Kiln Performance & Efficiency

S. Description Symbol Formula

No.
1 Degree of filling DF
%
P
Def
n
s
2 Thermal loading TL Formula-1
or Gcal/hr/m2
Burning zone loading
F
NCV
A

Formula-2

P
H
A
3 Volumetric loading VL
tpd/m3
P
A
L
4 Material residence time in kiln RTK
min
L
Def
n
s
5 Clinker residence time in cooler RTC
(Empirical relationship from min
F.L. Smidth) A
Ps
P
6 True CO2 in kiln exit gas TCO2
vol%
CO2
CO2
O2
7 Excess air EA
 %
O2
CO2
8 Radiation heat losses RHL
kcal/hr/m2 T
t

9 Convection heat losses CHL

kcal/hr/m2 T
t

10 Forced convection heat losses FCHL

(when wind speed > 3.0 m/s) kcal/hr/m2 T
t
v
D

11 %Ash absorption in clinker %AA

%
CC
Ash
P
12 Raw Mix:Clinker ratio RMCK
(dust to kiln) -
%AA
LOI
13 Raw Mix:Clinker ratio RMCS
(dust to silo) -
%AA
LOI
DL
14 Heat of reaction HR
or kcal/
Theoretical heat required to kg-clinker
produce 1 kg of clinker
or
Clinkerisation heat CaCO3
RMCK
(including Heat of combustibles) MgCO3
LOI
Al2O3
CH2O
SiO2
Fe2O3
K2O
 Na2O
C
S
15 False air w.r.t. mix FAMO
(based on O2 analysis) %
O2mix
O2gas
16 False air w.r.t. gas FAGO
(based on O2 analysis) %
O2mix
O2gas
17 False air w.r.t. mix FAMC
(based on CO2 analysis) %
CO2mix
CO2gas
18 False air w.r.t. gas FAGC
(based on CO2 analysis) %
CO2mix
CO2gas
Kiln Performance & Efficiency
Formula Example

3.2 * P P
Deff 3 * n * s Def
Clinker production, tpd n
Burning zone efective diameter, mts S
Kiln speed, rpm DF
Kiln slope, % Target
F
F * NCV NCV
A * 1000 * 1000 A
Fuel rate in kiln, kg/hr TL
Net calorific value of fuel, kcal/kg-fuel Target
Burning zone cross-sectional area, m2

