Clinker Weighing test result

11 September 1997 start Stop Total Ton/jam

Time (hour) 14.13 22.13 8
Kiln Feed totalizer (T) 813041 817186 4145 518.1
Kiln Coal totalizer (T) 11001.9 11120.5 118.6 14.8
ILC Calciner coal totalizer (T) 6312.82 6355.32 42.5 5.3
SLC Calciner coal totalizer 12078 12230.3 152.3 19.0
Clinker weighing total (T) 2719.5 339.9

L min 8.542 kg air/kg Coal

GHV 5763 kcal/kg Coal

Fuel consumption Ton % ton/jam

Kiln (PW1) 118.6 37.8% 14.8
ILC Calciner (PW2) 42.5 13.6% 5.3
SLC Calciner (PW3) 152.3 48.6% 19.0
Total 313.4 100.0% 39.2

Fuel Consumption 664 kcal/kg Clinker (note:pfister feeder calibration not co

Combustion air 334632.9 kg air/jam

5577.2 kg air/min
0.984 kg air/kg clinker

Clinker Faktor 1.52 (note:the dust return is not weighed)

Material Balance

Pulvurized X kcal/kg terak

Coal Ash 19.67 %

0.1967 x kg
3.413E-05 x kg

Raw mix to clinker LOI 35.18

= (1 - 3.413* X*(10^-2))*100
100 - 35.18
= 1.542733724 - 5.266E-05 x

CO2 From raw mix total carbonat 77.22 %

= 0.524171552 - 1.789E-05 x
Free H2O in the raw mix H2O 0.5 %

=( 1.542733724 - 5.265586E-05 x) * 0.0050251

= 0.007752431 - 2.646023E-07 x

Combined H2O in raw mix H2O 1.12 %

=( 1.542733724 - 5.265586E-05 x) * 0.0112
= 0.017278618 - 5.897456E-07

Carbon from raw mix C 0.11 %

=( 1.542733724 - 5.265586E-05 x) * 0.0011

= 0.001697007 - 5.792145E-08

Excess Air

% Excess Air = 79 * %O2

0.21 * (100 - % CO2) - %O2

Stage 1 ILC average exit gas analiysis

CO2 = 29
O2 = 3.5
Excess air = 24.2

Stage 1 SLC average exit gas analiysis

CO2 = 32
O2 = 3.5
Excess air = 25.6

Dust in Exit Gas 10.5%

Dust rate 56.28 tph

kiln Feed 511.1 tph 508.5445
Total 567.38 tph 564.5431

CLK = KF * (efficiency) * (1 - H2O) * (1-LOI) + (Coal Ash)

335 = 567.4 * (efficiency) * (1 - 0.05) * (1-0.3518) + (39.17*0.1967)
327.6227334711 = 365.9368374 * Efficiency
Efficiency = 89.5%

Dust = 0.177 kg dust/kg clinker

Water from Coal

Fine Coal H2O 2.29 %

LHV Fine Coal 5763 kcal/kg Coal

Fine Coal Consumption = x

5763

= 0.000174 x kg coal/kg terak

Dry Coal consumption = x + (1- 0.0229 )

5763

= 0.000169547 x kg coal Dry/kg terak

Water from Coal = x * 0.0229

5763

= 3.97362E-06 x kg air/kg terak

Combustion Air Rates:

L min 8.542 kg air/kg Coal

Air required = x * 8.542 kg air

5763 kg Coal

= 0.001482214 x kg air/kg Clk

= 8.3976694

Kiln Primary air

Flow 150.7 kg air/min (measurement pitot tube)

0.027 kg air/kg Clk

L min = 2110.585833 kg air/min

7.14% kebutuhan udara dari total combustion of kiln fuel.

Kiln Coal Transport air

Flow 81.8 kg air/min

0.015 kg air/kg Clk

L min = 2110.585833 kg air/min

3.9% kebutuhan udara dari total combustion of kiln fuel.

ILC Calciner coal transport and primary air

Flow 25.83 kg air/min

0.005 kg air/kg Clk

L min = 756.3229167 kg air/min

3.4% kebutuhan udara dari total combustion of ILC Calciner.

