Heat Balance-1

CHANDERIA CEMENT WORKS
3/23/2006 Basis Temp 00C

HEAT BALANCE
HEAT MASS
HEAT INPUT Kcal / Kg Clinker
1A) Fresh air (Primary air )
= (Pa ) X 1.293 X Cp X t =0.03372X1.293
=0.0337X1.293X0.238X37 0.38 0.0436
1B) Fresh air (Coal convy)
= ( Ka+PCa ) X 1.293 X Cp X t =0.0252X1.293

=0.0252X1.293X0.238X34.6 0.27 0.0326
1C) Cooling air

= Cla X 1.293X Cp X t =2.0261X1.293
=2.0261X1.293X0.238X37 23.06 2.6198
2) Coal
a) Latent Heat = Coal consp.X t X Cp
=52 X 0.28 X 0.11 1.68 0.1142
b) Combustion Heat = Coal consp.X UHV or (RED) NCV
=0.1142 X 5896 673.52
=0.1142 X 5653 645.76
3) Raw Meal Raw meal =1Kg
= 1 X Clk factore X t X Cp ="1.5504
=1.00 X 1.5504 X58 X 0.212 19.66 1.5504
Total Heat Input (on UHV basis) 718.56 4.361
Total Heat Input (on NCV basis) 690.80
HEAT OUTPUT Kcal / Kg Clinker
1) PH Outlet Gas
= Nm3 / KgClkX tX do X Cp ( do - density in Kg/Nm3) =1.288 X 1.483
=1.2877 X 342 X 1.483 X 0.2441 159.10 1.9100
2) Dust Loss
= dust loss X Clk factor X t X Cp =0.075X1.5504
=0.075 X 1.5504 X 342 X 0.2405 9.57 0.1163
3) Heat loss by Clinker
Clinker = 1 Kg
= 1 X t X Cp =1.00
= 1.00 X 162 X 0.195 31.55 1.00
4) Cooler exit gas
= Nm3 / KgClk X t X do X Cp ( do - density in Kg/Nm3) =1.3402 X 1.293
=1.3402 X 310 X 1.293 X 0.244 131.15 1.7329
5) Surface Losses 50
6) Heat of Reaction
=2.22(Al2O3)+6.48(MgO)+7.646(CaO)-5.116(SiO2)-0.59(Fe2O3)
=2.22X5.61+6.48X1.23+7.646X64.58-5.116X22.4-0.59X4.03 397.23
7) Coal mill (Run)
= Nm3 / KgClk X tX do X Cp ( do - density in Kg/Nm3) =0.04031X"1.293
=0.0403X640X0.252X1.293. 8.40 0.0521
Total Heat Output 786.99

By Difference : =786.99 -(23.06 + 1.68 + 19.66+0.27 + 0.38) 741.94 4.81
Kiln Feed 236.70 152.6702786378
Temp. oC Cp Pra (NM3/KgClk) Pra (NM3/Min)

Input air Cp(K cal/kg /C 37 0.237851 0.03372 0.00
Pra (NM3/Hrs)
Kcca + Pcca 5148.64
(NM3/KgClk) Kcca + Pcca (M3/Min)
34.6 0.2377958 0.02522 77.3
Kcca + Pcca (NM3/Min)

64.18
Cooling airNM3/Kg Clk Cooling airM3/Kg Clk

37 0.237851 2.026 2.43
Coal Cp(K cal/kg /C 52 0.282

Raw meal Cp(K cal/kg /C 58 0.212
Coal consumption 0.1142331

UHV 5896
NCV 5653
45.04
O2 Cp(K cal/kg /C 342 0.006 O2 CO2 N2

CO2 Cp(K cal/kg /C 342 0.074 0.026 0.32 0.654
N2 Cp(K cal/kg /C 342 0.164
PH air Cp(K cal/kg /C 342 0.244
Dust loss Cp(K cal/kg /C 342 0.241
Clinker Cp(K cal/kg /C 162 0.195
Cooler exit gasCp(K cal/kg /C 310 0.244

Cooler flow 1.340
Kiln Feed Rate (TPH)
A50T1 (OC)
Al2O3 5.61 A50P1 (mmwg)
MgO 1.23 A56T3 (OC)
CaO 64.58 K01T1 (OC)
SiO2 22.40 PH O/L O2 (%)
Fe2O3 4.03 PH fan RPM
PH fan KW
Cooler/coal mill Temp 640 Kiln Feed LSF
Cooler/coal mill Density 0.3655225 SM
Cooler/coal mill Cp 0.252 AM
Cooller/Coal mill NM3/Kg Clk 0.0403113 Coal Ash (%)
MASS
236.6
338
675
=
=
3.66
601
1255
=
=
=
=
PH Fan C V Fan
K.F. 236.7 DATE 23/03/06
Pitot factor 0.8438 0.8438
Density of
O2% 2.6 air 1.293
CO2% 32
N2% 65.4
Pd(mmwg) 12.770 Pd mmwg 17.844
Ps(mmwg) -695 Ps mmwg -38
Duct Temp 342 Duct Temp 310
Density(0 temp) 1.483 Density(t temp) 0.5715
Density(t temp) 0.580 Velocity 20.88
Velocity 17.54 Area 6.157
Flow M3/Sec 139.74 Flow M3/Sec 128.58
Flow M3/min 8384.263 Flow M3/min 7714.91
Flow M3/Hrs 503055.8 Flow M3/Hrs 462894.8
FlowNM3/Sec 54.610 FlowNM3/Sec 56.84 204613
Clk prod 152.670 Clk prod 152.670
Flow NM3/Clk 1.288 FlowNM3/Clk 1.340
Kg/Hrs 291594.51 Kg/Hrs 264564.31
Dust colle-gms/Nm3
Primary Air Fan Flow Coal mill HAD
By anenometer 0.861 ChImmeny O BDC inlet
146440 0
Pd(mmwg) - Pd(mmwg) 6.21 12 19.555
Ps(mmwg)fan in let -50.33
Ps(mmwg) -23.00 5.00 -450.0 0.073091
Duct Temp 37 Duct Temp 640.0 58.0 56.0
Density(0 temp) 1.293 Density(0 temp) 1.293 1.293 1.293
Density(t temp) 1.07906 Density(t temp) 0.36552 1.01111 0.97002
NCBM area 0.080457 Velocity 15.720 13.261 17.283
Density(t temp) 1.07351 Area 0.38470 1.01700 0.76976
NCBM velocity 21.30 Flow M3/Sec 6.04733 13.48593 13.30345
NCBM Flow NM3/Sec 1.4302 Flow M3/min 362.840 809.156 798.207
Flow M3/Hrs 21770.38 48549.35 47892.41
FlowNM3/Hrs 6154.342 632.752 598.819
Dust collection 2.52158
Fan No. 1S 1L 1R 2L 2R V4 V5A V5B V6

Pitot factor=1
Duct Temp (OC) 36.0 36.0 36.0 36.0 36.0 36.0 36.0 36.0 36.0
Ps, mmwg -53 -66 -73 -99 -87 -25 -31 -24 -15
Density (Kg/m3) 1.077 1.075 1.074 1.072 1.073 1.080 1.079 1.080 1.081
NCBM Dia (M) 0.810 0.5 0.5 0.560 0.560 1.170 1.085 1.16 1.4
NCBM Area (M2) 0.5155 0.1964 0.1964 0.2464 0.2464 1.0756 0.9250 1.0573 1.5400
Velocity (M/S) 20.78 26.19 29.57 29.58 27.34 15.14 16.24 16.55 12.055
NCBM M3/m 643 309 349 437 404 977 901 1050 1114
NCBM NM3/Kg Clk 0.210 0.101 0.114 0.142 0.132 0.321 0.296 0.345 0.366
2.026 2.4301
Coal = 12.64 4.8 Coal used = 17.44
Coal used % = 11.42331
Flow measurement with TEC Engineer H Suzuki
PH Fan ( Set I) Kiln ESP
5 floor
th
2nd floor Stack
Pitot Constant 0.8438 0.8438 0.8438
Date 2/7/2006 2/7/2006 2/7/2006
Time 9.31AM 9.40 AM 11.35AM
KILN FEED TPH 236.70 236.60 236.60
O2% (By Orsat) 3.4 O2% 7.2
CO2% 33 CO% 0.029
N2% 63.6 NOX% 0.05
Avg Pd (mmwg) 14.8875 17.19
Ps (mmwg) -720 -740
Duct Temp ( C) O
348 289
Density (Kg/Nm ) 3
1.4918 0.0000
Density (Kg/m ) 3
0.5758 0.0000
Velocity (m/s) 19.01 #DIV/0!
Flow (M3/Sec) 151.4 #DIV/0!
Flow (M3/min) 9,083.1 #DIV/0!
Flow (M /Hr)
3
544,987 #DIV/0!
Flow (Nm /Hr)
3
210,346 #DIV/0!
Clk prod (TPH)CCR 152.67 152.61
Nm3/Kg Clk CCR 1.378 #DIV/0!
Clk prod (TPH)Drop test 157.87 157.87 157.87
Nm /Kg Clk Drop test
3
1.332 #DIV/0! 0.000
Klin ESP
CCR DATA PH fan CV Fan
Stack
Date 2/7/2006 2/7/2006 2/7/2006
Time 9.31AM 2.55pm
Kiln Feed (TPH) 237 237
PH Fan RPM 636 636
PH Fan Damper % 100 100
PH Fan K W 1410 1438
C V Fan RPM 334 299
C V Fan Temp 296 288
C V Fan K W 121 98
ESP Fan GRR % 70 70
ESP Fan Damper % 75 80
ESP Fan KW 280 255
Kiln RPM 3.87 3.83
Kiln Torque% 25 29
Kiln KW 219 250
Kiln Coal (TPH)/RPM 6.63/12.8 6.97/14
PC Coal (TPH)/RPM 15.9/23.5 15.7/23.5
PH O/L O2% 2.7 3
PH O/L CO% 0.02 0.03
A50 T1 338 342
A50 P1 744 704
MENT WORKS
gineer H Suzuki
Cooler Vent Fan
Pitot Constant 0.8438

Date 2/7/2006
Time 2.55 PM
KILN FEED TPH 236.60
Density (Kg/Nm3) 1.293
Duct Temp (OC) 274
Ps (mmwg) -22
Avg Pd (mmwg) 12.80
Density (Kg/m3) 0.610
Velocity (m/s) 17.12
Area (m )
2 6.157
Flow (M3/Sec) 105.4
Flow (M3/min) 6324.0
Flow (M3/Hr) 379441
Flow (Nm3/Hr) 179056
Flow (M3/Clk) 2445.78
Nm /Kg Clk CCR
3
1.173
Clk prod (TPH)Drop test 157.87

3
1.134
FlowNM3/Sec #REF!
DUCT DIMENSIONS OF MILLS AND KILN SECTION
S.No. Section Duct Dia.(m.) Area(m2)

1 Raw Mill
a Raw Mill Vent Fan 1.8900 2.8055
b O'Sepa Fan Inlet 2.1300 3.5633
c BDC Fan Inlet 0.9100 0.6504
d Mill Inlet 2.3700 4.4115
e Mill Outlet 1.7800 2.4885
2 Kiln
a PH Outlet 3.1840 7.9623
b Kiln Stack 3.1000 7.5477
c Primary air fan 0.3100 0.0755
d Cooler Vent Fan 2.7840 6.0874
3 Cooler Fans:-
a 1L 0.4500 0.1590
b 1R 0.4500 0.1590
c 1S 0.7500 0.4418
d 2L 0.5000 0.1963
e 2R 0.5000 0.1963
f V4 1.0000 0.7854
g V5A 0.9940 0.7760
h V5B 1.0000 0.7854
I V6 1.2500 1.2272
j HAD(Cooler to Coal Mill) 0.7000 0.3848
4 Coal Mill
a BDC Fan Stack 1.1380 1.0171
b BDC Inlet 0.9900 0.7698
5 VRM
a Mill Outlet 0.9900 0.7698
b BDC Outlet 0.8880 0.6193
c BDC Stack 0.8880 0.6193
6 Cement Mill No.1
a Mill Outlet 0.5500 0.2376
ESP Stack 0.5880 0.2715
c O'Sepa Fan Outlet 1.2800 1.2868
d ESP Inlet 0.5500 0.2376
7 Cement Mill No.2
a Mill Outlet 0.0000
b Sepax Fan Inlet 1.8000 2.5447
c ESP Inlet 0.7400 0.4301
d ESP Stack 0.8900 0.6221
Flow measurement with NCCBM 21.03.06
PH Fan ( Set I) PH Fan (Set II) Kiln ESP
5 floor
th
2nd floor 5 floor
th
2nd floor Stack
Pitot Constant 0.8438 0.8438 0.8438 0.8438 0.8438
Date 2/15/2006 2/15/2006 2/15/2006 2/15/2006 2/15/2006
Time 8.45 AM 9.40 AM 11.40 AM 12.10 PM 10.10 AM
KILN FEED TPH 236.60 236.60 236.60 236.60 236.60
O2% (By Orsat) 4 4 4 4 7.2
CO2% 32 32 32 32 26.2
N2% 64 64 64 64 66.6
Avg Pd (mmwg) 14.52 13.26 15.87 16.18 17.19
Ps (mmwg) -720 -740 -720 -735 -21
Duct Temp ( C) O
340 289 337 295 132
Density (Kg/Nm ) 3
1.4857 1.4857 1.4857 1.4857 1.4500
Density (Kg/m ) 3
0.5809 0.6322 0.5838 0.6259 0.9242
Velocity (m/s) 18.69 17.12 19.49 19.00 16.12
Flow (M3/Sec) 148.8 136.3 155.2 151.4 128.4
Flow (M3/min) 8,930.5 8,180.6 9,313.6 9,082.1 7,703.6
Flow (M /Hr)
3
535,832 490,833 558,815 544,926 462,217
Flow (Nm /Hr)
3
209,511 208,871 219,572 229,567 294,623
Clk prod (TPH)CCR 152.61 152.61 152.61 152.61 152.61
Nm3/Kg Clk CCR 1.373 1.369 1.439 1.504 1.931
Clk prod (TPH)Drop test 157.87 157.87 157.87 157.87 157.87
3
1.327 1.323 1.391 1.454 1.866
Klin ESP
CCR DATA PH fan
Stack
Date 2/15/2006 2/15/2006
Time 9.00 AM 10.10 AM
Kiln Feed (TPH) 237 237
PH Fan RPM 612 612
PH Fan Damper % 100 100
PH Fan K W 1460 1453
C V Fan RPM 297 266
C V Fan Temp 293 263
C V Fan K W 73 73
ESP Fan GRR % 70 70
ESP Fan Damper % 80 80
ESP Fan KW 277 279
Kiln RPM 3.82 3.78
Kiln Torque% 24 24
Kiln KW 201 212
Kiln Coal (TPH) 4.27 4.18
PC Coal (TPH) 14.3 14.9
PH O/L O2% 3.66 3.04
PH O/L CO% 0.08 0.01
A50 T1 337 338
A50 P1 744 744
PH fan RPM measured by strobo scope 642 on 16/2/06
MENT WORKS
BM 21.03.06
Cooler Vent Fan
Pitot Constant 0.8438

Date 2/15/2006
Time 12.15 PM
KILN FEED TPH 236.60
Duct Temp (OC) 290
Ps (mmwg) -22
Avg Pd (mmwg) 12.06
Density (Kg/m3) 0.593
Velocity (m/s) 16.86
Area (m )
2 6.157
Flow (M3/Sec) 103.8
Flow (M3/min) 6227.6
Flow (M3/Hr) 373658
Flow (Nm3/Hr) 171315
Flow (M3/Clk) 2408.50
Nm /Kg Clk CCR
3
1.123
Clk prod (TPH)Drop

157.87
test
Nm3/Kg Clk Drop test 1.085
Primary Air Fan (By Anenometer)

