Slurry density vs material concentration

1,400

Slurry density [kg/m3]

1,300

1,200

1,100

1,000
0

10

20

30

40

50

60

Material concentration [%]

70

80

90

100

Material properties

Material

Top size

Bulk density in
pneumatic
conveyor

Bulk density in
mechanical
conveyor

Bulk density Bulk density Design Angle of Steel silo

in silos for
in silos for moisture repose
cone
Abrasiveness
volume
load
calculation calculation

d.b
t/m3

d.b
t/m3
1.5
1.4
1.48
1.5
1
0.8
0.8

d.b
t/m3
1.6
1.5
1.58
1.6
1.25
0.95
0.95

d.b
t/m3
1.8
1.7
1.8
1.8
1.5
1.3
1.3

w.b.
%
10.6
15.6
10.9
10.6
23.7
24.1
24.1

1.45
1.4
1.25
0.7

1.6
1.5
1.6
0.9

Limestone
Overburden
Lst&Overburden Mix
HG Limestone crushed
Pyrite
Moscow Ash
Ryazan Ash

mm
800
800
100
100
50
20
20

Raw mill feed

Raw mill reject
Kiln feed/Raw meal
Raw mill/Kiln filter dust

100
70
9% 90 m
2% 90 m

0.8
0.4

1.35
1.3
1
0.5

Raw coal
Fine coal

50
12% 90 m

0.3

0.8
0.4

0.9
0.5

Clinker
Off Std Clinker
Clinker dust

5% 25mm
5% 25mm
2

1.4
1.2
1.1

10
50

Slag as received
Gypsum as received
Cement not aerated

grd
38
40
37
37
35
35
35

grd
20
5
7
15
9
0
7

12.3
10
0.5
0

37
37

15
20

medium
medium
low
low

1
0.8

7.7
1

40

20

low
low

1.4
1.5
1.4

1.8
1.7
1.5

0
0
0

34
34
20

45
45

high
high
high

1.1
1.28

1.2
1.44

1.3
1.6

12
5

40
40

20
15

high
low

0.95

1.2

1.6

low
low
low
low
high
low
low

Slurry is a mixture of solids and liquid. The density of a slurry can be calculated as
m = 100 / (cw / s + (100 - cw) / l) (1)
The slurry concentration by weight can be measured by evaporating a known weight of slurry and measuring the
weight of dried solids.

cw
s
l
m

concentration of solids by weight in the slurry

density of the solids

kg/m3

density of the liquid

kg/m3

density of slurry

kg/m3

90
1,350
1,000
1,304

10

1,000

1,027

20
1,055

30

40

50

60

70

80

90

100

1,084

1,116

1,150

1,184

1,222

1,262

1,304

1,350

Massflow Calculation
Raw Materials
t/week,

wet

Correctives
(Sand,Ore,

Crusher

Laterite, etc.)

Rawmeal-Clinker ratio
Moisture contents
Raw mix components

t/h

Storage

Raw Meal

t/h

Raw mill
t/h

Clinker
t/y , t/d

Additives

Clinker storage

(Slag, Fly Ash,

Gypsum,
Limestone,etc.)

Heat consumption
kJ/kg cli

Fuel

Cement

t/h
t/y ,

t/d

Cement mill
Cement
Blending

Cement Silo

Kiln size
t/h

t
Cement Despatch

Bulk loading
t/h

HES/CBa,03/06/2013

Pack house
bags/h

Massflow Scheme 2

132668590.xls]

Kind of car washing

activity
Washing cars by hand with a
hose
Conventional car wash
installation
Car wash installation with
water recycling system

Beverages
Milk
Distilled water
Beer
Coffee
Orange juice
Soft drinks
Cola
Wines
(Stomach acid)
(Battery acid)

Average drinking water

consumption per car wash
installation
400 liters
150 liters
10-50 liters

pH
6.5
5.8
4.0-5.0
2.5-3.5
3.5
2.0-4.0
2.5
2.3-3.8
1.0-2.0
1.0

Drinking ,Cooling and process water chemistry requirements

Cooling water recycled

Calcium (Ca )
Magnesium (Mg2+)
Hardness (CaCO3)
Alcalinity (CaCO3)

50
130
200

Process
consumpti
on
mg/l
50
130
200

Sulphate (SO42-)
Chloride (Cl-)
Nitrate (NO3-)

200
500
50

200
500
50

TDS
Iron (Fe)
Manganese (Mn)

1000
0.1
0.05

1000
0.1
0.05

mg/l
2+

Ammonia (NH4-)
Organic matter (KMnO4)

0.1
6

quirements
Drinking water
mg/l
50
-

200
250
250
50
1000
0.2
0.05

0.5
-

Width
mm
400
400
400
400
400
600
600
600
600
600
800
800
800
800
800
1.000
1.000
1.000
1.000
1.000
1.200
1.200
1.200
1.200
1.200
1.400
1.400
1.400
1.400
1.400
1.600
1.600
1.600
1.600
1.600
1.800

Side wall
height mm
100
150
200
250
300
150
200
250
300
350
200
250
300
350
400
200
250
300
350
400
200
250
300
350
400
250
300
350
400
450
250
300
350
400
450
250

Plate
thickness
mm
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
5
5
6
6
6
6
6
6

0.10
12
19
26
33
40
28
39
50
60
71
52
66
81
95
109
65
83
101
119
137
78
99
121
143
164
116
141
166
192
217
132
161
190
219
248
149

Conveying speed m/s

0.15
0.20
0.25
0.30
17
23
29
35
28
37
47
56
39
52
65
78
50
66
83
99
60
81
101
121
42
56
70
84
58
78
97
117
75
99
124
149
91
121
151
181
107
143
178
214
78
104
130
156
99
132
166
199
121
161
202
242
143
190
238
285
164
219
274
328
97
130
162
194
124
166
207
248
151
202
252
302
178
238
297
356
205
274
342
410
117
156
194
233
149
199
248
298
181
242
302
363
214
285
365
428
246
328
410
492
174
232
290
348
212
282
353
423
249
333
416
499
287
383
479
575
325
433
542
650
199
265
331
397
242
323
403
484
285
380
475
570
328
438
547
657
372
495
619
743
224
298
373
447

1.800
300
6
181
272
363
454
544
1.800
350
6
214
321
428
535
642
1.800
400
6
246
369
492
616
739
1.800
450
6
279
418
557
697
836
2.000
250
6
166
248
331
414
497
2.000
300
6
202
302
403
504
605
2.000
350
6
238
356
475
594
713
2.000
400
6
274
410
547
684
821
2.000
450
6
310
464
619
774
929
2.200
250
6
182
273
364
455
546
2.200
300
6
222
333
444
554
665
2.200
350
6
261
392
523
653
784
2.200
400
6
301
451
602
752
903
2.200
450
6
341
511
681
851 1.022
2.400
250
6
199
298
397
497
596
2.400
300
6
242
363
484
605
726
2.400
350
6
285
428
570
713
855
2.400
400
6
328
492
657
821
985
2.400
450
6
372
557
743
929 1.115
The indicated conveying capacities correspond to a brimful filling (water filling) = 100%

eed m/s
0.35
40
66
91
116
141
98
136
174
212
249
181
232
282
333
383
227
290
353
416
479
272
348
423
499
575
406
494
582
670
759
464
564
665
766
867
522

Permissible
0.40 filling degree
46
80%
75
80%
104
80%
132
80%
161
80%
112
80%
156
80%
199
80%
242
80%
285
80%
207
90%
265
90%
323
90%
380
90%
438
90%
259
100%
331
100%
403
100%
475
100%
547
100%
311
100%
397
100%
484
100%
570
100%
657
100%
464
100%
564
100%
665
100%
766
100%
867
100%
530
110%
645
110%
760
110%
876
110%
991
110%
596
110%

635
748
862
975
580
706
832
958
1.084
638
776
915
1.053
1.192
696
847
998
1.149
1.300
100%

726
855
985
1.115
662
806
950
1.094
1.238
729
887
1.045
1.204
1.362
795
968
1.140
1.313
1.486

110%
110%
110%
110%
120%
120%
120%
120%
120%
120%
120%
120%
120%
120%
120%
120%
120%
120%
120%

Recirculating water [m3/h]

Q=2 x 360 mc/h

Warm water
Total
Cooling tower Cooling
tower
280

280

Temperature

Warm water tank

Temperature

Raw mill

51.0

Production
development

22.5

Preheater
precalciner
compressor
room

72.4

Kiln

17.2

B5
356.36
96%
30-35

350 m3
Leakage of
recycled water

25-27

14.85

Cooling water tank

350 m3
Recirculation water pump
Clinker
cooling

station including water treatment

14.5

9.6

Cement
grinding

Q=2x360 mc/h

188.0

Truck washing
consumption
10.6

Recycled water

B4 371.2

Incoming water [m3/h]

From Oka river

B7

73.3

50

Discharge to
the pond
storage

Storm
water
treatment
facilities

Incoming
water tank
with a
firefighting
reserve

Incoming
water tank
with a
firefighting
reserve

Storm
water tank
mc
7.0

15.7

7.6

53.4

Cooling tower

Conditioning tower

Cement mill

Total

9.4

8.6
Raw mill

Potable water

14.5
Leakage of recycled water

Second stage Recirculation

pump station water pump
station
including
water
treatment

K2

K2H

241

Storm
water from
the site

B1
Trucks washing consumption 10.6

Industrial water B3

2500

63.9
B2

Water for fire fighting

9.4

Potable water
Water for fighting
Consumed Water for process
Recycled water for process
Warm water for the process
Incoming river water
Domestic sewage
Storm water sewage
Pressure storm water sewage

Storm water

Hq
Ht
h
h

B1
B2
B3
B4
B5
B7
K1
K2
K2H

mc/h
9.4
63.9
371.2
356.4
73.3
21.1
241.0

393 mm

Qh =

10 x Hq x(F1x33,88+F2x32,29)

105,899 m3/y

167 mm

Qt=

10 x Htx(F1x33,88+F2x32,29)

44,998 m /y

33.88

Qm

NxnxFmxfm

32.29

QTotal

4,108 m3/y
155,005 m3/y

qw

### m3/h

Water Consumption
Design Data

Existing Plant

Shurovo Expansion Example

Kilns capacity

tpd clinker

1,680

5,500

3,000

Total clinker production

tpy clinker

867,972

1,666,225

908,850

Kiln Gross OEE

71%

83%

83%

Clinker / cement factor

0.85

0.79

0.79

1,021,144

2,098,520

1,144,647

Natural gas

Natural gas (Future

Coal/Petcoke utilization
foreseen in Layout)

Total cement production

tpy cement

Fuel

Specific heat energy consumption

MJ/kg clinker

5784 / 6018

3600

Specific consumption of electrical energy

Water consumption

kWh/tcement

119.5

100

m /y

815,910

579,552

263,989

m3/h

93

66

30

0.799

0.276

0.231

m /y

1,994,463

2,799,236

1,537,008

m3/h

322

385

211

1.953

1.334

1.343

m3/tcement
Water recycling

m /tcement
3

Water consumption

815,910
93
0.799

570,994
65
0.272

263,989
30
0.231

m/d
m3/h
m3/y
%

450
0.500
9.38
82,125
10.07%

450
0.500
9.38
82,125
14.38%

225
0.500
4.69
41,063
15.55%

trucks/d
m/truck
m3/d
%
m3/h
m3/d
m3/y
%

169
10
1690
15.00%
10.56
254
92,528
11.34%

169
10
1690
15.00%
10.56
254
92,528
16.20%

92
10
920
15.00%
5.75
138
50,370
19.08%

8.60
7.00
15.67
7.60
15.65
54.51

3.1
2.5
5.7
2.7
5.7
19.7

641,258

396,341

172,557

78.59%

69.41%

65.37%

8,039,000
918
7.87

2,799,414
320
1.33

1,537,008
211
0.231

m3/y
m3/h
m3/tcement

B1 - Potable Water
Number of employees
Consumption per FTE
Water consumption

B3 - Truck Washing Consumption

Maximum expected average washings
Consumption per wash
Total water
Water consumption

B3 - Consumed Industrial Water

Raw Mill
Cooling tower
Conditioning tower
Cement mill
Leackeage of recycled water 5%
Total water

Water recycling

m3/h
m3/h
m3/h
m3/h
m3/h
m3/h
m3/y
%

m3/y
m3/h
m3/tcement

B4 - Industrial consumption
Raw mill
Production development
Preheater precalciner
Kiln
Clinker cooling
Cement grinding
Total

m3/h
m3/h
m3/h
m3/h
m3/h
m3/h
m3/h
m3/y
%

7,514,678

51.0
12.5
72.4
17.2
9.6
150.3
312.9
2,275,091
81%

22.0
12.5
18.0
11.0
35.0
98.5
716,174
47%

B4 - Truck Washing Consumption

Maximum expected average washings
Consumption per wash
Water consumption

K1 - Sewage (from Offices, Showers

etc) / Kanalisation

trucks/d
m/truck
m3/d
m3/h
%
m3/d
m3/y
%

169
10
1690
70.42
85.00%
1,437
524,323
6.52%

169
10
1690
70.42
85.00%
1,437
524,323
18.73%

92
10
920
38.33
85.00%
782
285,430
18.57%

m3/y

185,000

185,000

92,475

Infrastructure in Shurovo (Numbers for Permitting and Communication to Authorities)

Electricity Consumption
Consumption
Yearly Energy Consumption

Existing Shurovo Grey

Cement Plant

New Shurovo Grey

Expansion Project

Existing Shurovo
White Cement

13 267 4484 kWh

500 000

13 286 543 kWh

External (None
Process Related)

Total new Grey + White

513 286 543

2 x 25 MVA (including the

needs for 3rd consumers as
Transformers (Installed power) (gray cementKBM,
plant)village, )
Peak Daily Demand
25 000 kW
Average Daily Demand
15 145 kW
Specific Power consumption per t of Cement (kWh/t)
122
Required grid power
Required grid voltage level
110kV
Short circuit capacity

2 x 25 MVA existing + 2 x
25 MVA new
36 000 kW
23 000 kW
100
90 MVA
110kV
?

Power grid quality

Power factor correction (cos Phi)
Power dip (brown out) > 30%
Meetering (CT, VT, Counters - class ?)
Voltage fluctoations
Frecuency
Tap changers

0.95
less than 15%
4 quadrant static meeters
%
50Hz
1.25% x 12

0.9

32/29770
7/17400

<10
<10
<10

13/10720
6/6000

23
16
5

24/22520

<30

13/11060

43

200
820416
606000
0.6
3600

19
105,000
93,000

220
925,416
699,000
0.6
3600/ 11829

Plant power distribution

Amount of MV-Motors
Synchro motors
Amount of MV VFD's (>1500 kW)
Short circuit capacity
Amount of transformers MV/LV

0.9

%
50Hz

Gas Demand
Yearly Demand (Mio m3/year)
157
Maximum Dayly Demand (m3/day)
600712
Average Dayly Demand (m3/day)
390,095
Required Pressure at Plant border (Mpa)
0.6
Specific thermal energy consumption per t of Cement
5808(kJ/kg clinker)

6kV

10000 kW
?

