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HOLTEC
OMAN CEMENT COMPANY, OMAN
RADIATION CALCULATION FOR PC AND PREHEATER
Ambient temperature
(Draft)
23
oC
II Method
Heat
Heat
Cyclon
Radiati transfer transfer Radiatio
e
Avg Radiation,
Clinke
on,
coeffici coefficie n, Kcal/
Diameter, Length,
m
m surface
Temp,
Kcal/
r, tph
Kcal/ kg
ent
nt
kg
Area
oC
hr/m2
clinker (Radiati (Convecti clinker
m2
on)
on)
SN
Location
1.1
Cyclone IV A
5.06
3.75
59.61
98.21
92.00
740.92
0.450
7.449
6.613
0.506
1.2
Bottom
5.06
8.3
79.01
98.21
56.00
293.58
0.236
6.247
5.739
0.274
1.3
Riser pipe
1.70
10.68
98.21
42.00
151.19
0.016
5.826
4.987
0.019
1.4
Meal pipe
0.40
8.3
10.43
98.21 260.00
4407.06
0.468
15.725
6.830
0.488
1.5
2.47
30
232.79
98.21
42.00
151.19
0.358
5.826
4.987
0.419
1.6
Roof
5.06
17.84
98.21
87.00
672.31
0.122
7.271
6.539
0.138
1.7
Cyclone IV B
5.06
3.75
59.61
6.00
60.00
337.77
3.356
6.372
5.890
3.876
1.8
Bottom
5.06
8.3
79.01
98.21
51.00
240.46
0.193
6.093
5.517
0.225
1.9
Riser pipe
1.70
10.68
98.21
42.00
151.19
0.016
5.826
4.987
0.019
2.0
Meal pipe
0.40
2.51
98.21 290.00
5410.22
0.138
17.735
6.728
0.144
2.1
Roof
5.06
17.84
98.21
87.00
672.31
0.122
7.271
6.539
0.138
2.2
Cyclone III A
4.83
3.7
56.14
98.21
65.00
395.03
0.226
6.531
6.053
0.260
2.3
Bottom
4.83
45.79
98.21
68.00
430.43
0.201
6.628
6.139
0.230
2.4
Riser pipe
2.60
7.5
20.20
98.21
52.00
250.89
0.052
6.124
5.565
0.060
2.5
Meal pipe
0.40
3.2
4.02
98.21 320.00
6550.17
0.268
19.928
6.618
0.278
2.7
Roof
4.83
13.01
98.21
70.00
454.46
0.060
6.693
6.193
0.069
2.8
Cyclone III B
4.83
3.7
56.14
98.21
80.00
579.70
0.331
7.029
6.416
0.377
2.9
Bottom
4.83
45.79
98.21
75.00
516.03
0.241
6.859
6.313
0.275
3.0
Riser pipe
2.60
7.5
20.20
98.21
60.00
337.77
0.069
6.372
5.890
0.080
3.1
Meal pipe
0.40
3.2
4.02
98.21 366.00
8597.45
0.352
23.663
6.443
0.364
3.2
Roof
4.83
13.01
98.21
87.00
672.31
0.089
7.271
6.539
0.101
3.3
Cyclone II
6.63
3.7
77.07
98.21 101.50
876.94
0.688
7.797
6.728
0.769
3.4
Bottom
6.63
6.5
77.90
98.21
99.00
840.42
0.667
7.704
6.701
0.747
3.5
Riser pipe
3.60
9.5
26.20
98.21 104.00
913.96
0.244
7.890
6.754
0.272
3.6
Meal pipe
0.40
3.2
4.02
98.21 366.00
8597.45
0.352
23.663
6.443
0.364
3.7
Roof
6.63
24.34
98.21
87.00
672.31
0.167
7.271
6.539
0.188
3.8
Cyclone I A
4.83
3.7
56.14
98.21
87.00
672.31
0.384
7.271
6.539
0.434
Page 1 of 1
Annexure 4.1 A
CLINKER CONVERSION FACTOR - LINE 2
MEASUREMENTS TAKEN ON 27.11.2013
Sn
13170
Parameter
Unit
Value
Basis
tph
351.00
CCR Indication
34.66
As provided by JKCL
9.42
5.0
1.52
Calculated
9.00
1.674
Calculated
Clinker produced
tph
209.69
Calculated
tpd
5033
Calculated
Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman
Tph
'tph
'tpd
165
98.2143
2357.14
KF to clinker conversion factor
1.68
oC
Raw meal temperature
60
Raw meal moisture
%
0.5
PH exit gas O2
%
6.0
Clinker temperature
oC
156.0
Natural Gas temperature to kil oC
75
Natural Gas temperature to PC oC
75
Kg/nm3
Atmosphere Gas density
1.293
Ambiant temperature
oC
23
Dust loss (assumed)
%
8.00
Cooler radiation
Kcal/kg clin
5
Drop in temp at two end of TA oC
96
Annexure 4.3 A
S.N.
