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    Overall Heat Balance - 11.08.2008

    Uploaded by

    Tamer Fathy
    This document contains data from an audit of the Arasmeta cement plant kiln, including input parameters like coal consumption and air flows, as well as output parameters like gas composition and temperatures. Key findings include: - Heat consumption on the kiln was 532,100 kcal/hr from 10 tons/hr of coal, and 9,775,000 kcal/hr on the calciner from 21.25 tons/hr of coal. - The theoretical heat of reaction for clinker formation is 84,000,000 kcal/hr. - Measured false air in the system was 45,000 kg/hr, close to the standard value.

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    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd

    Overall Heat Balance - 11.08.2008

    Uploaded by

    Tamer Fathy
    207 views8 pages
    This document contains data from an audit of the Arasmeta cement plant kiln, including input parameters like coal consumption and air flows, as well as output parameters like gas composition and temperatures. Key findings include: - Heat consumption on the kiln was 532,100 kcal/hr from 10 tons/hr of coal, and 9,775,000 kcal/hr on the calciner from 21.25 tons/hr of coal. - The theoretical heat of reaction for clinker formation is 84,000,000 kcal/hr. - Measured false air in the system was 45,000 kg/hr, close to the standard value.

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    Overall Heat Balance_11.08.2008

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    This document contains data from an audit of the Arasmeta cement plant kiln, including input parameters like coal consumption and air flows, as well as output parameters like gas composition and temperatures. Key findings include: - Heat consumption on the kiln was 532,100 kcal/hr from 10 tons/hr of coal, and 9,775,000 kcal/hr on the calciner from 21.25 tons/hr of coal. - The theoretical heat of reaction for clinker formation is 84,000,000 kcal/hr. - Measured false air in the system was 45,000 kg/hr, close to the standard value.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    207 views8 pages

    Overall Heat Balance - 11.08.2008

    Uploaded by

    Tamer Fathy
    This document contains data from an audit of the Arasmeta cement plant kiln, including input parameters like coal consumption and air flows, as well as output parameters like gas composition and temperatures. Key findings include: - Heat consumption on the kiln was 532,100 kcal/hr from 10 tons/hr of coal, and 9,775,000 kcal/hr on the calciner from 21.25 tons/hr of coal. - The theoretical heat of reaction for clinker formation is 84,000,000 kcal/hr. - Measured false air in the system was 45,000 kg/hr, close to the standard value.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 8

    Arasmeta cement plant - Kiln Audti traning 11.11.

    2008
    Ref Temp.
    Basis
    Input
    KF
    Coal sinsible heat
    Cooling Air
    Coal moisture
    Primary Air
    Transport Air
    GCT Water
    Heat Consumption
    Kiln
    Calciner
    False Air
    KF Moisture
    Total

    Output
    KS exit gas
    O2
    CO2
    N2
    H2O
    CO
    CS exit gas
    O2
    CO2
    N2
    H2O
    CO
    Cooler Vent Gas
    coal hot gas takeoff
    clinker
    ph dust
    Kiln String
    calciner string
    Radiation Loss
    Kiln +Ph+Cal
    Cooelr
    Theoretical heat of reaction

    0 c
    1 kg/hr of clinker
    Mass Flow (kg/h) Temp
    328680
    30468.75
    520970
    781.25
    5146
    9462
    28050
    10
    21.25
    95125
    1320
    923589

    Mass Flow (kg/h)

    Cp(kCal/Kg)
    70
    70
    32.5
    70
    60
    60
    25

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511

    32.5
    70

    5321
    4600
    Err:511
    Err:511

    Temp

    Cp(kCal/Kg)

    Heat(kCal/hr)

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511 kiln axial, swirl and cooling air
    Err:511 both the kiln and calciner coal
    Err:511 on the basis of design data
    53210000
    97750000
    Err:511
    Err:511
    Err:511

    Heat(kCal/hr)

    138446

    7973
    39705
    85905
    4849
    14

    Err:511

    362
    362
    362
    362
    362

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511

    20437
    162361
    136734
    46835
    364

    173
    173
    173
    173
    173

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511

    218306
    7836
    200000
    28253
    9323
    18929

    250
    365
    140

    Err:511
    Err:511
    Err:511

    Err:511 accuracy of measurement in d


    Err:511
    Err:511

    362
    173

    Err:511
    Err:511

    Err:511
    Err:511

    366732

    Err:511

    62.3
    7
    84000000 For clinker formation
    Err:511

    output - input

    Err:511

    Err:511

    GCT WATER SPRAY

    kiln axial, swirl and cooling air


    both the kiln and calciner coal blower
    on the basis of design data

    425 LPM
    25.5 m3/hr
    25500 kg/hr

    Heat Consumption on basis of coal cons.