SLC Calciner coal transport and primary air

Flow 91 kg air/min

0.016 kg air/kg Clk

L min = 2710.305417 kg air/min

3.4% kebutuhan udara dari total combustion of SLC Calciner.

Remaining air requirement ILC/kiln String

=[( 0.001482214 x * (1 + 0.242 )) * ( 37.8%

= 0.000946553 x -0.046 kg air/kg clk

Remaining air requirement ILC/kiln String

=[( 0.001482214 x * (1 + 0.256 )) * ( 48.6%

= 0.000905049 x -0.016 kg air/kg clk

Combustion products from coal 9.349 kg gas/kg coal including water in Coal

= X kcal/kg terak 9.349 kg gas/kg coal

5763 kcal/kg Coal

= 0.001622245 x kg gas/kg clk

Extra air required to burn carbon in the kiln feed

C + Air ® CO2

Lb 1 11.53 3.6666667

lb/lb clk 0.0017 0.019566492 0.0062224

---------- > Including 24.2 % Excess air in ILC 0.0243081 kg air/kg clk

---------- > Including 25.6 % Excess air in SLC 0.0245852 kg air/kg clk

Extra Product of Combustion for ILC

CO2 0.006 kg CO2/kg clk

N2 0.0187 Kg N2/kg Clk

Extra Product of Combustion for SLC

CO2 0.006 kg CO2/kg clk

N2 0.0189 Kg N2/kg Clk

Excess Air

ILC/kiln string = [( 37.8% + 13.6% ) * 8.542

5763

= 0.000184636 x + 0.0047 kg air/kg clk

 SLC string =[ 48.6% * 8.542 * 0.2564935
5763

= 0.000184752 x + 0.0050 kg air/kg clk

Sistem surface losses

Radiation losses
Kiln Radiation loss 23 kcal/kg clk
Cooler and firing hood radiation loss 6 kcal/kg clk
Preheater and tertiary air dust radiation loss 28 kcal/kg clk

Cooler

Average clinker discharge temperature 124 °C

Heat of Cooler = 1 kg/kg clk * 124 * 0.1898576

= 23.54 kcal/kg clk

Radiation Loss 6 kcal/kg clk

Excess Air

Flow 388554 kg/hr @ 238 °C

1.158726595 kg air/kg clk

CP 0.248327168

Heat Of excess Air 68.48290386 kcal/kg clk

Hot air for the raw mill

Flow 122897 kg/hr @ 407 °C

0.366497378 kg air/kg clk

CP 0.25229205

Heat Of excess Air 37.6 kcal/kg clk

Total Cooler loss 135.66 kcal/kg clk
er feeder calibration not correct)
+ (39.17*0.1967)
of kiln fuel.

of ILC Calciner.

of SLC Calciner.

+ 13.6% )] -0.027 -0.015 -0.005

kg air/kg clk

)] -0.016

kg air/kg clk
water in Coal

+ N2

8.85504

0.0150271

kg air/kg clk

kg air/kg clk

* 0.2423313 ] * x + ( 0.0243081 -0.0196 )

]*x +( 0.0245852 - 0.0196 )
 System Heat Input °C kg/kg kcal/kg C kcal/kg
Fuel : Combustion Heat 1x
Free heat w/ coal 80 0.000174 x 0.2932 0.004070102 x
Air : Primary 32 0.027 0.2377
Kiln Coal transport 32 0.015 0.2377
ILC Coal transport 32 0.005 0.2377
SLC Coal transport 32 0.016 0.2377
Remaining ILC 32 0.0009466 x -0.04622 0.2377 0.007200951 x
Remaining SLC 32 0.000905 x -0.01628 0.2377 0.006885208 x
Extra for C - ILC 32 0.024308 0.2377
Extra for C - SLC 32 0.024585 0.2377
Cooler : Excess Air 32 1.158727 0.2377
Hot air for RM 32 0.366497 0.2377
Water from coal 80 3.9736E-06 x 1.0000 0.00031789 x
Raw Feed 90 -5.266E-05 x 1.542734 0.2148312 -0.001018091 x +
Returned dust 90 0.177 0.2148312
Sum Of heat inputs 1.01745606 x +