Location
Preheater
Exit (WHR
inlet)
0.836
9859
mmWG
Site elevation
Duct dia.
Date
Clinker
Production
Rate
tph
26.11.13
209.69
3.5
374
Duct
area
Temp.
Static
pressure
m2
oC
mmWG
9.625
315
-670
Cooler
exhaust
26.11.13
(WHR inlet)
209.69
2.80
6.16
418
-27
Tertiary air
209.69
2.18
3.73
930
-70
13170
26.11.13
RMS Avg
dynamic
pressure
Density
Velocity on
RMS Avg
No of
points
mmWG
Kg/ Nm3
mps
m3/ h
Nm3/ h
Nm3/kg
clinker
30
19.85
1.42
21.55
746746
308326
1.470
20
16.93
1.293
21.86
484669
182203
0.87
24
22.63
1.293
33.41
449173
96568
0.46
10
10.0
13.0
13.0
12.0
17.0
25.0
24.0
23.0
26.0
27.0
27.0
27.0
26.0
26.0
24.0
20.0
23.0
19.0
20.0
14.0
16.0
18.0
20.0
21.0
16.0
17.0
16.0
15.0
26.0
25.0
15.0
18.0
18.0
17.0
18.0
19.0
18.0
17.0
16.0
17.0
18.0
15.0
17.0
16.0
15.0
15.0
17.0
17.0
18.0
18.0
25.0
27.0
24.0
23.0
24.0
24.0
28.0
24.0
23.0
24.0
23.0
24.0
23.0
24.0
26.0
28.0
24.0
27.0
10.0
12.0
13.0
25.0
22.0
23.0
Volume on
RMS
Average
Specific air
consp. on
RMS Avg.
Page 4 of 2
Annexure 4.3 A
Fan No
9859
mmWG
Site elevation
374
Suction duct
dia.
Duct area
tph
m2
Fan outlet
Static
pressure
mmWC
Date
Temp.
