Power Monitoring Tool

Cherat Cement company Limited, Line III

Process Engnieer

Fan Data line III

Rated Values Operating Vlaues

Equipment Equipment no.
Voltage Ampere Power (kw) RPM m3/hr Pa Ampere RPM Power Factor Power (kw)

Cooler's EP Fan 318FA02 6300 69.9 630 740 630000 2250 38 740 398

Kiln ID Fan 313FA07 6300 273 2600 994 1000000 6800 215 994 2252

Booster Fan 613FA34 400 330.3 185 980 155000 2500 174 980 0.96 116

Coal Mill Exhaust Fan 613FA18 6300 74 710 1485 165000 ---- 61 1485 639

Raw Press System Fan 216FA65 6300 242.6 2240 980 805000 7000 200 980 2095

Main Bag House Fan 314FA03 6300 127.8 1120 740 1000000 2800 90 740 943

Total Kw 6443
Motor list line CRUSHER (kw) Raw Press KILN Coal Mill Cement Mill Packing Utilities
III
Bag House Cooler EP kiln feed
Main motor #01 Main motor #02 Toatl Kw Main drive # 01 Main Drive# 02 Raw Fan Seperator Total KW ID Fan main motor cooler fans Pfister elevator Total Kw Main Motor Separator Booster fan Exhaust Fan Toatl Kw Main Motors Separator Exhaust Fan Total Kw
Fan fan elevator

Total Plant Kw
280 KW
Rated Power 800KW (each) 2240 KW (VFD) 2240 (VFD) 1120 2800 KW (VFD) 1000 KW (VFD) 630 800KW 185 (VFD) 710 (VFD) 1950KW (each) 916KW(VFD) 3150KW(VFD)

Total Kw Total Kws

Rated RPM 989 989 743 994 1494 740 991 990 1488

Rated Amp 242.6 242.6 127.8 273 961.8 69.9 81.6 330.3 74

Rated Voltage 6300 6300 6300 6300 690 6300 6300 400 6300 690 6300 6300

Operating
411 308 720 1990 2032 2095 77 943 7138 2252 599 398 1611 48 233 5141 608 47 116 639 1410 6600 278 3084 9962 421 512 25302
Power
Production TPH 1200 550 296.39 55 365 120
Kwh/ton of each unit 0.60 12.98 17.34 25.63 27.29 3.51 1.73
kwh/ton cement by M1 21.54 17.34 2.94 27.29
kwh/ton cement by M2 .
kwh/ton cement by M3 .
kwh/ton cement by M4

Kiln Audit 216 Raw press Area Motor List M1 is 1st method of calclation kwh/ton cement. According to this method , after finding kwh/ton of each
kwh/ton individual unit we convert it to the kwh/ton clinker by using clinker factor and then add this to kwh/ton of
cement by M1 kiln unit which is already kwh/ton clinker. After this, we devide this by % at which clinker is to be used in
cement mill and then again divide by clinker to cement factor to have a final kwh/ton cement.

