
0.00
Crystallization
3.38
3.38
5.0
509.8
0.00
Total Exothermic
117.36
111.81
Total Endothermic
0.256
kcal/kgck
Glas formation
Clinker Phases
C3S, [%]
19.5
410.24
1717.69
1.7
53 %
LSF 0 fCaO
90.8
S/R
2.23
398.01
For comparison: Perray's heat for clinker formation which is based on clinker analysis
410.24 [kcal / kgck]
Clinker
199.54
0
Clinker
22.48
5.34
4.74
65.69
0.64
0
0
0.52
0.07
0.28
0.116
0.033
0
3866
3866
-2
Flowrate, kg/h
8625
20466
0.23
0.00
0.00
0.00
0.00
0.00
8075
71250
1040
6917
20466
5120
12678
7457
33830
13120
0.21
0.47
0.02
0.07
0.00
0.00
01/25/2015
Date:
Kiln:
3/13/2012
RK3#
Comment:
PRIMARY FIRING
Type of fuel
Type of analyse (dry / wet)
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
LHV [kJ/kg]
LHV (kcal/kg)
H2O
Total
LHV calculated (kcal/kg)
SECONDARY FIRING
Servo Coal
dry
56.80%
5.90%
0.50%
15.50%
0.50%
19.50%
24,144
5,766
13.81%
98.70%
5,738
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
48.96%
5.09%
0.43%
13.36%
0.43%
16.81%
13.81%
20,465
4,888
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Type of fuel
Type of analyse (dry / wet)
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
LHV [kJ/kg]
LHV (kcal/kg)
H2O
Total
LHV calculated (kcal/kg)
Analyses as fired
LHV [kJ/kg]
LHV (kcal/kg)
Neutral combustion air
Nm / kg fuel
Nm / kgck
Nm / h
SO2
N2
% CO2
%H2O
%N2
Err:511
0.91
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.003
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
1.79
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.01
Err:511
Err:511
0.00
Err:511
Err:511
0.00
Err:511
Err:511
0.000
Err:511
Err:511
0.00
Err:511
Err:511
0.00
Err:511
Err:511
Err:511
Err:511
8,625.0
Err:511
885
Err:511
22.9%
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
0.0%
0.0%
0.0%
0.0%
0.0%
Mass
H2O
SO2
N2
% CO2
%H2O
%N2
Fuel feed rate (kg/h)
Total (Nm/kgck)
kJ/kgck
Nm/MJ
%
heat cons. including TOC&S:
Kiln production (kg.ck/h)
kJ/kgck total fuel consumption
decarbonatisation Nm CO2 / kg cli
%H2O in raw mix (cristall water)
3,865.4
199,540
3,865
0.31
1.19
Neutral
kiln
%N2
%O2
923
which
kcal/kgck
Including
0.00%
CO2hotmeal
%N2
%O2
%CO
CO2 decarbo kiln
Including
5.20%
O2 dry
SO2
N2
% CO2
%H2O
%N2
22.9%
in kiln
BY-PASS
POINT
By-pass
0.00%
extraction
Err:511
Extra
Air
for
extracted
bypass
Err:511
Err:511
0.039
Err:511
0.039
Err:511
0.039
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
0.0001
Err:511
0.0001
Err:511
0.0001
Err:511
0.0001
Err:511
0.00000
Err:511
H2O
SO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
N2
O2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
12.64%
1.03%
0.14%
5.02%
0.25%
77.66%
2.05%
5,120
1,223
33.64%
4.82%
0.05%
28.17%
0.74%
13.45%
18.36%
12,677
3,028
23.73%
4.29%
0.05%
21.87%
0.16%
1.29%
48.30%
7,453
1,780
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
100.00%
0
0
100.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