Date 2/15/2006
Time 10.55 AM
Avg Velocity (m/s) 28.98
FLS Area (m2) 0.08046
Ps (mmWg) -36
Temp OC 31
Flow (M3/Hr) 8394
Density (Kg/m ) 3
1.096
Flow (Nm /Hr)3 7,117
Nm /Kg Clk
3
0.0466
3
0.04508
FlowNM3/Sec #REF!
Flow measurement with FLS Engineer Mr Sudhir & Mr R Sharma
PH Fan ( Set I) PH Fan (Set II) Kiln ESP
Stack
Cooler Vent Fan
5 floor
th
2nd floor 5 floor
th
2nd floor
Pitot Constant 0.8438 0.8438 0.8438 0.8438 0.8438 Pitot Constant 0.8438
Date 2/15/2006 2/15/2006 2/15/2006 2/15/2006 2/15/2006 Date 2/15/2006
Time 8.45 AM 9.40 AM 11.40 AM 12.10 PM 10.10 AM Time 12.15 PM
KILN FEED TPH 236.60 236.60 236.60 236.60 236.60 KILN FEED TPH 236.60
O2% (By Orsat) 4 4 4 4 7.2 Density (Kg/Nm3) 1.293
CO2% 32 32 32 32 26.2 Duct Temp (OC) 290
N2% 64 64 64 64 66.6 Ps (mmwg) -22
Avg Pd (mmwg) 14.52 13.26 15.87 16.18 17.19 Avg Pd (mmwg) 12.06
Ps (mmwg) -720 -740 -720 -735 -21 Density (Kg/m3) 0.593
Duct Temp (OC) 340 289 337 295 132 Velocity (m/s) 16.86
Density (Kg/Nm ) 3
1.4857 1.4857 1.4857 1.4857 1.4500 Area (m )
2 6.157
Density (Kg/m ) 3
0.5809 0.6322 0.5838 0.6259 0.9242 Flow (M3/Sec) 103.8
Velocity (m/s) 18.69 17.12 19.49 19.00 16.12 Flow (M3/min) 6227.6
Flow (M3/Sec) 148.8 136.3 155.2 151.4 128.4 Flow (M3/Hr) 373658
Flow (M3/min) 8,930.5 8,180.6 9,313.6 9,082.1 7,703.6 Flow (Nm3/Hr) 171315
Flow (M /Hr)
3
535,832 490,833 558,815 544,926 462,217 Flow (M3/Clk) 2408.50
Flow (Nm /Hr)
3
209,511 208,871 219,572 229,567 294,623 Nm /Kg Clk CCR
3
1.123
Clk prod (TPH)CCR 152.61 152.61 152.61 152.61 152.61
Nm3/Kg Clk CCR 1.373 1.369 1.439 1.504 1.931
Clk prod (TPH)Drop test 157.87 157.87 157.87 157.87 157.87 Clk prod (TPH)Drop test 157.87
Nm3/Kg Clk Drop test 1.327 1.323 1.391 1.454 1.866 Nm3/Kg Clk Drop test 1.085
Klin ESP
CCR DATA PH fan Primary Air Fan (By Anenometer)
Stack
Date 2/15/2006 2/15/2006 Date 2/15/2006
Time 9.00 AM 10.10 AM Time 10.55 AM
Kiln Feed (TPH) 237 237 Avg Velocity (m/s) 28.98
PH Fan RPM 612 612 FLS Area (m2) 0.08046
PH Fan Damper % 100 100 Ps (mmWg) -36
PH Fan K W 1460 1453 Temp OC 31
C V Fan RPM 297 266 Flow (M3/Hr) 8394
C V Fan Temp 293 263 Density (Kg/Nm3) 1.293
C V Fan K W 73 73 Density (Kg/m ) 3
1.096
ESP Fan GRR % 70 70 Flow (Nm /Hr)
3 7,117
ESP Fan Damper % 80 80 Nm /Kg Clk
3
0.0466
ESP Fan KW 277 279 Nm /Kg Clk Drop test
3
0.04508
Kiln RPM 3.82 3.78
Kiln Torque% 24 24 FlowNM3/Sec #REF!
Kiln KW 201 212
Kiln Coal (TPH) 4.27 4.18
PC Coal (TPH) 14.3 14.9
PH O/L O2% 3.66 3.04
PH O/L CO% 0.08 0.01
A50 T1 337 338
A50 P1 744 744
PH fan RPM measured by strobo scope 642 on 16/2/06
Coal mill BDC Fan inlet/ (ChImmeny) outlet duct Flow Annexure-4(c)
Date 11/26/2005 2811.2005 H. Balance 12/5/2005
Cooler Cooler
CCR DATA O/L ChImmeny inlet O/L ChImmeny inlet Cooler O/L
BDC FanRPM 1255 1258 1255
BDC FanDamp 100 100 100
BDC Fan K W 120 115 128
AO1-RPM 310 322 304
AO2-RPM 1048 1089 1230
MILL KWH 519 542 563
MILLAmp 49 50 55
MILL-Pholaphone 68 69 78
Mill-I/t Temp 308 318 322
Mill o/t Temp 63 61 64
Mill-I/t Draft 34 34 38
Mill o/tDraft 110 116 122
Mill Sep Draft 256 264 275
BDC I/T temp 58 55 58
BDC O/T temp 57 54 58
Calculated Data 146440 146440 146440

Pd(mmwg) 10.29 12.5 21.2 10.18 12 19.55 9.75
Ps(mmwg) -26 -1 -455 -19 5 -450 -25
Duct Temp 485 61 58 558 58 56 502
Density(0 temp) 1.293 1.293 1.293 1.293 1.293 1.293 1.293
Density(t temp) 0.440131 1.001418 0.963638 0.401755 1.011113 0.970016 0.4305209
Velocity 18.61169 13.5993 18.05428 19.37592 13.2605 17.28038 18.317849
Area 0.3847 1.13 0.76976 0.3847 1.13 0.76976 0.3847
Flow M3/Sec 7.159918 15.36721 13.89746 7.453917 14.98437 13.30175 7.0468765
Flow M3/min 429.5951 922.0327 833.8477 447.235 899.0621 798.1047 422.81259
Flow M3/Hrs 25775.70 55321.96 50030.86 26834.10 53943.72 47886.28 25368.76
FlowNM3/Sec 2.437203 11.90178 10.35741 2.316048 11.71763 9.979041 2.3463477
FlowNM3/min 146.2322 714.1067 621.4445 138.9629 703.0577 598.7425 140.7809
Dust collection 0.059915 0.056936 0.0576813
VRM BDC Fan
Date 12/23/2005 Annexure-3(d)
BDC Fan Hot air CV

MILL O/L BDC O/L O/L Fan to Mill
BDC FanRPM Dol
BDC FanDamp 42
BDC Fan Amp 272
AO1-RPM 206
AO2-RPM -
MILL KWH 145
Mill-I/t Temp 158
Mill o/t Temp 69
Mill-I/t Draft 60
Mill o/tDraft 522
BDC I/L temp 68
BDC O/Ltemp 66
Pd(mmwg) 25.88438 28.675 8.14878 3.095833
Ps(mmwg) -501 -703 -5 -43
Duct Temp 68 62 71 210
Density(0 temp) 1.293 1.293 1.293 1.293
Density(t temp) 0.930771 0.926843 0.97191 0.689521
Velocity 19.71467 20.79412 10.82494 7.92149
Area 0.7698 0.61932 0.61932 0.430257
Flow M3/Sec 15.17635 12.87822 6.704099 3.408276
Flow M3/min 910.581 772.693 402.2459 204.4966
Flow M3/Hrs 54634.86 46361.58 24134.76 12269.80
FlowNM3/Sec 10.92475 9.231308 5.039272 1.81754
FlowNM3/min 655.4852 553.8785 302.3563 109.0524
Annexure-4(c)
CALCULATED DATA 00C 15/2/06
Fan No. 1S 1L 1R 2L 2R V4 V5A V5B V6
Kiln feed 236.6
Duct Temp (OC) 32.0 32.0 32.0 32.0 32.0 32.0 32.0 32.0 32.0
Ps, mmwg -50 -75 -90 -95 -90 -20 -29 -24 -20
Density (Kg/m3) 1.091 1.088 1.087 1.086 1.087 1.095 1.093 1.094 1.095
Clk Prod,TPH 152.61 152.61 152.61 152.61 152.61 152.61 152.61 152.61 152.61
FLS Dia (M) 0.810 0.5 0.5 0.560 0.560 1.170 1.085 1.16 1.4
FLS Area (M2) 0.5155 0.1964 0.1964 0.2464 0.2464 1.0756 0.9250 1.0573 1.5400
Velocity (M/S) 21.69 30.46 29.91 33.89 30.31 13.55 17.28 14.70 10.700
FLS M3/m 671 359 353 501 448 874 959 933 989
FLS NM3/m 566 302 296 421 377 740 811 789 837
FLS NM3/Kg Clk 0.223 0.119 0.116 0.165 0.148 0.291 0.319 0.310 0.329
T FLS NM3/m 3973.571
T FLS NM /Kg Clk
3 2.021
CCR Reading 236.600 236.600 236.600 236.600 236.600 236.600 236.600 236.600 236.600
Pressure 497 607 561 543 548 419 347 263 139
Flow M3/min 659 300 300 392 397 886 972 933 1199
Damp. 81 62 58 36 46 44 100 59 100
KWH/Amp 88 58 61 71 50 205 A 137A 52 133A
2/15/2006 Basis Temp 00C
HEAT BALANCE
HEAT MASS
HEAT INPUT Kcal / Kg Clinker
1A) Fresh air (PrImary air )
= (Pra ) X 1.293 X Cp X t =0.04664X1.293
=0.0466X1.293X0.238X31 0.44 0.0603
1B) Fresh air (Coal convy).
= ( kcca+pcca ) X 1.293 X Cp X t =0.0331X1.293

=0.0331X1.293X0.238X31 0.32 0.0428
1C) Cooling air

= Cla X 1.293X Cp X t =2.0206X1.293
=2.0206X1.293X0.238X31 19.25 2.6126
2) Coal
a) Latent Heat = Coal consp.X t X Cp
=52 X 0.28 X 0.1406 2.06 0.1406
b) Combustion Heat = Coal consp.X UHV or (RED) NCV
=0.1406 X 5896 829.12
=0.1406 X 5653 794.95
3) Raw Meal Raw meal =1Kg
= 1 X Clk factore X t X Cp ="1.6666
=1.00 X 1.6666 X65 X 0.213 23.03 1.6666
Total Heat Input (on UHV basis) 874.22 4.523
Total Heat Input (on NCV basis) 840.05
HEAT OUTPUT Kcal / Kg Clinker
1) PH Outlet Gas
= Nm3 / KgClkX tX do X Cp ( do - density in Kg/Nm3) =1.373 X 1.486
=1.373 X 340 X 1.486 X 0.2437 169.51 2.0397
2) Dust Loss
= dust loss X Clk factor X t X Cp =0.075X1.5504
=0.075 X 1.5504 X 340 X 0.2403 9.50 0.1163
3) Heat loss by Clinker
Clinker = 1 Kg
= 1 X t X Cp =1.00
= 1.00 X 135 X 0.193 26.09 1.00
4) Cooler exit gas
= Nm3 / KgClk X t X do X Cp ( do - density in Kg/Nm3) =1.11 X 1.293
=1.11 X 290 X 1.293 X 0.244 101.42 1.4352
5) Surface Losses 50
6) Heat of Reaction
'=2.22(Al2O3)+6.48(MgO)+7.646(CaO)-5.116(SiO2)-0.59(Fe2O3)
=2.22X5.67+6.48X1.24+7.646X64.34-5.116X22.39-0.59X3.87 395.74
7) Coal mill (Run)
= Nm3 / KgClk X tX do X Cp ( do - density in Kg/Nm3) =0.06332X"1.293
=0.0633X579X0.25X1.293. 11.87 0.0819
Total Heat Output 764.12

By Difference : =764.12 -(19.25 + 2.06 + 23.03+0.32 + 0.44) 719.02 4.67
pitot = 0.813 Only for PH Fan
Temp. oC Cp Pra (NM3/KgClk) Pra ( NM3/Min)
Input air Cp(K cal/kg /C 31 0.237713 0.04664 118.62
Pra (NM3/Hrs)
7117.05
Kcca + Pcca
Kcca + Pcca (NM3/KgClk) (M3/Min)
31 0.237713 0.03311 83.44
Kcca + Pcca
(NM3/Min)
84.20
Cooling airNM3/Kg Clk Cooling airM3/Kg Clk

31 0.237713 2.021 2.36
Coal Cp(K cal/kg /C 52 0.282

Raw meal Cp(K cal/kg /C 65 0.213
Coal consumption 0.1406238

UHV 5896
NCV 5653
45.10
O2 Cp(K cal/kg /C 340 0.009 O2 CO2

CO2 Cp(K cal/kg /C 340 0.074 0.04 0.32
N2 Cp(K cal/kg /C 340 0.161
PH air Cp(K cal/kg /C 340 0.244
Dust loss Cp(K cal/kg /C 340 0.240
Clinker Cp(K cal/kg /C 135 0.193
Cooler exit gasCp(K cal/kg /C 290 0.244

Cooler vent flow 1.110
Kiln Feed Rate (TPH)
A50T1 (OC)
Al2O3 5.67 A50P1 (mmwg)
MgO 1.24 A56T3 (OC)
CaO 64.34 K01T1 (OC)
SiO2 22.39 PH O/L O2 (%)
Fe2O3 3.87 PH fan RPM
PH fan KW
Cooler/coal mill Temp 579 Kiln Feed LSF
Cooler/coal mill Density 0.3915321 SM
Cooler/coal mill Cp 0.250 AM
Cooller/Coal mill NM3/Kg Clk 0.0633183 Coal Ash (%)
MASS
g airM3/Kg Clk
N2
0.64
eed Rate (TPH) 236.6

338
675
=
=
3.66
601
1255
=
=
=
=
K.F. 236.6 Basis Temp 00 DATE 15/02/06
PHFan Set I PHFan Set II
5thfloor 2thfloor 5thfloor 2thfloor
beforer after beforer after
water water water water
Pitot factor=.8438 spray spray spray spray CVFan 0.8438
O2% 4 4 4 4 Density of 1.293
air
CO2% 32 32 32 32
N2% 64 64 64 64
Pd(mmwg) 14.52 13.26 15.87 16.18 Pd mmwg 12.060
Ps(mmwg) -720 -740 -720 -735 Ps mmwg -20.000
Duct Temp 340 289 337 295 Duct Temp 290.000
Density(0 temp) 1.486 1.486 1.486 1.486 Density(t temp) 0.593
Density(t temp) 0.581 0.632 0.584 0.626 Velocity 16.856
Velocity 18.686 17.117 19.487 19.003 Area 6.087
Flow M3/Sec 148.84 136.34 155.23 151.37 Flow M3/Sec 102.603
Flow M3/min 8930.532 8180.558 9313.591 9082.105 Flow M3/min 6156.194
Flow M3/Hrs 535831.9 490833.5 558815.4 544926.3 Flow M3/Hrs 369371.7
FlowNM3/Sec 58.198 58.020 60.992 63.769 FlowNM3/Sec 47.051
Clk prod 152.606 152.606 152.606 152.606 Clk prod 152.606
FlowNM3/Clk 1.373 1.369 1.439 1.504 FlowNM3/Clk 1.1100