Identification Number Euipment Volts Ampere Power factor Power Kwh No Motor Tag Description Power (Kw) Volts (V) AMP (A) RPM Current Amps Operating power
22 216BC33MT01 Belt Conveyor 55 400 98.7 1479 63 41.90
M1 is 1st method of calclation kwh/ton cement. According to this method , after finding kwh/ton of each
kwh/ton cement individual
Kiln 23 216BC10MT01 Belt Conveyor 45 400 81.1 1479 50 33.26 unit we convert it to the kwh/ton clinker by using clinker factor and then add this to kwh/ton of kiln
by M2 (without
316DRO01MTO1 Kiln main drive 690 522 0.960 599 dividing by 0.9) unit which is already kwh/ton clinker. After this divide by clinker to cement factor to have a final kwh/ton
24 216BE41MT01 Bucket Elevator 185 400 312 1485 202 134.35 cement.
25 216BE41MT02 Bucket Elevator 185 400 312 1485 184 122.38
Cooler Fans 26 216BE41MT03 Auxilary Drive 18.5 400 34.5 0 0.00
317FA05 400 161 0.96 107 27 216BE41MT04 Auxilary Drive 18.5 400 34.5 0 0.00
317FA06 400 158 0.96 105 M2 is 2nd method. According to this method, kwh or mwh consumption of all units are added upto kiln and
28 216BE53MT01 Bucket Elevator 185 400 312 1485 220 146.32 kwh/ton cement
by M3 then divide it by product of clinker production and % at which it is to be used in cement mill. Then add this
317FA07 400 150 0.96 100 29 216BE53MT02 Bucket Elevator 185 400 312 1485 196 130.36 kwh/ton clinker to cement mill kwh/ton to have a final kwh/ton of cement
317FA08 400 190 0.96 126 30 216BE53MT03 Auxilary Drive 18.5 400 34.5 0 0.00
317FA09 400 232 0.96 154 31 216BE53MT04 Auxilary Drive 18.5 400 34.5 0 0.00
Cooler Fans kwh/ton cement M2 is 2nd method. According to this method, kwh or mwh consumption of all units are added upto kiln and
317FA10 400 344 0.96 229 32 216DR47MT01 Main Drive Raw press 2240 6300 242.6 989 190 1990.33 by M4 (without then divide it by clinker production. Then add this kwh/ton clinker to cement mill kwh/ton to have a final
317FA11 400 390 0.96 259 33 216DR48MT01 Main Drive Raw press 2240 6300 242.6 989 194 2032.24 diving by 0.9) kwh/ton of cement
317FA12 400 266 0.96 177 34 216FA65MT01 Raw press Fan 2240 6300 242.6 989 185 1937.96
 Kiln Feed 475.0 TPH Reactive Heat
Kiln Factor 1.62 Losses
Clinker Production 293.2 TPH SHC Kcal/kg clinker
Coal Consumption 35.20 TPH Rs in Millions
Specifica Coal cons 0.120
Coal NCV 6239.672
Reference Temperature 25c
power factor 0.960

Without considering coal ash

Molecular Clinker Compound Required oxide% = (% of compund containg oxide *

Clinker Targets Weights Coeffecient * molecular weight of oxide)/(molecular weight of compund
containing oxide)
Composition % g/gmole Cao % SiO2 Al2O3 Fe2O3
C3S 51.00 228.00 37.58 13.42 --
C2S 26.00 172.00 16.93 9.07 --
C3A 6.00 270.00 3.73 2.27
C4AF 11.75 486.00 5.42 2.47 3.87
Free CaO 0.50 --- 0.50
Mgo 1.29 ---
Others 3.46
100.00

With considering coal ash

consideration of coal ash mixing in clinker Ash Analysis Oxides contribution
NCV Kcal/kg 6239.67 SiO2 54.00 0.96 21.54%
SHC Kcal/kg clinker 694.20 Al2O3 20.00 0.35 4.38%
% coal used % 11.13% Fe2O3 13.00 0.23 3.64%
Ash in Coal % 15.93% CaO 3.00 0.05 64.12%
Coal Ash Absop % 1.77%
99.98
Raw Mix Design

Feed Target Clinker Targets %ages of RM

LSF Target 0.95 LSF 0.909 limestone
SM Target 2.69 SM 2.62 slate
Kiln factor 1.62 AM 1.58 Laterite

Components limestone slate laterite Raw Mix Clinker without ash Ash Analysis
SiO2 10.21 43.83 42.63 13.39 21.69 54.00
Al2O3 2.48 7.82 12.71 3.06 4.95 20.00
Fe2O3 1.43 4.15 20.56 1.93 3.12 13.00
CaO 43.00 15.79 6.79 40.28 65.26 3.00
MgO 0.77 1.12 1.13 0.80 1.30 0.70

consideration of coal ash mixing in clinker

NCV Kcal/kg 6239.67
SHC Kcal/kg clinker 694.20
% coal used % 11.13%
 Ash in Coal % 15.93%

