Page-1/5

PLANT : BINANI CEMENT

208.50 km3/hr False Air 5 mass%, w 47.31 km3/hr
Clinker Gypsum 172.64 tph 37.51 tph
Hopper Hopper Sepax Fan 106.0 deg.C 108.4 deg.C
ESP
E.S.P.
355/38 kW/amps Sepax
Cyclones 17.06 tph
Elevator 19.12 %
153.60 tph, dry 6.18 180 rpm 31.5 amps Stack
Separator
0.00 % H2O 3.50

Belt Conveyor
ESP Fan
50 amps

6.74 km3/hr Airslide

108.0 deg.C 62 amps
JPF
45.25 km3/hr
5.76 tph 35.64 tph 159.78 tph
Coarse Return 115.0 deg.C 17.68 %
160.00 tph
83.78 %
160 tph, wet 100.0 deg.C Folaphone 55 %
100.00 %
Cement
Ball Mill
28.35 km3/hr UMS 4.2x13 319.78 tph
31.05 tph 46.91 %
30.0 deg.C 90.0 deg.C Silos

Cement Mill - 1
110.0 deg.C 302.72 tph
48.67 %
0.00 m3/hr 0.00 m3/hr
Water Pump, I/L Water Pump, O/L Cement Silos

03/23/2019 07:47:47 412861265.xls Pic LU001016-CMP#Ver.2.3D***

03/23/2019 07:47:47 412861265.xls Pic LU001016-CMP#Ver.2.3D***
 Page-2/5
Cement Mill Basic Calculations : UMS 4.2 x 13 BM
Site Conditions Equipment Specifications
Plant Elevation mts +MSL 402 Mill Diameter mts 4.20
Barometric Pressure mmWG 9827 Mill Length mts 13.00
Barometric Pressure mmHG 723 Mill System open/closed closed
Ambient Air Temperature deg.C 30.0 Mill Speed rpm 15.80
Radiation Surface m2 198.74 Separator Type Sepax 400M-222
Pitot Constt. S-Type, L=1m S1 0.883 ESP Fields nos. 4
Pitot Constt. S-Type, L=2m S2 0.847 Cement Grade OPC grade 43
Pitot Constant - L Type L 1.000
Feed - Product - Water Mill Operation - CCR
Mill Feed Rate, wet tph 160.00 Mill Main Drive - I kW 3350
Mill Feed Rate, dry tph 159.78 Mill Main Drive - II kW 0
Clinker Feed Rate tph 153.60 Total Main Drive Power kW 3350
Gypsum Feed Rate, wet tph 6.40 Total Installed Power kW 3550
Percent Gypsum % 4.00 Separator Speed ( Max. 1800 ) rpm 180
Percent Water, Gypsum % 3.50 Separator Load amps 144
Gypsum Feed Rate, dry tph 6.18 Folaphone % 55.0
Clinker Temperature deg.C 105.0 Sepax Elevator Load amps 32
Gypsum Temperature deg.C 27.0 Silo Elevator Load amps 62
Mill Output, dry tph 159.78 Sepax Fan Load kW/amps 355/38
Coarse Return, Calc. tph 126.67 ESP Fan Load amps 50
Coarse Return, CCR tph 160.00 Mill Sp. Power Consumption kWh/ton-Cem 33.38
Coarse Return Temp. deg.C 100.0 Cement Fineness (Blaine) m /kg
2
311
Water Injection, Inlet m /hr3
0.000 Dampers / Speed
Water Injection, Outlet m /hr3
0.000 Sepax Fan Damper % 100
Water Injection, Total tph 0.00 Sepax Fan Speed % 98.50
Diaphragm Temperature deg.C 110.0 Mill Inlet % 100
Cement Temperature deg.C 90.0 ESP Fan % 84
Water Temperature deg.C 0.0 Dedusting Fan deg. 108
Mat. Concn. at Sep. Outlet gm/m -wg
3
1374 Water Vapor (ESP I/L) 0.1650