Kg/Hrs 311274 310323 Kg/Hrs 219014.76
Dust colle-gms/Nm3
Primary Air Fan Flow Coal mill BDC Fan inlet/ (ChImmeny) outlet duct Flow
Cooler O/L ChImmeny BDC inlet
146440 0
Pd(mmwg) 17.5 Pd(mmwg) 14.88 12 19.555
Ps(mmwg) -36 Ps(mmwg) -27.00 5.00 -450.0
Duct Temp 31 Duct Temp 579.0 58.0 56.0
Density(0 temp) 1.293 Density(0 temp) 1.293 1.293 1.293
Density(t temp) 1.09631 Density(t temp) 0.39153 1.01111 0.97002
NCBM area 0.080457 Area 0.38470 1.01700 0.76976
NCBM velocity 28.98 Velocity 23.041 13.261 17.283
NCBM Flow NM3/Sec 1.976958 FlowNM3/Hrs 9662.741 48549.35 47892.41
Fan No. 1S 1L 1R 2L 2R V4 V5A V5B
Pitot factor=1
Duct Temp (OC) 32.0 32.0 32.0 32.0 32.0 32.0 32.0 32.0
Ps, mmwg -50 -75 -90 -95 -90 -20 -29 -24
Density (Kg/m3) 1.091 1.088 1.087 1.086 1.087 1.095 1.093 1.094
Clk Prod,TPH 152.61 152.61 152.61 152.61 152.61 152.61 152.61 152.61
NCBM Dia (M) 0.810 0.5 0.5 0.560 0.560 1.170 1.085 1.16
NCBM Area (M2) 0.5155 0.1964 0.1964 0.2464 0.2464 1.0756 0.9250 1.0573
Velocity (M/S) 21.69 30.46 29.91 33.89 30.31 13.55 17.28 14.70
NCBM M3/m 671 359 353 501 448 874 959 933
NCBM NM /Kg Clk 0.223
3
0.119 0.116 0.165 0.148 0.291 0.319 0.310
2.021
Coal used = 21.46
Coal = 15.04 6.42 oal used % = 14.062377
V6 Coal conveying Air
32.0 22
-20 -5
1.095 1.305
152.61
1.4
1.5400
10.700
989 2.393
0.329
CHANDERIA CEMENT WORKS, CHANDERIA Time : 9.00 AM 21/12/05
Radiation & Convection Losses KilnFeed 236.6
Tm = qr = qc =
Temp. Temp. Area TR - Ta To= T1 = (T0+T1)/2 (K.Cal./Hr (K.Cal./Hr K.Cal./Kg.
(R) (OC) (a) (OC) (M2) (OC) (Tr+273) (Ta+273) (OC) M2 ) M2.) qr+qc Clinker Total
350 30 1 320 623 303 463 5688.609 2062.348 7750.9576 50790.72
Kiln 299.33 18 779.43 281.33 572.33 291 431.665 3121635 1424337 4545972 29.78899 29.78899
Cooler 102.5 18 18.83 70.5 375.5 291 340.25 9573.322 8226.332 17799.654 0.116638 29.90563
98 18 18.83 66 371 291 338 8868.307 7684.425 16552.732 0.108467 30.01409
81.5 18 18.83 49.5 354.5 291 329.75 6494.196 5749.892 12244.088 0.080233 30.09433
78 18 21.8 46 351 291 328 6982.64 6196.083 13178.723 0.086358 30.18069
75 18 21.8 43 348 291 326.5 6535.908 5805.826 12341.734 0.080873 30.26156
79.5 18 21.8 47.5 352.5 291 328.75 7210.345 6392.842 13603.187 0.089139 30.3507
72.5 18 28.65 40.5 345.5 291 325.25 8111.829 7207.317 15319.146 0.100384 30.45108
123 18 28.65 91 396 291 350.5 19963.76 16364.16 36327.918 0.238051 30.68913
113 18 28.65 81 386 291 345.5 17223.16 14470.1 31693.262 0.207681 30.89681
125 18 18.83 93 398 291 351.5 13498.06 11006.44 24504.5 0.160574 31.05739
141.5 18 18.83 109.5 414.5 291 359.75 16832.43 13103.15 29935.576 0.196163 31.25355
136 18 18.83 104 409 291 357 15675.64 12399.81 28075.454 0.183974 31.43752
96 18 21.8 64 369 291 337 9913.721 8619.703 18533.424 0.121446 31.55897
80 18 21.8 48 353 291 329 7286.895 6458.662 13745.557 0.090072 31.64904
73.5 18 21.8 41.5 346.5 291 325.75 6316.831 5612.398 11929.229 0.07817 31.72721
74 18 28.65 42 347 291 326 8397.264 7460.492 15857.756 0.103913 31.83113
118.5 18 28.65 86.5 391.5 291 348.25 18704.45 15508.17 34212.622 0.22419 32.05532
122 18 28.65 90 395 291 350 19680.18 16173.45 35853.623 0.234943 32.29026
103 18 11.6 71 376 291 340.5 5946.764 5105.031 11051.795 0.072421 32.36268
Cooler roof + Hood 105 18 78.55 73 378 291 341.5 41615.68 35581.83 77197.51 0.505862 32.86854
90 18 78.55 58 363 291 334 32023.88 28096.73 60120.612 0.39396 33.2625
80 18 78.55 48 353 291 329 26256.22 23271.92 49528.143 0.32455 33.58705
CHANDERIA CEMENT WORKS, CHANDERIA Time : 9.00 AM
Radiation & Convection Losses Tm = qr =PREHEATER
qc = KilnFeed 236.6
Temp. Temp. Area TR - Ta To= T1 = (T0+T1)/2 (K.Cal./Hr (K.Cal./Hr K.Cal./Kg.
(R) (OC) (a) (OC) (M2) (OC) (Tr+273) (Ta+273) (OC) M2 ) M2.) qr+qc Clinker Total
51 cone 36 18 42.21 18 309 291 300 3285.204 2571.198 5856.402 0.038376 33.62543
51 cylinder 52 18 112.00 34 325 291 308 17856.24 15625.95 33482.196 0.219403 33.84483
51 feed pipe 181.16 18 8.83 163.16 454.16 291 372.58 12493.69 8683.396 21177.088 0.13877 33.9836
51 Roof 112.33 18 30.68 94.33 385.33 291 338.165 18254.85 15590.22 33845.069 0.221781 34.20538
61cone 37 18 42.21 19 310 291 300.5 3485.429 2760.02 6245.4489 0.040925 34.24631
61cylinder 55.9 18 112.00 37.9 328.9 291 309.95 20298.9 17977.39 38276.292 0.250818 34.49712
61 feed pipe 166.14 18 8.83 148.14 439.14 291 365.07 10602.33 7747.906 18350.233 0.120246 34.61737
61 Roof 112.33 18 30.68 94.33 385.33 291 338.165 18254.85 15590.22 33845.069 0.221781 34.83915
52 to 51,61 riser duct 30.8 18 272.00 12.8 303.8 291 297.4 14659.62 10584.22 25243.84 0.165419 35.00457
52cone 46.5 18 94.92 28.5 319.5 291 305.25 12337.72 10535.45 22873.171 0.149884 35.15445
52cylinder 93 18 178.41 75 366 291 328.5 76882.85 68199.63 145082.48 0.950701 36.10516
52 roof 112.38 18 52.85 94.38 325.85 291 308.425 8673.622 28727.21 37400.833 0.245081 36.35024
52 feed pipe 109 18 10.81 91 382 291 336.5 6106.76 5254.948 11361.708 0.074451 36.42469
53 to 52 riser 30.8 18 207.00 12.8 303.8 291 297.4 11156.4 8054.9 19211.305 0.125888 36.55058
53cone 37.825 18 81.27 19.825 310.825 291 300.9125 7031.616 5618.269 12649.884 0.082893 36.63347
53cylinder 60.428 18 147.27 42.428 333.428 291 312.214 30566.41 27331.87 57898.28 0.379398 37.01287
53 roof 112.38 18 52.85 94.38 385.38 291 338.19 31470.38 26873.57 58343.946 0.382318 37.39518
53 feed pipe 109 18 13.07 91 382 291 336.5 7382.909 6353.092 13736 0.09001 37.48519
54 to 53 riser 50.6 18 197.00 32.6 323.6 291 307.3 29902.79 26029.62 55932.403 0.366516 37.85171
54cone 68.8 18 110.66 50.8 341.8 291 316.4 28673.03 25859.11 54532.143 0.35734 38.20905
54cylinder 83.27 18 128.10 65.27 356.27 291 323.635 45808.17 41130.12 86938.295 0.569692 38.77874
54 roof 112.38 18 30.00 94.38 385.38 291 338.19 17863.98 15254.63 33118.607 0.217021 38.99576
54 feed pipe 151.75 18 60.78 133.75 424.75 291 357.875 61698.56 47215.72 108914.27 0.713697 39.70946
55 to 54 riser 103 18 180.00 85 376 291 333.5 92277.37 80416.34 172693.71 1.131633 40.84109
55cone 60.14 18 115.33 42.14 333.14 291 312.07 23740.4 21217.75 44958.158 0.294603 41.1357
55cylinder 97.6 18 154.76 79.6 370.6 291 330.8 72381.88 63721.82 136103.7 0.891865 42.02756
55 feed pipe 191.36 18 42.69 173.36 464.36 291 377.68 67152.25 45069.74 112222 0.735372 42.76293
55 roof 112.38 18 33.00 94.38 385.38 291 338.19 19650.38 16780.09 36430.468 0.238723 43.00165
55,56 connecting piec 170 18 3.99 152 443 291 367 5002.311 3609.358 8611.6684 0.056431 43.05809
56cylinder 64.36 18 375.56 46.36 337.36 291 314.18 86863.23 78085.25 164948.48 1.08088 44.13897
56cone 95.86 18 58.90 77.86 368.86 291 329.93 26718.99 23592.71 50311.692 0.329684 44.46865
56 roof 112.38 18 50.90 94.38 385.38 291 338.19 30309.22 25882.02 56191.236 0.368212 44.83686
Inlet Riser 133.8 18 101.64 115.8 406.8 291 348.9 82185.39 66366.73 148552.12 0.973437 45.8103
HAD 101 18 483.45 83 374 291 332.5 239683.4 209692.7 449376 2.944686 48.75498
Radition calculated by formula : e) Tm1 = (Tr-Ta) (OC)
a) qr = 4X10-8 X area X [(TR)4-(TA)4] (K.Cal./Hr.) f) TA = (Ta+273) (OC)
b) qc = 80.33 X area X (Tm)-0.724 X (Tm1)1.33 (K.Cal./Hr.) g) Ta = Atmospheric temperature
c) Tm = [(Tr+Ta)/2 ] + 273 (OC) h) Tr = Radiation temperature
d) TR = (Tr+273) (OC) i) (qr+qc)X1.5504/KF [K. cal./KgCl.]
CHANDERIA CEMENT WORKS, CHANDERIA
Radiation & Convection Losses
Tm =
Temp. Temp. Area TR - Ta To= T1 = (T0+T1)/2
(R) (OC) (a) (OC) (M2) (OC) (Tr+273) (Ta+273) (OC)
MIN Max Avg. 30 1 ### #VALUE! 303 #VALUE!
Kiln 299.33 18 779.43 281.33 572.33 291 431.665
1 208 216 212 32 12.57 180 485 305 395
2 230 243 236.5 32 12.57 204.5 509.5 305 407.25
3 235 261 248 32 12.57 216 521 305 413
4 297 350 323.5 32 12.57 291.5 596.5 305 450.75
5 295 311 303 32 12.57 271 576 305 440.5
6 305 346 325.5 32 12.57 293.5 598.5 305 451.75
7 345 384 364.5 32 12.57 332.5 637.5 305 471.25
8 314 376 345 32 12.57 313 618 305 461.5
9 329 378 353.5 32 12.57 321.5 626.5 305 465.75
10 312 376 344 32 12.57 312 617 305 461
11 298 323 310.5 32 12.57 278.5 583.5 305 444.25
12 276 305 290.5 32 12.57 258.5 563.5 305 434.25
13 276 334 305 32 12.57 273 578 305 441.5
14 277 385 331 32 12.57 299 604 305 454.5
15 229 325 277 32 12.57 245 550 305 427.5
16 188 212 200 32 12.57 168 473 305 389
17 156 162 159 32 12.57 127 432 305 368.5
18 130 139 134.5 32 12.57 102.5 407.5 305 356.25
19 285 344 314.5 32 12.57 282.5 587.5 305 446.25
20 353 391 372 32 12.57 340 645 305 475
21 347 392 369.5 32 12.57 337.5 642.5 305 473.75
22 335 367 351 32 12.57 319 624 305 464.5
23 287 325 306 32 12.57 274 579 305 442
24 288 355 321.5 32 12.57 289.5 594.5 305 449.75
25 305 358 331.5 32 12.57 299.5 604.5 305 454.75
26 335 362 348.5 32 12.57 316.5 621.5 305 463.25
27 336 356 346 32 12.57 314 619 305 462
28 342 388 365 32 12.57 333 638 305 471.5
29 338 359 348.5 32 12.57 316.5 621.5 305 463.25
30 223 316 269.5 32 12.57 237.5 542.5 305 423.75
31 275 289 282 32 12.57 250 555 305 430
32 235 266 250.5 32 12.57 218.5 523.5 305 414.25
33 222 327 274.5 32 12.57 242.5 547.5 305 426.25
34 248 277 262.5 32 12.57 230.5 535.5 305 420.25
35 264 273 268.5 32 12.57 236.5 541.5 305 423.25
36 260 277 268.5 32 12.57 236.5 541.5 305 423.25
37 215 234 224.5 32 12.57 192.5 497.5 305 401.25
38 189 245 217 32 12.57 185 490 305 397.5
39 221 256 238.5 32 12.57 206.5 511.5 305 408.25
40 252 270 261 32 12.57 229 534 305 419.5
41 236 263 249.5 32 12.57 217.5 522.5 305 413.75
42 236 248 242 32 12.57 210 515 305 410
43 160 223 191.5 32 12.57 159.5 464.5 305 384.75
44 204 242 223 32 12.57 191 496 305 400.5
45 127 246 186.5 32 12.57 154.5 459.5 305 382.25
46 123 240 181.5 32 12.57 149.5 454.5 305 379.75
47 228 257 242.5 32 12.57 210.5 515.5 305 410.25
48 192 236 214 32 12.57 182 487 305 396
49 203 228 215.5 32 12.57 183.5 488.5 305 396.75
50 194 238 216 32 12.57 184 489 305 397
51 244 255 249.5 32 12.57 217.5 522.5 305 413.75
52 212 255 233.5 32 12.57 201.5 506.5 305 405.75
53 245 253 249 32 12.57 217 522 305 413.5
54 225 245 235 32 12.57 203 508 305 406.5
55 218 243 230.5 32 12.57 198.5 503.5 305 404.25
56 225 246 235.5 32 12.57 203.5 508.5 305 406.75
57 187 225 206 32 12.57 174 479 305 392
58 226 254 240 32 12.57 208 513 305 409
59 238 250 244 32 12.57 212 517 305 411
60 243 257 250 32 12.57 218 523 305 414
61 236 253 244.5 32 12.57 212.5 517.5 305 411.25
62 222 242 232 32 12.57 200 505 305 405
Cooler 102.5 32 18.83 70.5 375.5 305 340.25

98 32 18.83 66 371 305 338
81.5 32 18.83 49.5 354.5 305 329.75
78 32 21.8 46 351 305 328
75 32 21.8 43 348 305 326.5
79.5 32 21.8 47.5 352.5 305 328.75
72.5 32 28.65 40.5 345.5 305 325.25
123 32 28.65 91 396 305 350.5
113 32 28.65 81 386 305 345.5
125 32 18.83 93 398 305 351.5
141.5 32 18.83 109.5 414.5 305 359.75
136 32 18.83 104 409 305 357
96 32 21.8 64 369 305 337
80 32 21.8 48 353 305 329
73.5 32 21.8 41.5 346.5 305 325.75
74 32 28.65 42 347 305 326
118.5 32 28.65 86.5 391.5 305 348.25
122 32 28.65 90 395 305 350
103 32 11.6 71 376 305 340.5
Cooler roof + Hood 105 32 78.55 73 378 305 341.5
90 32 78.55 58 363 305 334
80 32 78.55 48 353 305 329

Radiation & Convection Losses Tm =
Temp. Temp. Area TR - Ta To= T1 = (T0+T1)/2
(R) (OC) (a) (OC) (M2) (OC) (Tr+273) (Ta+273) (OC)
51 cone 79 32 42.21 47 352 305 328.5
51 cylinder 70 32 112.00 38 343 305 324
51 feed pipe 173 32 8.83 141 446 305 375.5
51 Roof 115 32 30.68 83 388 305 346.5
61cone 69 32 42.21 37 342 305 323.5
61cylinder 74 32 112.00 42 347 305 326
61 feed pipe 219 32 8.83 187 492 305 398.5
61 Roof 112.33 32 30.68 80.33 385.33 305 345.165
52 to 51,61 riser duct 91 32 272.00 59 364 305 334.5
52cone 67.16 32 94.92 35.16 340.16 305 322.58
52cylinder 73.2 32 178.41 41.2 346.2 305 325.6
52 roof 113.16 32 52.85 81.16 325.85 305 315.425
52 feed pipe 119 32 10.81 87 392 305 348.5
53 to 52 riser 89 32 207.00 57 362 305 333.5
53cone 74.87 32 81.27 42.87 347.87 305 326.435
53cylinder 117.875 32 147.27 85.875 390.875 305 347.9375
53 roof 161.25 32 52.85 129.25 434.25 305 369.625
53 feed pipe 152 32 13.07 120 425 305 365
54 to 53 riser 126.85 32 197.00 94.85 399.85 305 352.425
54cone 87 32 110.66 55 360 305 332.5
54cylinder 128 32 128.10 96 401 305 353
54 roof 94 32 30.00 62 367 305 336
54 feed pipe 175 32 60.78 143 448 305 376.5
55 to 54 riser 150.19 32 180.00 118.19 423.19 305 364.095
55cone 148 32 115.33 116 421 305 363
55cylinder 163 32 154.76 131 436 305 370.5
55 feed pipe 236 32 42.69 204 509 305 407
55 roof 199 32 33.00 167 472 305 388.5
55,56 connecting piece 170 32 3.99 138 443 305 374
56cylinder 114 32 375.56 82 387 305 346
56cone 121 32 58.90 89 394 305 349.5
56 roof 182 32 50.90 150 455 305 380
139 133.8 32 101.64 101.8 406.8 305 355.9
HAD 118 32 483.45 86 391 305 348
Radition calculated by formula :
a) qr = 4X10-8 X area X [(TR)4-(TA)4] (K.Cal./Hr.)
b) qc = 80.33 X area X (Tm)-0.724 X (Tm1)1.33 (K.Cal./Hr.)
c) Tm = [(Tr+Ta)/2 ] + 273 (OC)
d) TR = (Tr+273) (OC)
HANDERIA Time : 9.00 AM 21/12/05
KilnFeed 236.6
qr = qc =
(K.Cal./Hr (K.Cal./Hr K.Cal./Kg.
M2 ) M2.) qr+qc Clinker Total
#VALUE! #VALUE! #VALUE! #VALUE!
3121635 1424337 4545972 29.78899 29.78899
23471.94 13508.41 36980.352 0.242326 0.242326
29534.53 15663.08 45197.613 0.296172 0.538498
32699.07 16677.9 49376.975 0.323559 0.862057
59311.35 23344.05 82655.395 0.541627 1.403684
51000.61 21537.42 72538.025 0.475329 1.879014
60169.47 23520.02 83689.495 0.548403 2.427417
78703.37 26938.7 105642.08 0.692255 3.119672
68998.18 25232.64 94230.82 0.617479 3.73715
73117.62 25977.18 99094.802 0.649352 4.386502
68524.58 25144.96 93669.539 0.613801 5.000303
53940.33 22198.93 76139.265 0.498928 5.499231
46349.89 20433.78 66783.669 0.437622 5.936853
51773.4 21713.88 73487.278 0.48155 6.418402
62574.07 24003.67 86577.731 0.567329 6.985732
41663.02 19240.8 60903.818 0.399092 7.384824
20818.8 12458.8 33277.594 0.218062 7.602887
13162.22 8923.434 22085.653 0.144724 7.74761
9514.574 6872.057 16386.631 0.107379 7.854989
55555.25 22551.5 78106.744 0.51182 8.366809
82681.36 27592.92 110274.27 0.722609 9.089418
81339.83 27374.97 108714.81 0.71239 9.801808
71888.47 25758.33 97646.798 0.639863 10.44167
52162.82 21802.09 73964.911 0.48468 10.92635
58461.81 23168.01 81629.829 0.534907 11.46126
62795.95 24047.61 86843.56 0.569071 12.03033
70673.99 25539.37 96213.365 0.63047 12.6608
69474.09 25320.3 94794.389 0.621172 13.28197
78964.24 26982.35 105946.6 0.69425 13.97622
70673.99 25539.37 96213.365 0.63047 14.60669
39204.01 18577.81 57781.821 0.378635 14.98532
43359.23 19682.73 63041.961 0.413103 15.39843
33415.35 16898.69 50314.045 0.329699 15.72813
40832.08 19019.81 59851.888 0.392199 16.12033
36999.12 17959.04 54958.159 0.360132 16.48046
38883.75 18489.41 57373.162 0.375957 16.85642
38883.75 18489.41 57373.162 0.375957 17.23237
26453.15 14606.16 41059.309 0.269055 17.50143
24637.16 13947.05 38584.209 0.252836 17.75426
30069.74 15839.46 45909.199 0.300835 18.0551
36537.75 17826.46 54364.21 0.35624 18.41134
33127.61 16810.37 49937.976 0.327235 18.73857
31021.58 16148.24 47169.824 0.309096 19.04767
19057.7 11718.53 30776.228 0.201671 19.24934
26083.31 14474.24 40557.548 0.265767 19.51511
18065.92 11284.56 29350.481 0.192329 19.70744
17106 10851.82 27957.825 0.183203 19.89064
31159.16 16192.36 47351.52 0.310287 20.20092
23933.73 13683.79 37617.514 0.246501 20.44743
24283.83 13815.39 38099.212 0.249658 20.69708
24401.24 13859.27 38260.51 0.250715 20.9478
33127.61 16810.37 49937.976 0.327235 21.27503
28743.45 15398.62 44142.075 0.289256 21.56429
32984.35 16766.21 49750.563 0.326007 21.8903
29137.24 15530.83 44668.075 0.292702 22.183
27966.3 15134.31 43100.612 0.282431 22.46543
29269.28 15574.91 44844.194 0.293856 22.75929
22120.45 12983.01 35103.457 0.230027 22.98931
30475.29 15971.77 46447.065 0.30436 23.29367
31574.28 16324.75 47899.032 0.313874 23.60755
33271.27 16854.53 50125.803 0.328466 23.93601
31713.46 16368.89 48082.347 0.315076 24.25109
28353.15 15266.45 43619.593 0.285832 24.53692
8456.493 6461.634 14918.126 0.097756 24.63468