Coal Ash Absop % 1.77%

99.98

Clinker Analysis With Ash Without Ash

Q = (4.11*Al2O3)+(6.48*MgO)+(7.646*CaO)-(5.116*SiO2)-
(0.59*Fe2O3) 411.80 414.96 kcal/kg clinker

C3S = 4.07HCa-(7.6HSi+ 6.72HAl+ 1.43HFe+ 2.85HS) 51.86

61.64 %
C2S = 2.87HSi- 0.75C3S 26.08 16.01 %
C3A = 2.65HAl- 1.69HFe 8.39 7.84 %
C4AF = 3.04HFe 10.19 9.49 %
LSF = 100HCa/ 2.8HSi+ 1.65HAl+ 0.65HFe 90.92 95.14 %
MS = HSi/ HAl+ HFe 2.62 2.69 %
MA = HAl/ HFe 1.58 1.58 %
Percent Liquid = (1.13*C3A)+(1.35*C4AF)+%MgO+%Alkalies 25.75 24.18 %
BT = 1300 +(4.51*C3S)-(3.74*C3A)-(12.46*C4AF) 1375.53 1430.38 C

Type of Coal TM (ARB) IM (ADB) GCV (ADB) Ash (ARB) Sulphur VM (ARB) H2 (Calc)

South African 1 10.00% 3.30% 6305.00 14.00% 0.73% 28.39% 3.73%

South African 2 11.00% 3.50% 6805.00 14.50% 0.73% 28.39% 4.06%
Afghan 1 10.80% 3.00% 6900.00 15.00% 0.83% 30.00% 4.22%
Afghan 2 10.80% 3.00% 7124.00 15.00% 0.83% 30.00% 4.37%
Afghan 3 10.80% 3.00% 7300.00 15.00% 0.83% 30.00% 4.48%
Afghan 4 10.80% 3.00% 7250.00 15.00% 0.83% 30.00% 4.45%
Darra 1 11.00% 4.00% 5000.00 18.00% 3.70% 20.00% 2.44%
Darra 2 11.00% 4.00% 6000.00 18.00% 3.50% 20.00% 3.10%
Darra 3 11.00% 4.00% 5059.00 18.00% 3.70% 20.00% 2.48%
Darra 4 11.00% 4.00% 5759.00 18.00% 3.70% 20.00% 2.94%
Indonesian 1 12.80% 0.00% 6900.00 7.00% 1.41% 40.00% 4.49%
Indonesian 2 12.50% 0.00% 6850.00 7.20% 1.39% 40.00% 4.47%

Fine Coal Mixture

Ash 15.93%
Sulphur 2.38%
TM (ARB) 12.45%
IM (ADB) 3.09%
VM 30.34%
GCV (ARB) 6530.45
H2 4.15%
NCV 6239.67

Clinker to be Produced (tons per day) 7037.037037

Targetted Fuel Consumption (kcal/kg) 694.2
NCV Calculated for Coal MixCoal 6239.67
Coal required for Clinker to be Produced (tons) 783
Handling Losses 2.50%
 Moisture Losses 4.00%
Gross Coal Requirement (tons) 834

PC Main
Ratio of Usage 70% 30%
Qty Used per day (ton) 548 235
Coal Feed Rate (tph) expected 25 10
Coal Feeder Limit (tph) at NCV of 6000 kcal/kg 30 30

SA Indonesia Afghan
Mix Ratios 10.00% 25.00% 25.00%
Coal required for Clinker to be Produced (tons per day)) 78 196 196
Value of Coal for Clinker (Rs) 1,487,532 3,523,102 3,797,121
Gross Coal Requirement (tons per Day) 83 208 208
Value of Gross Coal Required (Rs) 1,576,784 3,752,103 4,043,933
Coal Average Rate per ton (Rs) 1,900 4,500 4,850
Available Stocks (Tons) 24,687 15,846 19,501
Numbers of Days 297 76 94

