20 MOST IMPORTANT Kiln & COOLER Performance & Efficiency FORMULAS WITH EXAMPLE AND REFERENCE FIGURES
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KILN Degree of filling
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P | Clinker production, tpd |
Deff | Burning zone effective diameter, mts |
n | Kiln speed, rpm |
s | Kiln slope, % |
Thermal loading or Burning zone loading
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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
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P | Clinker production, tpd |
A | Burning zone cross-sectional area, m2 |
L | Kiln length, mts |
Material residence time in kiln
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L | Kiln length, mts |
Deff | Burning zone effective diameter, mts |
n | Kiln speed, rpm |
s | Kiln slope, % |
Clinker residence time in cooler
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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
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CO2 | Kiln exit gas CO2, vol% |
CO2 | Kiln exit gas CO, vol% |
O2 | Kiln exit gas O2, vol% |
Excess air
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O2 | O2 content in gas, vol% |
CO2 | CO2 content in gas, vol% |
Radiation heat losses
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T | Radiating body temperature, K |
t | Ambient air temperature, K |
Convection heat losses
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Forced convection heat losses
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%Ash absorption in clinker
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CC | Coal consumption, tph |
Ash | Ash content in fuel (as fired basis), % |
P | Clinker production, tph |
Raw Mix:Clinker ratio
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(dust to silo)
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%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)
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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)
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Cooler Loading
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