System Heat Input °C kg/kg kcal/kg C kcal/kg

Combustion Product (Coal) 348 0.0016222 x 0.2579 0.145595223 x
Combustion Product (Carbon in mix)
CO2 - ILC 348 0.006 0.2319
N2 - ILC 348 0.0187 0.2517
CO2 - SLC 348 0.006 0.2319
N2 - SLC 348 0.019 0.2517
Excess Air In exit gas - ILC 348 0.0001846 x 0.0047 0.2450 0.015742344 x
Excess Air In exit gas - ILC 348 0.0001848 x 0.005019 0.2450 0.01575218 x
CO2 from Raw Feed 348 -1.789E-05 x 0.524172 0.2319 -0.001443536 x
Vapor from free H2O In feed 348 0.007752 788
Vapor from comb H2O In feed 348 0.017279 0.4600
Dust 348 0.177 0.2367
Radiation : Kiln
Preheater
Cooler loss : Heat in Clinker 124 1 0.1927
Radiation
Hot air for mill 407 0.366497 0.2464
Excess Air 238 1.158727 0.2425
Heat of reaction
Sum Of heat inputs 0.17564621 x

1.017456 x + 45.22891639 =
0.175646 x 665.394721

0.84181 x = 620.1658047
x = 736.705332 Kcal/kg
 Summary

kcal/kg System Heat Input °C kg/kg

Fuel : Combustion Heat
Free heat w/ coal 80 0.127834
0.20513465 Air : Primary 32 0.027
0.11134714 Kiln Coal transport 32 0.015
0.03516011 ILC Coal transport 32 0.005
0.12387029 SLC Coal transport 32 0.016
-0.3516419 Remaining ILC 32 0.651108
-0.1238703 Remaining SLC 32 0.650472
0.18492487 Extra for C - ILC 32 0.0243081
0.18703296 Extra for C - SLC 32 0.0245852
8.81507283 Cooler : Excess Air 32 1.1587266
2.78814786 Hot air for RM 32 0.3664974
Water from coal 80 0.002927
29.8284585 Raw Feed 90 1.503942
3.42527933 Returned dust 90 0.177
45.2289164 Sum Of heat inputs

kcal/kg System Heat Input °C kg/kg

Combustion Product (Coal) 348 1.195117
Combustion Product (Carbon in mix)
0.50205773 CO2 - ILC 348 0.006
1.63492616 N2 - ILC 348 0.019
0.50205773 CO2 - SLC 348 0.006
1.65356384 N2 - SLC 348 0.019
0.40427313 Excess Air In exit gas - ILC 348 0.140764
0.42789948 Excess Air In exit gas - ILC 348 0.141126
42.2933435 CO2 from Raw Feed 348 0.510991
6.10891545 Vapor from free H2O In feed 348 0.0077524
2.76573811 Vapor from comb H2O In feed 348 0.0172786
14.5906078 Dust 348 0.1771561
23 Radiation : Kiln
28 Preheater
23.894304 Cooler loss : Heat in Clinker 124 1
6 Radiation
36.7482989 Hot air for mill 407 0.3664974
66.8687352 Excess Air 238 1.1587266
410 Heat of reaction
665.394721 Sum Of heat inputs
Kcal/kg
kcal/kg C kcal/kg
736.70533
0.2932 2.9984661
0.237736 0.2051346
0.237736 0.1113471
0.237736 0.0351601
0.237736 0.1238703
0.237736 4.953337
0.237736 4.9484988
0.237736 0.1849249
0.237736 0.187033
0.237736 8.8150728
0.237736 2.7881479
1 0.2341912
0.2148312 29.078426
0.2148312 3.4252793
794.79422

kcal/kg C kcal/kg
0.2579 107.26078

0.2318565 0.5020577
0.251656 1.6349262
0.2318565 0.5020577
0.251656 1.6535638
0.245004 12.001742
0.245004 12.032614
0.2318565 41.229882
788 6.1089155
0.4599629 2.7657381
0.2366672 14.590608
23
28
0.192696 23.894304
6
0.246361 36.748299
0.242474 66.868735
410
794.79422