2 x 25 MVA existing + 2 x 25 MVA

new
49 000 kW
24 517 kW
100/235
90 MVA
110 kV and 6 kV

0.92
less than 15%
less 5%
50Hz
1.25% x 12

11,829

The FS has outlined a rail/truck ratio of 50/50. Yet, we will apply for worst case scenario's in the Technical
Conditions, exaggerating each of the transport modes (80%)

Railway A71
Inbound (Yearly)

3 000 kW
1 517 kW
235

3532 wagons/year, 229'606

materials

28681 wagons/year,
1'864'304 tons material

329 wagons/year,
21'000 tons material

Comments

29'010 wagons/year, 1'885'305 tons

material

Yes, we are required to cover with one transformer the complete plant dem
The 3rd transformator is highly unlikely to receive. This capacity could be

Max. Inbound (Dayly)+ Month (Wagons/day)

28 wagons/day
Outbound (Yearly)

7313 wagons/year, 495'144

tons cement

39 wagons/july 26th, 803

Max. Outbound (Dayly)+ Month (Wagons/day)
wagons/month

Max. Inbound (daily)+ Month

Outbound (Yearly)

14 wagons/day, 350
wagons/month

150 wagons/day, 3'760

wagons/month

The days per month of

operation is 25

25'385 wagons/year,
1'650'000 tons cement

340 wagons/year,
21'716 tons cement

25'725 wagons/year, 1'672'000 tons

cement

The average wagon load is 65

tons

112 wagons/day, 2'812

wagons/month

2 wagons/ july 26th,

803 wagons per month

114 wagons/day, 3'615

wagons/month

The FS has outlined a rail/truck ratio of 50/50. Yet, we will apply for worst case scenario's in the Technical
Conditions, exaggerating each of the transport modes (80%)

Road
Inbound (Yearly)

136 wagons/day, 3'407

wagons/month

23185 trucks/year empty

55'000 trucks/year empty

152 trucks/june 19th empty

244 trucks/daily empty,

8 trucks/daily, 200
6'094 trucks monthly empty trucks monthly empty

252 trucks daily empty, 6'300 trucks

monthly empty

The days per month of

operation is 25

23185 trucks/year, 596700

tons cement

55'000 trucks/year,
1'650'000 tons cement

1400 trucks/year,
42'000 tons cement

57'000 trucks/year, 1'700'000 tons

cement

The average truck load is 30

tons

152 trucks/june 19th

244 trucks/daily, 6'094

trucks monthly

8 trucks/daily, 200
trucks monthly

252 trucks daily cement, 6'300 trucks

monthly

Max. Outbound (daily)+ Month

Water
Consumed Water
Total Consumed Water (m3/year)
815910
Consumed Industrial Water (Leakage, loss, water
586110
spray) (m3/year)
Truck Washing Consumption (m3/year)
0
Potable Water
229800
Recycled Industrial Water (closed system) (m3/year)
8039000
Recirculated Industrial Water (m3/year)
8039000
Truck Washing Recirculation (m3/year)
0

462000
253000
110000
99000
2233000
1650000
583000

Sewage (from Offices, Showers etc) / Kanalisation

Yearly Sewage
185000

185000

1'400 trucks/year empty

62090
45890
0
16200 Check
0
0
0

57'000 trucks/year empty

524090
298890
110000
115200
2233000
1650000
583000

Could be less due to decrease in personnel

Yes, Michael, after discussion with Vyacheslav and William, we can proba

plete plant demand and additional 3rd consumers. The demand of the 3rd consumers will be calculated by the respective electricity organ in the technical conditions. We submit only the future demand
city could be included in the 2 X 40 and will result in 2 x 63 MVA (standard capacity which is expected to be received in the technical conditions)

we can probably reduce this with 20 - 30%

Water Consumption
Design Data

Existing Plant

Shurovo Expansion

Kilns capacity

tpd clinker

1,680

5,500

Total clinker production

tpy clinker

867,972

1,666,225

Kiln Gross OEE

71%

83%

Clinker / cement factor

0.85

0.79

1,021,144

2,098,520

Natural gas

Natural gas (Future

Coal/Petcoke utilization
foreseen in Layout)

Total cement production

tpy cement

Fuel

Specific heat energy consumption

MJ/kg clinker

5784 / 6018

3600

Specific consumption of electrical energy

Water consumption

kWh/tcement

119.5

100

m /y

815,910

579,552

m3/h

93

66

0.799

0.276

1,994,463

2,799,236

322

385

1.953

1.334

m3/tcement
Water recycling

m3/y
m /h
3

m /tcement
3

Water consumption

815,910

587,869

93
0.799

67
0.280

m/d
m3/y
%

450
0.500
82,125
10.07%

450
0.500
99,000
16.84%

trucks/d
m/truck
m3/d
%
m3/d
m3/y
%

169
10
1690
15.00%
254
92,528
11.34%

169
10
1690
15.00%
254
92,528
15.74%

m3/y
m /h
m3/tcement
3

Potable Water
Number of employees
Consumption per FTE
Water consumption

Truck Washing Consumption

Maximum expected average washings
Consumption per wash
Total water
Water consumption

Consumed Industrial Water

Raw Mill
Cooling tower
Conditioning tower
Cement mill
Leackeage of recycled water 5%
Total water

Water recyrculation

m3/h
m3/h
m3/h
m3/h
m3/h
m3/h
m3/y
%

m3/y

8.60
7.00
15.67
7.60
15.65
54.51

641,258

396,341

78.59%

67.42%

8,039,000

2,799,414

m3/h
m3/tcement

918
7.87

320
1.33

Industrial consumption
Raw mill
Production development
Preheater precalciner
Kiln
Clinker cooling
Cement grinding
Total

m3/h
m3/h
m3/h
m3/h
m3/h
m3/h
m3/h
m3/y
%

7,514,678

51.0
12.5
72.4
17.2
9.6
150.3
312.9
2,275,091
81%

Truck Washing Consumption

Maximum expected average washings
Consumption per wash
Water consumption

Sewage (from Offices, Showers

etc) / Kanalisation

trucks/d
m/truck
m3/d
%
m3/d
m3/y
%

m3/y

169
10
1690
85.00%
1,437
524,323
6.52%

169
10
1690
85.00%
1,437
524,323
18.73%

185,000

185,000

Recommended size of horizontal storm drains below or above ground can be found in the table below. The drained area may be roofs, paved courtyards or similar.
Area to be drained
Drain pipe diameter

Slope of
1%

mm

inches

m2

2%
ft2

m2

ft2

80

75

820

110

1180

100

175

1880

245

2640

150

495

5350

700

7550

200

1070

11500

1515

16300

Area to be drained
Slope of
4%
m2

ft2

150

1620

350

3770

995

10700

2135

23000

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

Calculating Pressure Drop

Flow rate
Q0

Standard flow rate

G
0

Fluid density normal

Fluid density
Kinematic viscosity normal
Temperature
Altitude
Atmospheric pressure
Supplementary pressure on the start of pipe line
Absolute Pressure on the start of pipe line
Pipe properties
Nominal diameter

t
T
ASL
patm
p1
P1

Equivalent lengths of joints and fittings

Total
Safety factor

A
L0
Leq
L
F

mm
m
m2
m
m
m
%

Nominal pipe length

FxL

Free area
Nominal pipe length

Fluid
10.00
0.0028
10,000
1,000
1,001
1.34E-05
0
273
0
101,325
0
101,325

Nm3/h
Nm3/s
kg/h
kg/Nm3
kg/m3
mm2/s
o
C
o
K
m
Pa
Pa
Pa

50.0
0.050
0.0020
0.1
0.0
0.1
0.0
0.1

Type of pipe

22

Roughness of pipes

kr

Local constant coefficient

ksi

mm

0.0200
1.0000

Velocity and Reynolds

Gas velocity in the pipe

Reynolds

u1

m/s

1.415

u2

m/s

1.415

The boundary layer thickness

Re

5,279

Friction coefficient Re<2320

64/Re

0.0121

Blasius >kr

0,3164/Re-0,25

2.6969

Prandl Re<100000

Karman Re>100000

(2log(D/Kr)+1,14)

0.2668

Friction coefficient f(Re)

Pressure on the end of the pipe line

3
P2

Pa

0.0368
96,616

Pressure drop

Pa

4,708.84

mm

5.21

1.73

5.21

0.0368
-2

0.00

The water velocity in copper pipes should be kept within certain limits to avoid erosion, corrosion and excessive noise generation.
in cold water systems the velocities should not exceed 8 feet per second (2.4 m/s)
in hot water systems with temperatures below 140oF (60oC) the velocities should not exceed 5 feet per second
in hot water systems with temperatures above 140oF (60oC) the velocities should not exceed 2 feet per second
Be aware, and take care of, that local velocities in small pipes, bends and similar obstructions can exceed the values above.

Date : 03/06/2013
Revision : 0

132668590.xls/Water Calculation

Page 36 of 305

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

should be kept within certain limits to avoid erosion, corrosion and excessive noise generation.

atures below 140oF (60oC) the velocities should not exceed 5 feet per second (1.5 m/s)
atures above 140oF (60oC) the velocities should not exceed 2 feet per second (0.6 m/s)
al velocities in small pipes, bends and similar obstructions can exceed the values above.

Date : 03/06/2013
Revision : 0

132668590.xls/Water Calculation

Page 37 of 305

Kinematic viscosity of gases

0*(T0+C)/(T+C)*(T/T0)^3/2

=
Gas

Air
Nitrogen
Oxygen
Carbon dioxid
Carbon monoxid
Hydrogen
Ammonia
Sulfur dioxid
Helium

C
o
K

T0
o
K

0
Pa s

t
o
C

T
o
K

Pa s

120
111
127
240
118
72
370
416
79.4

273.15
300.55
292.25
293.15
288.15
293.85
293.15
293.65
273

1.34E-05
1.78E-05
2.02E-05
1.48E-05
1.72E-05
8.76E-06
9.82E-06
1.25E-05
1.90E-05

0
15
15
15
15
15
15
15
16

273
316
307
308
303
309
308
309
289

1.34E-05
1.85E-05
2.10E-05
1.55E-05
1.79E-05
9.07E-06
1.03E-05
1.32E-05
1.98E-05

Roughness of the pipes

1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

2
Aluminium drawn/pressed
Aluminium drawn/pressed
Asbestos cement
Brass drawn/presed
Brass drawn/presed
Cast iron
Cast iron
Cast iron
Cast iron
Cast iron
Cast iron
Clay
Clay drainage pipe
Concrete
Concrete
Concrete
Concrete
Concrete centrifugal
Concrete centrifugal
Concrete steel
Cooper drawn/pressed
Cooper drawn/pressed
Glass drawn/pressed
Glass drawn/pressed
Plastic drawn/pressed
Plastic drawn/pressed
Rubber
Steel
Steel
Steel
Steel
Steel longitudinal welded
Steel longitudinal welded
Steel longitudinal welded
Steel weldless
Steel weldless
Steel weldless
Steel weldless
Steel weldless
Stoneware

3
new
used
new
new
used
average
incrusted
new
new
operating several year
slighty rusty
new
new
new
new rough
new smooth
operating several year
new with plastered
new without plaster
new
new
used
new
used
new
used
new smooth
after long operation cleaned
homogeneous
intensely incrusted
slighty rusty
new bituminized
new galvanized
new rolling skin
new comm. size galvanized
new neatly galvanized
new pickled
new roling skin
new unpickled

4
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm

5
0.0014
0.0300
0.0650
0.0013
0.0300
1.2000
3.0000
0.1150
0.4000
1.5000
1.2500
9.0000
0.7000
1.5000
2.5000
0.5500
0.2500
0.1250
0.5000
0.1250
0.0014
0.0200
0.0014
0.0300
0.0014
0.0300
0.0016
0.1750
0.1500
3.0000
0.2750
0.0300
0.0080
0.0700
0.1300
0.0850
0.0350
0.0400
0.0450
0.2500

41
42

Wood
Wood

after long operating

new

22

Cooper drawn/pressed

used

mm
mm

mm

0.1000
0.6000

0.0200

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

Calculating Pressure Drop Compressible air flow

Flow rate
Type of gas (1 air/ 2 water)
Standard flow rate

Q0

2
500
0.1389
500,000
1,000.000
5,937.88
1.34E-05
1.34E-05
0
273
0
101,325

G
0

t
T
ASL
patm

Nm3/h
Nm3/s
kg/h
kg/Nm3
kg/m3
mm2/s
mm2/s
o
C
o
K
m
Pa

Pressure on the start of pipe line

Absolute Pressure on the start of pipe line

p1
P1

Pa
Pa

500,000
601,325

Pipe properties
Nominal diameter

Free area

Nominal pipe length

60.0
0.060
2827.4
0.0028
0.1

Equivalent lengths of joints and fittings

Total
Safety factor

L0
Leq
L
F

mm
m
mm2
m2
m

Nominal pipe length

FxL

Fluid density normal

Fluid density
Kinematic viscosity normal
Kinematic viscosity
Temperature
Altitude
Atmospheric pressure

m
%

0.0
0.1
0.0

0.1

Type of pipe

22

Roughness of pipes

kr

Local constant coeficient

ksi

mm

0.0200
1.0000

Velocity and Reynolds

Gas velocity in the pipe

Reynolds

u1

m/s

u2

m/s

Re

Friction coeficient

The boundary layer thikness

Friction coeficient
Pressure on the end of the pipe line

Pressure drop

8.273
8.273
37,042
0.17

mm

0.38

P2

Pa

4.39
516,736

Pa

84,589.15

Hydraulic Diameter of Rectangular Tubes or Ducts

Date : 03/06/2013
Revision : 0

132668590.xls/Air Calculation (2)

Page 43 of 305

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

Based on equation (1) the hydraulic diameter of a rectangular duct or pipe can be calculated as

dh = 2 a b / (a + b) (4)
where
a = width/height of the duct

b = height/width of the duct

4.8

dh = hidraulic diameter

Date : 03/06/2013
Revision : 0

132668590.xls/Air Calculation (2)

Page 44 of 305

Recommended pipe diameter vs flow

300

f(x) = 34.46 x^0.38

R = 1

Free diameter of pipe [mm]

250

200

Row 14
Power Regression for Row
14

150

100

50

0
0

50

100
Flow [mc/min]

150

200

250

Calculation of diaphragms on distribution of water piping

d = diameter of the diaphragm in m

D = internal diameter of the pipe in m
P1 - P2 = pressure drop to be created in bar (Differential pressure)
The calculation of the diaphragms is carried out from the following relation:

Qv = Water flow in m3/s

S = Section of the pipe
r = Density of water in kg/m3 (depends on the temperature)
g = 9.81

One deduces the diameter from the diaphragm (d) by the relation.

Pressure drop in direct galvanized piping [bar] for 100 m linear. Wall thickness [mm]
A free air
m3/min

A
B
outside
diameter
mm

1
2
3
4
5
6
7
8
9
10
12
14
16
18
20
25
30
35
40
45
50
60
70
80
90
100
150
200

15
1/2

20
3/4

25
1

32
1 1/4

40
1:1/2

50
2

65
2:1/2

80
3

21.3
1.187

26.90
0.290

33.70
0.081
0.324

42.4
0.018
0.077
0.170
0.300

48.3
0.008
0.032
0.072
0.134
0.204

60.3

76.1

88.9

0.009
0.020
0.036
0.055
0.079
0.108
0.142
0.180
0.222

0.013
0.021
0.030
0.041
0.055
0.069
0.085
0.112
0.167
0.218

0.010
0.013
0.017
0.022
0.027
0.039
0.053
0.069
0.087
0.107
0.168

90
3:1/2

100
4

115
4:1/2

114.3

0.013
0.018
0.025
0.032
0.041
0.051
0.080
0.115
0.159

0.009
0.012
0.016
0.021
0.025
0.040
0.051
0.078
0.102
0.129
0.160

Pressure 7kgf/cm2(700kPa)~ 6,866167 bar a pressure descent for pipe length 100m (kgf/cm2)

mc/min

Dpipe =

34,356 x Q

0,3736

mm

p = P1-sqrt(P12-46,742x100xQ1,82xD-4,82)

mc/h

120

45

mm

45

0.009
0.012
0.014
0.022
0.032
0.044
0.057
0.072
0.089
0.129

125
5

150
6

175
7

200
8

250
10

300
12

400
16

500
20

139.7

165/168

180.2

219.1

273

323.9

406.4

508

0.012
0.015
0.018
0.027
0.036
0.047
0.060
0.074

0.008
0.012
0.016
0.021
0.026
0.033

0.008
0.011
0.014
0.017
0.038
0.067

0.011
0.020

0.009

0.002

0.001

0.008
0.012
0.015
0.018
0.031
0.039
0.048
0.079
0.095
0.123

1/4
Screwing

90elbow

flange
Screwing

90long
elbow

flange
Screwing

45elbow

flange
Screwing

Tee

flange
Screwing

Tee

flange
Screwing

180bend

flange
long
flange
Screwing

Spherical
valve

flange
Screwing

Gate valve

flange
Screwing

Angle valve

flange
Screwing

Swing stop
valve
Coupling
and unit

flange
Screwing

SS
FC
SS
FC
SS
FC
SS

3/8
0.7

0.5

1/2
0.9

0.6

3/4

1:1/4

Pipe diameter(B)
2
2:1/2
2.60
2.90

1.10

1.30

1.60

2.0

1:1/2
2.30

0.3

0.4

0.5

0.6

0.7

0.9

1.10

0.7

0.7

0.8

1.0

1.0

1.10

1.10

0.3

0.4

0.5

0.6

0.7

0.8

0.9

FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS

0.1

0.2

0.7

0.7

6.40

0.2

0.4

1.10

0.9

6.70

0.2

0.3

0.4

0.5

0.7

0.8

1.0

0.1

0.2

0.3.

0.4

0.4

0.5

0.6

0.5

0.7

1.0

1.40

1.70

2.40

2.80

0.2

0.3

0.3

0.4

0.5

0.6

0.6

1.30

1.60

2.0

2.80

3.0

3.70

4.0

0.6

0.8

1.0

1.30

1.60

2.0

2.30

1.10

1.30

1.60

2.0

2.30

2.20

2.80

0.3

0.4

0.5

0.6

0.7

0.9

1.10

0.3

0.4

0.5

0.6

0.7

0.8

0.9

6.70

7.30

8.80

11.30

12.80

16.50

18.90

11.60

12.20

13.70

16.50

18.0

21.30

23.50

0.2

0.2

0.3

0.3

0.4

0.5

0.5

0.8

0.8

FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS

0.1

3.90

2.20

0.1

4.60

2.20

0.04

0.06

4
4.0
3.40
1.80
1.50
1.40
1.10
1.30

0.0
1.20
1.0
0.8
0.6
3.70
3.0
0.7
0.
5.20
4.20
2.90
2.40
3.40
2.70
1.30
1.10
1.0
0.9
24.10
19.80
28.60

1.0
1.70
1.40
1.10
0.9
5.0
4.20
0.9
0.
6.40
5.20
3.70
3.0
4.0
3.40
1.80
1.50
1.30
.1.0
33.5
26.20
36.5
30.2
0.8
0.6
0.9
0.7
5.50
4.60
11.60
9.40
11.60
9.50
11.60
9.50
0.2

4.60

4.60

5.20

5.50

5.50

5.50

5.50

4.60

4.60

5.20

5.50

5.50

6.40

6.70

2.40

2.70

3.40

4.00

4.60

5.80

6.70

1.20

1.60

2.20

3.10

3.70

5.20

6.40

0.1

6.70
0.1

0.06

0.07

0.09

0.1

0.1

0.1

3.40
2.70
1.30
1.10
1.20
1.0
1.0

23.50
0.6
0.5
0.9
0.7
5.50
4.60
8.50
7.0
8.20
6.70
8.20

FC
SS
FC

10

12

2.20

2.70
2.20

3.70
3.0

4.30
3.70

5.20
4.60

1.50

1.70

2.10

2.40

2.70

1.40

1.70

2.10

2.40

1.40

1.70
1.40

2.40
1.90

2.70
2.50

3.30
3.00

1.0

1.20
0.