7751.478 5946.268 13697.746 0.089759 24.72444
5377.367 4125.447 9502.8139 0.06227 24.78671
5689.657 4348.083 10037.739 0.065776 24.85248
5242.925 3987.46 9230.3841 0.060485 24.91297
5917.362 4530.603 10447.965 0.068464 24.98143
6412.564 4851.708 11264.272 0.073813 25.05524
18264.5 13522.3 31786.794 0.208294 25.26354
15523.9 11699.75 27223.645 0.178392 25.44193
12381.23 9129.898 21511.132 0.140959 25.58289
15715.6 11161.5 26877.101 0.176121 25.75901
14558.82 10478.56 25037.379 0.164066 25.92307
8620.738 6621.679 15242.417 0.099881 26.02296
5993.912 4591.758 10585.67 0.069366 26.09232
5023.848 3809.466 8833.3133 0.057883 26.15021
6697.999 5084.218 11782.217 0.077207 26.22741
17005.19 12697.43 29702.613 0.194636 26.42205
17980.91 13338.36 31319.271 0.20523 26.62728
5258.755 4016.154 9274.9084 0.060777 26.68806
36956.79 28161.67 65118.464 0.42671 27.11477
27364.99 21061.1 48426.093 0.317328 27.43209
21597.33 16545.07 38142.403 0.249941 27.68203
HANDERIA Time : 9.00 AM

qr =PREHEATER
qc = KilnFeed 236.6
(K.Cal./Hr (K.Cal./Hr K.Cal./Kg.
M2 ) M2.) qr+qc Clinker Total
11309.83 8654.22 19964.053 0.130821 27.81286
23240.61 17470.8 40711.41 0.266775 28.07963
10918.8 7107.714 18026.512 0.118125 28.19775
17192.88 12915.73 30108.616 0.197297 28.39505
8487.463 6361.463 14848.926 0.097303 28.49235
26184.15 19875.48 46059.628 0.301821 28.79418
17639.28 9919.579 27558.856 0.180589 28.97476
16435.18 12399.49 28834.674 0.188949 29.16371
96848.75 74529.74 171378.49 1.123014 30.28673
17977.4 13392.61 31370.006 0.205562 30.49229
40759.09 30886.7 71645.789 0.469483 30.96177
5539.027 23113.99 28653.017 0.187758 31.14953
6468.26 4825.339 11293.599 0.074005 31.22354
70536.32 54288.51 124824.83 0.817956 32.04149
19474.33 14807.43 34281.759 0.224643 32.26613
86530.41 64682.91 151213.31 0.990875 33.25701
56879.6 38317.79 95197.392 0.623812 33.88082
12531.47 8661.013 21192.48 0.138871 34.01969
133234.8 97872 231106.81 1.514404 35.5341
36042 27732.87 63774.869 0.417906 35.952
88149.77 64595.99 152745.76 1.000917 36.95292
11384.97 8753.616 20138.588 0.131965 37.08488
76895.08 49756.24 126651.32 0.829925 37.91481
168620.4 117106.5 285726.86 1.87232 39.78713
104999.8 73344.94 178344.7 1.168663 40.95579
170129.8 114039.8 284169.57 1.862115 42.81791
99842.2 53038.91 152881.11 1.001804 43.81971
54092.36 32475.34 86567.696 0.567264 44.38698
4765.659 3130.044 7895.7031 0.051739 44.43871
206965.1 155732.7 362697.87 2.376698 46.81541
36387.4 27044.2 63431.598 0.415657 47.23107
69642.81 44112.52 113755.33 0.74542 47.97649
76157 55094.56 131251.57 0.860069 48.83656
284635 212722 497357 3.259097 52.09566
e) Tm1 = (Tr-Ta) (OC)
f) TA = (Ta+273) (OC)
.33 (K.Cal./Hr.) g) Ta = Atmospheric temperature
h) Tr = Radiation temperature
i) (qr+qc)X1.5504/KF [K. cal./KgCl.]
CHITTOR CEMENT WORKS, CHITTORGARH
KILN SHELL
Temp. (R) Temp. (a) Area(M2) TR - Ta (O To(Tr+273) T1(Ta+273)Tm(OC) qr(K.Cal./H

350 30 1 320 623 303 463 5688.609
1 299.33 18 779.43 134 572.33 291 431.665 3121635
2 260 18 12.24 202.5 533 291 412 36003.07
3 280 18 12.24 264 553 291 422 42276.11
4 247.5 32 24.8 215.5 520.5 305 412.75 64226.18
5 265 32 24.8 233 538 305 421.5 74523.19
6 220 32 24.8 188 493 305 399 50015.81
7 282 32 24.8 250 555 305 430 85535.94
8 255 32 24.8 223 528 305 416.5 68514.33
9 287 32 24.8 255 560 305 432.5 88973.78
10 306 32 24.8 274 579 305 442 102903
11 297 32 24.8 265 570 305 437.5 96131.11
12 289 32 24.8 257 562 305 433.5 90374.95
13 293 32 24.8 261 566 305 435.5 93222.52
14 281 32 24.8 249 554 305 429.5 84859.43
15 270 32 24.8 238 543 305 424 77656.02
16 252 32 24.8 220 525 305 415 66776.97
17 246 32 24.8 214 519 305 412 63390.48
18 249 32 24.8 217 522 305 413.5 65069.13
19 247 32 24.8 215 520 305 412.5 63946.81
20 244 32 24.8 212 517 305 411 62287.44
21 244 32 24.8 212 517 305 411 62287.44
22 253 32 24.8 221 526 305 415.5 67352.79
23 250 32 24.8 218 523 305 414 65635.15
24 243 32 24.8 211 516 305 410.5 61740.7
25 234 32 24.8 202 507 305 406 56961.17
26 239 32 24.8 207 512 305 408.5 59585.3
27 226 32 24.8 194 499 305 402 52921.06
28 222 32 24.8 190 495 305 400 50972.53
29 243 32 24.8 211 516 305 410.5 61740.7
30 254 32 24.8 222 527 305 416 67931.91
31 247 32 24.8 215 520 305 412.5 63946.81
SUM 2150361
A56 Calciner (Cylindrical & Roof + Conical + Riser Duct )

Temp. (R) Temp. (a) Area (m TR - Ta (O To(Tr+273) T1(Ta+273)Tm (O qr (K.Cal.
Cylindrical 64.36 18 456 97.5 337.36 291 314.18 105468.2
124.5 32 133.07 92.5 397.5 305 351.25 86827.24
99 32 133.07 67 372 305 338.5 55870.67
118.5 32 30.93 86.5 391.5 305 348.25 18358.48
Conical 95.86 18 58.9 119.5 368.86 291 329.93 26718.99
130 32 45 98 403 305 354 31901.46
125 32 45 93 398 305 351.5 29588.72
Riser Duc 133.8 18 93.69 68 406.8 291 348.9 75757.07
SUM 364921.3
A55 Calciner (Cylindrical & Roof + Conical + Riser Duct + Feed Pipe )
Cylindrical 97.6 18 170.15 102.5 370.6 291 330.8 79579.85
125.5 32 50.18 93.5 398.5 305 351.75 33248.27
112.5 32 50.18 80.5 385.5 305 345.25 26959.42
126.5 32 60 94.5 399.5 305 352.25 40364.61
Conical 60.1428 18 146.05 95.5 333.1428 291 312.0714 40979.01
135 32 70.61 103 408 305 356.5 53823.5
feed pipe 263.166 18 42.69 90 536.166 291 413.583 44315.26
110 32 70.61 78 383 305 344 36333.12
218 32 45.24 186 491 305 398 89514.39
SUM 403515.9
A54 Calciner (Cylindrical & Roof + Conical + Riser Duct + Feed Pipe)
Cylindrical 83.27 18 141.1499 95.5 356.27 291 323.635 50474.78
103.5 32 50.92 71.5 376.5 305 340.75 23301.09
123.5 32 50.92 91.5 396.5 305 350.75 32715.16
Conical 68.8 18 142.39 58 341.8 291 316.4 36894.57
97 32 60 65 370 305 337.5 24211.1
129 32 45.34 97 402 305 353.5 31669.45
feed pipe 191.36 18 60.78 73 464.36 291 377.68 95608.19
120 32 45.34 88 393 305 349 27568.25
216 32 70 184 489 305 397 135870.6
SUM 0
107 32 50.92 75 380 305 342.5 24844.29
97 32 50.92 65 337.5 20547.16
81 32 50.92 49 329.5 14360.35
86.5 32 43.36 54.5 332.25 13960.86
96.5 32 43.36 64.5 337.25 17321.21
110 32 45.3 78 344 23309.59
96 32 45.3 64 337 17913.74
82 32 45.3 50 330 13098.31
188 32 25 156 383 36511.52
SUM 181867
96.5 32 52.45 64.5 369.5 305 337.25 20952.43
85 32 52.45 53 331.5 16306.41
89.5 32 52.45 57.5 333.75 18072.07
72 32 47.46 40 325 10466.45
76.5 32 47.46 44.5 327.25 11897.34
98 32 68.33 66 338 28128.44
88 32 68.33 56 333 22767.32
88 32 68.33 56 333 22767.32
176 32 10 144 377 12795.73
SUM 164153.5
A51 Calciner (Cylindrical & Roof + Conical + Feed Pipe)
68 32 66.52 36 341 305 323 12951.76
67.5 32 66.52 35.5 322.75 12741.22
63 32 66.52 31 320.5 10887.61
68.5 32 34.14 36.5 323.25 6755.76
63.5 32 34.14 31.5 320.75 5691.67
200 32 5.6 168 389 9273.83
SUM 58301.85
76.5 32 55.51 44.5 349.5 305 327.25 13915.32
68.5 32 55.51 36.5 323.25 10984.54
68 32 55.51 36 323 10808.06
71.5 32 17.85 39.5 324.75 3877.98
68.5 32 17.85 36.5 323.25 3532.23
200 32 5.6 168 389 9273.83
SUM 52391.96
HAD Duct
115.5 32 161.92 83.5 388.5 305 346.75 91497.06
165 32 161.92 133 371.5 182325
132.5 32 161.92 100.5 355.25 119067.3
SUM 392889.3
COOLER CCR SIDE (Ist GRATE)
102.5 32 18.83 70.5 375.5 305 340.25 8456.49
98 32 18.83 66 338 7751.48
81.5 32 18.83 49.5 329.75 5377.37
SUM 21585.34
COOLER CCR SIDE (IInd GRATE)
78 32 21.8 46 351 305 328 5689.66
75 32 21.8 43 326.5 5242.92
79.5 32 21.8 47.5 328.75 5917.36
SUM 16849.94
COOLER CCR SIDE (IIIrd GRATE)
72.5 32 28.65 40.5 345.5 305 325.25 6412.56
123 32 28.65 91 350.5 18264.5
113 32 28.65 81 345.5 15523.9
SUM 40200.96
COOLER COAL MILL SIDE (Ist GRATE)
125 32 18.83 93 398 305 351.5 12381.23
141.5 32 18.83 109.5 359.75 15715.6
136 32 18.83 104 357 14558.82
SUM 42655.65
COOLER COAL MILL SIDE (IIst GRATE)
96 32 21.8 64 369 305 337 8620.74
80 32 21.8 48 329 5993.91
73.5 32 21.8 41.5 325.75 5023.85
SUM 19638.5
COOLER COAL MILL SIDE (IIIst GRATE)
74 32 28.65 42 347 305 326 6698
118.5 32 28.65 86.5 348.25 17005.19
122 32 28.65 90 350 17980.91
SUM 41684.1
COOLER BACK SIDE

103 32 11.6 71 376 305 340.5 5258.75
COOLER ROOF + KILN HOOD

105 32 78.55 73 378 305 341.5 36956.79
90 32 78.55 58 334 27364.99
80 32 78.55 48 329 21597.33
SUM 85919.11

a) qr = 4X10-8 X area X [(TR)4-(TA)4] (K.Cal./Hr.)
b) qc = 80.33 X area X (Tm)-0.724 X (Tm1)1.33 (K.Cal./Hr.)
c) Tm = [(Tr+Ta)/2 ] + 273 (OC)
d) TR = (Tr+273) (OC)
f) TA = (Ta+273) (OC)
g) Ta = Atmospheric temperature
i) (qr+qc)X1.5504/KF [K. cal./KgCl.]
KILN SHELL
Temp. (R) Temp. (a) Area (m TR - Ta (O To(Tr+273) T1(Ta+273)Tm (O qr (K.Cal
167 36 12.4 131 440 309 374.5 14068.71
155 36 12.4 119 368.5 12122.12
158 32 12.4 126 368 12823.34
195 32 12.4 163 386.5 19501.66
206 32 12.4 174 392 21818.8
167 32 12.4 135 372.5 14298.35
155 32 12.4 123 366.5 12351.75
181 32 12.4 149 379.5 16779.76
182 32 12.4 150 380 16966.03
204 32 12.4 172 391 21385.43
208 32 12.4 176 393 22257.63
197 32 12.4 165 387.5 19911.01
198 32 12.4 166 388 20117.65
205 32 12.4 173 391.5 21601.44
300 32 12.4 268 439 49176.56
205 32 12.4 173 391.5 21601.44
153 32 12.4 121 365.5 12042.82
154 32 12.4 122 366 12196.75
197 32 12.4 165 387.5 19911.01
243 32 12.4 211 410.5 30870.35
245 32 12.4 213 411.5 31418.68
232 32 12.4 200 405 27966.51
226 32 12.4 194 402 26460.53
224 32 12.4 192 401 25970.46
145 32 12.4 113 361.5 10849.91
146 32 12.4 114 362 10995.33
107 32 12.4 75 342.5 6050.06
305 32 12.4 273 441.5 51067.4
262.5 32 12.4 230.5 420.25 36494.58
272 32 12.4 240 425 39466.82
258 32 12.4 226 418 35140.78
262.5 32 12.4 230.5 420.25 36494.58
257.5 32 12.4 225.5 417.75 34992.47
257.5 32 12.4 225.5 417.75 34992.47
246 32 12.4 214 412 31695.24
245 32 12.4 213 411.5 31418.68
241 32 12.4 209 409.5 30328.35
241 32 12.4 209 409.5 30328.35
237.5 32 12.4 205.5 407.75 29394.97
238 32 12.4 206 408 29527.14
240 32 12.4 208 409 30059.72
241 32 12.4 209 409.5 30328.35
257 32 12.4 225 417.5 34844.58
254.5 32 12.4 222.5 416.25 34111.35
244 32 12.4 212 411 31143.72
251 32 12.4 219 414.5 33102.21
249.5 32 12.4 217.5 413.75 32675.87
242 32 12.4 210 410 30598.56
237.5 32 12.4 205.5 407.75 29394.97
242 32 12.4 210 410 30598.56
247.5 32 12.4 215.5 412.75 32113.09
239.5 32 12.4 207.5 408.75 29925.99
244 32 12.4 212 411 31143.72
237.5 32 12.4 205.5 407.75 29394.97
248 32 12.4 216 413 32253.18
KILN SHELL
212.5 32 12.4 180.5 485.5 305 395.25 23265.21
249 32 12.4 217 413.5 32534.56
256.5 32 12.4 224.5 417.25 34697.1
249 32 12.4 217 413.5 32534.56
242.5 32 12.4 210.5 410.25 30734.26
240.5 32 12.4 208.5 409.25 30193.84
246.5 32 12.4 214.5 412.25 31834.12
AVG. 26940.94
A56 Calciner (Cylindrical & Conical)
133.5 32 12.4 101.5 406.5 305 355.75 9251.07
139 32 58 107 358.5 46769.75
102.5 32 58 70.5 340.25 26047.61
125.5 32 29.4 93.5 351.75 19479.86
97.5 32 29.4 65.5 337.75 11982.82
AVG. 22706.22
A55 Cyclone (Cylindrical & Conical)
134.5 32 40 102.5 407.5 305 356.25 30273.64
125.5 32 40 93.5 351.75 26503.21
112.5 32 40 80.5 345.25 21490.17
126.5 32 43.6 94.5 352.25 29331.62
127.5 32 43.6 95.5 352.75 29778.08
AVG. 27475.34
123 32 40 91 396 305 350.5 25500.17
107 32 40 75 342.5 19516.34
126 32 40 94 352 26706.09
84 32 43.6 52 331 13236.26
86 32 43.6 54 332 13876.42
AVG. 19767.05
112 32 40 80 385 305 345 21307.2
97.5 32 40 65.5 337.75 16303.15
86.5 32 40 54.5 332.25 12879.03
79 32 43.33 47 328.5 11609.93
99.5 32 43.33 67.5 338.75 18371.31
AVG. 16094.12
94.5 32 40 62.5 367.5 305 336.25 15338.46
99 32 40 67 338.5 16794.37
95 32 40 63 336.5 15497.61
74.5 32 47.46 42.5 326.25 11254.51
78.5 32 47.46 46.5 328.25 12551.29
AVG. 14287.25
68 32 54.33 36 341 305 323 10578.31
72 32 54.33 40 325 11981.5
75.5 32 54.33 43.5 326.75 13250
76.5 32 17.85 44.5 327.25 4474.66
67.5 32 17.85 35.5 322.75 3418.98
AVG. 8740.69
63 32 54.33 31 336 305 320.5 8892.42
76.5 32 54.33 44.5 327.25 13619.52
71 32 54.33 39 324.5 11626.09
68.5 32 17.85 36.5 323.25 3532.23
67.5 32 17.85 35.5 322.75 3418.98
AVG. 8217.85
HAD Duct
122.5 32 161.92 90.5 395.5 305 350.25 102421.8
130 32 161.92 98 354 114788.5
123 32 161.92 91 350.5 103224.7
AVG. 106811.7
102.5 32 18.83 70.5 375.5 305 340.25 8456.49
98 32 18.83 66 338 7751.48
81.5 32 18.83 49.5 329.75 5377.37
AVG. 7195.11
COOLER CCR SIDE (IIst GRATE)
78 32 21.8 46 351 305 328 5689.66
75 32 21.8 43 326.5 5242.92
79.5 32 21.8 47.5 328.75 5917.36
AVG. 5616.65
COOLER CCR SIDE (IIIst GRATE) To(Tr+273) T1(Ta+273)
Temp. (R) Temp. (a) Area (m TR - Ta (O #VALUE! #VALUE! Tm (O qr (K.Cal
72.5 32 28.65 40.5 325.25 6412.56
123 32 28.65 91 350.5 18264.5
113 32 28.65 81 345.5 15523.9
AVG. 13400.32
125 32 18.83 93 398 305 351.5 12381.23
141.5 32 18.83 109.5 359.75 15715.6
136 32 18.83 104 357 14558.82
AVG. 14218.55
96 32 21.8 64 369 305 337 8620.74
80 32 21.8 48 329 5993.91
73.5 32 21.8 41.5 325.75 5023.85
AVG. 6546.17
74 32 28.65 42 347 305 326 6698
118.5 32 28.65 86.5 348.25 17005.19
122 32 28.65 90 350 17980.91
AVG. 13894.7