oC
CF 1
26.11.13
209.69
0.71
0.396
+821
28
CF 2
26.11.13
209.69
0.71
0.396
+741
28
CF 3
26.11.13
209.69
0.63
0.312
+754
28
CF 4
26.11.13
209.69
0.90
0.636
+374
28
CF 5
26.11.13
209.69
0.9
0.636
+347
28
CF 6
26.11.13
209.69
0.9
0.636
+335
28
CF 7
26.11.13
209.69
0.9
0.636
+305
28
CF 8
26.11.13
209.69
1.12
0.985
+287
28
CF 9
26.11.13
209.69
1.12
0.985
+283
28
10
CF 10
26.11.13
209.69
1.12
0.985
+245
28
No of
values
10
9.4
9.3
9.6
10.2
10.3
13.0
12.6
12.4
12.2
11.0
9.9
16.6
12.2
13.3
13.4
12.3
12.6
9.2
11.2
10.2
10.7
11.1
9.0
8.8
9.7
9.3
8.6
9.3
8.6
9.9
9.8
11.2
12.7
12.4
11.8
10.9
15.7
16.6
16.8
15.7
14.7
17.3
17.3
15.8
16.9
16.0
16.7
16.4
16.4
17.3
17.7
17.3
17.1
17.2
17.8
17.4
17.0
17.1
17.5
15.4
16.7
16.3
17.2
24.3
21.6
21.8
24.5
23.8
24.0
25.8
25.7
26.7
25.9
26.2
24.2
25.0
26.1
24.9
23.9
24.1
21.5
21.5
22.7
22.0
20.8
22.8
23.5
21.6
20.6
23.4
14.5
14.8
13.6
15.5
13.0
14.0
12.0
14.8
14.9
15.0
14.0
15.8
15.7
15.4
13.8
13.0
13.2
13.2
12.9
14.3
13.7
14.1
12.6
12.0
12.0
13.7
12.3
12.5
13.9
11.7
10.9
11.0
10.0
12.3
11.6
10.0
13.6
12.4
12.5
10.0
13.1
11.0
11.0
Avg
velocity
Volume
Volume
mps
m3/ h
Nm3/ h
Nm3/kg clinker
17
11.79
16802
14540
0.069
19
10.23
14581
12618
0.060
13
16.32
18314
15849
0.076
14
17.07
39088
33826
0.161
23.20
53124
45973
0.219
25.51
58421
50557
0.241
13
22.55
51650
44697
0.213
16
14.37
50949
44091
0.210
13
13.10
46476
40220
0.192
14
11.50
40803
35310
0.168
13170
1.61
Page 2 of 2
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman
Page 1 of 1
Plant capacity
Sp. heat capacity
Fuel firing in Kiln
Air density
Ambient temp.
Combustion air for kiln
Combustion air for PC
Primary air to kiln
Primary air to PC
Secondary air to kiln
Tertiary air to PC
Cooler vent air
Total Cooling air
t/d
Kcal/kgclk.
%
Kg/nm3
oC
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
Kg/kg clinker
Nm3/kg clink
2357
800
40
1.293
23
0.494
0.382
0.748
0.579
0.029
0.022
#REF!
#REF!
0.465
0.360
#REF!
#REF!
1.124
0.869
#REF!
#REF!
Flow
Temp
Heat balance
Sn
1
2
Item
Secondary air to kiln
Tertiary air to PC
(Draft)
kg/ kg clink 0C
0.46514271
1060
#REF!
883
Cp
Heat
Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman
(Draft)
Page 1 of 1
Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman
(Draft)
Page 1 of 1
Page 1 of 1
Plant Upgradation Study for Line I and II, Oman Cement Company (SAOG), Oman
Page 1 of 1
M
Kg/kg
clk
#REF!
Tertiary air
Cp
T
oC
Kcal/
kgoC
Kcal/kg
clk
883
0.25
#REF!
Secondary air
Cp
T
Kg/kg
clk
OC
0.47
1060
Kcal/ Kcal/kg
Kiln clk
kgoC
0.26
128
Cooler
M
Kg/kg
clk
1.00
Hot clinker
Cp
T
OC
Kcal/
kgoC
Kcal/kg
clk
1450
0.26
377
M
Kg/kg
clk
#REF!
Cooling air
Cp
T
OC
Kcal/
kgoC
Kcal/kg
clk
23
0.24
#REF!
#REF!