1.40
1.

1.60
1.

1.80
1.

4.60

5.50
4.60

7.30
6.10

9.10
7.60

10.30
9.10

2.20

2.70
2.20
1.70
1.40

3.80
3.0
2.20
1.70

4.30
3.70
2.50
2.10

5.20
4.60
2.80
2.40

57.8

79.1

94.5

11.90

45.7

64.0

82.2

10.0

1.0

1.0
0.8

1.0
0.8

1.0
0.9

1.0
0.9

15.20

19.20
15.80

27.40
22.60

36.6
29.90

42.6
36.5

15.20

19.20

27.40

36.6

42.7

15.80

22.60

29.90

36.5

1.50

45.6

1
35.7

2
41.6

3
52.9

5
67.9

10
80.7

20
105.3

30
118.1

40
130.8

50
155.2

80
180.2

100
204.7

200
254.2

Pressure drop in direct galvanized piping [bar] for 100 m linear. Wall thickness [mm]
A
B
A free air
m3/h
m3/min
1
60
2
120
3
180
4
240
5
300
6
360
7
420
8
480
9
540
10
600
12
720
14
840
16
960
18
1,080
20
1,200
25
1,500
30
1,800
35
2,100
40
2,400
45
2,700
50
3,000
60
3,600
70
4,200
80
4,800
90
5,400
100
6,000
150
9,000
200
12,000
250
15,000
300
18,000
350
21,000
400
24,000
450
27,000
500
30,000
550
33,000
600
36,000

15
1/2

20
3/4

25
1

32
1 1/4

40
1:1/2

50
2

65
2:1/2

80
3

21.30
1.187
6.910

26.90
0.279
1.037
2.388
5.023

33.70
0.094
0.338
0.724
1.269
2.007
3.019
4.540

42.4
0.029
0.101
0.213
0.363
0.552
0.781
1.053
1.373
1.746
2.184
3.322
5.166

48.3
0.010
0.034
0.072
0.122
0.184
0.257
0.343
0.440
0.549
0.670
0.952
1.289
1.691
2.169
2.744
4.970

60.3
0.003
0.012
0.024
0.041
0.062
0.087
0.115
0.147
0.183
0.222
0.311
0.415
0.533
0.666
0.815
1.261
1.829
2.554
3.512
4.917

76.1
0.001
0.003
0.007
0.012
0.018
0.024
0.032
0.041
0.051
0.062
0.087
0.115
0.147
0.182
0.221
0.335
0.470
0.629
0.812
1.021
1.257
1.822
2.545
3.497
4.890

88.9
0.000
0.001
0.003
0.004
0.006
0.009
0.012
0.015
0.019
0.023
0.032
0.042
0.054
0.066
0.081
0.121
0.170
0.225
0.288
0.359
0.437
0.616
0.828
1.073
1.356
1.680
4.331

90
3:1/2

100
4

115
4:1/2

outside diameter [mm]

114.3
0.000
0.000
0.000
0.001
0.000
0.000
0.001
0.001
0.000
0.002
0.001
0.001
0.004
0.002
0.001
0.005
0.003
0.002
0.007
0.004
0.002
0.009
0.005
0.003
0.011
0.006
0.003
0.013
0.008
0.004
0.018
0.011
0.006
0.024
0.014
0.007
0.030
0.018
0.009
0.038
0.023
0.012
0.046
0.027
0.014
0.069
0.041
0.021
0.096
0.057
0.029
0.127
0.076
0.039
0.162
0.097
0.049
0.201
0.121
0.061
0.245
0.146
0.074
0.343
0.205
0.104
0.458
0.272
0.138
0.589
0.349
0.176
0.737
0.435
0.218
0.902
0.530
0.265
2.045
1.155
0.566
4.041
2.083
0.983
3.484
1.532
6.315
2.249
3.204
4.596

Pressure 7kgf/cm2(700kPa)~ 6,866167 bar a pressure descent for pipe length 100m (kgf/cm2)

mc/min

Dpipe =

34,356 x Q

0,3736

mm

mc/h

120

45

mm

45

p = P1-sqrt(P12-46,742xL(100)xQ(m3/min)1,82xD(mm)-4,82)
Pipe diameter(B)

125
5

150
6

175
7

200
8

250
10

300
12

400
16

500
20

139.7
0.000
0.000
0.000
0.000
0.001
0.001
0.001
0.002
0.002
0.003
0.004
0.005
0.006
0.008
0.009
0.014
0.020
0.026
0.033
0.041
0.050
0.069
0.092
0.117
0.145
0.177
0.374
0.643
0.987
1.417
1.948
2.610
3.456
4.629
7.006

165/168
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.001
0.001
0.001
0.002
0.002
0.003
0.003
0.004
0.006
0.008
0.011
0.014
0.017
0.021
0.029
0.038
0.048
0.060
0.073
0.153
0.260
0.394
0.555
0.744
0.963
1.214
1.500
1.826
2.198

180.2
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.001
0.001
0.001
0.002
0.002
0.003
0.004
0.005
0.007
0.008
0.010
0.014
0.018
0.023
0.029
0.035
0.072
0.123
0.185
0.259
0.345
0.442
0.552
0.674
0.809
0.958

219.1
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.001
0.001
0.001
0.001
0.002
0.003
0.003
0.004
0.005
0.007
0.009
0.012
0.015
0.018
0.038
0.064
0.097
0.135
0.179
0.229
0.285
0.347
0.414
0.488

273
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.001
0.001
0.001
0.002
0.002
0.003
0.004
0.005
0.006
0.013
0.022
0.033
0.046
0.061
0.077
0.096
0.117
0.139
0.163

323.9
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.001
0.001
0.001
0.002
0.002
0.003
0.005
0.009
0.014
0.019
0.025
0.032
0.040
0.048
0.057
0.067

406.4
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.001
0.001
0.002
0.003
0.005
0.006
0.008
0.010
0.012
0.014
0.017

508
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.001
0.002
0.002
0.003
0.003
0.004
0.005
0.006

1/4
Screwing

90elbow

flange
Screwing

90long
elbow

flange
Screwing

45elbow

flange
Screwing

Tee

flange
Screwing

Tee

flange
Screwing

180bend

flange
long
flange
Screwing

Spherical
valve

flange
Screwing

Gate valve

flange
Screwing

Angle valve

flange
Screwing

Swing stop
valve
Coupling
and unit

flange
Screwing

SS
FC
SS
FC
SS
FC
SS

3/8
0.7

0.5

1/2
0.9

0.6

1.10

3/4
1.30

1
1.60

1:1/4
2.0

1:1/2
2.30

0.3

0.4

0.5

0.6

0.7

0.7

0.8

0.3

0.4

0.5

2
2.60

2:1/2
2.90

0.7

0.9

1.10

1.0

1.0

1.10

1.10

0.6

0.7

0.8

0.9

FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS

0.1

0.2

0.7

0.7

6.40

0.2

0.4

1.10

0.9

6.70

0.2

0.3

0.4

0.5

0.7

0.8

1.0

0.1

0.2

0.3.

0.4

0.4

0.5

0.6

0.5

0.7

1.0

1.40

1.70

2.40

2.80

0.2

0.3

0.3

0.4

0.5

0.6

0.6

1.30

1.60

2.0

2.80

3.0

3.70

4.0

0.6

0.8

1.0

1.30

1.60

2.0

2.30

1.10

1.30

1.60

2.0

2.30

2.20

2.80

0.3

0.4

0.5

0.6

0.7

0.9

1.10

0.3

0.4

0.5

0.6

0.7

0.8

0.9

6.70

7.30

8.80

11.30

12.80

16.50

18.90

11.60

12.20

13.70

16.50

18.0

21.30

23.50

0.2

0.2

0.3

0.3

0.4

0.5

0.5

0.8

0.8

FC
SS
FC
SS
FC
SS
FC
SS
FC
SS
FC
SS

0.1

3.90

2.20

0.1

4.60

2.20

0.04

0.06

4
4.0
3.40
1.80
1.50
1.40
1.10
1.30

0.0
1.20
1.0
0.8
0.6
3.70
3.0
0.7
0.
5.20
4.20
2.90
2.40
3.40
2.70
1.30
1.10
1.0
0.9
24.10
19.80
28.60

1.0
1.70
1.40
1.10
0.9
5.0
4.20
0.9
0.
6.40
5.20
3.70
3.0
4.0
3.40
1.80
1.50
1.30
.1.0
33.5
26.20
36.5
30.2
0.8
0.6
0.9
0.7
5.50
4.60
11.60
9.40
11.60
9.50
11.60
9.50
0.2

4.60

4.60

5.20

5.50

5.50

5.50

5.50

4.60

4.60

5.20

5.50

5.50

6.40

6.70

2.40

2.70

3.40

4.00

4.60

5.80

6.70

1.20

1.60

2.20

3.10

3.70

5.20

6.40

0.1

6.70
0.1

0.06

0.07

0.09

0.1

0.1

0.1

3.40
2.70
1.30
1.10
1.20
1.0
1.0

23.50
0.6
0.5
0.9
0.7
5.50
4.60
8.50
7.0
8.20
6.70
8.20

FC
SS
FC

10

12

2.20

2.70
2.20

3.70
3.0

4.30
3.70

5.20
4.60

1.50

1.70

2.10

2.40

2.70

1.40

1.70

2.10

2.40

1.40

1.70
1.40

2.40
1.90

2.70
2.50

3.30
3.00

1.0

1.20
0.

1.40
1.

1.60
1.

1.80
1.

4.60

5.50
4.60

7.30
6.10

9.10
7.60

10.30
9.10

2.20

2.70
2.20
1.70
1.40

3.80
3.0
2.20
1.70

4.30
3.70
2.50
2.10

5.20
4.60
2.80
2.40

57.8

79.1

94.5

11.90

45.7

64.0

82.2

10.0

1.0

1.0
0.8

1.0
0.8

1.0
0.9

1.0
0.9

15.20

19.20
15.80

27.40
22.60

36.6
29.90

42.6
36.5

15.20

19.20

27.40

36.6

42.7

15.80

22.60

29.90

36.5

1.50

45.6

1
35.7

2
41.6

3
52.9

5
67.9

10
80.7

20
105.3

30
118.1

40
130.8

50
155.2

80
180.2

100
204.7

200
254.2

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

The diagram of air consumers - Expansion Project

Central Compressor Room
p1=7 bar V=714 Nm3/h

DN
L~
V
p
p2

50.0 mm
75 m
100 Nm3/h
0.006 bar

DN
L~
V
p
p2

6.970 bar

DN
L~
V
p
p2

Gypsum plant

65.0 mm
180 m
212 Nm3/h
0.016 bar

DN
L~
V
p
p2

6.976 bar

80.0 mm
30 m
499 Nm3/h
0.005 bar
6.993 bar

DN
L~
V
p
p2

115.0 mm
45 m
714 Nm3/h
0 bar

DN

65.0 mm

L~
V
p
p2

80 m
215 Nm3/h
0.007 bar

7 bar

50.0 mm
95 m
112 Nm3/h
0.010 bar
6.967 bar

Slag dryer

DN
L~
V
p
p2

65.0 mm
105 m
287 Nm3/h
0.017 bar

DN
L~
V
p
p2

50.0 mm
165 m
169 Nm3/h
0.019 bar

6.976 bar

6.958 bar

Old cement silos

Remarks: The calculation was made in the follow conditions:

DN
L~
V
p
p2
Packing plant

6.990 bar

50.0 mm
105 m
118 Nm3/h
0.023 bar
6.953 bar
New cement silos

1) One hypothesis regarding the pipe route, lengths and nominal pipe inside diameter of the transoms
2) The consumers list according to

The final values of the pressure will be possible to be calculated after the finalization of the compressed air project
Date: 03/06/2013
Revision: 0

132668590.xls/Air consumer

Page 55 of 305

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

Calculating Pressure Drop

P12-P22 =
P1,P2
L
Q

46.742**L*Q1.82*D-4.82
bar absolute pressure
m length of the pipe
m3/h flow rate at p=1,01325 bar 288oK
relative density ng/AIR 1,0 for air and 0.64 for gas
mm inside pipe diameter
Total

Standard flow rate

Q0

New silos

Total1

Total2

Packing plant Old silos

Total3

Slag dryer Gypsum

714

215

499

287

169

118

212

112

100

Nm3/min

11.90

3.58

8.32

4.79

2.82

1.97

3.53

1.86

1.67

P1

C
m
bar
m3/h
bar
bar

1
1.00
0
0
1.013
714
7.000
8.013

1
1.00
0
0
1.013
215
6.998
8.011

1
1.00
0
0
1.013
499
6.998
8.011

1
1.00
0
0
1.013
287
6.993
8.006

1
1.00
0
0
1.013
169
6.976
7.989

1
1.00
0
0
1.013
118
6.976
7.989

1
1.00
0
0
1.013
212
6.993
8.006

1
1.00
0
0
1.013
112
6.976
7.989

1
1.00
0
0
1.013
100
6.976
7.989

Nominal pipe length

L0

20

60

20

86

80

132

150

70

60

Equivalent lengths of joints and fittings

Leq

20

10

12

12

12

12

40

70

26

92

92

150

162

82

66

Type of gas (1 air/ 2 natural gas)

Relative Density
Temperature
Altitude
Pressure atm
Flow rate
Pressure on the start of pipe line
Absolute Pressure on the start of pipe line

t
ASL
patm
Q
p1

Nm3/h

Total

Safety factor

10

10

10

10

10

10

10

10

10

Nominal pipe length

FxL

45

80

30

105

105

165

180

95

75

Nominal diameter

DN

mm

115.0

65.0

80.0

65.0

50.0

50.0

65.0

50.0

50.0

Free area

0.010

0.003

0.005

0.003

0.002

0.002

0.003

0.002

0.002

Gas velocity in the pipe

m/s

19

18

28

24

24

17

18

16

14

Absolute Pressure on the end of the pipe line

P2

bar

8.011

8.003

8.006

7.989

7.966

7.971

7.989

7.980

7.983

Pressure drop

bar

0.002

0.007

0.005

0.017

0.023

0.019

0.016

0.010

0.006

Pressure on the end of the pipe line

p2

bar

6.998

6.990

6.993

6.976

6.953

6.958

6.976

6.967

6.970

Date : 03/06/2013
Revision : 0

132668590.xls/Air Calculation

Page 56 of 305

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

Date : 03/06/2013
Revision : 0

A
B
Inside diameter

mm
toll
mm

20
3/4
21.6

25
1
27.6

32
1 1/4
35.7

38
1 1/2
41.6

50
2
52.9

A
B
Inside diameter

mm
toll
mm

125
5
130.8

150
6
155.2

175
7
180.2

200
8
204.7

250
10
254.2

132668590.xls/Air Calculation

65
21/2
67.9

80
3
80.7

90
31/2
93.2

100
4
105.3

115
41/2
118.1

Page 57 of 305

LOCAL VENTILATION VOLUME FOR COMPRESSORS

H x 860
Q=
xCpx(t2-t1)x60
H
Htot

Cp
t1
t2
Q
V
w
A
p
P

Heat generation

kW

Heat generation
Air specific gravity
Air specific heat
Temp outdoor
Temp indoor
Exhaust air
Ventilation fan
3
Velocity
Window for exhaust air
Pressure of fan
Motor power

Mj/h
kg/m3
kcal/(kg grd)
deg
deg
m3/min
m3/min
m3/h
m/s
m2
Pa
kW

350
1260
1.2
0.24
10
30
870.9
2,612.8
156,771
20
2.18
100
6.22

VENT WINDOW AREA-AIR INTAKE PORT

Q+Q0
A=
60 x v x
Q Exhaust air
Q0 Outgoing air volume
Q0+Q Air intake
v
air speed
a
vent window opening ratio
A vent window area

length
2 x vent window area

2 x length

03/06/2013

m3/min
m3/min
m3/min
m/s
%
m2

870.9
7.5
878.4
2
100.0
7.3

m
m2

2.7
3.66

1.91

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

58/305

C o m p re ss ed
A ir S ys te m

4
1

3
14

12

8
5

13

10
11

9
7

14

14

14

3
14

15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

03/06/2013

Compressor
Hose connection
Cyclone separator
Ball valve
Pressure tank
By pass for tank
Dryer
By pass for dryer
Filter set
By pass for filter set
Pressure control set
Connecting pipe
Pipeline to consumer
Condensate drain unit
Drain pipeline system
Oil/Water separator