33,830
8,080
0.00%
0.00%
100.00%
0.00%
0.00%
0.00%
0.00%
13,120
3,134
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
0.91
Err:511
0.24
Err:511
0.63
Err:511
0.44
Err:511
0.00
Err:511
1.87
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.70
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
1.79
Err:511
0.46
Err:511
1.23
Err:511
0.87
Err:511
0.00
Err:511
3.66
Err:511
0.00
Err:511
0.01
Err:511
Err:511
0.00
Err:511
Err:511
0.00
Err:511
Err:511
0.00
Err:511
Err:511
0.00
Err:511
Err:511
0.00
Err:511
Err:511
2.00
Err:511
Err:511
Err:511
Err:511
8075
Err:511
828
Err:511
21.4%
Err:511
Err:511
71250
Err:511
1,828
Err:511
47.3%
Err:511
Err:511
1040
Err:511
66
Err:511
1.7%
Err:511
Err:511
6917
Err:511
258
Err:511
6.7%
Err:511
Err:511
0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
0.0%
Err:511
Err:511
1.3211
Err:511
Neutral
calciner
Err:511
Including
decarbo
total
Err:511
Excluding
Bypass
Err:511
0.140
Err:511
0.179
Err:511
0.486
Err:511
0.486
Err:511
0.486
Err:511
Err:511
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
0.000
0.000
Err:511
Volume
Flowrate (Nm/kgck)
CO2
Incl.H2O
Including
Neutral
kiln
Err:511
Including Including
1.30%
0.15%
O2 dry
CO dry
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
0.274
Err:511
0.352
Err:511
0.953
Err:511
0.953
Err:511
0.953
Err:511
Err:511
Err:511
0.0000
Err:511
0.000
Err:511
0.000
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
Err:511
0.000
Err:511
0.000
Err:511
0.000
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
(Nm/kgck)
(Nm/kgck)
(Nm/kgck)
0.306
Err:511
Err:511
/neutral air
(Nm/h)
(Nm/kgck)
(Nm/h)
Err:511
Err:511
Err:511
Err:511
(Nm/kgck)
(Nm/h)
Err:511
Err:511
Err:511
Err:511
CO
% CO2
%H2O
SO2 ppm
%N2
%O2
%CO
Mass
Err:511
0.078
Err:511
0.078
Err:511
0.078
Err:511
Err:511
Err:511
Err:511
Err:511
0.000
Err:511
0.000
Err:511
0.000
Err:511
0.000
Err:511
0.000
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
(Nm/kgck)
Err:511
(Nm/h)
(Nm/kgck)
(Nm/h)
Err:511
Err:511
Err:511
(Nm/kgck)
(Nm/h)
Err:511
Err:511
Err:511
Err:511
10,129
Err:511
Err:511
Err:511
Err:511
Err:511
4.0%
Flowrate (kg/kgck)
CO2
H2O
SO2
N2
O2
CO
% CO2
%H2O
%N2
%O2
%CO
CO2 decarbo calciner
0.000
(Nm/kgck)
Secondary air
Primary air kiln (% total kiln air)
including transport air
Kiln hood inleak.(%total kiln air)
Err:511
Total
Err:511
Err:511
Err:511
LHV [kJ/kg]
LHV (kcal/kg)
Neutral combustion air
Nm / kg fuel
Nm / kgck
Nm / h
Err:511
O2
CO
% CO2
%H2O
13120
3,134
48.96%
5.09%
0.43%
13.36%
0.43%
16.81%
13.81%
20,465
4,888
Mass
SO2
N2
100.00%
100.00%
2,245
%CO
Flowrate (kg/kgck)
CO2
H2O
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
H2O
Including
0.03%
CO dry
Err:511
%H2O
SO2 ppm
S-2
feed S-2
dry
100.00%
8,080
0.00%
CO
% CO2
0
100.00%
0.00%
0
TOC
feed TOC
dry
100.00%
0.00%
0.00%
0.00%
0.00%
0.00%
33,830
8,080
Mass
N2
O2
Water Inj.