a) qr = 4X10-10 X area X [(TR)4-(TA)4] (K.Cal.m2/Hr.)
b) qc = 80.33 X area X (Tm)-0.724 X (Tm1-Ta)1.33 (K.Cal.m2/Hr.)
c) Tm = [(Tr+Ta)/2 ] + 273 (OC)
d) TR = (Tr+273) (OC)
f) TA = (Ta+273) (OC)
g) Ta = Atmospheric temperature
KILN NO.1 RADIATION + CONVECTION LOSSES ( Kcal/Hr.M2 )
KILN SHELL
167 36 12.4 131 440 309 374.5 14068.71
155 36 12.4 119 368.5 12122.12
158 36 12.4 122 370 12593.7
195 36 12.4 159 388.5 19272.03
206 36 12.4 170 394 21589.17
167 36 12.4 131 374.5 14068.71
155 36 12.4 119 368.5 12122.12
181 36 12.4 145 381.5 16550.12
182 36 12.4 146 382 16736.39
204 36 12.4 168 393 21155.8
208 36 12.4 172 395 22028
197 36 12.4 161 389.5 19681.37
198 36 12.4 162 390 19888.02
205 36 12.4 169 393.5 21371.81
300 36 12.4 264 441 48946.92
205 36 12.4 169 393.5 21371.81
153 36 12.4 117 367.5 11813.19
154 36 12.4 118 368 11967.11
197 36 12.4 161 389.5 19681.37
243 36 12.4 207 412.5 30640.72
245 36 12.4 209 413.5 31189.05
232 36 12.4 196 407 27736.88
226 36 12.4 190 404 26230.9
224 36 12.4 188 403 25740.83
145 36 12.4 109 363.5 10620.28
146 36 12.4 110 364 10765.7
107 36 12.4 71 344.5 5820.43
99 36 12.4 63 340.5 4976.62
219 36 12.4 183 400.5 24541.27
236 36 12.4 200 409 28771.15
226 36 12.4 190 404 26230.9
234 36 12.4 198 408 28250.95
242 36 12.4 206 412 30368.93
234 36 12.4 198 408 28250.95
231 36 12.4 195 406.5 27482.12
290 36 12.4 254 436 45310.95
285 36 12.4 249 433.5 43564.14
289 36 12.4 253 435.5 44957.84
299 36 12.4 263 440.5 48574.64
304 36 12.4 268 443 50455.65
269 36 12.4 233 425.5 38281.61
114 36 12.4 78 348 6603.81
139 36 12.4 103 360.5 9769.42
189 36 12.4 153 385.5 18075.09
223 36 12.4 187 402.5 25498
226 36 12.4 190 404 26230.9
173 36 12.4 137 377.5 15103.67
195 36 12.4 159 388.5 19272.03
245 36 12.4 209 413.5 31189.05
238 36 12.4 202 410 29297.51
274 36 12.4 238 428 39883.06
287 36 12.4 251 434.5 44257.26
286 36 12.4 250 434 43909.77
Average
KILN NO.2 RADIATION + CONVECTION LOSSES ( Kcal/Hr.M2 )
KILN SHELL
158 36 12.4 122 431 309 370 12593.7
134 36 12.4 98 358 9088.19
131 36 12.4 95 356.5 8691.33
168 36 12.4 132 375 14238.29
191 36 12.4 155 386.5 18468.93
208 36 12.4 172 395 22028
200 36 12.4 164 391 20305.27
241 36 12.4 205 411.5 30098.72
251 36 12.4 215 416.5 32872.58
251 36 12.4 215 416.5 32872.58
262 36 12.4 226 422 36112.83
207 36 12.4 171 394.5 21807.9
237 36 12.4 201 409.5 29033.55
241 36 12.4 205 411.5 30098.72
234 36 12.4 198 408 28250.95
218 36 12.4 182 400 24305.7
180 36 12.4 144 381 16365.08
187 36 12.4 151 384.5 17686.34
202 36 12.4 166 392 20727.85
220 36 12.4 184 401 24778.27
212 36 12.4 176 397 22922.23
198 36 12.4 162 390 19888.02
285 36 12.4 249 433.5 43564.14
294 36 12.4 258 438 46742.32
330 36 12.4 294 456 61055.06
332 36 12.4 296 457 61929.41
257 36 12.4 221 419.5 34614.94
272 36 12.4 236 427 39237.19
270 36 12.4 234 426 38598.38
273 36 12.4 237 427.5 39559.24
266 36 12.4 230 424 37341.77
264 36 12.4 228 423 36723.87
153 36 12.4 117 367.5 11813.19
141 36 12.4 105 361.5 10048.94
132 36 12.4 96 357 8822.64
116 36 12.4 80 349 6835.59
130 36 12.4 94 356 8560.99
149 36 12.4 113 365.5 11208.26
160 36 12.4 124 371 12913.61
156 36 12.4 120 369 12278.22
142 36 12.4 106 362 10190.24
101 36 12.4 65 341.5 5182.54
103 36 12.4 67 342.5 5391.79
119 36 12.4 83 350.5 7190.02
113 36 12.4 77 347.5 6489.26
126 36 12.4 90 354 8049.26
148 36 12.4 112 365 11059.68
156 36 12.4 120 369 12278.22
158 36 12.4 122 370 12593.7
168 36 12.4 132 375 14238.29
205 36 12.4 169 393.5 21371.81
257 36 12.4 221 419.5 34614.94
276 36 12.4 240 429 40536.07
272 36 12.4 236 427 39237.19
275 36 12.4 239 428.5 40208.67
269 36 12.4 233 425.5 38281.61
201 36 12.4 165 391.5 20515.89
112 36 12.4 76 347 6375.6
109 36 12.4 73 345.5 6039.89
123 36 12.4 87 352.5 7675.42
Average

KILN SHELL
175 44 15.7 131 448 317 382.5 18955.59
188 44 15.7 144 461 317 389 22022.16
218 44 15.7 174 491 317 404 30157.82
232 44 15.7 188 505 317 411 34502.14
262 44 15.7 218 535 317 426 45107.17
314 44 15.7 270 587 317 452 68219.49
330 44 15.7 286 603 317 460 76687.26
345 44 15.7 301 618 317 467.5 85262.24
339 44 15.7 295 612 317 464.5 81756.29
344 44 15.7 300 617 317 467 84670.78
340 44 15.7 296 613 317 465 82333.5
335 44 15.7 291 608 317 462.5 79475.56
284 44 15.7 240 557 317 437 54106.22
262 44 15.7 218 535 317 426 45107.17
240 44 15.7 196 513 317 415 37152.41
298 44 15.7 254 571 317 444 60416.55
323 44 15.7 279 596 317 456.5 72898.47
336 44 15.7 292 609 317 463 80041.54
349 44 15.7 305 622 317 469.5 87656.99
355 44 15.7 311 628 317 472.5 91336.76
346 44 15.7 302 619 317 468 85856.59
340 44 15.7 296 613 317 465 82333.5
331 44 15.7 287 604 317 460.5 77239.4
325 44 15.7 281 598 317 457.5 73967.46
320 44 15.7 276 593 317 455 71315.04
310 44 15.7 266 583 317 450 66207.84
322 44 15.7 278 595 317 456 72368
300 44 15.7 256 573 317 445 61356.79
305 44 15.7 261 578 317 447.5 63750.84
299 44 15.7 255 572 317 444.5 60885.44
335 44 15.7 291 608 317 462.5 79475.56
309 44 15.7 265 582 317 449.5 65711.35
286 44 15.7 242 559 317 438 54979.1
305 44 15.7 261 578 317 447.5 63750.84
180 44 15.7 136 453 317 385 20103.97
165 44 15.7 121 438 317 377.5 16771.42
180 44 15.7 136 453 317 385 20103.97
160 44 15.7 116 433 317 375 15733.97
225 44 15.7 181 498 317 407.5 32284.19
190 44 15.7 146 463 317 390 22517.59
178 44 15.7 134 451 317 384 19640.03
185 44 15.7 141 458 317 387.5 21291.02
170 44 15.7 126 443 317 380 17845.02
205 44 15.7 161 478 317 397.5 26443.13
201 44 15.7 157 474 317 395.5 25359.43
206 44 15.7 162 479 317 398 26718.34
190 44 15.7 146 463 317 390 22517.59
173 44 15.7 129 446 317 381.5 18506.87
145 44 15.7 101 418 317 367.5 12830.31
Average
Sum

Temp. (R) Temp. (a) Area (m TR - Ta (OC) Tm (O qr (K.Cal.
115 44 18.83 71 352.5 9464.3
80 44 18.83 36 335 4089.4
125 44 18.83 81 357.5 11293.32
SUM 24847.02
COOLER CCR SIDE (IInd GRATE)
100 44 21.8 56 345 8073.71
90 44 21.8 46 340 6335.11
70 44 21.8 26 330 3264.11
SUM 17672.93
COOLER CCR SIDE (IIIrd GRATE)
76 44 28.65 32 333 5429.11
115 44 28.65 71 352.5 14400.01
120 44 28.65 76 355 15764.9
SUM 35594.02
140 44 18.83 96 365 14307.59
165 44 18.83 121 377.5 20115.02
120 44 18.83 76 355 10361.36
SUM 44783.98
96 44 21.8 52 343 7361.23
80 44 21.8 36 335 4734.41
78 44 21.8 34 334 4430.15
SUM 16525.79
74 44 28.65 30 332 5042.73
118.5 44 28.65 74.5 354.25 15349.92
122 44 28.65 78 356 16325.64
SUM 36718.29
COOLER BACK SIDE

135 44 11.6 91 362.5 8172.07
COOLER ROOF + KILN HOOD

128 44 78.55 84 359 49514.53
120 44 78.55 76 355 43222.78
132 44 78.55 88 361 52804.96
SUM 145542.3
A56 Calciner (Cylindrical & Roof + Conical + Riser Duct )

155 32 133.07 123 366.5 132552.2
160 32 133.07 128 369 141046.1
120 32 133.07 88 349 80911.05
121 32 30.93 89 349.5 19108.02
145 32 30.93 113 361.5 27063.53
130 32 45 98 354 31901.46
110 32 45 78 344 23155.22
175 32 45 143 376.5 56931.2
SUM 512668.8
A55 Calciner (Cylindrical & Roof + Conical + Riser Duct + Feed Pipe )
155 32 50.18 123 366.5 49984.75
130 32 50.18 98 354 35573.67
155 32 50.18 123 366.5 49984.75
140 32 60 108 359 49056.32
130 32 60 98 354 42535.28
130 32 70.61 98 354 50056.93
155 32 70.61 123 366.5 70335.26
210 32 70.61 178 394 129273.1
205 32 45.24 173 391.5 78810.41
SUM 555610.5
120 32 50.92 88 349 30961.08
103.5 32 50.92 71.5 340.75 23301.09
125 32 50.92 93 351.5 33481.28
115 32 60 83 346.5 33623.63
105 32 60 73 341.5 28229.25
129 32 45.34 97 353.5 31669.45
115 32 45.34 83 346.5 25408.26
120 32 45.34 88 349 27568.25
216 32 70 184 397 135870.6
SUM 370112.9
115 32 50.92 83 346.5 28535.25
110 32 50.92 78 344 26201.42
99 32 50.92 67 338.5 21379.23
93 32 43.36 61 335.5 16113.55
110 32 43.36 78 344 22311.34
112 32 45.3 80 345 24130.4
105 32 45.3 73 341.5 21313.08
95 32 45.3 63 336.5 17551.05
160 32 25 128 369 26498.47
SUM 204033.8
115 32 52.45 83 346.5 29392.66
98 32 52.45 66 338 21591.35
95 32 52.45 63 336.5 20321.25
78 32 47.46 46 328 12386.75
76.5 32 47.46 44.5 327.25 11897.34
98 32 68.33 66 338 28128.44
83 32 68.33 51 330.5 20248.54
92 32 68.33 60 335 24859.14
157 32 10 125 367.5 10213.74
SUM 179039.2
68 32 66.52 36 323 12951.76
67.5 32 66.52 35.5 322.75 12741.22
63 32 66.52 31 320.5 10887.61
68.5 32 34.14 36.5 323.25 6755.76
63.5 32 34.14 31.5 320.75 5691.67
350 32 5.6 318 464 31805.87
SUM 80833.89
76.5 32 55.51 44.5 327.25 13915.32
68.5 32 55.51 36.5 323.25 10984.54
68 32 55.51 36 323 10808.06
71.5 32 17.85 39.5 324.75 3877.98
68.5 32 17.85 36.5 323.25 3532.23
328 32 5.6 296 453 27286
SUM 70404.14
HAD Duct
115.5 32 161.92 83.5 346.75 91497.06
180 32 161.92 148 379 216694.8
200 32 161.92 168 389 268146.1
SUM 576338
Date : 21.12.2005
Time : 9.00 AM
KilnFeed 236.6
qc(K.Cal./ qr+qc[K. caK.Cal./Kg. Clinker Temp. (R) (OC) Temp. (a) (OC) Area (m TR - Ta (O
2062.348 7750.958 50790.72
1424337 4545972 29.78899
18927.77 54930.84 0.359953
20678.96 62955.07 0.412534
32289.17 96515.35 0.72
35282.5 109805.7 0.82
27596.56 77612.38 0.58
38190.78 123726.7 0.92
33571.72 102086.1 0.76
39045.77 128019.5 0.95
42291.39 145194.4 1.08
40754.76 136885.9 1.02
39387.68 129762.6 0.97
40071.34 133293.9 0.99
38019.75 122879.2 0.92
36137.98 113794 0.85
33058.63 99835.59 0.74
32032.75 95423.23 0.71
32545.63 97614.75 0.73
32203.69 96150.5 0.72
31690.91 93978.35 0.7
31690.91 93978.35 0.7
33229.65 100582.4 0.75
32716.61 98351.76 0.73
31520.01 93260.71 0.7
29982.92 86944.09 0.65
30836.63 90421.93 0.67
28618.45 81539.51 0.61
27937.03 78909.57 0.59
31520.01 93260.71 0.7
33400.68 101332.6 0.76
32203.69 96150.5 0.72
1036986 3187346 23.76
qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

94810.09 200278.3 1.31239
64091.23 150918.5 0.988943
42826.75 98697.42 0.646748
13707.9 32066.38 0.210126
23592.71 50311.69 0.329684
23276.42 55177.88 0.361571
21818.66 51407.38 0.336864
61175.71 136932.8 0.897297
265663.3 630584.5 2.539371