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

59/305

DUCT VENTILATION VOLUME FOR COMPRESSORS

H x 860 x 0,05
Q=
xCpx(t2-t1)x60
H
Htot

Cp
t1
t2
Q
V
w
A
p
P

Heat generation

kW

Heat generation
Air specific gravity
Air specific heat
Temp outdoor
Temp indoor
Exhaust air
Ventilation fan
3
Velocity
Window for exhaust air
Pressure of fan
Motor power

Mj/h
kg/m3
kcal/(kg grd)
deg
deg
m3/min
m3/min
m3/h
m/s
m2
Pa
kW

350
1260
1.2
0.24
10
30
43.5
130.6
7,839
20
0.11
100
0.31

VENT WINDOW AREA-AIR INTAKE PORT

Q+Q0
A=
60 x v x
Q Exhaust air
Q0 Outgoing air volume
Q0+Q Air intake
v
air speed
a
vent window opening ratio
A vent window area

2x

03/06/2013

m3/min
m3/min
m3/min
m/s
%
m2

43.5
7.5
51.0
2
100.0
0.4

length
2 x vent window area

m
m2

0.7
0.21

length

0.46

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

60/305

Motor
output

Ventilation amount (in case of

air cooling)
Heat amount generated
Exhausted air amount
If t = 3

If t = 5

(MJ/h)

(m3/min)

(m3/min)

7.5kW

32

20

85

11kW

47

30

125

15kW

68

45

180

[54]

[85]

[145]

Cooling tower
(in case of
water cooling)
CT exit
temperature
if 32C

5t over

(80)*3
22kW

97

55

260

[79]

[105]

[210]

10t over

(80)*3
30kW

(121)*3

(100)*3

(340)*3

37kW

159

85

430

[130]

[200]

[400]

(184)*3
201
[Please ask us]
272
[Please ask us]

(120)*3
(150)*3
140
[Please ask us]
190
[Please ask us]

(510)*3
880
[Please ask]
1.2
[Please ask]

45kW
55kW
75kW
90kW
100kW
120kW
150kW

03/06/2013

10t over

15t over
20t over
30t over
30t over
30t over
30t over

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

61/305

VENTILATION VOLUME FOR COMPRESSORS WITH DRYER

860 x (H + Hdryer)
Q=
xCpx(t2-t1)x60
H
Hdryer
Htot

Cp
t1
t2
Q
V
w
A
p
P

Heat generation
Dryer heat generation
Heat generation
Air specific gravity
Air specific heat
Temp outdoor
Temp indoor
Exhaust air
Ventilation fan
3
Velocity
Window for exhaust air
Pressure of fan
Motor power

kW
kW
Mj/h
kg/m3
kcal/(kg grd)
deg
deg
m3/min
m3/min
m3/h
m/s
m2
Pa
kW

350
9
1292.4
1.2
0.24
10
30
893.3
2680.0
160,802
20
2.23
100
6.38

VENT WINDOW AREA-AIR INTAKE PORT

Q+Q0
A=
60 x v x
Q
Q0
Q0+Q
v
a
A

2x

03/06/2013

Exhaust air
Outgoing air volume
Air intake
air speed
vent window opening ratio
vent window area

m3/min
m3/min
m3/min
m/s
%
m2

length
2 x vent window area

m
m2

2.80
3.75

length

1.94

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

893.3
7.5
900.8
2
100.0
7.5

62/305

Atlas Copco

X
Y
H
H
t
V

03/06/2013

Constant ZT 55 VSD
Constant ZT 55 VSD
Heat generation ZT 45
Heat generation ZT 55 VSD
Temperature increase
Ventilation fan
(X*H+Y)/t

kW
kW
o
C
m3/s
m3/h
%

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

1.12
3.72
90
55
10
17.36
62,482
2.57

63/305

ITH DRYER

DUCT VENTILATION VOLUME FOR COMPRESSORS WITH DRYER

860 x (H x 0.05 + Hdryer)

Q=
xCpx(t2-t1)x60

14.89
44.67
44.67

H
Heat generation
Hdryer Dryer heat generation
Htot Heat generation

Air specific gravity

Cp Air specific heat
t1
Temp outdoor
t2
Temp indoor
Q Exhaust air
V
Ventilation fan
3
w Velocity
A Window for exhaust air
p Pressure of fan
P
Motor power

kW
kW
Mj/h
kg/m3
kcal/(kg grd)
deg
deg
m3/min
m3/min
m3/h
m/s
m2
Pa
kW

350
9
1292.4
1.2
0.24
10
30
65.9
197.8
11,870
20
0.16
100
0.47

VENT WINDOW AREA-AIR INTAKE PORT

Q+Q0
A=
60 x v x
Q Exhaust air
Q0 Outgoing air volume
Q0+Q Air intake
v
air speed
a
vent window opening ratio
A vent window area

2x

03/06/2013

m3/min
m3/min
m3/min
m/s
%
m2

65.9
7.5
73.4
2
100.0
0.6

length
2 x vent window area

m
m2

0.8
0.31

length

0.55

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

64/305

Natural Draft Head

1.12
3.72
90
55
10
11.20
40,306

p = g x (o - r) h
o
h
to
ti
o
i
g
p

normal density of fluid

height between outlet and inlet air
temperature outside
temperature inside
density outside air
density inside air
gravity
Natural draft pressure of stack

Major and Minor System Loss

p = (l / dh) (r v2 / 2) + 1/2

03/06/2013

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

65/305

S WITH DRYER

Ventilation volume vs the volume of the room

L
length
W width
H
height
V
volume
The purpose for which it is used ACH
Ventilation necessary flow

PORT

03/06/2013

m
m
m
m3
no/h
m3/h

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

24
6.5
4.6
717.6
20
14,352

66/305

kg/m3
m
o
C
o
C
kg/m3
kg/m3
m/s2
Pa

1.29
10
5
20
1.27
1.20
9.81
6.36

or System Loss

v2 / 2) + 1/2 r v2

03/06/2013

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

67/305

0.40
20-30
4-8
6-10
6-8
2-4
6-8
15-30
10-12
8-12
3-10
1-3
10-15
10-12
10-20
8-10
8-12
20-30
10-12
15-30
3-5
8-10

Assembley Halls
Bakeries
Banks
Bathrooms
Battery Charging Rooms
Bedrooms
Billiard Rooms *
Boiler Rooms
Cafes & Coffee Bars
Canteens
Cellars
Churches
Cinemas & Theatres *
Club Room *
Compressor Rooms
Dairies
Dance Halls *
Dye Works
Electroplating Shops
Engine Rooms
Entrance Halls, Corridors
Factories & Workshops
Recommended minimum fresh air supply

03/06/2013

Air space per person

Air supply per

person

Air changes
per hour

m/person
3
6
9
12

m3/h
61.2
39.6
28.8
21.6

(ACH)
20
6.50
3.20
1.80

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

68/305

03/06/2013

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

69/305

Foundries
Garages
Glasshouses
Hairdressing salons
Hospitals
Kitchens
Laboratories
Laundrettes
Laundries
Lavatories
Lecture Theatres
Libraries
Living Rooms
Mushrooms Houses
Offices
Paint Shops (not cellulose)
Photo & X-ray dark rooms
Public House bars
Recording studios
Recording Control rooms
Restaurants
Schoolrooms
Shops & Showrooms
Shower Baths
Stores & Warehouses
Swimming Baths
Toilets
Welding Shops

03/06/2013

- Sterilising
- Wards
- Domestic
- Commercial

15-30
6-8
25-60
10-15
15-25
6-8
15-20
20-30 Min
6-15
10-15
10-30
6-15
5-8
3-5
3-6
6-10
6-10
10-20
10-15
10-15
10-12
12-25
8-12
5-7
8-12
15-20
3-6
10-15
6-10
15-30

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

70/305

03/06/2013

file:///var/www/apps/conversion/tmp/scratch_1/132668590.xls ventilation volume

71/305

CEPROCIM S.A.

5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0

Data: 03/06/2013

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

132668590.xls/Chart9 (2)

Converting from/to standard cubic meters

The standard volume is calculated on the basis of standard conditions
at pressure of 101.325 kPa (760 torr) and
DIN 1343 at a temperature of 273.15 oK ( 0 oC)
ISO 2533 at temperature of 288,15 oK (15 oC)
Altitude
Pressure

m
kPa
Pa
mbar
psi
at
atm
mmWG
torr

1,000.0
89.4
89,374.3
893.5
13.0
0.9
0.9
9,113.9
670.1

DIN 1343

ISO 2533

Local

Standard volume
VO
To

Nm3
C

K
Pa
kg/Nm3
kg
o

Po
o
M

100

Vi

Ti

273.15
101,325
1.29
129.300

Nm3

105.5

V1

15.0

T1

K
Pa
kg/Nm3
kg
o

Pi
i
M

288.2
101,325
1.226
129.300

Nm3

125.8

15.0

K
Pa
kg/Nm3
kg
o

P1
1
M

303.2
89,374
1.028
129.300

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

The diagram of gas consumers - grey cement - Expansion Project

Gas regulating station
from Gavrilovskoe
Monstransgas

Boundary

GAS CONTROL POINT 2

Pinput = 6 (4,5-5,0) bar
Poutput = 3 bar

DN
L~
V
p
p2

150 mm
250 m
2,500 Nm3/h
0.057 bar
2.666 bar

DN
L~
V
p
p2

200 mm
205 m
4,000 Nm3/h
0.027 bar

DN
L~
V
p
p2

100 mm
40 m
1,500 Nm3/h
0.025 bar

2.723 bar

2.698 bar

New Boiler

New Dryer

Remarks: The calculation was made in the follow conditions:

DN
L~
V
p
p2

250 mm
135 m
15,250 Nm3/h
0.069 bar

DN
L~
V
p
p2

200 mm
25 m
11,250 Nm3/h
0.022 bar

2.750 bar

2.728 bar

Kiln

Calciner

DN
L~
V
p
p2

300 mm
75 m
31,180 Nm3/h
0.057 bar

DN
L~
V
p
p2

250 mm
60 m
15,930 Nm3/h
0.033 bar

DN
300 mm
L~
145 m
V 33,680 Nm3/h
p
0.12 bar
p2
2.88 bar

2.819 bar

DN
L~
V
p
p2

2.786 bar

100 mm
30 m
2,500 Nm3/h
0.046 bar
2.830 bar

Raw mill

1) One hypothesis regarding the pipe route, lengths and nominal pipe inside diameter of the transoms
2) The consumers list according to SH 04C-400 305 A
3) The maximum gas flow indicated by FL Smidth for kiln, calciner , raw mill hot gas generator and slag dryer

The final values of the pressure will be possible to be calculated after the finalization of the natural gas project

Date: 03/06/2013
Revision: 0

132668590.xls/Gas consumer

Page 74 of 305

ANSI Screw and Nut threads size chart

Basic fastener
External thread
Designation
M 1.6 x 0.35
M 1.6 x 0.35
M 2 x 0,4
M 2 x 0,5
M 2,5 x 0.45
M 2,5 x 0.45
M 3 x 0,5
M 3 x 0,5
M 3,5 x 0,6
M 3,5 x 0,6
M 4 x 0.7
M 4 x 0.7
M 5 x 0.8
M 5 x 0.8
M 6 x 1,0
M 6 x 1,0
M 8 x 1,25
M 8 x 1,25
M 8 x 1,0
M 8 x 1,0
M 10 x 1,5
M 10 x 1,5
M 10 x 1,25
M 10 x 1,25
M 10 x 0,75
M 10 x 0,75
M 12 x 1,75
M 12 x 1,75
M 12 x 1,25
M 12 x 1,25
M 12 x 1,0
M 12 x 1,0
M 14 x 2,0
M 14 x 2,0
M 14 x 1,5
M 14 x 1,5
M 15 x 1,0
M 15 x 1,0
M 16 x 2,0
M 16 x 2,0
M 16 x 1,5
M 16 x 1,5
M 17 x 1,0
M 17 x 1,0
M 18 x 1,5

Tolerances
Class
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g
4g6g
6g

Major diameter
Max
1.581
1.581
1.981
1.981
2.480
2.480
2.980
2.980
3.479
3.479
3.978
3.978
4.976
4.976
5.974
5.974
7.972
7.972
7.974
7.974
9.97
9.97
9.97
9.97
9.98
9.98
11.97
11.97
11.97
11.97
11.97
11.97
13.96
13.96
13.97
13.97
14.97
14.97
15.96
15.96
15.97
15.97
16.97
16.97
17.97

Min
1.496
1.496
1.886
1.886
2.380
2.380
2.874
2.874
3.354
3.354
3.838
3.838
4.826
4.826
5.794
5.794
7.760
7.760
7.794
7.794
9.73
9.73
9.76
9.76
9.84
9.84
11.7
11.7
11.76
11.76
11.79
11.79
13.68
13.68
13.73
13.73
14.79
14.79
15.68
15.68
15.73
15.73
16.79
16.79
17.73

Pitch diameter -pas

Max
1.354
1.354
1.721
1.721
2.188
2.188
2.655
2.655
3.089
3.089
3.523
3.523
4.456
4.456
5.324
5.324
7.160
7.160
7.324
7.324
8.99
8.99
9.16
9.16
9.49
9.49
10.83
10.83
11.16
11.16
11.32
11.32
12.66
12.66
12.99
12.99
14.32
14.32
14.63
14.63
14.99
14.99
16.32
16.32
16.99

Min
1.291
1.314
1.654
1.679
2.117
2.143
2.580
2.607
3.004
3.036
3.433
3.467
4.361
4.396
5.212
5.253
7.042
7.085
7.212
7.253
8.86
8.91
9.04
9.09
9.39
9.43
10.68
10.73
11.03
11.08
11.21
11.25
12.5
12.56
12.85
12.9
14.21
14.25
14.5
14.56
14.85
14.9
16.21
16.25
16.85

Minor diameter
Max
1.202
1.202
1.548
1.548
1.993
1.993
2.439
2.439
2.829
2.829
3.220
3.220
4.110
4.110
4.891
4.891
6.619
6.619
6.891
6.891
8.34
8.34
8.62
8.62
9.17
9.17
10.07
10.07
10.62
10.62
10.89
10.89
11.8
11.8
12.34
12.34
13.89
13.89
13.8
13.8
14.34
14.34
15.89
15.89
16.34

Min
1.075
1.098
1.408
1.433
1.840
1.866
2.272
2.299
2.635
2.667
3.002
3.036
3.869
3.904
4.596
4.637
6.272
6.315
6.596
6.637
7.938
7.985
8.272
8.272
8.929
8.929
9.656
9.930
10.258
10.305
10.590
10.633
11.271
11.331
11.930
11.980
13.590
13.633
13.271
13.331
13.930
13.980
15.590
15.633
15.930

M 18 x 1,5

4g6g

17.97

17.73

16.99

16.9

16.34

15.980

Metric Wide Flange Beams - Light Weight

Section no

100
120
140
160
180
200
220
240
260
280
300
320
340
360
400
450
500
550
600
650

Depth
h
mm
96
114
133
152
171
190
210
230
250
270
290
310
330
350
390
440
490
540
590
640

Width
b
mm
100
120
140
160
180
200
220
240
260
280
300
300
300
300
300
300
300
300
300
300

thick
t
mm
8
8
8.5
9
9.5
10
11
12
12.5
13
14
15.5
16.5
17.5
19
21
23
24
25
26

web
s
mm
5
5
5.5
6
6
6.5
7
7.5
7.5
8
8.5
9
9.5
10
11
11.5
12
12.5
13
13.5

Weight
kg/m
16.7
19.9
24.7
30.4
35.5
42.3
50.5
60.3
68.2
76.4
88.3
97.6
105
112
125
140
155
166
178
190

Area Moment of Inertia for some common Cross Sections

Rectangular Cross Section
Ix = b h3 / 12 (2)
where

b = width
h = height
Circular Cross Section
Ix = r4 / 4
= d4 / 64 (3)
where
r = radius
d = diameter
Cylindrical Cross Section
Ix = (do4 - di4) / 64 (3)
where
do = cylinder outside diameter
di = cylinder inside diameter

Static
Parameters
Moment of
Inertia

Dimensions

HEA

Depth

Width

Web
Thickness

Sectional
Area

Weight

Ix

(cm )

(kg/m)

(cm )

(cm4)

Iy
4

(mm)

(mm)

(mm)