Recuperatuion Efficiency
:
%
(Draft)
Page 1 of 1
SN
Location
oC
Cyclone
surface Area
m2
Clinker,
tph
II Method
Avg
Temp,
oC
Radiation,
Kcal/ hr/m2
Radiation,
Kcal/ kg
clinker
Heat transfer
coefficient
(Radiation)
Heat transfer
coefficient
(Convection)
1.1
Cooler
145.04
93.24
113.11
1319.99
2.053
7.521
7.991
1.2
Cooler roof
61.48
93.24
138.50
1757.03
1.159
8.518
8.021
Total >>
3.21
Page 1 of 1
Radiation, Kcal/
kg clinker
2.347
1.299
3.646
Page 1 of 1
SN
Location
oC
Cyclone
surface Area
m2
Clinker,
tph
II Method
Avg
Temp,
oC
Radiation,
Kcal/ hr/m2
Radiation,
Kcal/ kg
clinker
Heat transfer
coefficient
(Radiation)
Heat transfer
coefficient
(Convection)
763.56
0.461
6.210
7.736
Kiln String
1.1
Cyclone - 1A
126.61
209.69
75.33
1.2
Bottom
38.85
209.69
90.00
966.76
0.179
6.695
7.877
1.3
Riser pipe
16.21
209.69
128.00
1569.83
0.121
8.094
8.018
1.4
meal pipe
9.24
209.69
264.00
4846.82
0.213
15.000
7.619
1.5
Roof
9.69
209.69
84.33
886.35
0.041
6.504
7.830
2.1
Cyclone - 1 B
126.61
209.69
91.67
990.86
0.598
6.752
7.889
2.2
Bottom
38.85
209.69
97.33
1074.40
0.199
6.949
7.925
2.3
Riser pipe
16.21
209.69
125.67
1529.48
0.118
8.002
8.015
2.4
meal pipe
9.24
209.69
260.67
4740.74
0.209
14.791
7.634
2.5
Roof
9.69
209.69
91.00
981.20
0.045
6.730
7.884
3.1
Cyclone - 2
152.76
209.69
68.67
676.47
0.493
5.999
7.648
3.2
Bottom
51.19
209.69
80.00
826.48
0.202
6.361
7.788
3.3
Riser pipe
36.63
209.69
110.00
1270.02
0.222
7.405
7.981
3.4
Meal pipe
9.24
209.69
147.33
1921.85
0.085
8.888
8.016
3.5
Roof
22.39
209.69
112.00
1302.05
0.139
7.480
7.988
4.1
Cyclone - 3
151.13
209.69
68.67
676.47
0.488
5.999
7.648
4.2
Bottom
50.64
209.69
74.00
745.88
0.180
6.168
7.720
4.3
Riser pipe
36.92
209.69
178.00
2549.28
0.449
10.268
7.956
4.4
meal pipe
9.24
209.69
178.67
2563.92
0.113
10.300
7.954
4.5
Roof
15.10
209.69
82.67
863.15
0.062
6.449
7.815
5.1
Cyclone - 4
166.84
209.69
90.00
966.76
0.769
6.695
7.877
5.2
Bottom
53.75
209.69
105.00
1191.32
0.305
7.223
7.963
5.3
Riser pipe
38.80
209.69
135.33
1699.59
0.314
8.388
8.021
5.4
Meal pipe
10.81
209.69
158.33
2136.80
0.110
9.366
8.001
5.5
Roof
16.45
209.69
83.33
872.41
0.068
6.471
7.821
6.1
Cyclone - 5
166.84
209.69
96.67
1064.45
0.847
6.926
7.921
6.2
Bottom
53.75
209.69
131.67
1634.15
0.419
8.240
8.020
6.3
Riser pipe
38.80
209.69
116.67
1378.02
0.255
7.655
8.000
6.5
Meal pipe
10.81
209.69
165.67
2286.29
0.118