70058.59 149638.4 0.980556
24160.97 57409.24 0.43
20068.19 47027.61 0.35
29270.71 69635.32 0.52
29652.91 70631.93 0.53
38293.62 92117.11 0.69
32432.56 76747.82 0.57
27149.48 63482.59 0.47
49720.7 139235.1 1.04
277801.2 681317.1 5.08

45320.16 95794.94 0.627728
17785.76 41086.86 0.269235
24197.04 56912.2 0.372936
33273.8 70168.37 0.459802
18585.42 42796.52 0.280438
23157.52 54826.97 0.359272
64168.16 159776.4 1.046988
20528.12 48096.36 0.315167
77170.91 213041.5 1.396025
235959.4 235959.4 1.546203

18642.47 43486.76 0.32
15576.53 36123.69 0.27
10884.28 25244.63 0.19
10612.89 24573.76 0.18
13135.43 30456.64 0.23
17417.81 40727.4 0.3
13589.12 31502.85 0.23
9935.78 23034.09 0.17
22358.24 58869.76 0.44
132152.5 314019.6 2.34

15889.14 36841.57 0.27
12390.25 28696.66 0.21
13741.19 31813.27 0.24
7822.43 18288.88 0.14
8969.15 20866.49 0.16
21308.21 49436.65 0.37
17311.3 40078.61 0.3
17311.3 40078.61 0.3
8132.59 20928.31 0.16
122875.6 287029.1 2.14

9573.04 22524.8 0.17
9401.88 22143.09 0.17
7890.81 18778.42 0.14
5001.32 11757.08 0.09
4134.56 9826.24 0.07
5465.17 14739 0.11
41466.78 99768.63 0.74

10490.47 24405.79 0.18
8131.91 19116.45 0.14
7988.56 18796.63 0.14
2894.87 6772.85 0.05
2614.93 6147.16 0.05
5465.17 14739 0.11
37585.91 89977.87 0.67

67771.85 159268.9 1.19
119743.2 302068.1 2.25
85206.44 204273.7 1.52
272721.5 665610.8 4.96 8.51

6379.66 14836.16 0.11
5872 13623.48 0.1
4077.44 9454.8 0.07
16329.1 37914.43 0.28

4298.43 9988.08 0.07
3942.72 9185.64 0.07
4478.43 10395.79 0.08
12719.58 29569.52 0.22

4798.13 11210.7 0.08
13340.54 31605.04 0.24
11546.52 27070.42 0.2
29685.19 69886.15 0.52

9006.59 21387.83 0.16
11005.36 26720.96 0.2
10333.58 24892.39 0.19
30345.53 73001.18 0.54

6539.58 15160.31 0.11
4538.74 10532.65 0.08
3767.12 8790.97 0.07
14845.44 34483.94 0.26

5027.53 11725.53 0.09
12528.66 29533.85 0.22
13159.51 31140.42 0.23
30715.7 72399.79 0.54 0.54 2.95

3965.12 9223.88 0.07

27801.52 64758.31 0.48
20806.1 48171.1 0.36
16354.04 37951.37 0.28
64961.66 150880.8 1.12
Date : 09.10.1999
Time : 15.00 Hrs.
qc (K.Cal qr/m2 (K.Caqc/m2 (K.CaK.Cal./Kg Clinker

8934.93 1134.57 720.56 42.48
7955.66 977.59 641.59 12.07
8592.48 1034.14 692.94 12.87
11679.19 1572.71 941.87 18.74
12609.3 1759.58 1016.88 20.7
9335.72 1153.09 752.88 14.21
8346.1 996.11 673.07 12.44
10502.38 1353.21 846.97 16.4
10586.14 1368.23 853.72 16.56
12439.88 1724.63 1003.22 20.33
12778.83 1794.97 1030.55 21.06
11847.98 1605.73 955.48 19.09
11932.43 1622.39 962.29 19.27
12524.57 1742.05 1010.05 20.51
20633.57 3965.85 1664 41.96
12524.57 1742.05 1010.05 20.51
8182.26 971.2 659.86 12.16
8264.14 983.61 666.46 12.3
11847.98 1605.73 955.48 19.09
15760.01 2489.54 1270.97 28.03
15930.91 2533.76 1284.75 28.46
14820.81 2255.36 1195.23 25.72
14309.22 2133.91 1153.97 24.51
14138.83 2094.39 1140.23 24.11
7530.49 874.99 607.3 11.05
7611.63 886.72 613.84 11.18
4539.8 487.91 366.11 6.37
21060.37 4118.34 1698.42 43.36
17427.38 2943.11 1405.43 32.41
18240.08 3182.81 1470.97 34.69
17042.45 2833.93 1374.39 31.37
17427.38 2943.11 1405.43 32.41
16999.68 2821.97 1370.94 31.25
16999.68 2821.97 1370.94 31.25
16016.37 2556.07 1291.64 28.68
15930.91 2533.76 1284.75 28.46
15589.14 2445.84 1257.19 27.6
15589.14 2445.84 1257.19 27.6
15290.23 2370.56 1233.08 26.86
15332.92 2381.22 1236.53 26.97
15503.72 2424.17 1250.3 27.39
15589.14 2445.84 1257.19 27.6
16956.92 2810.05 1367.49 31.14
16743.1 2750.92 1350.25 30.57
15845.45 2511.59 1277.86 28.25
16443.81 2669.53 1326.11 29.78
16315.56 2635.15 1315.77 29.45
15674.57 2467.63 1264.08 27.82
15290.23 2370.56 1233.08 26.86
15674.57 2467.63 1264.08 27.82
16144.58 2589.77 1301.98 29.01
15461.02 2413.39 1246.86 27.28
15845.45 2511.59 1277.86 28.25
15290.23 2370.56 1233.08 26.86
16187.33 2601.06 1305.43 29.12

13160.7 1876.23 1061.35 21.9
16272.81 2623.76 1312.32 29.34
16914.15 2798.15 1364.04 31.02
16272.81 2623.76 1312.32 29.34
15717.29 2478.57 1267.52 27.92
15546.43 2434.99 1253.74 27.5
16059.11 2567.27 1295.09 28.79
14097.01 2172.66 1136.86 25.13
6604.96 746.05 532.66 9.53
32956.12 806.37 568.21 10.25
19650.58 449.1 338.8 5.87
14155.69 662.58 481.49 8.53
9080.78 407.58 308.87 5.34
16489.63 614.34 446.01 7.9

21564.03 756.84 539.1 9.66
19259.44 662.58 481.49 8.53
15996.96 537.25 399.92 6.99
21270.05 672.74 487.85 8.65
21547.78 682.98 494.22 8.77
19927.65 662.48 480.51 8.52

18625.53 637.5 465.64 8.22
14644.51 487.91 366.11 6.37
19386.57 667.65 484.66 8.59
10052.94 303.58 230.57 3.98
10547.37 318.27 241.91 4.18
14651.38 482.98 357.78 6.27

15873.27 532.68 396.83 6.93
12354.8 407.58 308.87 5.34
9790.49 321.98 244.76 4.22
8781.83 267.94 202.67 3.51
13899.78 423.99 320.79 5.55
12140.03 390.83 294.79 5.11

11645.41 383.46 291.14 5.03
12712.08 419.86 317.8 5.5
11763.15 387.44 294.08 5.08
8455.75 237.14 178.17 3.1
9488.24 264.46 199.92 3.46
10812.93 338.47 256.22 4.43

7818.75 194.7 143.91 2.52
8954.75 220.53 164.82 2.87
9972.78 243.88 183.56 3.19
3373.35 250.68 188.98 3.28
2522.9 191.54 141.34 2.48
6528.51 220.27 164.52 2.87

6444.79 163.67 118.62 2.1
10267.47 250.68 188.98 3.28
8667.9 213.99 159.54 2.78
2614.93 197.88 146.49 2.57
2522.9 191.54 141.34 2.48
6103.6 203.55 151 2.64

74884.36 632.55 462.48 8.16
82609.61 708.92 510.19 9.09
75396.15 637.5 465.64 8.22
77630.04 659.66 479.43 8.49

6379.66 449.1 338.8 5.87
5872 411.66 311.84 5.39
4077.44 285.57 216.54 3.74
5443.03 382.11 289.06 5

4298.43 260.99 197.18 3.42
3942.72 240.5 180.86 3.14
4478.43 271.44 205.43 3.55
4239.86 257.64 194.49 3.37

4798.13 223.82 167.47 2.92
13340.54 637.5 465.64 8.22
11546.52 541.85 403.02 7.04
9895.06 467.72 345.38 6.06

9006.59 657.53 478.31 8.47
11005.36 834.6 584.46 10.58
10333.58 773.17 548.78 9.85
10115.18 755.1 537.18 9.63

6539.58 395.45 299.98 5.18
4538.74 274.95 208.2 3.6
3767.12 230.45 172.8 3.01
4948.48 300.28 226.99 3.93

5027.53 233.79 175.48 3.05
12528.66 593.55 437.3 7.68
13159.51 627.61 459.32 8.1
10238.57 484.98 357.37 6.28
8934.93 1134.57 720.56 42.48
7955.66 977.59 641.59 37.08
8199.36 1015.62 661.24 38.4
11257.41 1554.2 907.86 56.38
12180.28 1741.06 982.28 62.36
8934.93 1134.57 720.56 42.48
7955.66 977.59 641.59 37.08
10090.6 1334.69 813.76 49.19
10173.61 1349.71 820.45 49.69
12012.15 1706.11 968.72 61.25
12348.55 1776.45 995.85 63.48
11424.85 1587.21 921.36 57.44
11508.63 1603.87 928.12 57.98
12096.2 1723.53 975.5 61.8
20158.54 3947.33 1625.69 127.61
12096.2 1723.53 975.5 61.8
7793.64 952.68 628.52 36.21
7874.6 965.09 635.05 36.64
11424.85 1587.21 921.36 57.44
15309.93 2471.03 1234.67 84.85
15479.81 2515.25 1248.37 86.18
14376.52 2236.85 1159.4 77.77
13868.25 2115.4 1118.41 74.05
13698.99 2075.87 1104.76 72.83
7149.43 856.47 576.57 32.81
7229.6 868.2 583.03 33.23
4202.89 469.39 338.94 18.51
3615.51 401.34 291.57 15.87
13276.24 1979.13 1070.66 69.83
14715.73 2320.25 1186.75 80.3
13868.25 2115.4 1118.41 74.05
14546.09 2278.3 1173.07 79.03
15225 2449.11 1227.82 84.19
14546.09 2278.3 1173.07 79.03
14291.76 2216.3 1152.56 77.14
19308.12 3654.11 1557.11 119.32
18882.72 3513.24 1522.8 115.31
19223.05 3625.63 1550.25 118.52
20073.53 3917.31 1618.83 126.76
20498.52 4069 1653.11 131.02
17521.03 3087.23 1412.99 103.04
4728.05 532.57 381.29 20.93
6670.73 787.86 537.96 30.36
10756.16 1457.67 867.43 53.24
13614.39 2056.29 1097.93 72.22
13868.25 2115.4 1118.41 74.05
9428.66 1218.04 760.38 45.3
11257.41 1554.2 907.86 56.38
15479.81 2515.25 1248.37 86.18
14885.43 2362.7 1200.44 81.59
17946.57 3216.38 1447.3 106.79
19052.89 3569.13 1536.52 116.91
18967.81 3541.11 1529.66 116.11
68.88

8199.36 1015.62 661.24 44.87
6275.07 732.92 506.05 33.15
6039.22 700.91 487.03 31.79
9017.04 1148.25 727.18 50.18
10923.06 1489.43 880.89 63.43
12348.55 1776.45 995.85 74.18
11676.31 1637.52 941.64 69.02
15140.09 2427.32 1220.97 97.62
15989.74 2651.01 1289.49 105.44
15989.74 2651.01 1289.49 105.44
16925.34 2912.33 1364.95 114.45
12264.4 1758.7 989.06 73.53
14800.57 2341.42 1193.59 94.59
15140.09 2427.32 1220.97 97.62
14546.09 2278.3 1173.07 92.35
13191.77 1960.14 1063.85 80.92
10007.64 1319.76 807.07 56.91
10589.46 1426.32 853.99 61.02
11844.16 1671.6 955.17 70.29
13360.74 1998.25 1077.48 82.3
12685.48 1848.57 1023.02 76.84
11508.63 1603.87 928.12 67.75
18882.72 3513.24 1522.8 134.76
19648.36 3769.54 1584.55 143.27
22704.44 4923.8 1831 180.75
22873.79 4994.31 1844.66 183
16499.97 2791.53 1330.64 110.3
17776.35 3164.29 1433.58 123.03
17606.13 3112.77 1419.85 121.29
17861.46 3190.26 1440.44 123.91
17265.72 3011.43 1392.4 117.84
17095.52 2961.6 1378.67 116.14
7793.64 952.68 628.52 42.31
6829.84 810.4 550.79 36.42
6117.7 711.5 493.36 32.24
4879.82 551.26 393.53 25.28
5960.87 690.4 480.72 31.34
7470.73 903.89 602.48 40.31
8362.26 1041.42 674.38 45.91
8036.8 990.18 648.13 43.84
6909.57 821.79 557.22 36.9
3760.97 417.95 303.3 19.3
3907.37 434.82 315.11 20.07
5108.8 579.84 412 26.54
4652.44 523.33 375.2 24.04
5648.9 649.13 455.56 29.56
7390.25 891.91 595.99 39.81
8036.8 990.18 648.13 43.84
8199.36 1015.62 661.24 44.87
9017.04 1148.25 727.18 50.18
12096.2 1723.53 975.5 72.22
16499.97 2791.53 1330.64 110.3
18116.79 3269.04 1461.03 126.57
17776.35 3164.29 1433.58 123.03
18031.68 3242.63 1454.17 125.68
17521.03 3087.23 1412.99 120.42
11760.22 1654.51 948.4 69.65
4577.02 514.16 369.11 23.64
4351.94 487.09 350.96 22.43
5416.48 618.99 436.81 28.25
74.22
Date : 28.04.2000
Time : 9.00 AM
qc (K.Cal qr+qc [K. K.Cal./Kg Clinker

11140.97 30096.56 0.32
12481.77 34503.93 0.36
15620.24 45778.07 0.47
17099.6 51601.74 0.53
20287.66 65394.84 0.66
25832.77 94052.26 0.92
27536.43 104223.7 1.01
29130.57 114392.8 1.1
28493.32 110249.6 1.06
29024.4 113695.2 1.1
28599.57 110933.1 1.07
28068.18 107543.7 1.04
22633.4 76739.62 0.76
20287.66 65394.84 0.66
17947.8 55100.2 0.56
24126.87 84543.42 0.83
26791.43 99689.9 0.97
28174.48 108216 1.05
29555.07 117212.1 1.13
30191.3 121528.1 1.16
29236.72 115093.3 1.11
28599.57 110933.1 1.07
27642.8 104882.2 1.02
27004.35 100971.8 0.98
26471.97 97787.01 0.95
25406.46 91614.3 0.9
26684.95 99052.95 0.97
24340.19 85696.98 0.84
24873.4 88624.24 0.87
24233.53 85118.97 0.84
28068.18 107543.7 1.04
25299.86 91011.21 0.89
22846.76 77825.86 0.77
24873.4 88624.24 0.87
11654.95 31758.93 0.33
10120.32 26891.74 0.28
11654.95 31758.93 0.33
9614.08 25348.05 0.27
16359.03 48643.22 0.5
12689.25 35206.84 0.37
11449.09 31089.12 0.33
12171.11 33462.13 0.35
10629.36 28474.37 0.3
14253.97 40697.1 0.42
13835.34 39194.78 0.41
14358.76 41077.11 0.43
12689.25 35206.84 0.37
10936.03 29442.9 0.31
8114.81 20945.13 0.22
0.72
35.11

6277.09 15741.39 0.12
2639.23 6728.63 0.05
7403.57 18696.89 0.14
16319.9 41166.92 0.31

5383.23 13456.94 0.1
4188.05 10523.15 0.08
2003.76 5267.87 0.04
11575.04 29247.96 0.22

3448.28 8877.39 0.07
9550.65 23950.66 0.18
10402.05 26166.95 0.2
23400.98 58995 0.44

9142.16 23449.75 0.17
12137.93 32252.95 0.24
6836.67 17198.03 0.13
28116.77 72900.74 0.54

4898.53 12259.76 0.09
3055.51 7789.92 0.06
2837.98 7268.13 0.05
10792.02 27317.81 0.2

3171.54 8214.27 0.06
10145.42 25495.33 0.19
10745.79 27071.43 0.2
24062.74 60781.04 0.45

5271.35 13443.42 0.1

32316.7 81831.24 0.61
28519.42 71742.2 0.53
34241.34 87046.3 0.65
95077.46 240619.7 1.79

89565.79 222118 1.66
93976.68 235022.8 1.75
59444.85 140355.9 1.05
14011.69 33119.71 0.25
18783.72 45847.25 0.34
22958.45 54859.91 0.41
17302.46 40457.68 0.3
36293.88 93225.08 0.69
352337.5 865006.3 6.45

33774.79 83759.54 0.62
25601.22 61174.9 0.46
33774.79 83759.54 0.62
34482.14 83538.46 0.62
30611.27 73146.55 0.55
36024.36 86081.3 0.64
47525.67 117860.9 0.88
73733.24 203006.3 1.51
45694.49 124504.9 0.93
361222 916832.5 6.83

22746.92 53707.99 0.4
17559.4 40860.49 0.3
24355.58 57836.86 0.43
24926.3 58549.92 0.44
21236.04 49465.29 0.37
22841.88 54511.32 0.41
18835.97 44244.23 0.33
20254.22 47822.47 0.36
75972.98 211843.6 1.58
248729.3 618842.1 4.61