100A

96

100

21.20

16-Jul

349

134

120A

114

120

25.30

19-Sep

606

231

140A

133

140

5.50

31.4

24-Jul

1030

389

160A

152

160

38.8

30-Apr

1670

616

180A

171

180

45.3

35.5

2410

925

200A

190

200

6.50

43.8

42.3

3690

1340

220A

210

220

64.3

50.5

5410

1950

240A

230

240

7.50

76.8

60.3

7760

2770

260A

250

260

7.50

86.8

68.2

10450

3670

280A

270

280

97.3

76.4

13670

4760

300A

290

300

8.50

112

88.3

18260

6310

320A

310

300

124

97.6

22930

6990

340A

330

300

9.50

133

105

27690

7440

Metric Wide Flange Beams - Medium Weight

Section no

100
120
140
160
180
200
220
240
260
280
300
320
340
360
400
450
500
550
600
650

Depth
h
mm
100
120
140
160
180
200
220
240
260
280
300
320
340
360
400
450
500
550
600
650

Width
b
mm
100
120
140
160
180
200
220
240
260
280
300
300
300
300
300
300
300
300
300
300

thick
t
mm
10
11
12
13
14
15
16
17
17.5
18
19
20.5
21.5
22.5
24
26
28
29
30
31

web
s
mm
6
6.5
7
8
8.5
9
9.5
10
10
10.5
11
11.5
12
12.5
13.5
14
14.5
15
15.5
16

Weight
kg/m
20.4
26.7
33.7
42.6
51.2
61.3
71.5
83.2
93
103
117
127
134
142
155
171
187
199
212
225

Section
Modulus
Wx

Wy

(cm )

(cm )

HEB

Depth

Width

Dimensions
Web
Thickness

(mm)

(mm)

(mm)

Sectional
Area

Weight

(cm )

(kg/m)

72.8

26-Aug

100B

100

100

26

20.4

106

38.5

120B

120

120

6.5

34

26.7

155

55.6

140B

140

140

43

33.7

220

76.9

160B

160

160

54.3

42.6

294

103

180B

180

180

8.5

65.3

51.2

389

134

200B

200

200

78.1

61.3

515

178

220B

220

220

9.5

91

71.5

675

231

240B

240

240

10

106

83.2

836

282

260B

260

260

10

118

93

1010

340

280B

280

280

10.5

131

103

1260

421

300B

300

300

11

149

117

1480

466

320B

320

300

11.5

161

127

1680

499

340B

340

300

12

171

134

Metric Wide Flange Beams - Heavy Weight

Section no

100
120
140
160
180
200
220
240
260
280
300
320
340
360
400
450
500
550
600

Depth
h
mm
120
140
160
180
200
220
240
270
290
310
340
359
377
395
432
478
524
572
620

Width
b
mm
106
126
146
166
186
206
226
248
268
288
310
309
309
308
307
307
306
306
305

thick
t
mm
20
21
22
23
24
25
26
32
32.5
33
39
40
40
40
40
40
40
40
40

web
s
mm
12
12.5
13
14
14.5
15
15.5
18
18
18.5
21
21
21
21
21
21
21
21
21

Weight
kg/m
41.8
52.1
63.2
76.2
88.9
103
117
157
172
189
238
245
248
250
256
263
270
278
285

Static Parameters
Moment of Inertia
Ix

Iy

(cm )
4

(cm )
4

Section Modulus
Wx

Wy

(cm )

(cm )

HEM

Depth

Width

Dimensions
Web
Thickness

(mm)

(mm)

(mm)

450

167

89.9

33.5

100M

120

106

12

864

318

144

52.9

120M

140

126

12.50

1510

550

216

78.5

140M

160

146

13

2490

889

311

111

160M

180

166

14

3830

1360

426

151

180M

200

186

14.50

5700

2000

570

200

200M

220

206

15

8090

2840

736

258

220M

240

226

15.50

11260

3920

938

327

240M

270

248

18

14920

5130

1150

395

260M

290

268

18

19270

6590

1380

471

280M

310

288

18.50

25170

860

1680

571

300M

340

310

21

30820

9240

1930

616

320M

359

309

21

36660

9690

2160

646

340M

377

309

21

Static Parameters
Dimensions

Moment of Inertia
Sectional
Area

Weight

Ix

(cm )

(kg/m)

(cm )

53.2

41.8

66.4

52.1

80.6

Wx

Wy

(cm )

(cm )

(cm3)

1140

399

190

75.3

2020

703

288

112

63.2

3290

1140

411

157

97.1

76.2

5100

1760

566

212

113

88.9

7480

2580

748

277

131

103

10640

3650

967

354

149

117

14600

5010

1220

444

200

157

24290

8150

1800

657

220

172

31310

10450

2160

780

240

189

39550

13160

2550

914

303

238

59200

19400

3480

1250

312

245

68130

19710

3800

1280

316

248

76370

19710

4050

1280

Iy

Section Modulus

Precast elements DIN 993-5 DIN EN 993-6

Tolerances

For size <100 mm For size 100-130 mm For size > 130 mm
1 mm
1 %
1 %

Curvature
Max 1% of largest size

Insulating lining bricks

Group
BA
HAL
CH
W

Material characteristics
For size <100 mmFor size 100-130 mm For size > 130 mm
burnt
1,5 %
1,5 %
1,5 %
all
1,5 %
1,5 %
1,25 %
all
1,5 %
1,5 %
1,5 %
wet shaped
1,5 mm
2 mm
2%
dry shaped
1,0 mm
1,5 mm
1%
ground
1,0 mm
1,0 mm
1%

BA
HAL
CH
W

basic bricks
High alumina bricks
fire bricks
chamotte
Insulating lining bricks

Curvature
Max 1% of largest size
Max 1% of largest size
Max 1,5% of largest size
Max 1% of largest size
Max 1% of largest size
Max 0,75% of largest size

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

Renouard Equation
P12-P22 =
P1,P2
L
Q

46.742**L*Q1.82*D-4.82
bar absolute pressure
m length of the pipe
m3/h flow rate at p=1,01325 bar 288oK
relative density ng/AIR 1,2 for air and 0.64 for gas
mm inside pipe diameter
Calculating Pressure Drop
Total

Standard flow rate

Type of gas (1 air/ 2 natural gas)
Relative Density
Temperature
Altitude
Pressure atm
Flow rate

Raw mill

Total1

Total2

Calciner

Total3

Kiln

Boiler

Slag dryer

Q0

Nm3/h

33,680

2,500

31,180

15,930

15,250

11,250

4,000

1,500

2,500

t
ASL

kg/Nm3
o
C
m
bar
m3/h

2
0.64
15
110
0.999
36,024

2
0.64
15
110
0.999
2,674

2
0.64
15
110
0.999
33,350

2
0.64
15
110
0.999
17,039

2
0.64
15
110
0.999
16,312

2
0.64
15
110
0.999
12,033

2
0.64
15
110
0.999
4,278

2
0.64
15
110
0.999
1,604

2
0.64
15
110
0.999
2,674

bar
bar

3.000
3.999

2.876
3.875

2.876
3.875

2.819
3.818

2.819
3.818

2.750
3.749

2.750
3.749

2.723
3.722

2.723
3.722

Pressure on the start of pipe line

Absolute Pressure on the start of pipe line

Q
p1
P1

Nominal pipe length

L0

114

13

60

45

115

20

170

20

220

Equivalent lengths of joints and fittings

Leq

16

10

12

12

130

23

66

51

120

23

182

32

226

Total

Safety factor

10

10

10

10

10

10

10

10

10

FxL

145

30

75

60

135

25

205

40

250

Nominal diameter

mm

300

100

300

250

250

200

200

100

150

Free area

0.071

0.008

0.071

0.049

0.049

0.031

0.031

0.008

0.018

Gas velocity in the pipe

m/s

142

95

131

96

92

106

38

57

42

Absolute Pressure on the end of the pipe line

P2

bar

3.875

3.829

3.818

3.785

3.749

3.727

3.722

3.697

3.665

Pressure drop

bar

0.124

0.046

0.057

0.033

0.069

0.022

0.027

0.025

0.057

Pressure on the end of the pipe line

p2

bar

2.876

2.830

2.819

2.786

2.750

2.728

2.723

2.698

2.666

Nominal pipe length

Date : 03/06/2013
Revision : 0

132668590.xls/Gas Calculation

Page 92 of 305

SHUROVO CEMENT EXPANSION PROJECT

OJSC Shurovsky Cement

Date : 03/06/2013
Revision : 0

132668590.xls/Gas Calculation

Page 93 of 305

Air Receiver Sizing HOLCIM Recommendation

70

60

Receiver Volume VR [m3]

50

Column D
Column B
Column C
Column D

40

30

20

10

0
0

10

20

30

40

50

60

70

80

90 100 110 120 130 140 150 160 170 180 190 200

Compressor output V' [m3/min]

0
60
100
140
180
200

0
15
25
35
45
50

170
340
510
680
850
1275
1700
2550
3400
5100
6800
8500
12750
17000

m3/min
2.83
5.67
8.50
11.33
14.17
21.25
28.33
42.50
56.67
85.00
113.33
141.67
212.50
283.33

m3/h

0.00
10.00
16.67
23.33
30.00
33.33

0
20.00
33.33
46.67
60.00
66.67

0.4
0.8
1.1
1.5
1.9
2.9
3.8
5.7
7.6
11.4
15.2
19
28.5
38

0
2
4
8
14
20

0
1.5
3
6
9.7
13.5

0
1
2
4
7
9.5

an A0 sheet cut in half gives two A1 sheets

an A1 sheet in half you get two A2 sheets

Size of sheet
Designation

Size of frame

mm

mm

mm

mm

A0

841

1189

791

1139

A1

594

841

554

804

A2

420

594

380

554

A3

297

420

267

390

A4

210

297

180

267

A5

148

210

A6

105

148

Dissolved Air in Water (25oC)

Gauge
Pressure
(atm)
Dissolved Air
(g/kg)

0.023

0.045

0.068

0.091

0.114

0.136

0
14.5

20
8.75

40
6

60
5

80
3

100
0

Oxygen Solubillity [mg/l]

16
14
12
10
8
6
4
2
0
0

10

20

30

40

50

60

Water temperature [oC]

70

80

90

100

Oxygen Solubillity [m

12
10
8
6
4
2
0
0

10

20

30

40

50

60

Water temperature [oC]

70

80

90

100

OMMENDED FINENESS OF FUEL AS FUNCTION OF THE VOLATILE CONTENT FOR ROTARY KILN AND CALCINE
16
Column B
Column C

14

Residue [%]

12
10
8
6
4
2
0

10

12

Volatile content [%]

14

16

18

20

Determination of acid dew point

1000
t=

-273
1.7842+0.0269*logpwater - 0.1029*logpSO3+0.0329*logpwater*logpSO3
SO3(ppm)*pB(hPa)

pSO3=

[bar]
10 *10
6

H2O(vol%)*pB(hPa)
pwater=

[bar]
10 *10
2

pB=

1013 hPa

[oC]

CEPROCIM S.A.
ENGINEERING AND CONSULTING DIVISION

1
2
3
4
5
6

OPTIMISATION POTENTIAL OF BALL MILL

MIN
MAX
%
%
15
30

CONTROL+PREGRINDING
MILL

CHAMBER 1
CHAMBER 2
TOTAL

LINING+FLOW
CONTROL
DIAPHRAGM
LINING+FLOW
CONTROL
DIAPHRAGM

SEPARATOR
VENTILATION
VENTILATION
min
max*
m/s
m/s

CLOSED CIRCUIT MILL

OPEN CIRCUIT MILL

1.20
1.00

10

3
10
3

10
30
10

THE FREE CROS SECTION ABOVE THE BALL

1.50
1.20

*THE HIGHER SPEED CAN BE CONSIDERED IF THE DEDUSTING SYSTEM IS PROVIDED WITH STATIC SEPARATOR
AIR VELOCITY
INLET CHUTE
CHAMBER 1
INTERMEDIATE DIAPHRAGM
CHAMBER 2
DISCHARGE DIAPHRAGME
OUTLET MILL

100/305

OPTIMUM

MAX

MIN

MAX

1.2
8.0
1.2
8.0

1.5
14.0
1.5
14.0

25.0

ROMANIAN TECHNICAL ASSISTANCE

18.0
18.0
25.0

prepred by A.Toader

CEPROCIM S.A.
ENGINEERING AND CONSULTING DIVISION

THE CHARGE OF RAW MILLS

Balls diameter

101/305

Characteri
Density

CHARGE

mm

No

m2

m2/t

100

90

80

9.74

15

7,170

144

0.94

70

16.88

26

18,564

286

1.86

60

22.08

34

38,556

436

2.83

50

24.68

38

74,442

584

3.80

40

14.94

23

87,998

442

2.87

30

11.69

18

163,242

461

3.00

100

154

389,972

2,354

15.28

ROMANIAN TECHNICAL ASSISTANCE

Diameter
mm
cm
100
10
90
9
80
8
70
7
60
6
50
5
40
4
30
3
25
20

2.5
2

prepred by A.Toader

CEPROCIM S.A.
ENGINEERING AND CONSULTING DIVISION

Characteristics of balls
Density = 7.8 t/m3
Weight
i [g]
i[kg]
4,001 4.00
2,916 2.92
2,048 2.05
1,372 1.37
864
0.86
500
0.50
256
0.26
108
0.11
63
32

102/305

0.06
0.03

Surface
o [cm2/g] o [m2/t]
0.0769
7.85
0.0854
8.73
0.0961
9.81
0.1099
11.22
0.1282
13.08
0.1538
15.71
0.1923
19.63
0.2563
26.17
0.3076
0.3845

31.41
39.26

No
1/t
250
343
488
729
1,157
2,000
3,905
9,233

Density
t/m3
4.56
4.59
4.62
4.64
4.66
4.71
4.76
4.85

15,995
31,250

4.95
4.95

ROMANIAN TECHNICAL ASSISTANCE

200
0

9.74

0.45

16.88

0.78

22.08

1.03

24.68

1.16

14.94

0.71

11.69

0.57

100

4.7

25200

prepred by A.Toader

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

THE CORRELATION BETWEEN H AND FILLING DEGREE q

RAW MILLS
H
m
2.73
2.74
2.75
2.76
2.77
2.78
2.79
2.80
2.81
2.82
2.83
2.84
2.85
2.86
2.87
2.88
2.89
2.90
2.91
2.92
2.93
2.94
2.95
2.96
2.97
2.98
2.99
3.00
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19

h
m
0.607
0.617
0.627
0.637
0.647
0.657
0.667
0.677
0.687
0.697
0.707
0.717
0.727
0.737
0.747
0.757
0.767
0.777
0.787
0.797
0.807
0.817
0.827
0.837
0.847
0.857
0.867
0.877
0.887
0.897
0.907
0.917
0.927
0.937
0.947
0.957
0.967
0.977
0.987
0.997
1.007
1.017
1.027
1.037
1.047
1.057
1.067

h/D

h/r

0.143
0.145
0.148
0.150
0.152
0.155
0.157
0.159
0.162
0.164
0.166
0.169
0.171
0.173
0.176
0.178
0.181
0.183
0.185
0.188
0.190
0.192
0.195
0.197
0.199
0.202
0.204
0.206
0.209
0.211
0.213
0.216
0.218
0.221
0.223
0.225
0.228
0.230
0.232
0.235
0.237
0.239
0.242
0.244
0.246
0.249
0.251

0.286
0.290
0.295
0.300
0.305
0.309
0.314
0.319
0.323
0.328
0.333
0.337
0.342
0.347
0.352
0.356
0.361
0.366
0.370
0.375
0.380
0.385
0.389
0.394
0.399
0.403
0.408
0.413
0.417
0.422
0.427
0.432
0.436
0.441
0.446
0.450
0.455
0.460
0.465
0.469
0.474
0.479
0.483
0.488
0.493
0.497
0.502

deg
147
146
146
145
145
144
143
143
142
142
141
141
140
139
139
138
138
137
136
136
135
135
134
134
133
132
132
131
131
130
129
129
128
128
127
126
126
125
125
124
123
123
122
122
121
120
120

rad
2.56
2.55
2.54
2.53
2.52
2.51
2.50
2.49
2.48
2.47
2.46
2.45
2.44
2.43
2.42
2.41
2.40
2.39
2.38
2.37
2.36
2.35
2.34
2.33
2.32
2.31
2.30
2.29
2.28
2.27
2.26
2.25
2.24
2.23
2.22
2.21
2.20
2.19
2.18
2.16
2.15
2.14
2.13
2.12
2.11
2.10
2.09

q
%
32.06
31.77
31.48
31.20
30.91
30.63
30.34
30.06
29.77
29.49
29.21
28.93
28.64
28.36
28.08
27.80
27.52
27.24
26.96
26.69
26.41
26.13
25.86
25.58
25.31
25.03
24.76
24.48
24.21
23.94
23.67
23.40
23.13
22.86
22.59
22.32
22.06
21.79
21.52
21.26
20.99
20.73
20.47
20.21
19.95
19.68
19.43

a
m
0.582
0.584
0.587
0.590
0.592
0.595
0.597
0.600
0.602
0.605
0.607
0.610
0.613
0.615
0.618
0.620
0.623
0.625
0.628
0.630
0.633
0.635
0.638
0.640
0.643
0.645
0.647
0.650
0.652
0.655
0.657
0.660
0.662
0.665
0.667
0.669
0.672
0.674
0.677
0.679
0.681
0.684
0.686
0.688
0.691
0.693
0.695

