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20 MOST IMPORTANT Kiln & COOLER Performance & Efficiency FORMULAS WITH EXAMPLE AND REFERENCE FIGURES
KILN Degree of filling
| P | Clinker production, tpd |
| Deff | Burning zone effective diameter, mts |
| n | Kiln speed, rpm |
| s | Kiln slope, % |
Thermal loading or Burning zone loading
| F | Fuel rate in kiln, kg/hr |
| NCV | Net calorific value of fuel, kcal/kg-fuel |
| A | Burning zone cross-sectional area, m2 |
| P | Clinker production, tpd |
| H | Specific heat consumption in kiln, kcal/kg-clinker |
| A | Burning zone cross-sectional area, m2 |
Volumetric loading
| P | Clinker production, tpd |
| A | Burning zone cross-sectional area, m2 |
| L | Kiln length, mts |
Material residence time in kiln
| L | Kiln length, mts |
| Deff | Burning zone effective diameter, mts |
| n | Kiln speed, rpm |
| s | Kiln slope, % |
Clinker residence time in cooler
| A | Cooler grate cross-sectional area, m2 |
| Ps | Static pressure at clinker droping area, mmWg |
| P | Clinker production, tpd |
True CO2 in kiln exit gas
| CO2 | Kiln exit gas CO2, vol% |
| CO2 | Kiln exit gas CO, vol% |
| O2 | Kiln exit gas O2, vol% |
Excess air
| O2 | O2 content in gas, vol% |
| CO2 | CO2 content in gas, vol% |
Radiation heat losses
| T | Radiating body temperature, K |
| t | Ambient air temperature, K |
Convection heat losses
Forced convection heat losses
%Ash absorption in clinker
| CC | Coal consumption, tph |
| Ash | Ash content in fuel (as fired basis), % |
| P | Clinker production, tph |
Raw Mix:Clinker ratio
(dust to silo)
| %AA | %Ash absorption, % |
| LOI | Loss on ignition of raw mix, % |
| DL | Dust losses from preheater, % |
Theoretical heat required to produce 1 kg of clinker Clinkerisation heat (including Heat of combustibles)
| CaCO3 | CaCO3 content in kiln feed, % |
| RMCK | Kiln feed:Clinker ratio, – |
| MgCO3 | MgCO3 content in kiln feed, % |
| LOI | LOI content in kiln feed, % |
| Al2O3 | Al2O3 content in clinker, % |
| CH2O | Water of crystalisation in kiln feed, % |
| SiO2 | SiO2 content in clinker, % |
| Fe2O3 | Fe2O3 content in clinker, % |
| K2O | K2O content in clinker, % |
| Na2O | Na2O content in clinker, % |
| C | Carbon content in kiln feed, % |
| S | Sulphur as pyrites in kiln feed, % |
False air w.r.t. mix (based on O2 analysis)
Cooler Loading
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