SNCR
wet
Volume
H2O
SO2
Wood
dry
45.90%
8.30%
0.10%
42.30%
0.30%
2.50%
16,747
4,000
48.30%
99.40%
4,576
Volume
Flowrate (Nm/kgck)
CO2
Rice husk
dry
41.20%
5.90%
0.06%
34.51%
0.91%
16.47%
16,089
3,843
18.36%
99.05%
3,786
Analyses as fired
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
H2O
KILN EXIT
Err:511
%N2 air
Err:511
Err:511
Tertiary air
Primary air preca including transport air
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
(Nm/kgck)
Err:511
24997
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/kgck)
(Nm/h)
(Nm/h)
Err:511
(Nm/h)
4.0%
6,700
0.055
10,985
Err:511
Err:511
0.0335772276
Err:511
Err:511
%H2O air
Err:511
Err:511
Err:511
CO2 decarbo total: 0.306
Am/h
Am/h
PC Exit Gas
Density
kg/Nm
Err:511
Total
Err:511
Err:511
Err:511
KILN AUDIT HEAT BALANCE TOOL - COOLER HEAT CALCULATIONS SUPPORT SHEET
kg/h
kcal/h
kJ/h
TC
kg/h
Fan # 1
Fan # 2
Err:511
Err:511
Err:511
30
Err:511
Err:511
Err:511
30
Fan # 3
Fan # 4
Err:511
Err:511
Err:511
30
Err:511
Err:511
Err:511
Fan # 5
Err:511
Err:511
Fan # 6
Fan # 7
Err:511
Err:511
Err:511
Fan # 8
Fan # 9
Err:511
Fan # 10
Fan # 11
Fan # 12
kcal/h
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Tertiary Air
Mill take off #1
Err:511
Err:511
Err:511
901
30
Err:511
Err:511
Err:511
Err:511
30
Err:511
Err:511
Err:511
Err:511
30
Err:511
Err:511
Err:511
30
Err:511
Err:511
30
Err:511
Err:511
Err:511
Wall losses
Vaporisation Heat
Err:511
Err:511
Err:511
Cold clinker
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
199540
199540
Err:511
Err:511
Err:511
Err:511
0
360
Err:511
Err:511
1143769
4788960
Err:511
Err:511
Err:511
Err:511
kcal/h
Err:511
Err:511
Err:511
kg/h
TC
Fan # 13
Fan # 14
Hot clinker
kJ/h
kcal/h
kJ/h
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
TC
KILN AUDIT HEAT BALANCE TOOL - KILN HEAT CALCULATIONS SUPPORT SHEET
Fuel sensible heat calculations
1
kg/h, wet
kg/h dry
kg/h,H2O
enthalpy fuel
C
kcal/h, fuel
kJ/h, fuel
enthalpy H2O
kcal/h, H2O
kJ/h, H2O
Servo Coal
8625.00
7433.89
1191.11
Err:511
60.00
Err:511
Err:511
Err:511
Err:511
Err:511
0.00
0.00
0.00
Err:511
0.00
Err:511
Err:511
Err:511
Err:511
Err:511
Humidity calculations
Absolute humidity, kgH2O/kg dry air
Air moisture by mass, %
Air moisture by volume, %
Err:511
Err:511
Err:511
Err:511
PRIMARY FIRING
2
0.00
0.00
0.00
Err:511
0.00
Err:511
Err:511
Err:511
Err:511
Err:511
0.00
0.00
0.00
Err:511
0.00
Err:511
Err:511
Err:511
Err:511
Err:511
1
0.00
0.00
0.00
Err:511
0.00
Err:511
Err:511
Err:511
Err:511
Err:511
SECONDARY FIRING
1
Servo Coal
Bottom feed
Rice husk
Wood
8075.00
71250.00
1040.00
6917.00
6959.84
69789.38
849.06
3576.09
1115.16
1460.63
190.94
3340.91
Err:511
Err:511
Err:511
Err:511
60.00
70.00
30.00
30.00
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
0.00
0.00
0.00
Err:511
0.00
Err:511
Err:511
Err:511
Err:511
Err:511
kcal/h
30
30
65
30
30
Err:511
kJ/h
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Water inputs
C
kcal/h
kJ/h
kg/h
Kiln feed total H2O
C
643
kcal/h
kJ/h
Primary 1
Primary 2
Transport 1
Transport 2
Transport 3