9.695
7.987
6.6
Roof
16.45
209.69
150.33
1979.39
0.155
9.016
8.012
6.1
Cyclone - 6
166.84
209.69
122.50
1475.44
1.174
7.878
8.011
6.2
Bottom
53.75
209.69
136.67
1723.67
0.442
8.443
8.021
6.3
Riser pipe
38.80
209.69
466.67
14940.49
2.765
32.124
6.687
6.5
Meal pipe
10.81
209.69
225.00
3696.67
0.191
12.690
7.790
6.6
Roof
16.45
209.69
101.33
1134.84
0.089
7.091
7.946
Calciner String
1.1
Cyclone - 1
148.64
209.69
83.33
872.41
0.618
6.471
7.821
1.2
Bottom
49.94
209.69
153.33
2037.74
0.485
9.146
8.009
1.3
Riser pipe
26.28
209.69
67.33
659.45
0.083
5.958
7.628
1.4
meal pipe
9.24
209.69
194.33
2920.98
0.129
11.067
7.906
1.5
Roof
20.87
209.69
100.00
1114.56
0.111
7.043
7.939
3.1
Cyclone - 2
145.34
209.69
97.00
1069.42
0.741
6.937
7.923
3.2
Bottom
48.93
209.69
74.00
745.88
0.174
6.168
7.720
3.3
Riser pipe
35.80
209.69
88.33
942.86
0.161
6.639
7.864
3.4
Meal pipe
9.24
209.69
155.33
2077.09
0.091
9.234
8.006
Page 1 of 1
3.5
Roof
13.67
209.69
107.33
1227.81
0.080
7.307
7.972
4.1
Cyclone - 3
141.69
209.69
112.33
1307.42
0.883
7.492
7.989
4.2
Bottom
48.36
209.69
78.00
799.31
0.184
6.296
7.767
4.3
Riser pipe
35.14
209.69
115.00
1350.69
0.226
7.592
7.996
4.4
meal pipe
9.24
209.69
156.33
2096.90
0.092
9.277
8.004
4.5
Roof
13.45
209.69
67.33
659.45
0.042
5.958
7.628
5.1
Cyclone - 4
151.13
209.69
95.67
1049.58
0.756
6.891
7.915
5.2
Bottom
50.64
209.69
125.00
1518.03
0.367
7.976
8.014
5.3
Riser pipe
36.92
209.69
138.00
1747.91
0.308
8.498
8.021
5.4
Meal pipe
9.24
209.69
193.67
2905.27
0.128
11.033
7.908
5.5
Roof
14.92
209.69
121.67
1461.35
0.104
7.846
8.010
6.1
Cyclone - 5
151.13
209.69
100.00
1114.56
0.803
7.043
7.939
6.2
Bottom
50.64
209.69
117.33
1389.02
0.335
7.680
8.001
6.3
Riser pipe
36.92
209.69
98.67
1094.41
0.193
6.996
7.932
6.5
Meal pipe
9.24
209.69
206.33
3211.98
0.141
11.682
7.863
6.6
Roof
14.92
209.69
98.33
1089.40
0.078
6.984
7.930
6.1
Cyclone - 6
151.13
209.69
101.00
1129.76
0.814
7.079
7.944
6.2
Bottom
50.64
209.69
136.67
1723.67
0.416
8.443
8.021
6.3
Riser pipe
36.92
209.69
154.67
2063.93
0.363
9.204
8.007
6.5
Meal pipe
9.24
209.69
181.67
2630.35
0.116
10.444
7.946
6.6
Roof
14.92
209.69
165.67
2286.29
0.163
9.695
7.987
PC
1.988
Riser ducts
3.128
Total >>
26.94
Page 1 of 1
Radiation, Kcal/
kg clinker
0.545
0.209
0.137
0.226
0.048
0.697
0.231
0.134
0.221
0.053
0.587
0.238
0.254
0.094
0.159
0.581
0.213
0.491
0.124
0.073