Sepax Dust Load kg-cem/kg-wg 1.66

Heat & Dust Parameters Miscellaneous Parameters
Evaporation Heat kcal/kg 594.6 Gas Velocity a/c Ch.I m/s 0.66
Grinding Heat kcal/kW 860 Gas Velocity a/c Ch.II m/s Err:502
Mill Surf. Radiation Heat kcal/m2/hr 413 False Air a/c ESP w.r.t. Mix, vol.% dry% 5.00
Mill Surf. Convection Heat kcal/m2/hr 323 False Air a/c ESP Fan (Norms) % 0.50
Cyclone Dust (FLS Norms) gm/m -wg
3
30.0 Avg. Surface Temp. of Mill deg.C 97.0
ESP Dust gm/m -wg
3
377.0 Wind Speed m/s 3.0
ESP+Aux. Heat Emissions Mcal/hr 19.76 Junction Draft mmWG 101

PLANT : BINANI CEMENT

Cem. Mill No. 1 << ERRORS >>

Error1 14.7282
Error2 -4.3651
 Page-3/5
Cement Mill Power & Separator Calculations : UMS 4.2 x 13 BM
BALL MILL POWER CALCULATION
Description Comp. I Comp. II Combined
Effective Length, L m 2.570 9.690 12.260
Lining Thickness, t mm 60.0 60.0 -
Effective Diameter, D m 4.080 4.080 -
Charge Density t/m 3
4.6 4.600 -
Charge Amount Comp.I Comp.II
Hichrome Balls 40 mm 20 mm t 10.000 51.000 -
Hichrome Balls 30 mm 17 mm t 15.000 54.000 -
Hichrome Balls 25 mm 15 mm t 15.000 45.000 -
Hichrome Balls 20 mm t 10.000 - -
Total Charge (booked), F t 50.000 150.000 200.00
Total Charge (calc.), F t 59.463 Err:502 Err:502
Specific Surface m /t
2
48.26 75.88 -
Mean Piece Weight gms/ball 41.22 11.77 -
Total Surface m 2
2413 11382 -
Relative Efficiency t/kWhnet 5.30 14.30 Err:502
Torque Factor (B4), u - 0.73 0.73 0.73
Media Bulk Weight, g t/m 3
4.60 4.60 4.60
Arm of Gravity, a m 0.524 Err:502 -
Segment Width, W m 4.010 4.170 -
Free Height, H m 2.416 Err:502 -
Centre Distance, h m 0.376 Err:502 -
Compartment Volume, V m 3
33.60 126.69 160.29
Filling Degree, q % 38.47 Err:502 Err:502
Critical Speed, nc % 20.94 20.94 20.94
Mill Speed, n rpm 15.80 15.80 15.80
Calculated Power, Nnet kWnet 635 Err:502 Err:502
Calculated Power, Ngr kWgr 673 Err:502 Err:502
SEPARATOR PERFORMANCE & EFFICIENCY
Parameters % Residue Used for Blaine
212µm 90µm 45µm Calculation m2/kg
Feed, Ro % 100.00 100.00 100.00 100.00 -
Coarse, Rg % - - 83.78 83.78 95
Mill Discharge, Rd % - - 48.67 48.67 219
Separator Feed, Rm % - - 46.91 46.91 236
ESP Dust, Re % - - 19.12 19.12 265
Fines, Rf % - - 17.68 17.68 311
Circ. Factor, Calc. - - - 1.79 1.79 -
Circ. Factor, CCR - - - 2.00 2.00 -
Sep. Efficiency, Vs % - - 80.72 80.72 -
Fines Efficiency, Vf % - - 86.49 86.49 -
Coarse Effciency, Vc % - - 78.98 78.98 -
Rg > 44 * Rf0.2 yes/no - - yes yes -
Dust from ESP tph - - 17.06 17.06 265
HMB Simulation
 Volume, m3/ball

0.0000335

0.0000141

0.0000082

0.0000042

Balls, nos.