Coal Mix Derived Can be Used for Days --> 3

411.8 kcal/kg ck
267.6 kcal/kg ck
679.4 kcal/kg ck
14.2 Rs

Total Compound Required Parameters Required

Cao 64.16 LSF 0.90

SiO2 22.49 SM 2.61
Al2O3 4.73 AM 1.22
Fe2O3 3.87

Feed Target
LSF 0.95
SM 2.69
AM 1.20

550.00 Rs/ton Rs/ton meal Rs/ton clinker

90.51 497.80 200.00 1974.79
8.01 44.04 300.00 225.81 Rs/ton coal
1.48 8.16 1400.00 17750.00

Ash Absorption clinker with Ash

0.96 22.64
0.35 5.30
0.23 3.35
0.05 65.30
0.01 1.31
 Quantity to be used

Tonnage Heat Price (Coal Rs

GCV (ARB) NCV (Calc) Cost Rs / NCV % Used Rs / NCV per ton/ GCV ARB)=
Required
Rs/1000Kcal

5868.15 5614.29 20000 3.562 5.00% 0.18 39 3.408

6276.11 5999.31 18000 3.000 5.00% 0.15 39 2.868
6345.15 6061.07 17000 2.805 0.00% 0.00 0 2.679
6551.14 6259.64 19400 3.099 25.00% 0.77 196 2.961
6712.99 6415.67 18000 2.806 0.00% 0.00 0 2.681
6667.01 6371.34 17500 2.747 0.00% 0.00 0 2.625
4635.42 4438.60 19200 4.326 0.00% 0.00 0 4.142
5562.50 5332.33 13000 2.438 50.00% 1.22 391 2.337
4690.11 4491.33 13100 2.917 0.00% 0.00 0 2.793
5339.07 5116.94 1200 0.235 0.00% 0.00 0 0.225
6016.80 5712.25 18000 3.151 25.00% 0.79 196 2.992
5993.75 5691.84 15000 2.635 0.00% 0.00 0 2.503
17750 110.00%
 Darra
50.00%
391
5,088,925
417
5,419,705
6,500 17,750
1,385
3
 SM* (A+F)-S1
a2 0.27
b2 -11.69
c2 -46.75
(c1b2-c2b1)/(a1b2-a2b1)
x
61.01
(a1c2 - a2c1)/(a1b2-a2b1)
y
5.40
x+y+1
Total
67.41

2.8*LSF Target*S 1.18*Al2O3 0.65*Fe2O3 CaO value

a1 27.03 2.92 0.93 43.00 -12.12
B1 115.99 9.22 2.70 15.79 112.12
C1 112.80 15.00 13.36 6.79 -134.38

total*x1=100
x1 1.48
 final values

limestone x1*x 90.51

slate x1*y 8.01
laterite x1*1 1.48

0.797

Rs saved
Mixture Heat Price
(Rs/1000 Kcal) Rs in Millions against saved
Kcal/kg clinker

2.971 14.202 2.368

 Heat Balance @ line 03

Data
Kiln Feed 475.00 TPh
Kiln Factor 1.62
Clinker Production 293.21 TPh
Moisture In feed 0.30 %
Reference Temperature 25.00 C
Kiln (tph) Pc Tph
Coal Consumption 35.20
0.120
Coal Calorific Value 6239.67 Kcal/kg

Heat In
Mc Hc
Heat from the combustion
of coal 0.12 6239.67
kg/kg clinker kcal/kg.f

Mc Cc Tc
Sensible Heat from the
0.12 0.29 70.00
coal
kg/kg clinker kcal/kg.K C
Mf Cf Tf
Sensible heat from the 1.62 0.21 70.00
raw meal feed
kg/kg clinker kcal/kg.K C
Mw Cw Tw
Sensible heat from 0.00486 1.48 70.00
moisture in feed
kg/kg clinker kcal/kg.K C
Density Flow rate Ma
Sensible heat from cooler 1.08 2.59
Air 707492.14
kg/m3 m3/hr kg/kg clinker
Density Flow rate Ma
Sensible heat from 1.07 260.00 0.0009
Primary Air
kg/m3 m3/hr kg/kg clinker
Density Flow rate Ma
Sensible heat from coal 0.95 0.02
conveyor Air 5308.50
kg/m3 m3/hr kg/kg clinker
Wall Losses
Radiation Losses in Cooler
Average Surface Temperature 150
Ambient Temperature
Alpha Emisivity Boltzmann Constant
1 0.9 5.67E-08
Length 26 m
Width 4.8 m