G
t
149
147
146
145
143
142
141
139
138
137
135
134
133
131
130
129
128
126
125
124
122
121
120
119
117
116
115
113
112
111
110
108
107
106
105
103
102
101
100
99
97
96
95
94
92
91
90

REMARKS

0.659
0.666
0.674
0.681
0.688
0.696
0.703
0.710
0.717
0.724
0.731
0.738
0.745
0.752
0.759
0.766
0.772
0.779
0.785
0.792
0.798
0.804
0.811
0.817
0.823
0.829
0.835
0.841
0.846
0.852
0.858
0.863
0.869

03/06/2013

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

Dext
D
R
L
V

4.50
4.25
2.13
7.26
103

03/06/2013

CARBUNI
Temperatura de mocnire
t cea mai mica a unei suprafete orizontale fierbinti care determina aparitia pct. de jar pe un strat de 5 mm grosime depus prin cadere libera

Temperatura minima de aprindere

t cea mai mica a unei surse care determina aprinderea prafului aflat in suspensiende aer
Concentratia minima de explozie
Cantitatea cea mai mica de pulbere raportata la volumul de umiditate care in amestec cu O2 din aer in contact cu o sursa de aprindere avand t superficiala
> decat t min de aprindere a pulberii se aprinde iar arderea se propaga in intreg amaestecul pulbere
Temperatura de autoaprindere
la o incalzire programata se urmaresc modificarile de masa si de entalpie precum si cantitatile de gaze produse

indicatie

UM

Filipesti

umiditate
Ash per umed
Ash per uscat
Vol. Per umed
Vol. Per uscat

%
%
%
%
%

6.13
58.36
62.16
22.85
24.34

T mocnire
T min aprindere
Con explozie
T autoaprindere

oC
g/m3

505
139
110

Schitu
Golesti
12.48
37.6
43.14
28.85
58.21

Cocs
I
0.51
3.21
3.22
8.56
8.89

Cocs
II
0.51
3.26
3.27
9.33
9.69

230
435
112

400
645
1000
325

400
645
1000
325

Gazul metan se aprinde in amestec cu aerul in proportie de 5 - 15 % la Taprindere =735 oC la 1 at

A.TOADER

TEMPERATURA DE AUTOAPRINDERE PENTRU DIVERSE GAZE

Tauto
oC
550
650
641
850
810
800
594
540
588
500
335
335
373
290
487

30
100
200
400

370
412
440
462

480
460
440
TEMPERATURE [deg C]

Concentratie
%
H2
28.5
CO
23.55
61.9
metan
2
4
8
etan
1.9
8.15
propan
1.25
10
acetilena
45
55
H2S
1
12
60

TEMPERATURA DE APRINDERE SI DIMENSIUNILE PARTICULELOR

420
400
380
360
340
320
300

50

100

150

200

250

300

350

400

450

PARTICLE SIZE [MICRON]

A.TOADER

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

OPERATING CHARACTERISTICS OF KILN SYSTEM

Long wet

KILN

Capacity
Heat consumption
Heat exchange devices

tpd
300-3600
kcal/kg 1200-1400
chains
crosses
chamber
preheater
raw slurry
%
32-40

Feedstock
Feedstock mass content of water
Waste gas upstream of precipitator

Specific waste gas volume

Waste gas analyses

CO2
O2
CO

m3/kg
%
%
%
o
C
o
C

Waste gas temperature

Water dewpoint
Dust
Dust content in crude gas (dry at standard condition) g/m3
Mass proportion of dust < 10 mm
%
Dust precipitator
Separator

3.2 - 4.2
25-18
4-8
<0.1
130-180
65-75

Long dry

Lepol Preheater

300-3000
850-950
chains
lift shovels
crosses
chamber insertion
dry raw meal
0.5-15.0
waste gas
without
recycling
waste gas
recycling
with water
injection
2.5-3.0
2.2-2.8
20-17
24-19
6 - 10
4-7
<0.1
<0.1
130-180
150-200
45-75
45-60

300-3300
720-900
grate-type
preheater of
various types
granules
11 - 22

1.8-2.2
29-20
4 - 10
<0.1
90-150
50-65

S.P.
300-5000
720-900
cyclone or chamber
preheater of various
types
dry raw meal
0.5-1.0
waste gas without
recycling waste gas
recycling
with water
injection
2.1-2.5
1.7-2.0
22-14
33-20
8 - 13
3-9
<0.1
<0.1
90-150
120-200
45-60
50-65

3 - 22
20 - 60

35-150
70 - 90

15-25
70-90

1.5-12
10 - 45

35-150
80-99

20-50
85-99

E.S.P.

E.S.P.

E.S.P.

E.S.P.

E.S.P.

E.S.P.

Tab 1

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

THE CORRELATION BETWEEN CLINKER OUTPUT AND HEAT CONSUMPTION

900

HEAT CONSUMPTION [kcal/kg]

880
860
840
820
800
780
760
740
2,500

2,700

2,900

3,100

3,300

CLINKER OUTPUT [t/d]

3,500

3,700

3,900

Output
Heat consumption
Cooling air flow
Secondary air flow
Primary air flow
Excess air flow
Gases Temperature
Preheater and Kiln radiation

t/d
kcal/kg
Nm3/kg
Nm3/kg
Nm3/kg
Nm3/kg
o
C
kcal/kg

2500
876
2.31
0.99
0.06
1.32
380
91

3100
836
2
0.95
0.05
1.05
360
75

3800
806
2
0.92
0.04
1.08
340
64

4000
798
2
0.91
0.04
1.09
330
62

BYPASS RATE

BY PASS CALCULATION

Na2O
K2O
R2O
Cl
SO3
DS

%
%
%
%
%
%

LIMIT
feed
0.600
0.015
1.000
100

ACTUAL

LIMIT
clinker

ACTUAL

0.270
0.720
0.744
0.010
0.350
37

0.44
1.06
1.14
0
0.59
40

RAW MEAL after BY PASS

BY PASS RATE
Na2O
K2O
SO3
Cl

BY PASS RATE

10

15

20

35

50

%
%
%
%

0.261
0.625
0.324
0.002

0.252
0.582
0.309
0.001

0.244
0.539
0.293
0.000

0.235
0.496
0.278
0.000

0.209
0.367
0.232
0.000

0.184
0.238
0.186
0.000

CLINKER after BY PASS

loi=

35.50

10

15

20

35

50

Na2O
K2O

%
%

0.405
0.969

0.391
0.908

0.378
0.841

0.365
0.774

0.325
0.572

0.285
0.371

R2O

1.035

0.982

0.925

0.868

0.697

0.526

SO3
Cl

%
%

0.502
0.002

0.478
0.001

0.455
0.001

0.431
0.000

0.360
0.000

0.289
0.000

Eng.A.Toader

03/06/2013
g/kgcl within clinker
1-

BYPASS RATE

EVALUATION OF MINOR CIRCUIT

evaporation factor

g/kgcl within clinker

1g/kgcl at kiln inlet

circulation factor

g/kgcl kiln inlet

g/kgcl at inlet system

valve

g/kgcl at by pass dust

g/kgcl at kiln inlet - g/kgcl within clinker

residual component

g/kgcl within clinker

g/kgcl at inlet system

K
V
R

Eng.A.Toader

SO3
Studies Calculated
0.4 - 0.6
0.42
1.0 - 2.0
1.51
0.65
0.72
0.88

Na2O
K2O
Studies
Calculated Studies Calculated
0.4 - 0.7
0.40
0.4 - 0.75
0.42
1.2 - 2.0
1.63
1.0 - 2.0
1.52
0.61
0.61
0.73
0.97
0.73
0.88

03/06/2013

BYPASS RATE

CL

Na

SO3

1.00

60

66.56

2.5

80

1.5

10

76.7

5.00

90

2.5

15.5

84.37

7.50

92.5

18

10

88.86

10.00

95

20

12.5

92.04

12.50

95

8.5

22.5

15

94.51

15.00
17.50
20.00

95
95
95

10
11
12.5

25
27.5
30

16
18
20

96.53
98.23
99.71

BY PASS RATE%

5.00

10.00

15.00

0.26
0.63
0.32
0.00

0.25
0.58
0.31
0.00

0.24
0.54
0.29
0.00

Na2O
K2O
SO3
Cl

Eng.A.Toader

%
%
%
%

CL

Na

20.00

35.00

50.00

0.24
0.50
0.28
0.00

0.21
0.37
0.23
0.00

0.18
0.24
0.19
0.00

03/06/2013

BYPASS RATE

DISTRIBUTION of R2O IN CLINKER

a (K2O)
1.060
b (Na2O)
0.440
K2O eq
0.669
K2O total
1.729
c (SO3)
0.590
F
0.341
KS
34.128
K2O eq sulfate0.590
K2O eq clinker1.139

Eng.A.Toader

total
sulfate
clinker

Na2O
0.44
0.22
0.22

K2O
1.06
0.36
0.70

SO3
0.59
0.28

0.31
0.00

03/06/2013

Parametrii tehnologici
actual
Granulometrie concasoare rest pe ciurul de 25 mm
Umiditate argila la iesire uscator
Umiditate zgura la iesire uscator
Eroare dozatoare
Mori faina
CaCO3
Grad de saturare
Rezidiu R020
R009
Omogenizare faina CaCO3
LSF
SM
AM
Cuptor
LW
CaOlibera
Clinker bine ars
Clinker sub ars
Flacara reducatoare
Flacara oxidanta

propus
0
12
4
1
2.5
8
2
12
0.25
1.5
0.01
0.01
1250
1

culoare inchisa
culoare deschisa

0
12
2
1.5

4
20
0.5

1350
1.5
granulozitate mare
granulozitate mica
granulozitate mare
granulozitate mica

CEPROCIM S.A.

HEAT EXCHANGER PARAMETERS

Range

Alarm
L

HH

420

280

320

450

-60

-40

-78

-25

330
300

420
350

150

-45

-40

-55

-25

530
410

560
520

450
350

600

-35

-30

-45

-30

650
600

700
650

600
550

750

top
down

-25

-20

-30

-15

CYCLONE 4
Temperature [o C] gas
top
material down

800
760

850
800

750
710

900

Pressure [mbar]

-15

-10

-17

-8
-8

ID FAN
Temperature [o C] gas
Pressure [mbar]
CYCLONE 1
top
Temperature [o C] gas
material down
Pressure [mbar]
top
CYCLONE 2
Temperature [o C] gas
top
material down
Pressure [mbar]
top
CYCLONE 3
Temperature [o C] gas
top
material down
Pressure [mbar]

top
down

KILN INLET
Temperature [o C] gas
outlet
material down

min

max

330

900
810

1050
830

Pressure [mbar]
Precalcinator
Temperature [o C] gas

outlet

-7

-3

outlet

880

920

Pressure [mbar]

outlet

Kiln inlet

O2

Preheater

O2

max 5

LL

400

-15

450

-5

850
150

1150
850

-10

-1

880

920

970

-15

-5

The burning time of the fuel coal vs fuel coal size

3.5

3.0

Burning time [sec]

2.5

2.0

1.5

1.0

0.5

0.0
0

10

20

30

40

50

60

70

80

90 100 110 120 130 140 150 160 170 180 190 200

Fuel coal size [microns]

m
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200

d2
mm
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12
0.13
0.14
0.15
0.16
0.17
0.18
0.19
0.20

cm
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
0.009
0.010
0.011
0.012
0.013
0.014
0.015
0.016
0.017
0.018
0.019
0.020

cm2
0.000001
0.000004
0.000009
0.000016
0.000025
0.000036
0.000049
0.000064
0.000081
0.000100
0.000121
0.000144
0.000169
0.000196
0.000225
0.000256
0.000289
0.000324
0.000361
0.000400

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000
4000

T
s
0.0
0.0
0.1
0.1
0.2
0.3
0.4
0.5
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.3
2.6
2.9
3.2

min
0.0001
0.0005
0.0012
0.0021
0.0033
0.0048
0.0065
0.0085
0.0108
0.0133
0.0161
0.0192
0.0225
0.0261
0.0300
0.0341
0.0385
0.0432
0.0481
0.0533

L
W
t

64 m
24 m/s
2.67

CEPROCIM S.A.
Annex

NORMAL KILN PARAMETERS

Kiln
feed
t/h
40
45
50
55
60
65
70

Kiln
sped
rpm
0.8
0.9
1.0
1.1
1.2
1.3
1.4

75
80
85
90
95
100

1.5
1.6
1.7
1.8
1.9
2.0

5300
t/h
4.07
4.51
4.94
5.39
5.83
6.26
6.68

Fuel coal
5500
t/h
3.92
4.35
4.76
5.19
5.62
6.03
6.44

5700
t/h
3.78
4.20
4.60
5.01
5.42
5.82
6.21

7.10
7.50
7.90
8.29
8.69
9.04

6.84
7.23
7.61
7.99
8.38
8.71

6.60
6.98
7.34
7.71
8.08
8.40

GAS
Cyclone 1
Cyclone 2
Cyclone 3
Cyclone 4
CO
O2

TEMPERATURE [oC]
330
400
530
560
680
710
790
810
<

0.3

<

5-6

03/06/2013

CEPROCIM S.A.

900
887.5
875
867.5
860
852.5
845
837.5
830
822.5
815
810
800

03/06/2013

Specific water evaporation as function of the hot gas temperature in the rotary dryer heated with furnace gas
280

Specific w ater evaporation

[kg/m *h]

240

200

Column
Column
Column
Column
Column
Column

160

120

D
D
D
D
D
D

80

40

0
0

200

400

600

800

Hot gas temperature

1000
[oC]

1200

1400

1600

Slopes
No.

Hot gas
temperature

Specific water
evaporation

C
300
400
500
600
700
800
900
1000
1100
1200
300
400
500
600
700
800
900
1000
1100
1200
325
400
500
600
700
800
900
1000
1025
300
400
500
600
700
800
900
1000
1100
1200
320
400
500
600
700
800
900
1000
1100
1200
320

24
30
37
45
54
64
75
88
103
120
33
39
46
55
64
75
87
102
118
138
44
49
56
65
74
85
98
114
119
52
58
66
75
85
98
113
131
156
188
60
66
75
85
97
113
133
159
195
250
56

400
500
600
700
800
900
1000
1100
1200

62
70
80
91
105
123
145
175.5
219

GRINDABILITY OF COKE,COAL AND BLENDS

45

Column C
Column D
Column B

40

SPECIFIC ENERGY [kwh/t]

35
30
25
20
15
10
5
0
1

10
RESIDUE 90 mm

100

Sheet11
Grindability of cokes, coal and blends
coal HGI=50
R009

Kwh/t
1
2
3
4
5
10
20
30
40
50
60
80
100

40
30
26
24
22
17.5
14
11
8
6.5
5
3
1

cokeHGI=86.5 60coal+40coke
HGI 77
Kwh/t
Kwh/t

37
29.1
26.5
24
16
10
7.5
5.3
4
3
1.7
1

31
26
24
21
20
16
12
9
7.5
6
4
2
1

Page 125

Direct coal firing - primary air velocity versus primary air ratio
160

Primary air velocity [m/s]

140

120

100

80

60

40

10

15
Primary air ratio [%]

20

5
10
15
20

140
100
80
70

125
90
70
60

CEPROCIM S.A.

RELATII CEPROCIM PENTRU DIMENSIONAREA CUPTORULUI

No Denumire parametru
1 Productie cuptor
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Consum specific
Proportie combustibil in cuptor
Sarcina termica cuptor
Incarcare termica volumetrica zona de ardere
Diametru interior cuptor
Aria interioara
Raport lungime/diametru
Lungime cuptor
Volum interior
Incarcare cuptor
Incarcare termica pe suprafata
Incarcare termica volumetrica
Grad decarbonatare
Incarcare cuptor

Date: 03/06/2013

Simbol
P

Formula

CS
ST
q
Di
S
L/Di
L
V
K
Qs
Qv
Gr
K

P*CS
(4*ST/(3*pi*q))1/3
pi*d2/4

L*pi*d2/4
24P/V
ST/S
ST/V

UM

tpd
t/h
kcal/kg
%
Gcal/h
Gcal/(hm3)
m
m2

m3
Gcal/(hm2)
Gcal/(hm3)
%
tpd/m3

Sistem SP

24
1080
1.08
1.08
0.91
19.4
17.7
1.36
1.18
0.06

*P
*P
*P
100
*P
0.37
*P
*P
18
*P
*P
*P
*P
*P

-0.07
0.93
0.31
0.62
0.31
0.93
0.07
0.31
0

0.04 *Gr+ 0.56

4,200
175.00
756
100.00
132.34
0.37
5.35
22.42
96.21
2,158
1.95
5.90
0.06
30.00
1.88

24
1150
1.150
1.097
0.945
19.75
18.66
1.286
1.217

*P
P
*P
100
*P
0.37
*P
*P
18
*P
*P
*P
*P
0.06

-0.08
0.92
0.31
0.62
0.31
0.92
0.08
0.31

0.04 *Gr+ 0.56

CEPROCIM S.A.

