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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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