21154.12 49689.37 0.37
19578.69 45780.11 0.34
16182.48 37561.72 0.28
12242.06 28355.6 0.21
16671.88 38983.22 0.29
17976.48 42106.88 0.31
16033.21 37346.29 0.28
13321.76 30872.81 0.23
17655.5 44153.97 0.33
150816.2 354850 2.64

21789.74 51182.39 0.38
16356.15 37947.49 0.28
15424.43 35745.67 0.27
9357.95 21744.7 0.16
8969.15 20866.49 0.16
21308.21 49436.65 0.37
15370.12 35618.66 0.27
18892.87 43752.01 0.33
6863.12 17076.87 0.13
134331.7 313370.9 2.34
9573.04 22524.8 0.17
9401.88 22143.09 0.17
7890.81 18778.42 0.14
5001.32 11757.08 0.09
4134.56 9826.24 0.07
11239.19 43045.05 0.32
47240.79 128074.7 0.95

10490.47 24405.79 0.18
8131.91 19116.45 0.14
7988.56 18796.63 0.14
2894.87 6772.85 0.05
2614.93 6147.16 0.05
10396.06 37682.06 0.28
42516.8 112920.9 0.84

67771.85 159268.9 1.19
136047.8 352742.7 2.63
158021.5 426167.6 3.18
361841.1 938179.1 6.99
Tm (O qr (K.Cal qc (K.Cal qr/m2 (K.Caqc/m2 (K.Ca
K.Cal./Kg Clinker
21/12/05 velocity
cooler out PH stack

Damper 1S 1R 1L 2R 2L V4 V5a V5b V6 PR FAN let (ESP)
I\L
Draft -101 120 -115 -155 -111
Damper
O\L
Draft -210 -206 -330 -214
CO2 27.4
O2 6.2
PS -59 -101 -120 -115 -155 -30 -38 -38 -22 -75 -18 -22
Temp 25 21 19 25 19 25 19 26 25 18 570 130
AVERAG
E 22.17 29.5606 28.2713 29.39 30.37065 14.75667 16.428 16.963 11.9577 24.371 5.124 15.461
23/12/05 23/12/05 23/12/05 19/12/05 19/12/05
PH fan PH fan
down PC Coal Kiln Coal down RM O
PH fan commer . air of air of PH fan . PH fan . commer . Raw Mill Raw Mill RM Vent sepa FAN RM BDC cm1 mill
0.844 844 CV fan blower blower 844 813 813 O/L Hot air FAN O/L I/L O/L 80tph
Area=.81* Area=.81*
-706 53 .715 .715 .
-755 61
33 33.3 31.6
3.8 2.4 3.4 6
-665 -687 -38 -651 -651 -682 -291 -11 -342 -1 17 -110
324 288 297 330 330 286 77 283 76 72 67 120
12.375 13.986 16.35556 1.2783 1.123 10.9158 13.2793 14.391 22.30303 22.30303 4.963 45.36957 35.2619 12.175
18/12/05 12/18/2005 PD Average
cm mill 2 cm mill 2
cm mill 2 mill ESP Sepax fan
mill O/L O/L I/L
cm1 mill 1 cm1 mill cm1 mill 1 cm1 mill 1 cm1 mill 1 152TPH 152TPH 152TPH HOT air
ESP fan 1O sepa ESP I/L ESP I/L ESP I/L (f a (f a (f a VRM BDC VRM BDC CVFan to
O/L fan O/L 1st 2nd 3rd 23%) 23%) 23%) VRM O/L O/L FAN O/L VRM
-19 -97 -125 -125 -125 -120 0 -478 -501 -703 -5 -43
106 117 118 118 118 123 110 107 68 62 71 210
29.90286 36.04048 42.16667 43.20833 42.3913 7.04359 5.019672 29.76545 25.88438 28.675 8.14878 3.095833
21/12/05 velocity
1S 1R 1L 2R 2L V4 V5a V5b V6
Damper
I \ L Draft -101 120 -115 -155
Damper
O \ L Draft -210 -206 -330
CO2
O2
PS -59 -101 -120 -115 -155 -30 -38 -38 -22
Temp 25 21 19 25 19 25 19 26 25
34.77 28.02 34.73 21.86 29.81 15.39 17.75 16.17 9.36
30.02 31.55 34.34 22.68 31.8 15.45 16.05 17.1 11.16
21.54 30.68 36.45 25.91 29.05 16.43 17.22 17.1 11.88
21.47 29.52 26.41 30.52 30.47 15.79 15.65 17.31 11.48
22.47 28.91 25.6 27.21 31.82 15.37 16.4 17.02 8.61
11.19 29.57 25.01 29.22 32.75 12.1 17.38 16.07 12.04
23.87 28.16 28.54 20.93 31.97 12.93 17.81 16.37 10.24
20.21 28.42 26.86 29.33 32.6 14.16 18.17 17.7 8.4
19.61 29.64 21.37 28.49 30.17 13.6 16.38 17.29 11.37
18.18 31.11 22.51 30.32 22.08 15.8 15.84 19.54 12.31
20.84 28.99 26.59 31.52 28.37 15.7 15.28 16.94 11.54
22.33 30.16 27.31 34.76 28.76 14.48 16.02 17.38 10.56
16.35 29.56083 32.85 25.78 27.31 13.96 15.08 15.38 13.36
19.45 28.71 32.76 34.61 15.28 16 16.2 13.34
21.49 17.83 36.89 32 15.18 16.18 16.77 10.02
11.49 16.2 32.17 29.43 15.79 18.68 17.06 10.78
21.03 30.61 32.04 27.8 14.11 11.91 16.963 11.47
20.14 34.99 29.61 30.11 14.1 14.03 12.79
15.28 33.77 37.08 36.88 14.75667 19.13 10.98
24.19 30.82 29.46 32.36 19.29 11.48
22.43 38 32.18 31.83 15.37 12.27
24.56 23.29 26.77 31.01 16.62 12.35
23.73 27.45 28.48 36.17 16.97 9.44
19.12 28.2713 29.3900 37.6 15.55 10.27
34.8 40.85 15.94 13.05
28.88 44.12 16.428 10.54
32.66 26.28 11.19577
22.88 21.33
21.39 24.99
18.81 29.74
22.172667 7.42
30.37065
30.04773
31.13567
22.172667
23/12/05 23/12/05 23/12/05 19/12/05
PH fan PH fan
PH down PC Coal Kiln Coal down
cooler stack PH fan commer air of air of PH fan . PH fan . commer Raw Mill
PR FAN out let (ESP) 0.844 .844 CV fan blower blower 844 813 .813 O/L
Area= Area=
-111 -706 53 0.81*.715 0.81*.715
-214 -755 61
27.4 33 33.3 31.6
6.2 3.8 2.4 3.4
-75 -18 -22 -665 -687 -38 -651 -651 -682 -291
velocity
32 570 130 324 288 297 330 330 286 77
23.32 5.9 16.6 12.1 11.9 13.9 0.93 1.5 11.4 12.1 12.4 22
24.83 6.1 16.7 11.4 12.2 14.1 1.32 0.96 11.7 11.8 13.1 24
22.84 6.3 16.4 11.7 12.5 14.3 1.33 0.96 11.5 11.9 13.5 25
25.67 6.2 16.6 11.9 12.9 14.7 1.13 1.14 11.5 12.3 12.8 26
22.59 6.4 16.5 12.4 13.2 14.5 1.33 0.93 11.6 12 12.6 27
24.38 6.3 16.3 12.2 13.5 14.3 1.03 0.91 11.9 12.4 12.7 26
23.63 6.2 16.2 12.2 13.7 13.8 1.37 1.26 11.5 12.7 13.1 23
23.02 6.4 15.9 12.1 13.9 13.9 1.37 1.27 11.3 12.8 13.6 25
23.65 6.3 15.6 12.5 13.5 14.5 1.23 0.96 11 12.5 13.8 24
29.78 6.2 15.2 12.4 13.6 14.8 1.56 1.07 10.5 12.1 13.6 23
24.371 6.1 14.9 12.7 14 15.5 1.09 1.27 10.3 12.2 14 25
5.9 15.1 12.9 13.5 16 1.22 0.97 10.7 12.5 13.5 26
5.7 15.2 12.6 13.3 15.6 1.19 0.89 10.9 12.9 13.9 25
5.2 14.8 12.8 13.9 15.7 1.14 1.01 11.1 12.4 14.2 20
4.8 15.1 13.1 13.7 15.3 1.28 1.41 11 12.7 14.3 18
4.7 15.3 12.8 13.7 15.5 1.29 1.19 11 12.5 14.5 16
4.6 15.4 12.7 14.1 15.2 1.64 1.45 11.7 12.8 14.7 14
4.6 15.5 12.7 14.4 15.5 1.56 1.13 11.4 12.6 15 13
4.5 15.1 12.6 14.6 15.6 1.278333 0.96 11.7 12.6 15.5 15
4.7 14.9 12.7 14.7 16 1.21 11.9 13 15.6 16
4.6 14.8 12.9 14.9 15.8 1.1225 11.8 12.8 15.1 18
4.5 14.3 13 14.8 16.3 11.7 12.7 15 19
4.4 14.5 13.5 15 16.2 11.8 12.5 14.6 20
4.3 14.4 13.5 15.1 15.9 11.5 12.3 14.9 22
4.2 14.6 13.1 14.7 16.2 11.1 13.2 14.7 24
4 14.8 12.8 15.2 16.4 10.8 13 14.5 25
3.8 15.1 12.1 15.5 16.4 10.6 13.6 14.1 27
3.2 15.4 11.9 15 16.7 10.6 13.1 14.4 28
3 15.3 11.7 15.2 17.4 9.6 13.5 14.1 26
3.4 15.7 11.5 14.8 17.9 9.7 13.7 14.3 25
3.6 15.8 12 14.7 18.4 9.8 13.4 14.6 23
4.4 15.7 12.4 14.6 17.9 9.9 13.1 14.4 24
4.3 15.8 12.6 14.9 17.8 9.9 13.6 14.7 22
4.5 15.6 12.5 14.5 17.8 10.1 14.1 14.6 22.30303
4.3 15.2 12.4 14.4 17.6 10.5 14.5 14.1
4.6 15.4 12.1 14.1 18.6 10.3 15 13.7
5 15.3 12 13.8 18.7 9.8 15.3 13.5
5.4 15.6 11.8 14 19.1 9.7 15.2 13.4
5.7 15.9 11.7 13.6 18.8 10.9158 16 13.5
5.9 15.8 11 13.1 18.4 15.2 13.7
6.1 15.6 12.375 13.2 17.9 14.9 13.4
6.3 15.461 12.9 17.8 14.7 13.8
6 12.6 18 15 14.1
6.1 14.6 17.8 15.2 14.7
5.9 13.986 17.6 15 15.1
5.1244 17.4 14.8 15.4
17.2 14.9 15.9
16.7 14.6 15.8
16.8 14.3 15.8
16.4 13.6 15.5
16.6 13.5 15.6
15.9 12.7 15.6
15.2 12.4 15.4
14.9 12.6 15.3
16.35556 11.8 15
11.9 15
11.7 15.1
12 15.2
13.2793 15
14.9
14.6
14.2
14
14.3921
19/12/05 19/12/05 19/12/05 19/12/05 19/12/05 19/12/05 19/12/05 19/12/05
cm mill 2
mill O/L
RM O cm1 mill 1 cm1 mill cm1 mill 1 cm1 mill 1 cm1 mill 1 152TPH
Raw Mill RM Vent sepa FAN RM BDC cm1 mill ESP fan 1O sepa ESP I/L ESP I/L ESP I/L (f a
Hot air FAN O/L I/L O/L 80tph O/L fan O/L 1st 2nd 3rd 23%)
6
-11 -342 -1 17 -110 -19 -97 -125 -125 -125 -120
283 76 72 67 120 106 117 118 118 118 123

3.7 52 36 11.1 30.6 34.5 38 45 46 7.2
3.9 51 36.8 10.8 30 34.3 38 47 45 7.3
3.8 50 35.7 11.3 30.9 34.1 42 48 46 7.1
4 49 34.3 11.4 31 34.3 45 48 44 7.2
4.1 48 35 11.3 30.5 35.4 48 48 46 7.1
4.3 47 34.5 11.5 31.2 35.9 48 47 45 6.9
4.3 49 35.3 11.7 30.4 36.1 47 46 42 7.2
4.5 48 35.9 11.9 30.6 35.9 45 44 41 7.3
4.6 49 36.3 12.4 29.8 36.4 43 41 40 7.6
4.5 47 35.7 13.1 30.4 34.7 41 39 39 7.5
4.6 48 34.9 13.5 29.8 33.7 38 38 38 7.8
4.3 47 34.5 13.8 29.9 32.7 37 35 37 7.6
4.8 46 34.2 14.1 29.8 32.5 39 37 39 7.7
4.9 45 32.7 13.9 29.9 33.7 40 38 41 7.6
5.1 46 33.3 13.8 29.7 34 42 40 41 7.5
5.2 44 34.8 13.6 30 33.6 44 42 42 7.7
5.3 46 35.8 13.2 30.3 35.6 45 43 42 7.8
5.2 45 36.5 12.8 30.1 36.7 46 44 43 6.7
5.4 44 37.1 12.6 29.8 37.4 47 45 44 5.8
5.5 43 37.3 12.1 28.7 39.4 45 46 45 5.3
5.6 42 33.9 11.5 28.9 40.1 43 47 44 4.6
5.7 41 35.261905 11.3 27.6 41.5 41 46 43 4.5
5.6 40 11.1 29.8 42.8 38 42 42 6
5.8 41 11.2 29.7 43.4 32 41 6.4
5.9 40 11.4 30 44.6 42.16667 43.20833 42.3913 6.5
5.8 41 11.3 30.2 42 6.9
5.9 42 11.5 30.2 41.9 42.16667 7.1
5.8 41 11.7 30.3 39.5 43.20833 7.2
5.7 40 12.175 30.1 38.5 42.3913 7.4
5.6 42 30 37.5 7.3
5.6 41 31 35.6 7.2
5.4 43 30.6 34.1 7
5.2 42 29.7 34 7
5.2 43 28.6 34.5 7.6
5.1 42 26.5 34.7 6.9
5 44 29.90286 35.4 7.3
4.8 45 34.6 7.7
4.5 46 33.9 8
4.3 45 32.7 8.2
4 44 31.4 7.04359
4.963 46 30.4
48 29.7
50 36.04048
51
52
51
45.369565
12/23/2005
cm mill 2 cm mill 2
mill ESP Sepax fan
O/L I/L
152TPH 152TPH HOT air
(f a (f a VRM BDC VRM BDC CVFan to
23%) 23%) VRM O/L O/L FAN O/L VRM
0 -478 -501 -703 -5 -43
110 107 68 62 71 210

4.8 22.5 24.7 21.1 9 3.1
4.9 23.7 25.2 20.6 9.1 3.2
4.8 24 24.6 20.3 8.9 3.3
4.7 26.5 25.5 21.2 8.8 3.2
4.8 27.3 25.9 24.6 9 3.3
4.9 28.8 25.7 26.2 9.1 3.2
5.1 29.2 26.1 27.5 9 3.1
5.2 29.6 26.5 28.2 9 3.2
5.3 30.5 26.2 30.5 9.1 3.1
5.3 30.9 25.5 31.2 9.2 3.2
5.4 30.8 25.1 31.8 9.1 3.2
5.5 31.1 25.3 32.1 9.3 3.3
5.4 30.9 25.2 32.4 9.5 3.2
5.5 31.2 26.4 32.8 9.4 3.1
5.4 31.5 26.3 33.3 9.2 3
5.5 32 27.1 33.4 9 2.9
5.6 32.6 27.5 32.9 8.6 3
5.4 31.5 28.2 33.6 8.2 2.7
5.2 30.7 27.5 33 8 2.9
5.2 30.5 26.2 31.8 7.2 3
5.1 30.2 26.7 30.3 6.8 3.1
5.2 30.6 26.1 30.9 6.6 3.1
5.3 31.1 26.6 31.2 6.3 3
5.2 30.9 26.9 31.5 6 2.9
5.1 31.1 27.2 32.4 5.9 3.095833
5 31.2 26.6 32.7 6
4.9 31.2 25.8 32.8 6.2
4.9 30.5 25.3 31.4 6.4
5 30.2 24.7 31.3 6.8
4.9 29.8 24.4 30.7 7.1
4.8 29.5 24.2 28.6 7.5
4.8 28.9 23.1 25 7.8
4.7 29 25.884375 24 7.9
4.6 29.4 22 8.1
4.7 29.7 20 8.2
4.8 29.9 19 8.5
4.7 30.1 28.675 8.6
4.6 30.4 8.7
4.7 30.7 8.9
4.8 30.6 9
4.9 30.2 9.1
4.9 29.9 8.14878
4.8 31
4.6 30.7
4.4 31
4.6 30.6
4.8 29.9
4.7 29.5
4.8 29.8
4.9 30.2
4.7 31.1
4.8 30
4.9 28.9
5.2 27.9
5.3 25.6
5.4 29.76545
5.5
5.4
5.3
5.3
5.3
5.019672
C B
E D
A B
F
A61 A51
A52
I
J
A53
A54
M
N
A55 PC
PH Fan
456664552.xls
KILN
456664552.xls
Temperature & Pressure measurement of Preheater Cyclones in presence of

