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Kiln Performance & Efficiency Formulas

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Kiln Performance & Efficiency
S.	Description	Symbol	Formula			Example
No.
1	Degree of filling	DF			3.2 * P	P	5500
		%			Deff ³ * n * s	Deff	4.15
				P	Clinker production, tpd	n	3.8
				Deff	Burning zone effective diameter, mts	S	4
				n	Kiln speed, rpm	DF	16.20
				s	Kiln slope, %	Target	14-16
2	Thermal loading	TL	Formula-1			F	10000
	or	Gcal/hr/m2			F * NCV	NCV	6500
	Burning zone loading				A * 1000 * 1000	A	13.52
				F	Fuel rate in kiln, kg/hr	TL	4.81
				NCV	Net calorific value of fuel, kcal/kg-fuel	Target	4.0-5.0
				A	Burning zone cross-sectional area, m2

			Formula-2			P	5500
					P * H	H	280
					A * 24 * 1000	A	13.52
				P	Clinker production, tpd	TL	4.75
				H	Specific heat consumption in kiln, kcal/kg-clinker	Target	4.0-5.0
				A	Burning zone cross-sectional area, m2
3	Volumetric loading	VL			P	P	5500
		tpd/m3			A * L	A	13.52
				P	Clinker production, tpd	L	68
				A	Burning zone cross-sectional area, m2	VL	5.98
				L	Kiln length, mts	Target	5.0-5.5
4	Material residence time in kiln	RTK			19 * L	L	68
		min			Deff * n * s	Deff	4.15
				L	Kiln length, mts	n	3.8
				Deff	Burning zone effective diameter, mts	S	4
				n	Kiln speed, rpm	RTK	20.5
				s	Kiln slope, %	Target	20-25
5	Clinker residence time in cooler	RTC			1.55 * A * Ps	A	100
	(Empirical relationship from	min			P	Ps	700
	F.L. Smidth)			A	Cooler grate cross-sectional area, m2	P	5500
				Ps	Static pressure at clinker droping area, mmWg	RTC	19.7
				P	Clinker production, tpd	Target	20-25
6	True CO2 in kiln exit gas	TCO2			100 * ( CO2 + CO )	CO2	36.5
		vol%			100 + ( 1.89 * CO ) – ( 4.78 * O2 )	CO	0.002
				CO2	Kiln exit gas CO2, vol%	O2	4.2
				CO2	Kiln exit gas CO, vol%	TCO2	45.7
				O2	Kiln exit gas O2, vol%	Target	–
7	Excess air	EA			79 * O2	O2	2.8
		%			0.21 * ( 100 – CO2 ) – O2	CO2	26.5
				O2	O2 content in gas, vol%	EA	17.5
				CO2	CO2 content in gas, vol%	Target	10-15
8	Radiation heat losses	RHL			4 * 10^-8 * ( T⁴ – t⁴ )	T	517
		kcal/hr/m2		T	Radiating body temperature, K	t	305
				t	Ambient air temperature, K	RHL	2512
						Target	–
9	Convection heat losses	CHL			80.33 * ( ( T + t ) / 2 )^-0.724 * ( T – t )^1.333	T	443
		kcal/hr/m2		T	Radiating body temperature, K	t	308
				t	Ambient air temperature, K	CHL	760
						Target	–
10	Forced convection heat losses	FCHL			28.03 * ( ( T + t ) / 2 )^-0.351 * v^0.805 * D^-0.195 * ( T – t )	T	525
	(when wind speed > 3.0 m/s)	kcal/hr/m2		T	Radiating body temperature, K	t	302
				t	Ambient air temperature, K	v	5
				v	Wind speed, m/s	D	4.15
				D	Radiating body diameter, mts	FCHL	2088
						Target	–
11	%Ash absorption in clinker	%AA			CC * Ash	CC	26
		%			P	Ash	15
				CC	Coal consumption, tph	P	208