0.897
0.351
0.353
0.122
0.080
0.982
0.472
0.291
0.130
0.173
1.332
0.496
2.882
0.204
0.103
0.726
0.539
0.099
0.140
0.128
0.859
0.206
0.188
0.101
Page 1 of 1
0.092
1.010
0.218
0.258
0.102
0.050
0.878
0.415
0.345
0.139
0.118
0.928
0.382
0.223
0.153
0.090
0.940
0.467
0.403
0.127
0.179
24.686
Page 1 of 1
oC
II Method
SN
Location, m
Kiln Dia,
m
Kiln
Length,
m
Total C. S,
m2
Clinker,
tph
0 to 2
4.27
26.83
209.69
2 to 4
4.27
26.83
209.69
4 to 6
4.27
26.83
6 to 8
4.27
26.83
8 to 10
4.27
10 to 12
4.27
12 to 14
4.27
14 to 16
4.27
Avg
Temp,
oC
Radiation, Kcal/
hr/m2
Radiation,
Kcal/ kg
clinker
Heat transfer
coefficient
(Radiation)
Heat transfer
coefficient
(Convection)
Radiation, Kcal/
kg clinker
364
9418.04
1.205
22.304
7.148
1.179
280
5703.77
0.730
16.032
7.545
0.726
209.69
281
5740.67
0.735
16.098
7.540
0.731
209.69
291
6118.62
0.783
16.770
7.494
0.777
26.83
209.69
246
4540.15
0.581
13.899
7.700
0.585
26.83
209.69
204
3325.53
0.425
11.561
7.872
0.436
26.83
209.69
165
2388.36
0.306
9.665
7.988
0.320
26.83
209.69
347
8558.33
1.095
20.913
7.228
1.074
16 to 18
4.27
26.83
209.69
318
7223.53
0.924
18.686
7.366
0.911
10
18 to 20
4.27
26.83
209.69
351
8755.29
1.120
21.235
7.209
1.098
11
20 to 22
4.27
26.83
209.69
201
3247.30
0.415
11.406
7.883
0.427
12
22 to 24
4.27
26.83
209.69
225
3904.14
0.500
12.690
7.790
0.507
13
24 to 26
4.27
26.83
209.69
257
4897.79
0.627
14.564
7.651
0.628
14
26 to 28
4.27
26.83
209.69
327
7620.71
0.975
19.358
7.323
0.960
15
28 to 30
4.27
26.83
209.69
215
3621.73
0.463
12.142
7.830
0.472
16
30 to 32
4.27
26.83
209.69
318
7223.53
0.924
18.686
7.366
0.911
17
32 to 34
4.27
26.83
209.69
309
6841.09
0.875
18.030
7.408
0.865
18
34 to 36
4.27
26.83
209.69
305
6675.73
0.854
17.745
7.427
0.845
19
36 to 38
4.27
26.83
209.69
307
6758.06
0.865
17.887
7.418
0.855
20
38 to 40
4.27
26.83
209.69
257
4886.69
0.625
14.544
7.653
0.627
21
40 to 42
4.27
26.83
209.69
260
4987.13
0.638
14.729
7.639
0.639
22
42 to 44
4.27
26.83
209.69
215
3621.73
0.463
12.142
7.830
0.472
23
44 to 46
4.27
26.83
209.69
228
3991.38
0.511
12.858
7.778
0.518
24
46 to 48
4.27
26.83
209.69
221
3789.64
0.485
12.469
7.806
0.493
25
48 to 50
4.27
26.83
209.69
212
3539.47
0.453
11.982
7.842
0.462
26
50 to 52
4.27
26.83
209.69
218
3695.80
0.473
12.287
7.820
0.481
27
52 to 54
4.27
26.83
209.69
209
3449.38
0.441
11.805
7.855
0.451
28
54 to 56
4.27
26.83