Tabel nr.6

IM PENTRU DIMENSIONAREA CUPTORULUI

Sistem SP

4,200
175.00
777
100.00
135.91
0.37
5.38
22.76
96.92
2,205
1.90
5.97
0.06
30.00
1.88

Date: 03/06/2013

3,000
125.00
797
100.00
99.37
0.27
5.40
22.90
18.00
97.00
2,222
1.35
4.34
0.20
25.00
1.66

International emission level limits

Country

1 Ausria
2 Belgium
3 Chile
4 Denmark
5 Eire
6 Finland
7 France

Kiln
dust
mg/Nm3
50
150
56
100
50
50
50

Cooler
dust
mg/Nm3
50
400
100
75
50
100

SO2
Other
dust
mg/Nm3 mg/Nm3
50
200
50
400
20
50
50
30

500
400
150
500

Inorganics

mg/Nm3
500
1500

Cd,Tl,Be,As,Co,Ni,Pb

500
1300
1800
1200

Hg,Cd,Tl,As,Se,Te,Co,Pb,Sb,Cr,Ni,Cu

500

Hg,Cd,Tl,As,Se,Te,Co,Pb,Sb,Cr,Ni,Cu,Mn,V,Sn,Cn,F,Pt,Rh,
HCl,HF

Hg,Cd,Tl,Be,As,Se,Te,Co,Pb,Sb,Cr

Organics

dioxins,furans

Continuous
monitors

Comments

yes
dust,SO2,NOx
yes
yes
yes
dust,SO2,NOx

dry 10% O2
wet 6% O2
dry 10% O2
dry 10% O2
dry,average
dry,average

dust,SO2,NOx

dry,average

dust
yes

wet

varie

wet,average

8 Germany

50

50

50

9 Grece
10 Iceland

100
150

100
100

100
100

11 Italy

30

20

10

400

700

12 Japan

50

50

50

250

510

Cd,Pb,Cl,HCl,F

dust

wet,10%O2

13 Luxemburg
14 Malaysia

50
100

100
200

800
2000

Hg,Cd,Tl,Be,As,Se,Te,Co,Pb,Sb,Cr,Ni,V,HCl

dust,NOx
no

dry,10%O2

100

30
100

15 Netherland

50

10

400

1300

yes

dry,10%O2

16 Nigeria

400

NOx

50

25

25

30
400

350

17 Norway
18 Portugal

50

100

50

400

1300

19 Spain
20 Sweden

150
50

50
250

150
20

2400
500

800

21 Switzerland

50

50

50

500

800

120
40
0.15 kg/t*
50

50
50
0.05 kg/t*
50

50
50

275
200

414
900

22 Turkey
23 UK
24 USA
25 E.C.
t*=

50-100

World Cement - November 1998

1 mg/Nm3 la x % O2=(21-6)/(21-x) mg/Nm3 la 6 % O2

Cd,Ni,Pb,Cr,Cu,V
Hg,Cd,Tl,As,Se,Te,Co,Pb,Sb,Cr,Ni,Cu,Mn,V,Sn,Cn,F,Pt,Rh,
HCl,HF,NH3
TOC

Hg,Cd,As,Cu,Zn,Sb,HCl,Cl,F,H2S
Hg,Cd,Tl,As,Se,Te,Co,Pb,Sb,Cr,Ni,Cu,Mn,V,Sn,Cn,F,Pt,Rh,
Zn,CN,F

Hg,Cd,Tl,As,Se,Te,Co,Pb,Sb,Cr,Ni,Cu,Mn,V,Sn,HCl,HF,CO

Hg,Cd,Tl,As,Se,Te,Co,Pb,Sb,Cr,Ni,Cu,Mn,V,Sn,Cn,F,Pt,Rh,
HCl,HF
CO
CO
Hg,Cd,Tl,As,Se,Te,Ni,Pb,Sb,Cr,Cu,V,F,Cl,HCl,HF

wet

no
dust,SO2

dry,11%O2

TOC,dioxins,furans

yes

wet,10%O2

dioxins,furans

varie
yes

wet,7%O2
dry

yes

dry,average

dust
dust,SO2,NOx
yes
yes

dry
dry,11%O2

Cd,Ni,Cr,Cu,V,Pb,HCl,HF

40-750 1300-1800

dry feed

TOC

TOC
dioxins
TOC,dioxins,furans
TOC,dioxins,furans

1 mg/Nm3 la x % O2=(21-10)/(21-x) mg/Nm3 la 10 % O2

EVALUATION OF VIBRATION

VDI 2056/ISO 2372

Vibration severity
mm/s

evaluation grade

28.00
18.00

not acceptable

11.00
7.00
4.50

high level

2.80
1.80

acceptable

1.10
0.70
0.45

good

0.28
Group K
Small
machines

Group M
Medium
machines

Group N
Fan
machines

Group G
Large
machines

Group T
Turbo
machines

1490
1434
1879
1864
1924
1945
1857
1929
1984
2058
2064
2176
2017
1988
2119
2206
2147
2238
2264
2350

Lower calorific value versus flame temperature

2500
2400
2300
2200
2100
Flame temperature [oC]

1700
1750
2653
3250
3277
3635
4436
5069
5226
5300
5360
5493
5556
5668
5735
5777
6022
7356
7767
8000

2000
1900
1800
1700
1600
1500
1400
1300
1200
1000

2000

3000

4000

5000

6000

Lower calorific value [kcal/kg]

7000

8000

9000

cicloane

SCHIMBATOR DE CALDURA TIP WEDAG

800 t/d
d

a/b

H1

Di

H2

Numar bucati cicloane

Diametru exterior
Diametru interior
Suprafata utila
Inaltime parte cilindrica
Inaltime parte conica
Inaltime totala
Latime racord intrare gaze
Inaltime racord intrare gaze
Sectiune intrare gaze
Diametru tub imersie
d

dc

Page 134

De
Di
Su
H1
H2
H
a
b
Si

mm
mm
m2
mm
mm
mm
mm
mm
m2

C1
2
###
###
5.81
###
###
###
744
###
1.05

C2
1
###
###
###
###
###
###
800
###
1.28

C3
2
###
###
8.14
###
###
###
930
###
1.46

C4
1
###
###
15.9
###
###
###
###
###
2.81

LIMITS REGARDING KILN CHARGE

KILN
D
Di
S
L
V
Volumetric load
P

m
m
sq.m
m
m3
tpd/m3
tpd

KILN CHARGE
P
production
n
speed
max.speed
max.speed

kiln inclination
Di
kiln inner diameter
S
inside surface
L
length
V
volume
K

Max
4.6
4.2
13.85
69
956
2.30
2,199

Min
4.6
4.2
13.85
69
956
1.80
1,721

Average
4.6
4.2
13.85
69
956
1.89
1,807

tpd
rpm
rph
%
%
m
sq.m
m
m3

1,807
2.2
132
82.50
3
4.2
13.85
69
956
0.15

1,807
2.0
120
75.00
3
4.2
13.85
69
956
0.15

1,807
1.8
108
67.50
3
4.2
13.85
69
956
0.15

1,807
1.6
96
60.00
3
4.2
13.85
69
956
0.15

1,807
1.4
84
52.50
3
4.2
13.85
69
956
0.15

36.09

39.70

44.11

49.63

56.72

4.31

4.74

5.26

5.92

6.77

rad
deg
%
m

1.27
72.68
5.00
0.41

1.32
75.74
5.61
0.44

1.40
80.06
6.56
0.49

1.48
84.74
7.69
0.55

1.60
91.75
9.58
0.64

DURATION IN THE KILN

=

K*L
[min]
Di*n*

THEORETICAL DEGREE OF FILLING

P/24/60/1.1*100
=
V

angle of mat.in kiln

largest arrow height

N1=

86.4*(Disin)3Lnc

N2

A.Toader

kW

153.68
0

03/06/2013

MAX FILING DEGREE

Di
di
Hmax
1-Hmax/r

kiln inner diameter

kiln inlet opening

m
m

4.20
2.55

largest arrow height

angle of mat.in kiln

rad
deg

0.83
0.61
1.84
105.25

100
max=

100*sin( )
-

max=

A.Toader

13.88

%
2*

360
%

03/06/2013

LIMITS REGARDING KILN CHARGE

KILN
D
Di
S
L
V
Volumetric load
P

m
m
sq.m
m
m3
tpd/m3
tpd

KILN CHARGE
P
production
n
speed
max.speed
max.speed

kiln inclination
Di
kiln inner diameter
S
inside surface
L
length
V
volume
K

Max
5.8
5.4
22.90
97
2222
2.30
5,109

Min
5.8
5.4
22.90
97
2222
1.80
3,999

Average
5.8
5.4
22.90
97
2222
2.05
4,000

tpd
rpm
rph
%
%
m
sq.m
m
m3

4,000
2.0
120
75.00
3
5.4
22.90
97
2,222
0.15

4,000
1.8
108
67.50
3
5.4
22.90
97
2,222
0.15

4,000
1.6
96
60.00
3
5.4
22.90
97
2,222
0.15

4,000
1.4
84
52.50
3
5.4
22.90
97
2,222
0.15

4,000
1.2
72
45.00
3
5.4
22.90
97
2,222
0.15

43.41

48.23

54.26

62.01

72.35

4.93

5.48

6.17

7.05

8.22

rad
deg
%
m

1.27
72.68
5.00
0.53

1.32
75.74
5.61
0.57

1.40
80.06
6.56
0.63

1.48
84.74
7.69
0.71

1.60
91.75
9.58
0.82

DURATION IN THE KILN

=

K*L
[min]
Di*n*

THEORETICAL DEGREE OF FILLING

P/24/60/1.1*100
=
V

angle of mat.in kiln

largest arrow height

MAX FILING DEGREE

A.Toader

03/06/2013

Di
di
Hmax
1-Hmax/r

kiln inner diameter

kiln inlet opening

m
m

5.40
3.28

largest arrow height

angle of mat.in kiln

rad
deg

1.06
0.61
1.84
105.25

100
max=

100*sin( )
-

max=

A.Toader

13.88

%
2*

360
%

03/06/2013

ANSWER
1 KILN SYSTEM
Heat Consumption
Power consumption
L/d ratio
Volumetric load
Burning zone load

WET
kcal/kg
kWh/t

SEMIWET SEMIDRY

1100-1600
110-120
25-40
tpd/m3
0.8-1
kcal/h/m2 *10 6
6.5

1100-950
115-120
20-25
6.5

DRY
SP
NSP
800-850 790-820
120-125 100-115
14-16
14-16
1.8-2.3
3.6-4.8
2.8-5.5
2.4-4.8

5 STAGES
750-790
10 - 14
2.4-4.8

2
efficiency of preheater tower (type of cyclones particle size distribution of material)
false air in preheater tower ( integrity of installation)
characteristics of preheater fan( real flow of fan)
efficiency of calcinator
the circulation of material inside of preheater ( flaps or cutting)
the correlation between feed and oil in installation (operation)
daily running time of kiln
by pass rate at minimum in correlation with kiln feed characteristics
3 Criteria for chose the kiln system is depending by limestone humidity
4 L/D ratio
L
68.00
D
4.80
L/D
14.17
OIL CONSUMPTION
kiln
5.8 m3/h
Pyroclon
9.3 m3/h
Total oil
15.1 m3/h
15100 l/h
Density of oil at 120 o C
0.88 kg/l
Total oil
13,213 kg/h
Burning zone load
oil in kiln
5.8 m3/h
Density of oil at 120 o C
0.88 kg/l massic flow[kg/h]= volumetric flow[m3/h]*density[kg/m3]
massic flow of oil for kiln
5,075 kg/h
inside diameter
4.36 m
cross section of kiln
14.92 sq. m
oil in kiln [kg/h]lower heat of comb[kcal/kg]
Burning zone load
3.23E+06 kcal/sq.m/h
cross section [sqm]
Volumetric load
inside diameter
4.36 m
inside volume[m3]=PI*inside dia.2*lenght/4
length of kiln
68 m
inside volume of kiln
1,015 m3
production of kiln
3100 tpd
clinker output [t/d]
Volumetric load
3.05 tpd/m3
inside volume of kiln[ [m3]
Heat consumption
production of kiln
3100
tpd
129,167
kg/h
lower heat of combustion
9500
kcal/kgoil
oil for kiln
5075
kg/h
main burner [kgoil/h]lower heat of comb[kcal/kgoil]
heat consumption for kiln 373
kcal/kg
oil for pyroclon
8,138
kg/h
clinker output [kg/h]
heat consumption for Py
599
kcal/kg
total heat consumption
972
kcal/kg
Pyroclon [kgoil/h]low calorifique value[kcal/kgoil]
Max production
Volumetric load
volume of kiln
Max production

4.80
1,015
4,871

Max Burning zone load

heat consumption for kiln
373
Max production
202,946
Cross section of kiln
14.92
Max Burning zone load 5.08E+06

tpd/m3
m3
tpd

clinker output [kg/h]

202,946 kg/h

kcal/kg
kg/h
sq. m
kcal/h/m2

Page 139

5 POSITION
kiln inlet
stage 4
stage 3
stage 2
stage 1
ID
TERTIARY AIR
6 Wet process
slurry water content
exaust.gases temp
heat consumption
7 Kiln wet process
Production
length
diameter
inside diameter
L/D
cross section of kiln
volume of kiln
Volumetric load
oil kiln
heat consumption
thermal load
max thermal load
calorific flow
heat consumption min.
max production
max. volumetric load

T gas
deg C
950-1100
830-870
700-780
530-600
320-370
320-350
750-850

Tmat
deg C
790-820
650-700
500-550

35-45
%
250-300 deg C
1100-1600 kcal/kg
720
150
4
3.6
37.5
10.17
1,526
0.47
5,400
1,710
5.04E+06
6.50E+06
6.61E+07
1,100
60,117
0.95

tpd
m
m
m

p
mbar
3-5
10 - 15
20-28
30-35
40-50
55-70

5,434

6,688 kJ/kg
30 t/h

sqm
m3
tpd/m3
kg/h
kcal/kg
kcal/h/sqm
kcal/h/sqm
kcal/h
kcal/kg
kg/h
tpd/m3

180 kgoil/tcl

1,443 tpd

SCHIMBATOR DE CALDURA SI PYROCLON S

OUTLET STAGE 1

OUTLET STAGE 2

OUTLET STAGE 3

OUTLET STAGE 4

INLET KILN

p
t gas
O2
CO2
CO
Dust content
Total flow
p
t gas
O2
p
t gas
O2
p
t gas
O2
t mat
LOI
p
t gas
O2
CO2
CO
Dust content
Total flow

49
320
2
26
0
20
1.4
35
480
2
23.5
650
2
11.8
780
2
780
15
2
1050
1
18
0
50
1.15

mbar
380 o C
5%
34 %
%
30 g/m3
1.6 Nm3/kg
mbar
550 o C
5%
mbar
730 o C
5%
mbar
850 o C
5%
830 o C
25 %
mbar
1250 o C
3%
24 %
%
150 g/m3
1.25 Nm3/kg

Page 140

(760 mm Hg)

30000

25000

20000

15000

Column B

10000

5000

0
0

100

200

300

400

Page 141

500

600

700

15

30000

25000

20000

15000

Column D

10000

5000

0
0

100

200

300

400

Page 142

500

600

700

30

30000

25000

20000

15000

Column F

10000

5000

0
0

100

200

300

400

Page 143

500

600

700

45

30000

25000

20000

15000

Column H

10000

5000

0
0

100

200

300

400

Page 144

500

600

700

RADIATIE

0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
265
270

0
0
33
68
106
147
191
238
288
340
395
452
510
570
632
697
763
831
901
972
1044
1119
1196
1275
1356
1439
1524
1611
1700
1791
1885
1981
2079
2179
2282
2387
2495
2605
2717
2832
2950
3070
3192
3316
3442
3571
3702
3837
3976
4120
4268
4421
4577
4736
4898
5063

-130
-71
-12
47
107
167
228
290
352
414
478
542
608
674
741
810
880
951
1023
1097
1172
1249
1327
1407
1489
1572
1658
1745
1834
1926
2019
2115
2213
2314
2416
2522
2630
2740
2853
2969
3088
3209
3334
3462
3592
3726
3863
4003
4147
4294
4445
4599
4757
4918
5083

15
0
0
0
0
31
68
109
154
202
253
306
361
418
477
538
602
668
736
805
875
947
1021
1098
1178
1261
1346
1432
1520
1610
1703
1797
1894
1993
2094
2197
2301
2408
2518
2632
2750
2871
2994
3119
3246
3376
3508
3643
3782
3925
4071
4220
4372
4527
4685
4856

-211
-157
-104
-49
5
61
117
173
231
289
348
408
469
531
594
659
724
791
859
929
1000
1073
1147
1223
1301
1380
1461
1545
1630
1717
1806
1897
1991
2087
2185
2285
2388
2494
2602
2712
2825
2941
3060
3182
3306
3434
3564
3698
3835
3975
4118
4265
4415
4568
4725