Height 4.1 m

Convection Losses in Cooler

Velocity Hnat e
5 2.78 0.6
h 6.25
Flow Calculation
Plant Elevation (m)

Temp C Temp K
AT PH exit
286.00 559.00

Temp C Temp K
AT Stack
105.00 378.00

Cooler's Heat Recover

Tertiary Air
 Secondry Air

m T2
Hot Clinker mCp(T2-
T1) 1.00 1450.00

kg/kg clnkr C

Flow Desnity
Coling Air mCp (T2- 707492.14 1.29
T1)
m3/hr kg/Nm3

760562.76

m T2
Cold Clinker mCp 1.00 95.00
(T2-T1)
kg/kg clnkr C

Flow Desnity
AQC Air mCp (T2-
Cooler calculation T1) 712000.00 1.29
m3/hr kg/Nm3
755890.00 1.29
m3/hr kg/Nm3

Flow Desnity
Secondry Air mCp
(T2-T1) 395808.00 1.29
m3/hr kg/Nm3
 Heat (Kcal/Kg)
Total in 772.73
Total Out 679.39

Losses 267.59 (Kcal/Kg)

Reaction 411.80 (Kcal/Kg)
Total 679.39 (Kcal/Kg)

Heat Out
Q = Mc * Hc
Heat of Clinker
749.08 Reaction
kcal/kg clinker

Q = Mc*Cc*(Tc-T1) Heat carried by

1.57 clinker @ cooler
kcal/kg clinker outlet
Q = Mf*Cf*(Tf-T1) Heat lost through
15.31 evaporation of
kcal/kg clinker moisture
Q = Mw*Cw*(Tw-T1)
0.32
kcal/kg clinker
Ca Ta Q = Ma*Ca*(Ta-T1)
0.24 35.00 6.24 Heat @ Pre heater
Exit Gases
kcal/kg.K C kcal/kg clinker
Ca Ta Q = Ma*Ca*(Ta-T1)
0.24 75.00 0.01 Heat @ cooler outlet
Gases
kcal/kg.K C kcal/kg clinker
Ca Ta Q = Ma*Ca*(Ta-T1)
0.24 75.00 0.21 Heat lost through PH
dust
kcal/kg.K C kcal/kg clinker

Heat @ cooler outlet

with clinker dust
er
Wall Losses
°C 423.15 K
°C 273.15 K
Boltzmann Constant Eq Dia
5.67E-08 4.84575591387218
Kj/hr
Total Heat Losses
1149653.26546014

Total Clinker Production 293209.88

Total Wall Losses 46.1803162579308

Tot.Rediation Losses 27.8625246101147
Tot.Convection Losses 18.3177916478161

Ne
Back xt
267.59

Normal Den kg/Nm3 Desired Dens Kg/m3 Inlet Nozzle Dia m Area suction mbar
1.289 0.59048210 4.50 15.90 0.75

Normal Den kg/Nm3 Desired Dens Kg/m3 Inlet Nozzle Dia m Area suction mbar
1.29 0.87 4.60 16.61 0.52

Hot Clinker

Cooler
Cooling Air
 Cooler

Cold Clinker AQC Air

T2 T1 T2-T1

1723.00 30.00 303.00 Cp Calculation

1420.00
K C K

Elevatoin T2 T2 Desnity Flow

510.00 35.00 308.00 1.08 588215.59

m C k kg/m3 Nm3/hr

T2 T1 T2-T1

368.00 25.00 298.00 Cp Calculation

70.00
K C K

Elevatoin T2 T2 Desnity Flow

510.00 350.00 623.00 0.53 292656.10
m C k kg/m3 Nm3/hr
510.00 908.00 1181.00 0.28 163898.26
m C k kg/m3 Nm3/hr

