Kiln Heat Balance Calculator

Preliminary cement kiln fuel and selected sensible-energy screening on a consistent per-kg-clinker basis. Not a closed kiln heat balance.

How to Use This Calculator

Enter production data: clinker output kg/h, feed ratio, coal rate, fuel NCV
Enter coal ultimate analysis: C, H, S, ash, moisture percentages
Enter raw meal chemistry and process temperatures: feed, exit gas, cooler, clinker, shell zone temps
Enter air flows and shell dimensions: cooling air, primary air mass kg/h, kiln shell area, zone temperatures, HTC
Click Calculate: obtain fuel specific heat input, selected sensible-energy figures and shell-loss screening in kcal/kg clinker. Actual gas losses, full closure and cooler recovery cannot be inferred from these inputs.

Production & Fuel Data

Clinker Output (kg/h)e.g. 110,220 kg/h = 2,645 tpd

Kiln Feed Ratio (kg/kg.cli)Dry feed per kg clinker

Coal Rate (kg/kg.cli)As-fired fuel rate

Fuel NCV (kcal/kg)As-fired coal net calorific value; 7,323 kcal/kg ≈ 30.6 MJ/kg, illustrative

Coal Ultimate Analysis (%) — reference only

Carbon (C)% wt

Hydrogen (H)

Sulphur (S)

Ash

Moisture

Raw Meal Chemistry (%) — reference only, not used in this screening

SiO2

Al2O3

Fe2O3

CaO

MgO

LOI (%)

Temperatures (°C) & Air Flows (kg/h)

Feed Entering Kiln

Primary Air Temp

Kiln Exit Gas

Cooler Stack

Clinker at Cooler Exit

Fuel as Fired

Ambient

Cooling Air (kg/h)Total cooler air mass

Primary Air (kg/h)

Kiln Shell Effective Heat Transfer (combined HTC in W/m²K)

Shell Area (m²)

Lower 1/3 Temp (°C)

Mid 1/3 Temp (°C)

Upper 1/3 Temp (°C)

HTC Zone 1

HTC Zone 2

HTC Zone 3

Zone 1 Length (m)

Zone 2 Length (m)

Zone 3 Length (m)

Continue your cement engineering work

Explore the 20 free cement engineering calculators and the cement manufacturing process guide to cross-check process assumptions.

Need a downloadable workbook to complement this quick online estimate? Inspect the filenames of the 54 Excel Tools Pack ($49), including published kiln heat-balance and kiln pyro-balance files. Check the model inputs and units against your plant data before use.

If you also need kiln, preheater, maintenance, quality and training references, compare the full 931-file Complete Package ($249.99) and its actual file previews.