    Kiln
    coal cons
    10 tph
    Coal Cv
    5321 kCal/kg
    53210000 kCal/hr
    266.05

    Calciner
    coal cons
    Coal Cv

    21.25 tph
    4600 kCal/kg
    97750000 kCal/hr

    KF distribution
    Calciner string
    Kiln String

    488.75
    754.8

    220
    110

    67%
    33%

    Calciner Gas Composition


    Vol
    Mol wt
    O2
    5.4
    CO2
    31.2
    N2
    41.29
    H2O
    22
    CO
    0.11

    32
    44
    28
    18
    28

    Kiln Gas Composition


    Vol
    Mol wt
    O2
    5.55
    CO2
    20.1
    N2
    68.339
    H2O
    6
    CO
    0.011

    wt
    wt%
    32
    177.6
    5.8%
    44
    884.4
    28.7%
    28 1913.492
    62.0%
    18
    108
    3.5%
    28
    0.308
    0.0%

    wt

    wt%
    172.8
    1372.8
    1156.12
    396
    3.08

    5.6%
    44.3%
    37.3%
    12.8%
    0.1%

    accuracy of measurement in doubt.

    For clinker formation

    Clinkerization Factor
    Ph dust%

    1.65
    8.6%

    8.6%

    Cross Checking the PH ID fan Data


    with ideal GCT false air the power consumption of ID fan
    PC string Outlet flow

    316607 kg/hr

    with GCT 3% False air and Downcomer 4% false air


    the total volume should be handle by ID fan=
    338770 kg/hr

    False air Calculation


    Analysis Data

    O2
    CO2
    CO
    N2
    O2
    CO2
    CO
    N2
    wt%
    O2
    CO2
    CO
    N2

    B61 o/l
    B61 o/l
    B51o/l
    B51
    B52
    B53
    B54
    B55
    GCT OL
    2.43
    2.79
    2.57
    2.43
    1.98
    1.76
    2.24
    0.37
    5.43
    37
    37
    37.6
    37
    38.5
    39.1
    34.5
    39.1
    31
    0.1355
    0.1044
    0.1692
    0.0983
    0.1684
    0.205
    0.176
    0.2567
    0.0971
    60.4345 60.1056 59.6608 60.4717 59.3516
    58.935
    63.084 60.2733 63.4729
    77.76
    89.28
    82.24
    77.76
    63.36
    1628
    1628
    1654.4
    1628
    1694
    3.794
    2.9232
    4.7376
    2.7524
    4.7152
    1692.166 1682.957 1670.502 1693.208 1661.845
    2.29%
    47.86%
    0.11%
    49.74%

    2.62%
    47.84%
    0.09%
    49.45%

    2.41%
    48.49%
    0.14%
    48.96%

    False Air
    Across GCT
    50125 kg/hr
    by standard values
    45000 kg/hr
    for all over system
    False Air According to Standard Values
    Calciner
    0.01 kg/kk
    2000
    Kiln Hood
    0.03 kg/kk
    6000
    Kiln inlet
    0.03 kg/kk
    6000
    Cy Kiln
    0.07 kg/kk
    14000

    2.29%
    47.86%
    0.08%
    49.78%

    1.85%
    49.48%
    0.14%
    48.54%

    56.32
    71.68
    11.84
    173.76
    1720.4
    1518
    1720.4
    1364
    5.74
    4.928
    7.1876
    2.7188
    1650.18 1766.352 1687.652 1777.241
    1.64%
    50.12%
    0.17%
    48.07%

    2.13%
    45.17%
    0.15%
    52.55%

    0.35%
    50.20%
    0.21%
    49.24%

    5.24%
    41.11%
    0.08%
    53.57%

    measured values
    14% PC string
    33063 kg/h
    Kiln string
    Kiln inlet analysis is not correct and also ccr va
    take.

    Cy PC

    0.085 kg/kk

    17000
    45000

    3317.72

    not correct and also ccr values can not be

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