Transport 4
Preca burners
Primary 1
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
30
0
30
0
0
0
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Primary 2
Err:511
Err:511
Err:511
CO2
0 Err:511
Primary 3
Err:511
Err:511
Err:511
H2O
0 Err:511
Transport 1
Err:511
30
Err:511
Err:511
SO2
0 Err:511
Transport 2
Err:511
30
Err:511
Err:511
N2
0 Err:511
Transport 3
Err:511
Transport 4
Err:511
Total primary air
Err:511
Recalculated energy for mixed TC
30
30
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
O2
Preheater
Cooler
Total injected water
0
0
0 Err:511
By-Pass
Gas Composition
kg/h
0
0
69
Err:511
Err:511
0
0
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
kcal/h
0 Err:511
0
Err:511
0
Err:511
kJ/h
Err:511
Err:511
Total
95907
88608
7299
Err:511
Err:511
Err:511
Err:511
01/25/2015
Date:
Kiln:
3/13/2012
RK3#
Comment:
PRIMARY FIRING
Type of fuel
Type of analyse (dry / wet)
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
LHV [kJ/kg]
LHV (kcal/kg)
H2O
Total
LHV calculated (kcal/kg)
SECONDARY FIRING
Servo Coal
dry
56.80%
5.90%
0.50%
15.50%
0.50%
19.50%
24,144
5,766
13.81%
98.70%
5,738
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
0
0
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0
0
0.00%
0.00%
0
48.96%
5.09%
0.43%
13.36%
0.43%
16.81%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
13.81%
20,466
4,888
0.00%
0
0
0.00%
0
0
0.00%
0
0
0.00%
0
0
0.00%
0
0
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Type of fuel
Type of analyse (dry / wet)
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
LHV [kJ/kg]
LHV (kcal/kg)
H2O
Total
LHV calculated (kcal/kg)
Analyses as fired
Water Inj.
TOC
SNCR
wet
feed TOC
dry
100.00%
0.00%
0.00%
0.00%
0.00%
0.00%
33,830
8,080
feed S-2
dry
100.00%
8,080
100.00%
2,245
Wood
dry
45.90%
8.30%
0.10%
42.30%
0.30%
2.50%
16,747
4,000
48.30%
99.40%
4,576
0
100.00%
0.00%
0
S-2
100.00%
13120
3,134
Analyses as fired
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
H2O
LHV [kJ/kg]
LHV (kcal/kg)
Neutral combustion air
Nm / kg fuel
Nm / kgck
Nm / h
Carbone
Hydrogen
Sulphur
Oxygen
Nitrogen
Ash
H2O
Total
Err:511
Err:511
Err:511
LHV [kJ/kg]
LHV (kcal/kg)
Neutral combustion air
Nm / kg fuel
Nm / kgck
Nm / h
48.96%
5.09%
0.43%
13.36%
0.43%
16.81%
12.64%
1.03%
0.14%
5.02%
0.25%
77.66%
33.64%
4.82%
0.05%
28.17%
0.74%
13.45%
23.73%
4.29%
0.05%
21.87%
0.16%
1.29%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
100.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
100.00%
0.00%
0.00%
0.00%
13.81%
20,466
4,888
2.05%
5,120
1,223
18.36%
12,678
3,028
48.30%
7,457
1,781
100.00%
0
0
0.00%
33,830
8,080
0.00%
13,120
3,134
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Volume
Volume
Err:511
0.91
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.91
Err:511
0.24
Err:511
0.63
Err:511
0.44
Err:511
0.00
Err:511
1.87
Err:511
0.00
H2O
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
H2O
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
SO2
N2
0.003
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.70
