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HEAT OUTPUTS

HEAT OF FORMATION
Q = 2.2A + 6.48M + 7.646C-5.1165S - 0.59F
% Of AL2O3
A=
M=
C=
S=

% Of MgO
% Of CaO
% Of SiO2

F=

% Of Fe2O3+% Of P2O5

Q=

0 Kcal/Kg clinker

HEAT IN PREHEATER EXIT DUST


Gross dust loss
Clinker output rate

=
=

tph
tph

Dust in preheater exit gas =

#DIV/0!

Kg dust/Kg clinker

Qd=md X Cpd X ( td - tr )
Mean sp. Heat Cpd

A + B.T 10 -6 +C.T. 10 -9 Kcal/KgC

A = 0.206
B = 101
C = -37
T=
Therefore
Cpd =
0.206

md =

#DIV/0! Wt. of dust Kg / Kg clinker

Cpd =

0.206 mean sp. Heat of dust, Kcal /Kg C

td =

0 temperature of dust, C

tr =

0 reference temperature, C

Qd =

#DIV/0! Kcal/Kg clinker

HEAT IN PREHEATER EXIT GASES


Qe=me X Cpe X ( te - tr )
me =

Wt. of preheater exit gases Kg / Kg clinker

Cpe =

mean sp. Heat of exit gas, Kcal /Kg C

te =

temperature of exit gases, C

tr =

reference temperature, C

Pitot measurement of kiln exit gases


Clinker production

=
=

me

71.09
2817.6
= 32.611
2.1799

Exit gas composition :


O2
=
CO2
=
CO
=
Assuming balance gases as N2
N2
=
100

Qe =

%
%
%
%

HEAT IN CLINKER FROM COOLER DISCHARGE

Kg/Sec
tpd
Kg/Sec
Kg/Kg clinker

Radiation & Convection Losses From Kiln


Kiln Dia
Kiln Length
Emissivity
Ambient Temperature K
From Outlet M
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

3.6 M
54M
0.9
298
Surface
Surface Temp
Radiation
Convection Rad.+ Conv. Rad.+ Conv.
Area
K Losses
Losses
Losses
Losses
M2
Kcal/h*M2
Kcal/h*M2
Kcal/h*M2
Kcal/h
11.30
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!
11.31
-316
#VALUE!
#VALUE!
#VALUE!

45
46
47
48
49
50
51
52
53
54

11.31
11.31
11.31
11.31
11.31
11.31
11.31
11.31
11.31
11.31

-316
-316
-316
-316
-316
-316
-316
-316
-316
-316

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

TOTAL

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

Radiation & Convection Losses From Preheater


Surface
Surface Temp
Area
K
M2
Kiln inlet
43.51
378
Firing Hood
50.25
473
Raiser Duct
944.30
393
Mixing chamber
298.79
383
Precalciner
100.28
373
T.A.D.
980.41
413
P.H. Down commer
849.71
473

Radiation
Losses
Kcal/h*M2
501.519894
1687.85933
639.157368
545.622136
459.133447
848.867972
1687.85933

Grate cooler
Cooler exhaust

379.32818 314.493107 693.82128779 260876.8042


501.519894
408.09477 909.6146638 172271.9212

C 1A
Cyclone
Feed pipe
C 1B
Cyclone
Feed pipe
C-2
Cyclone
Feed pipe
C-3
Cyclone
Feed pipe
C - 4A
Cyclone
Feed pipe
C - 4B
Cyclone
Feed pipe
C-5
Cyclone
Feed pipe
GAS DUCTS

376.00
189.39

161.80
9.43
161.80
9.57
230.02
30.20
283.95
16.74
140.55
17.67
140.55
15.42
293.05
37.10

363
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378
378

Convection
Losses
Kcal/h*M2
408.09477
1053.33335
505.064616
440.088888
376.472314
638.234261
1053.33335

Rad.+ Conv.
Losses
Kcal/h*M2
909.6146638
2741.1926774
1144.2219833
985.71102399
835.60576132
1487.1022337
2741.1926774

Rad.+ Conv.
Losses
Kcal/h
39577.33402
137744.932
1080488.819
294520.5969
83794.54575
1457969.901
2329218.83