				Ash	Ash content in fuel (as fired basis), %	%AA	1.88
				P	Clinker production, tph	Target	–
12	Raw Mix:Clinker ratio	RMCK			100 – %AA	%AA	1.74
	(dust to kiln)	–			100 – LOI	LOI	35.58
				%AA	%Ash absorption, %	RMCK	1.525
				LOI	Loss on ignition of raw mix, %	Target	–
13	Raw Mix:Clinker ratio	RMCS			( 100 – %AA ) * 100	%AA	1.74
	(dust to silo)	–			( 100 – LOI ) * ( 100 – DL )	LOI	35.5
				%AA	%Ash absorption, %	DL	8.1
				LOI	Loss on ignition of raw mix, %	RMCS	1.658
				DL	Dust losses from preheater, %	Target	–
14	Heat of reaction	HR			( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMCK )	CaCO3	75.1
	or	kcal/			+ ( 222 * Al2O3 / ( 100 – LOI ) ) + ( 11.6 * CH2O * RMCK )	RMCK	1.53
	Theoretical heat required to	kg-clinker			– ( 511.6 * SiO2 / ( 100 – LOI ) ) – ( 59 * Fe2O3 / ( 100 – LOI ) )	MgCO3	1.6
	produce 1 kg of clinker				– ( 1000 * ( K2O + Na2O ) / ( 100 – LOI ) )	LOI	34.5
	or				– ( 79 * C * RMCK ) – ( 32 * S * RMCK )	Al2O3	4.17
	Clinkerisation heat			CaCO3	CaCO3 content in kiln feed, %	CH2O	1.05
				RMCK	Kiln feed:Clinker ratio, –	SiO2	13.47
	(including Heat of combustibles)			MgCO3	MgCO3 content in kiln feed, %	Fe2O3	2.41
				LOI	LOI content in kiln feed, %	K2O	0.38
				Al2O3	Al2O3 content in clinker, %	Na2O	0.27
				CH2O	Water of crystalisation in kiln feed, %	C	0.2
				SiO2	SiO2 content in clinker, %	S	0.04
				Fe2O3	Fe2O3 content in clinker, %	HR	389
				K2O	K2O content in clinker, %	Target	–
				Na2O	Na2O content in clinker, %
				C	Carbon content in kiln feed, %
				S	Sulphur as pyrites in kiln feed, %
15	False air w.r.t. mix	FAMO			( O2mix – O2gas ) * 100	O2mix	3.6
	(based on O2 analysis)	%			21 – O2gas	O2gas	2.8
				O2mix	O2 content in mixture of gas, vol%	FAMO	4.4
				O2gas	O2 content in unmixed gas, vol%	Target	5-7
16	False air w.r.t. gas	FAGO			( O2mix – O2gas ) * 100	O2mix	3.6
	(based on O2 analysis)	%			21 – O2mix	O2gas	2.8
				O2mix	O2 content in mixture of gas, vol%	FAGO	4.6
				O2gas	O2 content in unmixed gas, vol%	Target	5-7
17	False air w.r.t. mix	FAMC			( CO2gas – CO2mix ) * 100	CO2mix	32.1
	(based on CO2 analysis)	%			CO2gas	CO2gas	34.5
				CO2mix	CO2 content in mixture of gas, vol%	FAMC	7.0
				CO2gas	CO2 content in unmixed gas, vol%	Target	5-7
18	False air w.r.t. gas	FAGC			( CO2gas – CO2mix ) * 100	CO2mix	32.1
	(based on CO2 analysis)	%			CO2mix	CO2gas	34.5
				CO2mix	CO2 content in mixture of gas, vol%	FAMC	7.5
				CO2gas	CO2 content in unmixed gas, vol%	Target	5-7

IF YOU WORK IN A CEMENT PLANT AND YOU NEED COURSES AND MANUALS LIKE THIS MANUAL AND BOOKS AND EXCEL SHEETS AND NOTES I SPENT 23 YEARS COLLECTING THEM YOU SHOULD CLICK HERE TO DOWNLOAD THEM NOW

Kiln Performance & Efficiency Formulas

Kiln Performance & Efficiency Formulas

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