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    Kiln Heat Balance

    Uploaded by

    gvrr
    This document provides heat balance calculations for a cement plant. It lists inputs such as heat from coal combustion and sensible heat from materials. It also lists outputs including theoretical heat of reaction, heat losses, and heat carried away with exhaust gases and cooler air. A key finding is that the total heat input of 780.12 Kcal/Kg clinker is less than the total heat output of 803.34 Kcal/Kg clinker, indicating an imbalance in the heat calculations. Radiation and convection losses from the kiln and preheater are also presented.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd

    Kiln Heat Balance

    Uploaded by

    gvrr
    1K views17 pages
    This document provides heat balance calculations for a cement plant. It lists inputs such as heat from coal combustion and sensible heat from materials. It also lists outputs including theoretical heat of reaction, heat losses, and heat carried away with exhaust gases and cooler air. A key finding is that the total heat input of 780.12 Kcal/Kg clinker is less than the total heat output of 803.34 Kcal/Kg clinker, indicating an imbalance in the heat calculations. Radiation and convection losses from the kiln and preheater are also presented.

    Original Description:

    Kiln Heat Balance

    Copyright

    © © All Rights Reserved

    Available Formats

    XLS, PDF, TXT or read online from Scribd

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    This document provides heat balance calculations for a cement plant. It lists inputs such as heat from coal combustion and sensible heat from materials. It also lists outputs including theoretical heat of reaction, heat losses, and heat carried away with exhaust gases and cooler air. A key finding is that the total heat input of 780.12 Kcal/Kg clinker is less than the total heat output of 803.34 Kcal/Kg clinker, indicating an imbalance in the heat calculations. Radiation and convection losses from the kiln and preheater are also presented.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    1K views17 pages

    Kiln Heat Balance

    Uploaded by

    gvrr
    This document provides heat balance calculations for a cement plant. It lists inputs such as heat from coal combustion and sensible heat from materials. It also lists outputs including theoretical heat of reaction, heat losses, and heat carried away with exhaust gases and cooler air. A key finding is that the total heat input of 780.12 Kcal/Kg clinker is less than the total heat output of 803.34 Kcal/Kg clinker, indicating an imbalance in the heat calculations. Radiation and convection losses from the kiln and preheater are also presented.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
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    HEAT OUTPUTS

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

    % Of MgO
    % Of CaO
    % Of SiO2

    F=

    % Of Fe2O3+% Of P2O5

    Q=

    0 Kcal/Kg clinker

    HEAT IN PREHEATER EXIT DUST


    Gross dust loss
    Clinker output rate

    =
    =

    tph
    tph

    Dust in preheater exit gas =

    #DIV/0!

    Kg dust/Kg clinker

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

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

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

    md =

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

    Cpd =

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

    td =

    0 temperature of dust, C

    tr =

    0 reference temperature, C

    Qd =

    #DIV/0! Kcal/Kg clinker

    HEAT IN PREHEATER EXIT GASES


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

    Wt. of preheater exit gases Kg / Kg clinker

    Cpe =

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

    te =

    temperature of exit gases, C

    tr =

    reference temperature, C

    Pitot measurement of kiln exit gases


    Clinker production

    =
    =

    me

    71.09
    2817.6
    = 32.611
    2.1799

    Exit gas composition :


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

    Qe =

    %
    %
    %
    %

    HEAT IN CLINKER FROM COOLER DISCHARGE

    Kg/Sec
    tpd
    Kg/Sec
    Kg/Kg clinker

    Radiation & Convection Losses From Kiln


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

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

    45
    46
    47
    48
    49
    50
    51
    52
    53
    54

    11.31
    11.31
    11.31
    11.31
    11.31
    11.31
    11.31
    11.31
    11.31
    11.31

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

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

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

    TOTAL

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

    Radiation & Convection Losses From Preheater


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

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

    Grate cooler
    Cooler exhaust

    379.32818 314.493107 693.82128779 260876.8042


    501.519894
    408.09477 909.6146638 172271.9212

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

    376.00
    189.39

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

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

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

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

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

    501.519894
    501.519894

    408.09477
    408.09477

    909.6146638 147175.6526
    909.6146638 8577.66628

    501.519894
    501.519894

    408.09477
    408.09477

    909.6146638 147175.6526
    909.6146638 8705.012333

    501.519894
    501.519894

    408.09477
    408.09477

    909.6146638 209229.565
    909.6146638 27470.36285

    501.519894
    501.519894

    408.09477
    408.09477

    909.6146638 258285.0838
    909.6146638 15226.94947

    501.519894
    501.519894

    408.09477
    408.09477

    909.6146638 127846.341
    909.6146638 16072.89111

    501.519894
    501.519894

    408.09477
    408.09477

    909.6146638 127846.341
    909.6146638 14026.25812

    501.519894
    501.519894

    408.09477
    408.09477

    909.6146638 266562.5772
    909.6146638 33746.70403

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

    157.78
    132.13
    128.04
    128.04
    168.91

    TOTAL

    6095.39

    378
    378
    378
    378
    378

    501.519894
    501.519894
    501.519894
    501.519894
    501.519894

    408.09477
    408.09477
    408.09477
    408.09477
    408.09477

    909.6146638
    909.6146638
    909.6146638
    909.6146638
    909.6146638

    7914694.264

    HEAT BALANCE

    HEAT INPUT

    Kcal/Kg clinker

    Combustion heat through coal


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

    750.00
    2.20
    1.80
    26.12

    TOATL

    780.12

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

    402.60
    172.74
    10.84
    85.14
    26.88
    9.14
    90.00
    6.00

    TOATL

    803.34

    Clinker production

    143519.0017
    120187.3855
    116467.0616
    116467.0616
    153643.0129

    kg/hr

    0.000001 0.000000001

    #VALUE!

    Radiation
    K4

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

    04

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

    10

    -8

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

    ( 298+T)/2

    -0.724

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

    ( T-298)

    1.333

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

    0
    0
    0
    0
    0
    0
    0
    0
    0
    0

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

    7886150416
    7886150416
    7886150416
    7886150416
    7886150416
    7886150416
    7886150416
    7886150416
    7886150416
    7886150416

    298

    04

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

    0.00000001
    0.00000001
    0.00000001
    0.00000001
    0.00000001
    0.00000001
    0.00000001
    0.00000001
    0.00000001
    0.00000001

    10

    -8

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

    0.0267062642
    0.0267062642
    0.0267062642
    0.0267062642
    0.0267062642
    0.0267062642
    0.0267062642
    0.0267062642
    0.0267062642
    0.0267062642

    ( 298+T)/2

    -0.724

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

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

    ( T-298)

    1.333

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

    20415837456
    20415837456
    20415837456
    20415837456
    20415837456

    750.08
    2.22
    1.80
    18.06
    772.16

    402.60
    172.74
    10.84
    85.14
    26.88
    6.43
    90.00
    6.00
    800.63

    7886150416
    7886150416
    7886150416
    7886150416
    7886150416

    0.00000001
    0.00000001
    0.00000001
    0.00000001
    0.00000001

    0.0147592507
    0.0147592507
    0.0147592507
    0.0147592507
    0.0147592507

    344.2064091
    344.2064091
    344.2064091
    344.2064091
    344.2064091

    23.86165
    23.86607

    339.228

    HEAT BALANCE
    DATE OF COMPUTATION :17.02.09

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

    TOATL

    Kcal/Kg clinker
    750
    2.2
    1.8
    26.12

    787

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

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

    402.6
    172.74
    10.84
    85.14
    26.88
    9.14
    90
    6

    803.34

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