64873

230659

398579

518984

1213095

Arm of Gravi

h/D

a
Volume, m3/ball Weight, gms/ball Surface, m2/ball

0.0000042 154.15 19.27 0.00503 0.00126

0.0000026 65.03 11.83 0.00283 0.00091

0.0000018 37.63 8.13 0.00196 0.00071

19.27 0.00126

Balls, nos. Mean Piece Wt., gms/ball Sp. Surface, m2/t

2646816 10000000 51000000 326.09 3326.09

4563421 15000000 54000000 652.17 4143.22

5535824 15000000 45000000 782.61 3913.04

10000000 652.17

12746061 50000000 150000000 2413.04 11382.35

41.22 11.77 48.26 75.88

Arm of Gravity

Comp-I Comp-I

4.010 Err:502

13.074 13.074

1.068 Err:502

0.524 Err:502

0.092 Err:502

0.526 Err:502

38.32 Err:502
 Page-4/5

Cement Mill Heat & Mass Balance Calculations : UMS 4.2 x 13 BM

S. Constraints Amount Temp. Cp Heat

No. tph kNm3/hr deg.C kcal/kg/deg.C kcal/hr x 103 kcal/kg-Cem

INPUT

1 Clinker, dry 153.60 - 105.0 0.188 3027 18.95

2 Gypsum, dry 6.18 - 27.0 0.211 35 0.22

3 Water, gyp 0.22 - 27.0 1.000 6 0.04

4 Water Spray, Inlet 0.00 - 0.0 1.000 0 0.00

5 Water Spray, Outlet 0.00 - 0.0 1.000 0 0.00

6 Inlet Air, dry 30.59 24.22 30.0 0.242 222 1.39

7 Water, air 0.46 - 30.0 1.000 14 0.09

8 Coarse Return 126.67 - 100.0 0.187 2370 14.83

9 Grinding Heat - - - - 2737 17.13

TOTAL INPUT 8411 52.64

OUTPUT

1 Cement 269.38 - 90.0 0.186 4508 28.21

2 Total Air, dry 30.59 23.65 115.0 0.270 950 5.95

3 ESP Dust 17.06 - 90.0 0.186 285 1.79

4 Water Vapour 0.68 - 115.0 0.449 35 0.22

5 Evaporation 0.22 - - - 133 0.83

6 Surface Heat Losses - - 97.0 - 146 0.92

7 Balance / Losses - - - - 2353 14.73

TOTAL OUTPUT 8411 52.64

PLANT : BINANI CEMENT

03/23/2019 07:47:47 412861265.xls HMB LU000111-CMP#Ver.1.4***

 Heat Cap - Coefficients

Gas/Mat *T^0 *T^1 *T^2 *T^3 *T^4

0.2485 -3.340E-06 4.440E-08 -2.797E-11 5.597E-15 Not used in calc.

0.1244 0.000E+00 0.000E+00 0.000E+00 0.000E+00 Not used in calc.

O2 0.2130 7.796E-05 -7.563E-08 4.074E-11 -8.183E-15

CO2 0.1906 1.771E-04 -1.733E-07 9.315E-11 -1.894E-14

N2+Ar 0.2465 -3.284E-06 4.366E-08 -2.750E-11 5.504E-15

H2O,steam 0.4445 2.910E-05 6.887E-08 -3.726E-11 6.472E-15

H2O, liq. 1.0000

Rawmeal 0.2060 1.014E-04 -3.673E-08

Clinker 0.1742 1.414E-04 -1.283E-07 5.074E-11

Cement 0.1742 1.414E-04 -1.283E-07 5.074E-11

Gypsum 0.2070 1.414E-04 -1.283E-07 5.074E-11

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 Page-5/5
Cement Mill Air Flow Calculations : UMS 4.2 x 13 BM
Flow Analysis Mill Mill ESP False Air Sepax Fan Sepax
Inlet Outlet Outlet ESP Inlet Vent
Dry Bulb Temp. deg.C 30.0 115.0 108.4 30.0 106.0 108.0