Elevatoin T2 T2 Desnity Flow

510.00 1030.00 1303.00 0.25 77786.78
m C k kg/m3 Nm3/hr
 Heat Out
Q = 4.11 (Al%)+6.48(MgO%)+7.646(CaO%)-5.116(SiO2%)-0.59(Fe2O3%)
Cao Sio2 Al3O3 Fe2O3 MgO 411.80
65.30 22.64 5.30 3.35 1.31

Mc Cc Tc Q = Mc*Cc*(Tc-T1) Total Losses 267.59

1.00 0.180 95 3.01
kg/kg clinker kcal/kg.K C kcal/kg clinker
Mw Cw Tw Hw Q = Mw*(HW+(Cw*Tw-T1))
0.0049 1.00 100.00 539.00 2.98
kg/kg clinker kcal/kg.K C kcal/kg.K kcal/kg clinker

Density Flow rate Ma Ca Ta Q = Ma*Ca*(Ta-T1)

0.59 785184.57 1.58 0.253 286 104.41
kg/m3 m3/hr kg/kg clinker kcal/kg.K C kcal/kg clinker
Density Flow rate Ma Ca Ta Q = Ma*Ca*(Ta-T1)
0.53 712000.00 1.29 0.24 350 100.66
kg/m3 m3/hr kg/kg clinker kcal/kg.K C kcal/kg clinker
Dust Md Cd Td Q = Md*Cd*(Td-T1)
33250.00 0.113400 0.253 286.00 7.48814
kg/hr Kg/kg clin Kcal/Kg.k C kcal/kg clinker
Md Cd Td Q = Md*Cd*(Td-T1)
10702.16 2.84700
0.240 350.00
kg/hr kcal/kg clinker

Tot.Rediation Losses 27.86

Tot.Convection Losses 18.32
 46.18

Kcal/hr
988701.8083

Kg/hr

Kcal/kg clk
Kcal/kg clk
Kcal/kg clk

Elevation
Density Calculation Temperature
m3/hr Nm3/hr Desired Dens
785184.57 359687.69

m3/hr Nm3/hr Inlet Nozzle Dia m Area

558307.05 378222.14 4.60 16.61

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Cooler's Effeciency % (Out/in) 68.83%

Cooler'sHeat Recovery % (Heart

96.55%
Recovered/Heat in)
 Cooler'sHeat Recovery % (Heart
96.55%
Recovered/Heat in)

0.00

A B C D Cp (kcal/kg.K)
A+ BT + C(T)^2
+ D(T^3)
0.17 0.00014 0.00000013 0.00000000005 0.26

Flow m Cp at 25C T1
760562.76 2.59 1.01 0.00 273.00

Kg/hr kg/kg Clnkr kj/kg.k C K Kj/ kg clinker

A B C D Cp (kj/kg.K)
A+ BT + C(T)^2
+ D(T^3) 0.17 0.00014 0.00000013 0.00000000005 0.18

Flow m Cp at 380C T1
378404.33 1.29 0.24 25.00 298.00
Kg/hr kg/kg Clnkr kcal/kg.k C K
211920.44 0.72 1.16 25.00 298.00
Kg/hr kg/kg Clnkr kj/kg.k C K Kj/ kg clinker

Flow m Cp at 380C T1
100578.30 0.34 1.20 25.00 298.00
Kg/hr kg/kg Clnkr kj/kg.k C K Kj/ kg clinker
Kcal/kg clk
Kcal/kg clk
 510.00 m
381.00 k
0.87 kg/m3

suction mbar m3/hr Nm3/hr

0.50 551653.9 370772.3

Ho
me
 Heat Heat Total IN

374.88 374.88
Kcal/kg Kcal/kg

416.69
Heat Heat
91.24 21.81

Kj/ kg clinker Kcal/kg

Heat Heat Total Out

12.93 12.93
Kcal/kg Kcal/kg

Heat Heat
102.34 102.34
Kcal/kg Kcal/kg 404.07
740.31 176.93
Kj/ kg clinker Kcal/kg

Heat Heat
414 98.87
Kj/ kg clinker Kcal/kg