% CO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
SO2
N2
% CO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%H2O
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%H2O
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%N2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%N2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
1.79
0.46
1.23
0.87
0.00
3.66
0.00
Err:511
0.01
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
0.00
Err:511
2.00
Mass
Mass
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
1.79
0.00
0.00
0.00
0.00
0.00
H2O
Err:511
0.01
Err:511
0.00
Err:511
0.00
Err:511
0.000
Err:511
0.00
Err:511
0.00
H2O
N2
% CO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
N2
% CO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%H2O
Err:511
Err:511
8,625.0
Err:511
885
Err:511
22.9%
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
Err:511
Err:511
0.0
Err:511
0
%H2O
0.0%
0.0%
Err:511
Err:511
6917
Err:511
258
Err:511
6.7%
Err:511
Err:511
0.0
Err:511
0
0.0%
Err:511
Err:511
1040
Err:511
66
Err:511
1.7%
Err:511
Err:511
0.0
Err:511
0
0.0%
Err:511
Err:511
71250
Err:511
1,828
Err:511
47.3%
Err:511
Err:511
0
Err:511
0
0.0%
Err:511
Err:511
8075
Err:511
828
Err:511
21.4%
Incl.H2O
Including
3.65%
O2 dry
SO2
%N2
Fuel feed rate (kg/h)
Total (Nm/kgck)
kJ/kgck
Nm/MJ
%
heat cons. including TOC&S:
Kiln production (kg.ck/h)
kJ/kgck total fuel consumption
decarbonatisation Nm CO2 / kg cli
%H2O in raw mix (cristall water)
3,865.7
199,540
3,866
1.09%
1.19
Neutral
kiln
Including
0.00%
CO2hotmeal
22.9%
in kiln
Err:511
Err:511
1.3211
0.21%
305,980
Including
5.20%
O2 dry
Including
0.03%
BY-PASS
POINT
Extra
Air
By-pass
0.00%
for
extracted
bypass
Err:511
Volume
Err:511
Err:511
CO dry
Err:511
extraction
Err:511
0.039
0.039
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
0.0001
Err:511
0.0001
Err:511
0.00000
Err:511
Err:511
Err:511
Err:511
Err:511
Flowrate (Nm/kgck)
CO2
Err:511
0.039
H2O
SO2
Err:511
0.0001
Err:511
0.0001
Err:511
N2
which
kcal/kgck
%N2
Err:511
O2
CO
% CO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%H2O
Err:511
Err:511
Err:511
Err:511
SO2 ppm
%N2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%O2
%CO
Neutral
calciner
Including
Neutral
Including
decarbo
Excluding
Flowrate (Nm/kgck)
CO2
Err:511
kiln
Err:511
total
Err:511
Bypass
Err:511
0.140
0.179
0.486
H2O
SO2
Err:511
Err:511
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
Err:511
N2
Err:511
O2
Err:511
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
0.000
0.000
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
SO2 ppm
%N2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Flowrate (kg/kgck)
CO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
0.274
0.352
0.953
0.9533
0.953
Err:511
Err:511
0.0000
Err:511
0.000
Err:511
0.000
Err:511
0.0000
Err:511
0.0000
Err:511
0.0000
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
0.000
0.000
0.000
Err:511
Err:511
Err:511
%O2
%CO
Mass
Err:511
Err:511
0.078
0.078
0.078
Err:511
Err:511
H2O
Err:511
0.000
Err:511