Wet Bulb Temp. deg.C 22.0 - 65.0 22.0 39.0 39.0

Dew Point (F4) deg.C 19.5 - 62.7 19.5 25.0 35.0

Dew Point, calc. deg.C 19.6 62.1 62.7 19.6 25.1 35.2

Water Vapor kg/kg-dg 0.015 0.165 0.170 0.015 0.021 0.038

Avg. Ps mmWG -25.00 -110 -190 -110 -524 -93

RMS Pd mmWG - 3.33 7 - 20.00 5.08

Duct Diameter mts 0.80 1.00 1.20 - 2.00 0.50

O2, dry vol % 21.00 21.00 21.00 21.00 21.00 21.00

CO2, dry vol % 0.00 0.00 0.00 0.00 0.00 0.00

N2, dry vol % 79.00 79.00 79.00 79.00 79.00 79.00

Density, dry - O2 kg/m 3

1.221 0.945 0.954 1.210 0.927 0.964

Density, dry - CO2 kg/m 3

1.689 1.308 1.319 1.675 1.282 1.334

Density, dry - N2 kg/m 3

1.074 0.832 0.839 1.065 0.815 0.848

Density - H2O kg/m 3

0.687 0.532 0.537 0.681 0.521 0.543

Mass - O2, dry kg 25.64 19.85 20.03 25.42 19.46 20.25

Mass - CO2, dry kg 0.00 0.00 0.00 0.00 0.00 0.00

Mass - N2, dry kg 84.85 65.69 66.28 84.12 64.38 67.01

Mass - H2O kg 1.66 14.12 14.67 1.64 1.76 3.32

O2, wet mass % 22.86 19.92 19.83 22.86 22.73 22.36

CO2, wet mass % 0.00 0.00 0.00 0.00 0.00 0.00

N2, wet mass % 75.66 65.92 65.64 75.66 75.21 73.98

H2O mass % 1.48 14.17 14.53 1.48 2.06 3.66

Gas Density, dry kg/Nm 3

1.293 1.293 1.293 1.293 1.293 1.293

Gas Density, wet kg/Nm 3

1.282 1.191 1.188 1.282 1.277 1.265

Gas Density, dry kg/m 3

1.105 0.855 0.863 1.095 0.838 0.873

Gas Density, wet kg/m 3

1.095 0.788 0.793 1.086 0.828 0.854

Pitot Tube S1/S2/L - - S1 - S2 S1

Gas Velocity m/s 15.67 16.00 11.62 - 18.44 9.54

Duct C.S. Area m2 0.503 0.785 1.131 - 3.142 0.196

Gas Flow Rate, wet tph 31.05 35.64 37.51 1.88 172.64 5.76

Gas Flow Rate, wet kNm3/hr 24.22 29.93 31.57 1.46 135.18 4.55

Gas Flow Rate, wet km3/hr 28.35 45.25 47.31 1.73 208.50 6.74

Gas Flow Rate, wet m3/min 473 754 788 29 3475 112

Moisture, by diff. tph 0.46 5.05 5.45 0.03 3.55 0.21

Gas Flow Rate, dry tph 30.59 30.59 32.06 1.85 169.09 5.55

Gas Flow Rate, dry kNm3/hr 23.65 23.65 24.79 1.43 130.76 4.29

Gas Flow Rate, dry km3/hr 27.68 35.76 37.15 1.69 201.68 6.35

Gas Flow Rate, dry m3/min 461 596 619 28 3361 106

Sp. Heat, gas kcal/kg/C 0.242 0.270 0.271 0.242 0.245 0.248

Heat Content, gas Mcal/hr 225.62 1107.10 1100.98 13.63 4479.80 154.28

Dust, gas tph - 17.06 0.00 - 6.25 0.20

Sp. Heat, Dust kcal/kg/C - 0.186 0.188 - 0.188 0.188

Heat Content, Dust Mcal/hr - 364.78 0.00 - 124.52 4.11

Heat Content, total Mcal/hr 225.62 1471.88 1100.98 13.63 4604.32 158.38
MILL VELOCITY Heat Cap - Coefficients
Mill I/L Diaph. Gas/Mat *T^0 *T^1 *T^2 *T^3
Diaph. Mill O/L 0.2485 -3.340E-06 4.440E-08 -2.797E-11
70.0 112.5 0.1244 0.000E+00 0.000E+00 0.000E+00
- - O2 0.2130 7.796E-05 -7.563E-08 4.074E-11
- - CO2 0.1906 1.771E-04 -1.733E-07 9.315E-11
N2+Ar 0.2465 -3.284E-06 4.366E-08 -2.750E-11
0.053 0.128 H2O,steam 0.4445 2.910E-05 6.887E-08 -3.726E-11
-25 -110 H2O, liq. 1.0000
- 3.33 Rawmeal 0.2060 1.014E-04 -3.673E-08
0.80 1.00 Clinker 0.1742 1.414E-04 -1.283E-07 5.074E-11
21.00 21.00 Cement 0.1742 1.414E-04 -1.283E-07 5.074E-11
0.00 0.00 Gypsum 0.1742 1.414E-04 -1.283E-07 5.074E-11
79.00 79.00
1.079 0.951
1.492 1.316