209.69
209
3449.38
0.441
11.805
7.855
0.451
28
56 to 58
4.27
26.83
209.69
222
3827.58
0.490
12.542
7.801
0.498
28
58 to 60
4.27
26.83
209.69
285
5889.90
0.754
16.364
7.522
0.749
Total >>
20.18
20.15
Page 1 of 1
HEAT BALANCE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
C
%
%
%
%
%
o
C
o
C
o
C
Kg/nm3
o
C
%
Kcal/kg clinker
Kcal/kg clinker
Kcal/kg clinker
o
60
0.2
0.5
18
4.0
78.0
130
50
50
1.293
28
9.00
3.21
20.2
26.94
C
Primary air temp
%
%
%
%
%
o
C
o
C
o
C
Kg/nm3
o
C
%
Kcal/kg clinker
Kcal/kg clinker
Kcal/kg clinker
o
Deg C
50
Stream
5033
Gas flow, Nm3/kg
Flow, Kg/ Kg clinker
clinker
tpd
Temp, oC
Heat,
Kcal/ kg clk
% Heat
Mass flow
tph
Sp. heat
Kcal/KgoC
1.671
60
21.24
2.78
350.30
0.21
0.003
60
0.20
0.03
0.70
1.00
0.094
50
1.31
0.17
19.64
0.28
0.0005
50
0.01
0.001
0.10
0.28
0.022
0.029
50
0.35
0.05
6.09
0.24
0.009
0.012
50
0.15
0.02
2.58
0.24
1.610
2.082
28
13.86
1.82
436.62
0.24
0.305
0.394
28
2.62
0.34
82.66
0.24
0.014
0.017
50
0.21
0.03
3.66
0.24
723
94.77
0.00
763
100.00
902.4
10
11
Calcination Gases
0.278
12
0.024
2.26
4.30
Heat Output
0.003
0.0005
1.426
0.87
2.30
1.000
130
25.09
3.29
209.69
0.193
2.025
315
157.0
20.57
424.69
0.25
0.151
315
11.11
1.46
31.59
0.23
1.124
418
115.8
15.18
235.59
0.25
401.1
52.57
315
2.27
0.30
0.70
0.46
315
0.32
0.04
0.10
0.46
26.94
3.53
0.00
23.39
3.07
0.00
763.0
100.00
902
4.30
Sn
Description
tpd
kcal/kg clinker
%
%
Deg C
Deg C
Deg C
Deg C
kg/kg clinker
kg/kg clinker
kg/kg clinker
kg/kg clinker
kg/nm3
Deg C
5033
723
31.1
68.9
130
418
1140
930
0.029
0.017
0.363
0.595
1.293
28
Flow
Temperature
kg/kg clinker
Deg C
Cp
Heat
HEAT INPUT
1
Hot Clinker
1.00
1450
0.264
383
Cooling Air
2.08
28
0.238
13.9
Total
3.08
397.1
HEAT OUTPUT
3
1.12
418
0.247
115.8
Secondary air
0.363
1140
0.263
109.0
Tertiary Air
0.595
930
0.258
143.1
1.00
130
0.193
25.1
3.2
3.08
396.2
64
144
Annexure 4.7 A
0.36
1140
109.00
Kg/ kg clk
0
C
Kcal/ kg clk.
Tertiary Air
Mass
Temp.
Heat flow
0.60
930
143.09
Kg/ kg clk
0
C
Kcal/ kg clk.
Cooler exhaust
Mass
Temp.
Heat flow
1.12
418
115.82
Kg/ kg clk
C
Kcal/ kg clk.
Clinker
Mass
Temp.
Heat flow
Clinker
Mass
Temp.
Heat flow
1.00
1450
383.24
Kg/ kg clk
C
Kcal/ kg clk.
Kg/ kg clk
0
C
Kcal/ kg clk.
Total cooling air
13170
1.00
130
25.09
Mass
Temp.
Heat flow
2.08
28
13.86
Kcal/ kg clk.
Kg/ kg clk
C
Kcal/ kg clk.
Page 1 of 1
Annexure 4.4A
KILN SHELL TEMPERATURE LINE 2
S.N.