0.000
Err:511
0.000
Err:511
0.000
Err:511
0.000
H2O
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
N2
O2
CO
% CO2
%H2O
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%N2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%O2
0.486
Err:511
Err:511
Err:511
0.486
Err:511
%H2O
Err:511
CO dry
Err:511
Err:511
Err:511
%CO
CO2 decarbo kiln
Err:511
Err:511
Err:511
Err:511
Flowrate (kg/kgck)
CO2
N2
O2
Including
0.08%
CO
% CO2
Mass
SO2
0.0%
0.31
KILN EXIT
923
SO2
(Nm/kgck)
Err:511
Err:511
Err:511
Err:511
(Nm/kgck)
(Nm/h)
Err:511
Err:511
Err:511
Err:511
10,129
Err:511
Err:511
Err:511
Err:511
Err:511
4.0%
%N2 air
Err:511
False air assesment along preheater (calciner exit till preheater exit):
CO2 out of decarbonatisation:
CO2 out of combustion:
Total CO2:
0.601
0.352
0.953
kg/kg cl
kg/kg cl
kg/kg cl
0.078
0.274
0.352
kg/kg cl
kg/kg cl
kg/kg cl
0.953
kg/kg cl
CO
% CO2
%H2O
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%N2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
%O2
%CO
CO2 decarbo calciner
0.000
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
Secondary air
Primary air kiln (% total kiln air)
including transport air
Kiln hood inleak.(%total kiln air)
SO2
Err:511
Err:511
Err:511
Err:511
0.306
Err:511
Err:511
Err:511
Err:511
Err:511
/neutral air
Err:511
(Nm/kgck)
(Nm/h)
Err:511
Err:511
Err:511
Err:511
0.055
10,985
Err:511
Err:511
Err:511
Err:511
Tertiary air
Primary air preca including transport air
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
(Nm/kgck)
24997
Err:511
(Nm/h)
4.0%
Err:511
Err:511
(Nm/h)
Err:511
PH Exit Gas
Density
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/kgck)
(Nm/h)
(Nm/h)
%H2O air
(Nm/kgck)
(Nm/kgck)
(Nm/kgck)
(Nm/h)
(Nm/kgck)
(Nm/h)
Am/h
Am/h
kg/Nm
Err:511
Err:511
Total
Err:511
Err:511
Err:511
#VALUE!
RK3#
Date:
Kiln:
Comment:
KILN AUDIT HEAT BALANCE TOOL - COOLER BALANCE AND PERFORMANCE SHEET
Cooler input
Cooling fans
Hot Clinker
Exhaust air water injection
False air
kg/h
Err:511
199540
0
Err:511
Total
Out - In
TC
Err:511
1450
0
Err:511
Err:511
Cooler output
Nm3/kgck
1.77
Err:511
0.00
kJ/kgck
Err:511
Err:511
Err:511
0.00
%
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Secondary air
Tertiary air
Mill take off #1
Mill take off #2
Exhaust air
Cold clinker
Wall losses
Vap. Heat
Air leakage
Total
kg/h
Err:511
Err:511
Err:511
Err:511
Err:511
199540
TC
Err:511
901
0
0
360
227
Err:511
Err:511
Err:511
Nm3/kgck
Err:511
Err:511
0.00
0.00
Err:511
0.00
Err:511
Cooling Efficiency,
Recovery Factor, k
Err:511
Err:511
Err:511 Nm3/kgck
Err:511 C
Secondary air
199540 kg/h
1450 C
Hot Clinker
Err:511
Err:511 Nm3/kgck
901 C
Tertiary air
0.00 Nm3/kgck
0 C
0.00 Nm3/kgck
0 C
Err:511 Nm3/kgck
360 C
%
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
47.40
1.77
Recovery Efficiency,
kJ/kgck
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
24.00
Err:511
0.00
Err:511
0.97
Err:511
Cooling fans
1.77 Nm3/kgck
Err:511 C
Cold
Clinker
199540 kg/h
227 C
0.40
0.20
0.00
0.00
20.00
40.00
60.00
80.00
100.00
120.00
#VALUE!