0.949 0.837 A 23.5771 Sp. Gravity, dry - O2

0.607 0.535 B -4042.90 Sp. Gravity, dry - CO2

22.65 19.98 C -37.58 Sp. Gravity, dry - N2

0.00 0.00 Rho H2O-Steam, kg/Nm3 0.804 Sp. Gravity - H2O

74.96 66.12
5.13 10.98 23
22.05 20.58
0.00 0.00
72.96 68.11
4.99 11.31
1.293 1.293
1.255 1.210

0.976 0.861
0.947 0.806

10.56 7.95
0.503 0.785

18.1 18.1
14.4 15.0
19.1 22.5

319 375
0.90 2.05
17.2 16.1
13.3 12.4
17.6 18.7

294 311
0.250 0.264
317.14 538.14
- #REF!
- 0.000
- #REF!
317.14 #REF!
Heat Cap - Coefficients
*T^4
5.597E-15 Not used in calc.
0.000E+00 Not used in calc.
-8.183E-15
-1.894E-14
5.504E-15
6.472E-15

kg/Nm3 1.429
kg/Nm3 1.977
kg/Nm3 1.257
kg/Nm3 0.804
 sheet 1 of 2
Process, Efficiency & Performance Monitoring

Section : CEMENT MILL - UMS 4.2 x 13 BM

MILL No. 1 / 2 Time : Date :

Site Conditions & Constants :

Plant Elevation : mts +MSL

Ambient Air Temperature : deg.C
Pitot Constant (S-Type : L=01m) : 0.883 (P.S. No. 601)
Pitot Constant (S-Type : L=02m) : 0.847 (P.S. No. V422)
Pitot Constant (L-Type : L=01/02m) : 1.000 -

Process Parameter Requirement :

Mill Feed Rate-Wet, tph : Coarse Temp., deg.C :

Gypsum, %
Free H2O in Gypsum, %
Clinker Temp., deg.C
Gypsum Temp., deg.C
Wind Speed, m/s
: Cement Temp., deg.C :
: Water Inj. I/L, m3/m :
: Water Inj. O/L, m /m 3
:
: Water Temp., deg.C :
: Mill Surf. Temp. deg.C :

Residue (+45/+90/+212 mm) / Blaine analysis :

Sepax Inlet, S : ESP Dust, D :

Fines, F : ESP Drop-test, tph :
Coarse, G :

Mill Inside Dimensions :

Chmb.I/II Dia., mts : GM Type, Bal/Cpb/Dpb :

Chmb.I/II Length, mts : GM Const. Mat. :
Chmb.I/II Lin. Thick., mm : Chmb.I Ball Dia., mm :
Chmb.I/II Loading, % : Chmb.II Ball Dia., mm :
Chmb.I/II Seg. Width, mts : Chmb.I/II Free Ht., mts :

Other Parameters in CCR :

Folaphone, % : Main Drive Load, kW :

Coarse Return (CCR), tph
Diaphragm Temp., deg.C
Spx. Elev. Load, amps
Silo Elev. Load, amps
Spx. Fan Load, kW/amps
Spx. Fan Spd./Dmp., %/%
: Spx. Sep. Load, amps :
: Spx. Sep. Speed, rpm :
: ESP Fan Load, amps :
: ESP Fan Damper, % :
: Mill Sp. Power, kWh/t :
: Ded. Fan Damper, % :

03/23/2019 07:47:47 412861265.xls Mon-Form

 sheet 2 of 2
Flow Measurement & Gas Analysis :

Flow/Gas Analysis Tapping Location

Mill Mill ESP Spx. JPF Sepax
Inlet Outlet Outlet Inlet Duct
Dry Bulb Temperature deg.C

Wet Bulb Temperature deg.C

Static Pressure "WG

Dynamic Pressure "WG

Time Period hh.mm - hh.mm

Signature
Process Engineer (Monitoring)