13170
Average temperature, oC
0 to 2
364
2 to 4
280
4 to 6
281
6 to 8
291
8 to 10
246
10 to 12
204
12 to 14
165
14 to 16
347
16 to 18
318
10
18 to 20
351
11
20 to 22
201
12
22 to 24
225
13
24 to 26
257
14
26 to 28
327
15
28 to 30
215
16
30 to 32
318
17
32 to 34
309
18
34 to 36
305
19
36 to 38
307
20
38 to 40
257
21
40 to 42
260
22
42 to 44
215
23
44 to 46
228
24
46 to 48
221
25
48 to 50
212
26
50 to 52
218
27
52 to 54
209
28
54 to 56
209
29
56 to 58
222
30
58 to 60
285
Page 1 of 1
Plant Operational Audit for two production lines ( Line 2& 3),
J K Lakshmi Cement Ltd, Sirohi Rajasthan
Annexure 4.5A
13170
Component
Unit
Value
SiO2
20.94
Al2O3
5.71
Fe2O3
3.75
CaO
63.87
MgO
3.02
SO3
1.45
K2O
0.73
Na2O
0.31
Cl
0.00
Free CaO
1.89
Page 1 of 1
Heat loss by
Radiation
6.60%
15.18%
2.78%
20.57%
3.29%
Heat Balance of Kiln 2
94.77%
Heat of Formation
52.57%
Kiln
Dia
CSA
Volume
Coal tpt
Velocity at tpt line
Coal to air ratio
power cons
sp power
kg of air required for 4
kg ratio
Extra air going
% Extra air going
% reduction in power
for 20% speed red
kw saving
annual cost saving
kW
mm
m2
m3/sec
kg/sec
m3/hr
Nm3/kg clinker
TPH
kg/sec
m/sec
PC
141.2
0.0157
0.6393
0.7224
2301
0.009
6
1.67
40.82
2.31
110
18.33
179.2
0.0252
0.9098
1.0280
3275
0.014
13.4
3.72
36.07
3.62
110
8.21
0.42
0.93
0.31
0.42
0.10
0.09
0.512
0.512
53.7
8.59
0.0
0.00
32.13610586
321.3610586
3.880
present level
Reduce pressure drop across duct from WHR outlet to ph fan inlet
Installation of Precalciner
10
11
70.0
278.0
471 FN2,3,4,5,6,7
7
Reduce pressure drop across cyclone & cyclone outlet bend in Raw mill circuit
10
11
115.0
12
47.0
13
14
15
Reduce pressure drop across damper in Sepax fan Slag HPGR roller press
80.0
16
Reduce pressure drop across damper in bag house fan in Slag VRM
113.0
17
Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF1)
64.0
18
Avoid damper loss by installing VFD in Auxilary bag filter fan (551 BF3)
303.0
19
Avoid damper loss by installing VFD in Auxilary bag filter fan (221BF1)
440.0
160.0
40.0
INR
new one
Coal cost
861.6
10.19
40
1893.0
1893.0
742.0
742.0
77
94.65
7920
7920
23.5
29.1
40.76
90
2075.1
830.0
235
8000
7.3
2075.1
830.00
92.1
8000
1.43
75.0
8000
23.3
8000
45.0
0.0
8000
3.06
130
20.0
8000
6.2
1580.0
903.0
52.5
7000
14.3
1580.0
903.0
145
7000
39.4
803.0
294.0
27.3
8000
8.5
380.0
893.0
39
5000
7.6
40
380.0
893.0
31.9
5000
6.2
20
60.0
141.0
11.5
5000
2.2
67.0
8000
20.8
109
8000
33.8
20
20
400.0
464.0
25.9
7000
7.0
20
1435.0
686.0
97.3
7000
26.4
10
22.0
351.0
3.4
5000
0.7
10
45.0
496.0
13.3
5000
2.6
10
55.0
515.0
23.0
5000
4.5
157.0
417
Thermal savings
Electrical savings
investement Lakhs
payback, months
kcal/kg
MTOE/ year
KW
10
1171
101
5.1
0.5
3.6
424
40.00
20
20.0
2.2
0.1
40
2.40
235
0.13
1.1
92.1
2.5
1.3
2.5
2.3
0.6
2.0
1.5
5.9
77
40
77.3
20
16.8
20
6.1
0.0
25
39.4
25
48.5
16.2
20
11.5
50
17.7
0.0
0.0
36.6
18.6
10.8
600
45.9
826
Electrical savings
kW/ t of clinker
0.68
6.6
39895
1.6
0.6
0.5
59996
0.11
False air %
43376
11890
Primary air_kiln _ PC
Page 1