P
P*H H
A * 24 * 1000 A
Clinker production, tpd TL
Specific heat consumption in kiln, kcal/kg-clinker Target
Burning zone cross-sectional area, m2
P P
A* L A
Clinker production, tpd L
Burning zone cross-sectional area, m2 VL
Kiln length, mts Target
19 * L L
Deff * n * s Def
Kiln length, mts n
Burning zone efective diameter, mts S
Kiln speed, rpm RTK
Kiln slope, % Target
1.55 * A * Ps A
P Ps
Cooler grate cross-sectional area, m2 P
Static pressure at clinker droping area, mmWg RTC
Clinker production, tpd Target
100 * ( CO2 + CO ) CO2
100 + ( 1.89 * CO ) - ( 4.78 * O2 ) CO
Kiln exit gas CO2, vol% O2
Kiln exit gas CO, vol% TCO2
Kiln exit gas O2, vol% Target
79 * O2 O2
 0.21 * ( 100 - CO2 ) - O2 CO2
O2 content in gas, vol% EA
CO2 content in gas, vol% Target
4 * 10-8 * ( T4 - t4 ) T
Radiating body temperature, K t
Ambient air temperature, K RHL
Target
80.33 * ( ( T + t ) / 2 )-0.724 * ( T - t )1.333 T
Radiating body temperature, K t
Ambient air temperature, K CHL
Target
28.03 * ( ( T + t ) / 2 )-0.351 * v0.805 * D-0.195 * ( T - t ) T
Radiating body temperature, K t
Ambient air temperature, K v
Wind speed, m/s D
Radiating body diameter, mts FCHL
Target
CC * Ash CC
P Ash
Coal consumption, tph P
Ash content in fuel (as fired basis), % %AA
Clinker production, tph Target
100 - %AA %AA
100 - LOI LOI
%Ash absorption, % RMCK
Loss on ignition of raw mix, % Target
( 100 - %AA ) * 100 %AA
( 100 - LOI ) * ( 100 - DL ) LOI
%Ash absorption, % DL
Loss on ignition of raw mix, % RMCS
Dust losses from preheater, % Target
( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMCK ) CaCO3
+ ( 222 * Al2O3 / ( 100 - LOI ) ) + ( 11.6 * CH2O * RMCK ) RMCK
- ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) ) MgCO3
- ( 1000 * ( K2O + Na2O ) / ( 100 - LOI ) ) LOI
- ( 79 * C * RMCK ) - ( 32 * S * RMCK ) Al2O3
CaCO3 content in kiln feed, % CH2O
Kiln feed:Clinker ratio, - SiO2
MgCO3 content in kiln feed, % Fe2O3
LOI content in kiln feed, % K2O
Al2O3 content in clinker, % Na2O
Water of crystalisation in kiln feed, % C
SiO2 content in clinker, % S
Fe2O3 content in clinker, % HR
K2O content in clinker, % Target
Na2O content in clinker, %
Carbon content in kiln feed, %
Sulphur as pyrites in kiln feed, %
( O2mix - O2gas ) * 100 O2mix
21 - O2gas O2gas
O2 content in mixture of gas, vol% FAMO
O2 content in unmixed gas, vol% Target
( O2mix - O2gas ) * 100 O2mix
21 - O2mix O2gas
O2 content in mixture of gas, vol% FAGO
O2 content in unmixed gas, vol% Target
( CO2gas - CO2mix ) * 100 CO2mix
CO2gas CO2gas
CO2 content in mixture of gas, vol% FAMC
CO2 content in unmixed gas, vol% Target
( CO2gas - CO2mix ) * 100 CO2mix
CO2mix CO2gas
CO2 content in mixture of gas, vol% FAMC
CO2 content in unmixed gas, vol% Target
Example

3300
4.3
4
4
8.30
14-16
10000
6980
13.52
5.16
4.0-5.0

3300
280
13.52
2.85
4.0-5.0

3300
13.52
60
4.07
5.0-5.5
60
4.3
3.8
4
17.4
20-25
87
700
3300
28.6
20-25
36.5
0.002
4.2
45.7
-
2.8
 26.5
17.5
10-15
517
305
2512
-
443
308
760
-
525
302
5
4.15
2088
-
14.5
15
137.5
1.58
-
1.74
35.58
1.525
-
1.74
35.5
8.1
1.658
-
75.1
1.53
1.6
34.5
4.17
1.05
13.47
2.41
0.38
0.27
0.2
0.04
389
-
 3.6
2.8
4.4
5-7
3.6
2.8
4.6
5-7
32.1
34.5
7.0
5-7
32.1
34.5
7.5
5-7
Kiln % loading

Feed rate 240 tph

Clear 4.3 m
Kiln rpm 4 rpm
Slope 4%
Raw meal/clinker factor 1.65
Kiln loading 8.78 %
Ratio Feed/rpm*100 0.60

Specific coal consumption

PC 9.00 tph
Main burner 5.50 tph
Kiln feed 240 tph
Coal CV 6980 kcal/kg
Spec consumption 696 kcal/kgclinker
Coal - Kiln 38 %
Coal - PC 62 %
R meal/clinker factor 1.65

Kiln thermal loading

Coal CV 6980 kcal/kg
Main burner coal 5.60 tph
Kiln thermal loading 3.13 MW/m2
2.69 million kcal/hr/m2

Volumetric loading

Feed rate 240 tph

Kiln length 60 m
Volumetric loading 4.11 tpd/m3

Kiln residence time

Kiln rpm 4 rpm

Kiln residence time (Duda) 19.5 min
Kiln residence time (Labhan) 17.9 min
cal/kgclinker

illion kcal/hr/m2