03/23/2019 07:47:47 412861265.xls Mon-Form

 Cement Mill Tromp Curve - Sepax Separator 400M-222

Sieve % Residue Cir. Factor Vs Sieve Tromp

mm Rf Rm Rg C
1.0 93.40 95.50 97.00 2.40 10.72 - -
2.0 89.20 92.50 95.10 2.27 12.02 1.5 39.86
4.0 81.80 87.30 91.50 2.31 11.44 3.0 41.61
8.0 71.50 80.90 88.10 2.31 24.44 6.0 32.59
12.0 63.20 76.40 86.60 2.29 37.46 10.0 20.93
16.0 53.70 71.40 85.30 2.27 49.27 14.0 16.70
24.0 38.30 65.80 85.25 2.41 67.76 20.0 0.47
32.0 23.60 55.60 76.90 2.50 65.50 28.0 45.42
48.0 8.50 36.00 52.60 2.66 50.75 40.0 70.21
64.0 5.70 25.90 38.20 2.64 33.91 56.0 88.28
96.0 2.40 14.00 21.00 2.66 12.28 80.0 88.42
128.0 1.20 8.80 12.90 2.85 -4.12 112.0 90.82
12 - - - 2.46 - - -
Wt.% in Coarse, %

Tromp Curve
100.00

90.00

80.00

70.00

60.00

50.00

40.00

30.00

20.00

10.00

0.00
1.0 10.0 100.0 1000.0
Particle , mm

CUT SIZE 30.22 KAPPA 0.55 DELTA 0.47

Separator Efficiencies
Efficiency, %

100.00

90.00

80.00

70.00

60.00

50.00

40.00

30.00

20.00

10.00

0.00
1.0 10.0 100.0 1000.0
Particle Size, mm

Vs Vf Vc Vf*Vc

PLANT : BINANI CEMENT

Cement Mill : 2
 Tromp
39.86
41.61 0 0.00
32.59 0 0.00
20.93 0 0.00
16.70 0 0.00
0.47 0 0.00
45.42 20 0.47
70.21 0 45.42
88.28 0 70.21
88.42 0 88.28
90.82 0 88.42
0 90.82
20 -

45.42 28.00 50
70.21 40.00

CUT SIZE 30.22

KAPPA 0.55

DELTA 0.47
Sieve Ro 100.00
0.00 0.00
1.50 0.00 0.00
3.00 0.00 0.00 Tromp Rg Corr. Vs Vf
6.00 0.00 0.00 Corr. Rm Tromp Rm
10.00 0.00 0.00 95.54 1.5 61.11
14.00 0.47 20.00 92.71 2.83 1.90 11.37 3.0 63.46
20.00 45.42 28.00 87.56 5.14 3.60 11.73 6.0 62.05
28.00 70.21 40.00 81.37 6.20 3.40 17.94 10.0 64.72
40.00 88.28 56.00 77.11 4.26 1.50 30.95 14.0 67.97
56.00 88.42 80.00 72.48 4.63 1.30 43.36 20.0 71.21
80.00 90.82 112.00 66.20 6.28 0.05 58.52 28.0 74.74
112.00 55.28 10.93 8.35 66.63 40.0 68.76
34.71 20.57 24.30 58.13 56.0 53.82
25.01 9.69 14.40 42.33 80.0 48.16
0.47 20.00 25 13.45 11.56 17.20 23.09 112.0 42.71
45.42 28.00 8.15 5.30 8.10 4.08 37.96
X25 24.37

70.21 40.00 75

88.28 56.00

X75 44.24
Corr. Vf Vc Corr. Vc Vf*Vc Corr.
Vf*Vc
59.25 36.21
62.28 57.50 58.38 36.49 36.35
62.75 59.43 58.47 36.88 36.68
63.39 61.67 60.55 39.91 38.39
66.35 63.94 62.80 43.46 41.69
69.59 66.92 65.43 47.65 45.56
72.97 75.89 71.40 56.72 52.18
71.75 83.04 79.46 57.10 56.91
61.29 91.11 87.07 49.03 53.07
50.99 91.67 91.39 44.15 46.59
45.44 93.55 92.61 39.96 42.05
40.34 95.22 94.38 36.15 38.05