501.519894
501.519894

408.09477
408.09477

909.6146638 147175.6526
909.6146638 8577.66628

501.519894
501.519894

408.09477
408.09477

909.6146638 147175.6526
909.6146638 8705.012333

501.519894
501.519894

408.09477
408.09477

909.6146638 209229.565
909.6146638 27470.36285

501.519894
501.519894

408.09477
408.09477

909.6146638 258285.0838
909.6146638 15226.94947

501.519894
501.519894

408.09477
408.09477

909.6146638 127846.341
909.6146638 16072.89111

501.519894
501.519894

408.09477
408.09477

909.6146638 127846.341
909.6146638 14026.25812

501.519894
501.519894

408.09477
408.09477

909.6146638 266562.5772
909.6146638 33746.70403

CD -1
CD -2
CD -3A
CD -3B
CD -4

157.78
132.13
128.04
128.04
168.91

TOTAL

6095.39

378
378
378
378
378

501.519894
501.519894
501.519894
501.519894
501.519894

408.09477
408.09477
408.09477
408.09477
408.09477

909.6146638
909.6146638
909.6146638
909.6146638
909.6146638

7914694.264

HEAT BALANCE

HEAT INPUT

Kcal/Kg clinker

Combustion heat through coal


Sensible heat in coal
Sensible heat in air
Sensible heat in kiln feed

750.00
2.20
1.80
26.12

TOATL

780.12

HEAT OUTPUT
Theoretical heat of reaction
Heat in preheater exit gases
Heat in dust in preheater exit gases
Heat in cooler exhaust air
Heat in clinker
Heat in air from cooler to coal mill
Radiaion and convection losses
Heat for kiln feed and fine coal moisture removal

402.60
172.74
10.84
85.14
26.88
9.14
90.00
6.00

TOATL

803.34

Clinker production

143519.0017
120187.3855
116467.0616
116467.0616
153643.0129

kg/hr

0.000001 0.000000001

#VALUE!

Radiation
K4

298
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

04

7886150416
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7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416

10

-8

0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001

( 298+T)/2

-0.724

0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642

( T-298)

1.333

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

0
0
0
0
0
0
0
0
0
0

K4
20415837456
50054665441
23854493601
21517662721
19356878641
29093783761
50054665441
0
17363069361
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456
20415837456

7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416

298

04

7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
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7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
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7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416
7886150416

0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001

10

-8

0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001
0.00000001

0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642
0.0267062642

( 298+T)/2

-0.724

0.0147592507
0.0134189442
0.0145265877
0.014680715
0.0148387942
0.0142295815
0.0134189442
0.0267062642
0.0150009879
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

( T-298)

1.333

344.2064091
977.1690856
432.8182511
373.1774803
315.8323881
558.3547578
977.1690856
#VALUE!
260.9837724
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091
344.2064091

20415837456
20415837456
20415837456
20415837456
20415837456

750.08
2.22
1.80
18.06
772.16

402.60
172.74
10.84
85.14
26.88
6.43
90.00
6.00
800.63

7886150416
7886150416
7886150416
7886150416
7886150416

0.00000001
0.00000001
0.00000001
0.00000001
0.00000001

0.0147592507
0.0147592507
0.0147592507
0.0147592507
0.0147592507

344.2064091
344.2064091
344.2064091
344.2064091
344.2064091

23.86165
23.86607

339.228

HEAT BALANCE
DATE OF COMPUTATION :17.02.09

HEAT INPUT
Combustion heat through coal
Sensible heat in coal
Sensible heat in air
Sensible heat in kiln feed

TOATL

Kcal/Kg clinker
750
2.2
1.8
26.12

787

HEAT OUTPUT
Theoretical heat of reaction
Heat in preheater exit gases
Heat in dust in preheater exit gases
Heat in cooler exhaust air
Heat in clinker
Heat in air from cooler to coal mill
Radiaion and convection losses
Heat for kiln feed and fine coal moisture removal

TOATL
Note: The following are considered in above calaculations
Clinker Prod.: 125 TPH
P.H Exit temp.: 330OC
Cooler Exit Temp.: 275 0C
Coal consumption : 16%
Coal mill hot air temperature :350OC
Clinker temperature :140OC
Kiln feed temperature :90OC

402.6
172.74
10.84
85.14
26.88
9.14
90
6

803.34