RK3#
Date:
Kiln:
Comment:
Kiln Feed
H2O
Total Fuel
TC
System Out
Nm3/kgck
69
643
69
95907
Err:511
kJ/kgck
Err:511
heat%
Err:511
Err:511
Err:511
Gas Composition
CO2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
H2O
Err:511
Err:511
Err:511
Err:511
Err:511
content
Preheater Exit Gas
kg/h
Err:511
TC
462
Sensible Heat
88608
Combustion
H2O
88608
Err:511
3865.67
Err:511
SO2 (ppm)
Err:511
Err:511
Err:511
7299
Err:511
Err:511
Err:511
N2
Err:511
Err:511
Err:511
Err:511
TOC Combustion
S-2 Combustion
0
0
Err:511
Err:511
Err:511
0
Err:511
Err:511
Err:511
0.11
1.77
Err:511
0.00
0.00
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
O2
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
360
Err:511
Err:511
Err:511
199540
0
0
227
0.00
0
41720
0
0
445
0
0
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
1717.69
Err:511
Err:511
0.00
0.00
Err:511
248.10
11.40
115.40
97.30
24.00
69
69
Err:511
Err:511
Err:511
Err:511
Total Heat In
3866
kJ/kgck
CO
Heat Loss CO Preheater Exit
Cooler Exhaust Air
Cooler Exhaust Inj. Water Vap.
Cooler Mill Take Off #1
Cooler Mill Take Off #2
Clinker
Clinker Formation Heat
Preheater Dust
By-Pass Gas
By-Pass Dust
By-Pass Decarbonisation Heat
Water Vaporization Heat
Wall Losses
Tertiary Air Duct
Preheater
Kiln
Cooler
643
Err:511
Err:511
Total Heat Out
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Err:511
Date:
Kiln:
Comment:
12/30/1899
RK3#
Unit
Audit Result
Comments
Levers
Unit
Lafarge
standard
[t/d]
[-]
[g/Nm]
[%]
[kJ/kgck]
4789 Load is high due to upraded kiln from 4000 tpd to 5000 tpd
1.53
Err:511
86.37
3866 Very high SPC due to low PF. Quartz in material streams to be confirmed
Err:511
86%
3866
[%]
22.9 Too low. High high load at FF due to dual feed system.
AF Substitution Rate
Thermal Load (Burning Zone)
[%]
[MW/m2]
[Nm3/kgck]
[Am3/kgck]
1.6 Nm3/kgkk
4 Normal practice, Am3/kgkk
Err:511
Err:511
[%]
[Nm3/kgck]
Err:511
Err:511 High. Will repair on shut down
Err:511
Err:511
[C]
462
Calcination Degree
Kiln Residence Time
CO2 total
CO2 fossil total
Kiln Loading
Burning zone filling degree
(Fuller Formula)
Cooler
Secondary Air Volume
Secondary Air Temperature
Tertiary Air Volume
[%]
[min.]
[kg/kg cl]
[kg/kg cl]
[%]
[%]
[Nm3/kgck]
[C]
[Nm3/kgck]
100.00 28
0.953
0.953
6.28
17 High filling. To be optimized
Err:511 Low.
Err:511
Err:511 High
4.9
92 %
14 % filling degree
0.31 Nm3/kgkk
1200 C
0.47 Nm3/kgkk
885
3.5
100.0
16.8
Err:511
Err:511
Err:511
[C]
[Nm3/kgck]
[C]
[%]
[-]
[t/d/m2]
901
1.77
227
Err:511
1.20
47.4
850
2.00
125
72
1.5
C, normal practice.
Nm3/kgkk
C. Good practice
%
901
1.77
227.0
Err:511
1.20
Number of cyclones:
Diameter of stage exit:
Area per stage:
Total area:
Gas Speed:
Err:511 Nm/h
462 C
-84.93 hPa
Err:511
Am/h
4
1.7 m
2.27 m
9.08 m
Err:511 m/s
Absolute Pressure:
1008 hPa
Err:511 Nm/h
914 C
-8.8 hPa
Err:511
Am/h
Calciner Volume:
gas volume:
740 m
Err:511 Am/s
residence time:
Err:511 sec
Absolute Pressure:
1008 hPa