TEC Engineer Mr Suzuki
Date 2/7/2006 2/8/2006
Time 11.30 AM to 12.30 Noon 5 PM to 6.30 PM
Pressure Pressure
Point Description Temp (OC) Temp (OC)
(mmWg) (mmWg)
A A50 (7th floor) -710 -705 Not Taken
A50 (5th floor) Not Taken -720 348
A50 (2nd floor) Not Taken -740 289

B A51 (C1) O/L -695 340 -700 339
C A61(C1) O/L -700 350 -712 357
D A51(C1) I/L -630 -630 Not Taken

E A61(C1) I/L -640 -625 Not Taken
G A52 (C2) O/L -590 -590 440
H A52 (C2) I/L -535 -530 560
I A53 (C3) O/L -505 -510 660
A53 (C3) Roof Top Not Taken -475 708
J A53 (C3) I/L -460 -460 705
K A54 (C4) O/L -280 -400 807
A54(C4) Roof Top Not Taken -270
L A54 (C4) I/L -270 -270 820

M A55 (C5) O/L -185 -190 930
PC Roof Top -130 -135 874
A52 (C2) Material Not Taken 567

Main Riser Duct
Not Taken -130
Top
Smoke Chamber
(below A54 feed Not Taken -60
box)
Smoke Chamber
O (below A55 feed -30 -45
pipe)
Pressure drop across Cyclones

mmWg mmWg
A51/61 A51/61 O/L-A52 O/L -110 -122
A52 A52 O/L-A53 O/L -85 -80
A53 A53 O/L-A54 O/L -225 -110
A54 A54 O/L-A55 O/L -95 -210
A55 A55 O/L-Kiln I/L -155 -145
Temperature & Pressure measurement of Preheater Cyclones in presence of

FLS Engineer Mr Sudhir & Mr Rajesh Sharma
Date 2/15/2006
Time 5 PM to 6.15 PM
Pressure
Point Description Temp (OC)
(mmWg)
A A50 (7th floor) * *
A50 (5th floor) * *
A50 (2nd floor) * *
B A51 (C1) O/L -705 336
C A61(C1) O/L -725 346
D A51(C1) I/L * *
E A61(C1) I/L * *
G A52 (C2) O/L -600 *
A52 (C2) Roof * 550
H A52 (C2) I/L * *
I A53 (C3) O/L -510 *
A53 (C3) Roof * 705
J A53 (C3) I/L * *
K A54 (C4) O/L -405 *
A54(C4) Roof * 833
L A54 (C4) I/L * *
M A55 (C5) O/L -210 *
A55 (C5) Roof * 935-955
N A56 (PC) O/L -182.5 *
A56 (PC) Roof * 890-915
A56 (PC) I/L * 900 HAD
A51 (C1) Material * 330
A61 (C1) Material * 342 Temp 890 OC
A52 (C2) Material * 550 Static Pressure -140
A55 (C5) Material * 890-915
Main Riser Duct Top -105 950-990
Pressure drop across Cyclones C linker Temperature

mmWg Date 2/15/2006 Temp (OC)
A51/61 A61 O/L-A52 O/L -125 Time 4:00 PM 163
A52 A52 O/L-A53 O/L -90 7:00 PM 123
A53 A53 O/L-A54 O/L -105 2/16/2006
A54 A54 O/L-A55 O/L -195 9.50 AM 123
A55/ A56 A55 O/L-Kiln I/L -105 11:00 AM 150
12.35 PM 128
AVG 137.4
Chanderia Cement Works Dt. :15-02-06
Energy Measurement of P. H. Fan H. T. Motor :
Sr.No. Time KW Counter Rdg. Power Factor Voltage
1 8:30 1391 6239.643 0.809
2 9:40 1453 6241.3076 0.816
3 11:05 1441 6243.3112 0.812 6490
4 11:55 1445 6244.4748 0.813 6540
5 14:00 1405 6247.5908 0.807 6680
6 15:20 1434 6249.5016 0.817 6680
7 16:20 1422 6250.8976 0.811 6510
8 18:30 1470 6254.0444 0.81 6680
P.H. Fan M.F.= 1000
Avg. Energy Consumption during 10 Hrs. = ( 6254.0444 - 6239.643 ) x 1000 / 10
=1440.14KWH
Energy Measurement of R.M. H. T. Motor :
Sr. No. Time KW Counter Rdg. Power Factor Voltage
1 8:35 9499.58
2 9:50 9500.07
3 11:05 9500.67 6490
4 11:55 9501.01 6540
5 14:00 9501.96 6680
6 15:20 9502.54 6680
7 16:20 9502.96 6510
8 18:35 9503.91 6680
R.M.Main Motor M.F.= 7200
Avg. Energy Consumption during 10 Hrs. = ( 9503.91 - 9499.58 ) x 7200 / 10
= 3117.6KWH
Chanderia Cement Works Dt. :16-02-06

Energy Measurement of R.M. H. T. Motor :
Sr.No. Time Counter RdPower Factor Voltage
1 8:53 9510.1
2 9:53 9510.52
3 13:53 9512.24
4 15:06 9512.75
5 16:06 9513.18
R.M.Main Motor M.F.= 7200

Avg. Energy Consumption during 7:13 Hrs. = ( 9513.18 - 9510.10) x 7200 / 7.216
= 3072.886 KWH
Energy Measurement of Coal Mill Main Motor : 2/15/2006
Sr. No. Time KW Counter Rdg. Power Factor Voltage
1 8:40 510.2 0.947
2 11:15 529.5 3515.1712 0.948
3 12:00 538.6 3515.546 0.952
4 14:25 526.2 3516.8148 0.942
5 15:25 0 3517.1812 1
6 16:30 523 3517.5584 0.947
7 18:40 515.5 3518.6732 0.938 6600
Mill Stoppage Hrs. = 0:50 Hrs (15:10 To 15:50)
Coal Mill Main Motor M.F.= 1000
Avg. Energy Consumption during 7:15 Hrs. = ( 3518.6732 - 3515.1712) x1000 / 6.58
{ ( 7:15Hrs - 0:50 Hrs)=6:35Hrs}
= 531.976 KWH
(PET COKE, IMPORTED COAL AND LINKAGE COAL / FSC)
UHV IM + GCV NCV UHV IM + GCV NCV

(Kcal/Kg.) Ash (%) (Kcal/Kg.) (Kcal/Kg.) (Kcal/Kg.) Ash (%) (Kcal/Kg.) (Kcal/Kg.)
4025 34.62 4413 4208 4975 27.82 5143 4942

4050 34.44 4433 4228 5000 27.64 5162 4962
4075 34.26 4452 4247 5025 27.46 5182 4981
4100 34.08 4471 4266 5050 27.28 5201 5001
4125 33.90 4491 4286 5075 27.10 5220 5020
4150 33.72 4510 4305 5100 26.92 5240 5039
4175 33.54 4529 4325 5125 26.74 5259 5059
4200 33.36 4549 4344 5150 26.56 5278 5078
4225 33.18 4568 4364 5175 26.38 5298 5098
4250 33.01 4586 4382 5200 26.21 5316 5116
4275 32.83 4605 4401 5225 26.03 5335 5136
4300 32.65 4625 4421 5250 25.85 5354 5155
4325 32.47 4644 4440 5275 25.67 5374 5174
4350 32.29 4663 4460 5300 25.49 5393 5194
4375 32.11 4683 4479 5325 25.31 5412 5213
4400 31.93 4702 4499 5350 25.13 5432 5233
4425 31.75 4721 4518 5375 24.95 5451 5252
4450 31.57 4741 4537 5400 24.77 5470 5272
4475 31.40 4759 4556 5425 24.59 5490 5291
4500 31.22 4778 4575 5450 24.42 5508 5309
4525 31.04 4797 4595 5475 24.24 5527 5329
4550 30.86 4817 4614 5500 24.06 5547 5348
4575 30.68 4836 4633 5525 23.88 5566 5368
4600 30.50 4855 4653 5550 23.70 5585 5387
4625 30.32 4875 4672 5575 23.52 5605 5407
4650 30.14 4894 4692 5600 23.34 5624 5426
4675 29.96 4913 4711 5625 23.16 5643 5445
4700 29.78 4933 4731 5650 22.98 5662 5465
4725 29.61 4951 4749 5675 22.80 5682 5484
4750 29.43 4970 4768 5700 22.63 5700 5503
4775 29.25 4990 4788 5725 22.45 5719 5522
4800 29.07 5009 4807 5750 22.27 5739 5542
4825 28.89 5028 4827 5775 22.09 5758 5561
4850 28.71 5048 4846 5800 21.91 5777 5580
4875 28.53 5067 4866 5825 21.73 5797 5600
4900 28.35 5086 4885 5850 21.55 5816 5619
4925 28.17 5105 4904 5875 21.37 5835 5639
4950 27.99 5125 4924 5900 21.19 5855 5658
E COAL / FSC) (PET COKE, IMPORTED COAL AND LINKAGE COAL
UHV IM + GCV NCV UHV IM + GCV NCV UHV

(Kcal/Kg.) Ash (%) (Kcal/Kg.) (Kcal/Kg.) (Kcal/Kg.) Ash (%) (Kcal/Kg.) (Kcal/Kg.) (Kcal/Kg.)
5925 21.02 5873 5676 6875 14.21 6604 6412 7825

5950 20.84 5892 5696 6900 14.04 6622 6430 7850
5975 20.66 5911 5715 6925 13.86 6641 6450 7875
6000 20.48 5931 5735 6950 13.68 6661 6469 7900
6025 20.30 5950 5754 6975 13.50 6680 6488 7925
6050 20.12 5969 5774 7000 13.32 6699 6508 7950
6075 19.94 5989 5793 7025 13.14 6719 6527 7975
6100 19.76 6008 5813 7050 12.96 6738 6547 8000
6125 19.58 6027 5832 7075 12.78 6757 6566 8025
6150 19.40 6047 5851 7100 12.60 6776 6586 8050
6175 19.23 6065 5870 7125 12.42 6796 6605 8075
6200 19.05 6084 5889 7150 12.25 6814 6623 8100
6225 18.87 6104 5909 7175 12.07 6833 6643 8125
6250 18.69 6123 5928 7200 11.89 6853 6662 8150
6275 18.51 6142 5947 7225 11.71 6872 6682 8175
6300 18.33 6162 5967 7250 11.53 6891 6701 8200
6325 18.15 6181 5986 7275 11.35 6911 6721 8225
6350 17.97 6200 6006 7300 11.17 6930 6740 8250
6375 17.79 6219 6025 7325 10.99 6949 6759 8275
6400 17.61 6239 6045 7350 10.81 6969 6779 8300
6425 17.44 6257 6063 7375 10.63 6988 6798 8325
6450 17.26 6276 6082 7400 10.46 7006 6817 8350
6475 17.08 6296 6102 7425 10.28 7025 6836 8375
6500 16.90 6315 6121 7450 10.10 7045 6856 8400
6525 16.72 6334 6141 7475 9.92 7064 6875 8425
6550 16.54 6354 6160 7500 9.74 7083 6894 8450
6575 16.36 6373 6180 7525 9.56 7103 6914 8475
6600 16.18 6392 6199 7550 9.38 7122 6933 8500
6625 16.00 6412 6218 7575 9.20 7141 6953 8525
6650 15.83 6430 6237 7600 9.02 7161 6972 8550
6675 15.65 6449 6256 7625 8.85 7179 6990 8575
6700 15.47 6468 6276 7650 8.67 7198 7010 8600
6725 15.29 6488 6295 7675 8.49 7218 7029 8625
6750 15.11 6507 6315 7700 8.31 7237 7049 8650
6775 14.93 6526 6334 7725 8.13 7256 7068 8675
6800 14.75 6546 6353 7750 7.95 7276 7088 8700
6825 14.57 6565 6373 7775 7.77 7295 7107 8725
6850 14.39 6584 6392 7800 7.59 7314 7127 8750
ND LINKAGE COAL / FSC)
IM + GCV NCV
Ash (%) (Kcal/Kg.) (Kcal/Kg.)
7.41 7333 7146

7.23 7353 7165
7.06 7371 7184
6.88 7390 7203
6.70 7410 7223
6.52 7429 7242
6.34 7448 7261
6.16 7468 7281
5.98 7487 7300
5.80 7506 7320
5.62 7526 7339
5.44 7545 7359
5.27 7563 7377
5.09 7582 7396
4.91 7602 7416
4.73 7621 7435
4.55 7640 7455
4.37 7660 7474
4.19 7679 7494
4.01 7698 7513
3.83 7718 7532
3.66 7736 7551
3.48 7755 7570
3.30 7775 7590
3.12 7794 7609
2.94 7813 7629
2.76 7832 7648
2.58 7852 7667
2.40 7871 7687
2.22 7890 7706
2.04 7910 7726
1.87 7928 7744
1.69 7947 7764
1.51 7967 7783
1.33 7986 7802
1.15 8005 7822
0.97 8025 7841
0.79 8044 7861
LOSS OF WEIGHT READINGS WITH FLS ENGINEERS
(A) Kiln Feed (LOW System) Date :- 17.02.2006
Sl. No. Initial Final Net Time CCR set Calculated % Error
Reading reading difference (Sec) point (TPH) TPH
(MT) (MT) (MT)
1 37.424 31.424 6.00 88.50 236.7 244.07 3.11
2 36.910 30.810 6.10 89.62 236.7 245.03 3.52
3 37.439 31.379 6.06 88.06 236.7 247.74 4.66
Fine Coal Bin L11 & L21 Loss of Weight Date :- 15.02.2006
(B) L21 (Bin For PC Coal)
Time Bin weight (MT) Loss (MT) Calculated CCR % Error

TPH TPH
Initial Final Difference Initial Final
15.05 15.55 0.50 55.44 47.92 7.52 15.04 14.30 -5.17
(C) L11 (Bin for Kiln Fuel)
Time Bin weight (MT) Loss (MT) Calculated CCR % Error

TPH TPH
Initial Final Difference Initial Final
16.25 17.25 1.00 45.28 39.76 5.52 * 5.52 4.20 -31.43
Calculations :-
* 0.90 MT process BDC coal is fed to kiln schenck, therefore total fuel in kiln = 5.52 + 0.90 = 6.42 TPH
Kiln Fuel (Pet coke) = 5.52 + 0.90 = 6.42 TPH
PC Coal = 15.04 TPH
Total Fuel = 6.42 + 15.04 = 21.46 TPH
% Coal consumption = (21.46 X 100) / 157.87 = 13.60 %
(D) Clinker drop test :- Date :- 15.02.2006
Duration Kiln Feed Kiln feed Clinker by Clinker by weighment % Error

(Hrs.) set point counter counter (MT)
(TPH) (MT) (MT)
8 236.7 1903 1227.43 1262.97 2.90

Heat Balance-1

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CHANDERIA CEMENT WORKS

3/23/2006 Basis Temp 00C

= ( Ka+PCa ) X 1.293 X Cp X t =0.0252X1.293

1C) Cooling air

Total Heat Output 786.99

Temp. oC Cp Pra (NM3/KgClk) Pra (NM3/Min)

Kcca + Pcca (NM3/Min)

Cooling airNM3/Kg Clk Cooling airM3/Kg Clk

Coal Cp(K cal/kg /C 52 0.282

Coal consumption 0.1142331

O2 Cp(K cal/kg /C 342 0.006 O2 CO2 N2

Dust loss Cp(K cal/kg /C 342 0.241

Clinker Cp(K cal/kg /C 162 0.195

Cooler exit gasCp(K cal/kg /C 310 0.244

Fan No. 1S 1L 1R 2L 2R V4 V5A V5B V6

Cooler Vent Fan

Pitot Constant 0.8438

Clk prod (TPH)Drop test 157.87

S.No. Section Duct Dia.(m.) Area(m2)

Cooler Vent Fan

Pitot Constant 0.8438

Clk prod (TPH)Drop

Primary Air Fan (By Anenometer)

Calculated Data 146440 146440 146440

BDC Fan Hot air CV

= ( kcca+pcca ) X 1.293 X Cp X t =0.0331X1.293

1C) Cooling air

Total Heat Output 764.12

Cooling airNM3/Kg Clk Cooling airM3/Kg Clk

Coal Cp(K cal/kg /C 52 0.282

Coal consumption 0.1406238

O2 Cp(K cal/kg /C 340 0.009 O2 CO2

Dust loss Cp(K cal/kg /C 340 0.240

Clinker Cp(K cal/kg /C 135 0.193

Cooler exit gasCp(K cal/kg /C 290 0.244

eed Rate (TPH) 236.6

FlowNM3/Clk 1.373 1.369 1.439 1.504 FlowNM3/Clk 1.1100

Cooler 102.5 32 18.83 70.5 375.5 305 340.25

CHANDERIA CEMENT WORKS, CHANDERIA

8456.493 6461.634 14918.126 0.097756 24.63468

HANDERIA Time : 9.00 AM

Temp. (R) Temp. (a) Area(M2) TR - Ta (O To(Tr+273) T1(Ta+273)Tm(OC) qr(K.Cal./H

A56 Calciner (Cylindrical & Roof + Conical + Riser Duct )

COOLER BACK SIDE

COOLER ROOF + KILN HOOD

Radition calculated by formula :

Radition calculated by formula :

KILN NO.1 RADIATION + CONVECTION LOSSES ( Kcal/Hr.M2 )

KILN NO.2 RADIATION + CONVECTION LOSSES ( Kcal/Hr.M2 )

CHITTOR CEMENT WORKS, CHITTORGARH

COOLER CCR SIDE (Ist GRATE)

COOLER BACK SIDE

COOLER ROOF + KILN HOOD

A56 Calciner (Cylindrical & Roof + Conical + Riser Duct )

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker

qc (K.Cal.qr+qc [K. K.Cal./Kg. Clinker