30
0
0
0
0
0
0
0
39
80
123
167
215
267
323
382
445
509
574
641
709
778
850
925
1003
1083
1163
1251
1338
1427
1518
1610
1704
1801
1901
2004
2110
2218
2328
2440
2554
2671
2791
2914
3041
3172
3306
3443
3583
3726
3871
4019
4170
4324
4481
4641

Page 145

-197
-155
-113
-70
-26
18
64
110
157
206
255
306
358
411
466
522
580
639
700
762
826
892
960
1030
1101
1175
1251
1329
1409
1491
1576
1663
1753
1845
1940
2037
2137
2240
2345
2454
2565
2679
2797
2917
3041
3168
3298
3432
3569
3709
3853
4001
4152
4307
4465

45
0
0
0
0
0
0
0
0
0
0
37
80
127
178
232
289
348
409
472
538
608
679
753
829
906
985
1066
1150
1237
1327
1420
1515
1612
1711
1812
1913
2018
2126
2238
2353
2471
2594
2722
2854
2987
3121
3254
3388
3524
3661
3801
3947
4100
4260
4426

-267
-230
-192
-153
-113
-71
-29
14
59
104
151
200
250
301
354
408
465
523
582
644
707
773
840
910
982
1056
1132
1211
1292
1375
1461
1550
1641
1735
1831
1931
2033
2138
2246
2358
2472
2590
2711
2835
2962
3093
3227
3365
3507
3652
3801
3953
4110
4270
4435

RADIATIE
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530
535
540
545
550

5231
5402
5576
5753
5933
6116
6303
6494
6690
6891
7096
7305
7518
7736
7959
8188
8421
8658
8899
9144
9392
9645
9904
10169
10440
10716
10998
11286
11580
11880
12184
12493
12806
13123
13444
13770
14104
14448
14803
15169
15545
15925
16309
16696
17086
17481
17884
18296
18717
19148
19587
20033
20485
20943
21408
21879

5253
5426
5602
5783
5969
6158
6351
6549
6751
6958
7169
7384
7605
7830
8060
8294
8534
8778
9028
9282
9542
9807
10078
10354
10635
10922
11214
11512
11816
12125
12441
12762
13089
13422
13762
14108
14460
14818
15182
15553
15931
16315
16706
17104
17508
17920
18338
18763
19195
19635
20081
20535
20997
21465
21941
22425

5011
5181
5356
5539
5721
5907
6097
6290
6485
6682
6882
7088
7300
7519
7744
7975
8209
8446
8685
8925
9168
9418
9676
9942
10217
10499
10785
11075
11369
11667
11968
12274
12586
12904
13228
13559
13898
14245
14601
14966
15338
15714
16094
16478
16866
17259
17661
18072
18493
18924
19364
19810
20262
20721
21186
21657

4886
5050
5218
5390
5565
5744
5928
6115
6306
6502
6701
6905
7113
7326
7543
7764
7990
8221
8456
8696
8940
9190
9444
9704
9968
10238
10512
10792
11077
11367
11663
11964
12271
12583
12901
13224
13554
13889
14230
14576
14929
15288
15653
16024
16401
16785
17175
17571
17974
18383
18799
19221
19650
20086
20529
20978

4805
4973
5145
5322
5503
5689
587
6070
6266
6466
6671
6880
7092
7308
7528
7751
7980
8215
8456
8703
8957
9214
9474
9738
10005
10276
10554
10839
11132
11433
11741
12053
12369
12689
13013
13340
13676
14020
14373
14735
15104
15478
15857
16242
16632
17029
17434
17847
18268
18697
19133
19574
20029
20488
20954
21426

Page 146

4628
4794
4965
5139
5317
5500
5687
5878
6073
6273
6477
6685
6899
7116
7339
7566
7798
8035
8276
8523
8775
9032
9294
9561
9833
10111
10394
10683
10977
11276
11582
11893
12210
12532
12861
13195
13535
13882
14234
14593
14958
15329
15706
16090
16481
16878
17281
17692
18108
18532
18963
19400
19844
20296
20754
21220

4598
4774
4945
5120
5296
5473
5656
5845
6040
6241
6449
6659
6871
7086
7304
7524
7751
7985
8226
8475
8731
8989
9249
9512
9778
10048
10326
10612
10905
11205
11513
11825
12141
12461
12785
13115
13452
13796
14148
14508
14875
15247
15624
16007
16396
16792
17197
17611
18033
18463
18900
19344
19795
20254
20721
21193

4603
4775
4952
5133
5318
5507
5701
5899
6101
6308
6520
6737
6958
7184
7415
7651
7891
8137
8388
8644
8905
9172
9444
9721
10003
10292
10585
10885
11190
11501
11818
12140
12469
12803
13144
13490
13843
14202
14568
14939
15317
15702
16093
16491
16895
17306
17724
18149
18581
19019
19465
19917
20377
20844
21318
21800

RADIATIE
555
560
565
570
575
580
585
590
595
600

22359
22850
23352
23865
24388
24917
25452
25992
26538
27089

22916
23415
23922
24436
24959
25489
26028
26574
27129
27691

22137
22627
23127
23638
24158
24685
25219
25760
26307
26861

21435
21899
22369
22847
23332
23824
24323
24830
25344
25866

21907
22397
22897
23407
23927
24455
24991
25535
26088
26649

Page 147

21693
22173
22660
23155
23657
24166
24683
25208
25741
26281

21674
22164
22664
23174
23694
24221
24755
25296
25844
26399

22289
22785
23289
23801
24320
24846
25381
25923
26473
27031

0.2900

0.2700

0.2500

0.2300
Column B
Column C
Column F

0.2100

0.1900

0.1700

0.1500
0

200

400

600

800

1000

1200

1400

1600

T3
T2
3.00E-11 -1.00E-07

T
0

K
0.38

0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
T2

T
0 1.18E-04

kcal/kggrd
0.1960
0.2057
0.2145
0.2224
0.2296
0.2361
0.2421
0.2476
0.2527
0.2576
0.2622
0.2668
0.2713
0.2760
0.2807

K
0.2

0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400

0
100
200
300
400
500
600
700
800
900
1000
1100

kcal/Nm3grd
0.3848
0.4038
0.4210
0.4366
0.4507
0.4636
0.4753
0.4861
0.4962
0.5057
0.5148
0.5237
0.5326
0.5417
0.5511

0.1960
0.2074
0.2179
0.2275
0.2363
0.2443
0.2513
0.2575
0.2629
0.2674
0.2710
0.2738
0.2757
0.2767
0.2769

real
0.1966
0.2063
0.2175
0.2272
0.2353
0.2425
0.2491
0.2547
0.2598
0.2649
0.2695
0.2741

EU
0.1960
0.2057
0.2145
0.2224
0.2296
0.2361
0.2421
0.2476
0.2527
0.2576
0.2622
0.2668

0.0006
0.0006
0.0030
0.0048
0.0057
0.0063
0.0070
0.0071
0.0071
0.0073
0.0072
0.0073

FLS
0.1960
0.2074
0.2179
0.2275
0.2363
0.2443
0.2513
0.2575
0.2629
0.2674
0.2710
0.2738

0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400

0.0006
-0.0011
-0.0004
-0.0003
-0.0010
-0.0018
-0.0022
-0.0028
-0.0031
-0.0025
-0.0015
0.0003

0.38

0.386
0.405
0.427
0.446
0.462
0.476
0.489
0.500
0.510
0.520
0.529
0.538
0.544
0.550
0.556

1200
1300
1400

0.2771
0.2802
0.2832

0.2713
0.2760
0.2807

0.0058
0.0042
0.0025
0.0765

0.2757
0.2767
0.2769

0.0014
0.0034
0.0063
-0.0045

0.2
0.21
0.22
0.23
0.24
0.24
0.25
0.25
0.26
0.26
0.27
0.27
0.28
0.28
0.28

CALDURI

SPECIFIC HEAT
T3

T2

CO2

kcal/Nm3

3.00E-11

H2O

kcal/Nm3

3.00E-12

N2
AIR
CLINKER
MATERIAL
COAL
oil

kcal/Nm3
kcal/Nm3
kcal/kg
kcal/kg
kcal/kg

-2.00E-11
-1.00E-11

-1.00E-07

0.38

6.00E-09

5.00E-05

0.36

4.00E-08
3.00E-08

4.00E-06
7.00E-06
0
0
0
0

0.31
0.31
0.19
0.23
0.26
0.42

T2
CO2

kcal/kg

1.18E-04

0.2

kcal/kg
N2
kcal/kg
AIR
kcal/kg
CLINKER kcal/kg
MATERIAL kcal/kg
COAL kcal/kg
oil
kcal/kg

2.80E-08

3.90E-05

0.44

0
0
0
0
0

0.24
0.24
0.19
0.21
0.26

H2O

air
0.370
0.365

f(x) = 0x + 0.32
R = 0.99

0.360
0.355
0.350
0.345
0.340
Column P
Linear Regression for
Column P

0.335
0.330
1,000

1,200

1,400

1,600

1,800

2,000

2,200

Page 153

2,400

2,600

CALDURI

co2
0.61
0.6

f(x) = 0x + 0.5
R = 0.99

0.59
0.58
0.57
0.56
0.55
Column J
Linear Regression for
Column J

0.54
0.53
0.52
1000

1200

1400

1600

1800

2000

2200

2400

2600

h2o
0.5
0.49

f(x) = 0x + 0.37
R = 1

0.48
0.47
0.46
0.45
0.44
0.43
Column L
Linear Regression for
Column L

0.42
0.41
0.4
1000

1200

1400

1600

1800

2000

2200

Page 154

2400

2600

0.45
0.44

CALDURI
0.43
Column L
Linear Regression for
Column L

0.42
0.41
0.4
1000

1200

1400

1600

1800

2000

2200

2400

2600

n2
0.37

0.36

f(x) = 0x + 0.32
R = 0.99

0.36

0.35

0.35

0.34

Column N
Linear Regression for
Column N

0.34

0.33
1000

t
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400

1200

1400

1600

1800

CO2
H2O
kcal/Nm3grd kcal/Nm3grd
0.386
0.355
0.405
0.360
0.427
0.365
0.446
0.370
0.462
0.375
0.476
0.380
0.429
0.385
0.500
0.390
0.510
0.397
0.520
0.403
0.529
0.410
0.538
0.417
0.544
0.422
0.550
0.427
0.556
0.433

2000

O2
kcal/Nm3grd
0.314
0.319
0.322
0.326
0.331
0.335
0.339
0.343
0.347
0.350
0.354
0.355
0.357
0.359
0.361

2200

2400

N2
kcal/Nm3grd
0.310
0.311
0.313
0.314
0.317
0.319
0.322
0.325
0.328
0.331
0.334
0.337
0.339
0.342
0.345

Page 155

2600

AIR
kcal/Nm3grd
0.311
0.312
0.313
0.315
0.318
0.321
0.324
0.327
0.330
0.334
0.337
0.340
0.342
0.344
0.347

VISCOZITATE

VISCOZITATE CINEMATICA [m2/s] x 10 6

T
-50
0
50
100
200
300
400
500
600
700
800
900
1000
1100
1200

AIR
9.5
13.7
18.5
23.7
35.6
49.1
63.9
80.2
97.7
118.5
136
156.8
178.4
201
224.5

VISCOZITATE OIL
oE
normal
2-2.5

oil

oil

N2
9.6
13.7
18.4
23.6
35.4
48.5
64.1
80.9
98.8
118.2
139
161.1
184.3
208.8
234.5

O2
9.5
13.9
18.8
24.1
36.1
49.9
65.4
82.4
100.9
120.8
142.1
164.1
188.4
215.5
239.4

H2
68.5
96.6
127.8
162.8
242.4
334
437.5
550.7
674.8
808.2
951.8

CO
9.5
13.7
18.4
23.7
35.9
49.8
63.5
82.4
100.6
120.8
142.2
164.7
188.6
213.6
239.9

CO2
4.8
7.2
9.9
13
20.3
28.5
37.9
48.2
59.4
71.4
84.2
97.9
112.3
127.5
143.5

84.75
11.46
2.39
0.1
9740

t
C
80
100
110
120

E
5.78
2.75
2.27
2.02

85.54
11.83
1.48
0.1
9715

t
C
80
100
110
120

E
5.78
3.70
3.00
2.50

cSt
11 - 17

s Saybolt s Redwood
80 - 95.5
65 - 90

oE
2.48
3
4.8
8.8
14
23
43
87

cSt
17
20.6
34.2
65
108
173
324
648

s Saybolt s Redwood

c
h
s
w
Hi

%
%
%
%
kcal/kg

c
h
s
w
Hi

%
%
%
%
kcal/kg

100
160
300
500
800
1500
3000

89
145
292
438
800
1400
2800

Page 156

H2O
1.79
0.55
0.3
0.16
0.13

Determination of acid dew point

1000
t=

-273
1.7842+0.0269*logpwater - 0.1029*logpSO3+0.0329*logpwater*logpSO3
SO3(ppm)*pB(hPa)

pSO3=

[bar]
106*103
H2O(vol%)*pB(hPa)

pwater=

[bar]
102*103

pB=

1013 hPa

[oC]

Productie [tpd]

CUPTOARE ROTATIVE CU SCHIMBATOARE DE CALDURA IN SUSPENSIE PENTRU DIFERITE ALTITUDINI

2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
800
700
600
500
400
3.5

Column E
Column F
Column G
Column H
Column I

3.6

3.7

3.8

3.9

4.0

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

5.0

5.1

Diametrul tolei cuptorului [m]

A.Toader

03/06/2013

Pierderile de caldura prin peretii cuptorului

Trcerea caldurii

Q=

kF(q1-q2)

k=

1/(1/1 +/+1/2)

1,2

suprafata incalzita [m2]

grosime perete in m
coeficienti de transmitere a caldurii [kcal/m2hgrad]
conductibilitate termica [kcal/mhgrad]

Tip

Grosime
400

Samota

1 caramida

kcal/m2h

Temperatura interioara a peretelui [oC]

600
800
1000
1200

1400

 conductibilitate termica aer [kcal/mhgrad]

5
0.037

10
0.056

20
0.096

30
0.136

grosime in [mm]
40
50
60
0.178
0.222
0.268

80
0.364

100
0.470

120
0.580

150
0.740

50
100

0.051
0.068

0.081
0.113

0.142
0.204

0.204
0.295

0.268
0.390

0.334
0.480

0.400
0.580

0.540
0.780

0.690
0.990

0.840
1.200

1.070
1.510

200
300
500
1000

0.118
0.190
0.410
1.740

0.206
0.346
0.800
3.420

0.390
0.660
1.550
6.780

0.560
0.970
2.300
10.100

0.750
1.290
3.060
13.500

0.930
1.600
3.820
16.900

1.110
1.920
4.590
20.200

1.490
2.560
6.120
27.000

2.870
3.210
7.650
33.700

2.250
3.760
9.190
40.400

2.840
4.840
11.500
50.500

temperatura

VARIATIA PRODUCTIEI CUPTORULUI FUNCTIE DE ALTITUDINE

1700

1600

PRODUCTIE [tpd]

1500

1400

1300

1200

1100

1000

500

1000

1500
ALTITUDINE [m]

2000

2500

3000

PROPERTY OF DRY AIR AT PRESSURE P=1 bar

oC

kg/m3
-180
-160
-140
-120
-100
-80
-60
-40
-20
0
20
40
60
80
100
120
140
160
180
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000

cp
o
o
-3
o
-6
kJ/kg/ K 10-3 K
10 W/m/ K 10 kg/m/s 10-6m2/s
3.85
1.07
11.7
9
6.44
3.13
1.04
9.32
10.9
7.85
2.64
1.02
7.76
12.7
9.2
2.29
1.01
6.66
14.6
2.02
1.01
5.85
16.4
1.81
1.01
5.22
18.16
1.64
1.01
4.72
19.83
1.5
1.01
4.3
21.45
1.38
1.01
3.96
23.01
1.28
1.01
3.67
24.54
1.19
1.01
3.42
26.03
1.11
1.01
3.2
27.49
1.05
1.01
3.01
28.94
0.99
1.01
2.84
30.38
0.93
1.01
2.68
31.81
0.89
1.01
2.55
33.23
0.84
1.02
2.42
34.66
0.8
1.02
2.31
36.07
0.77
1.02
2.21
37.49
0.74
1.03
2.12
38.91
0.67
1.04
1.91
42.43
0.61
1.05
1.75
45.91
0.56
1.06
1.61
49.31
0.52
1.07
1.49
52.57
0.48
1.08
1.38
55.64
0.45
1.09
1.29
58.48
0.4

1.12

1.15

63.5

0.36

1.14

1.03

67.8

0.32

1.16

0.93

71.3

0.3

1.17

0.85

74.3

0.27

1.19

0.79

76.8

10-6m2/s

Pr

altitudine

INFLUENTA ALTITUDINII ASUPRA INDICILOR REALIZABILI

TEMPERATURA MEDIU AMBIANT
t

15

h
m
1800

0.0065*h

t
C
3.3
o

1.00E-04

PRESIUNE ATMOSFERICA
p
p

=
=

p0 *(1-0.225694*10 h)
-4*

5.2553

10333*e-0.0001255*H
mmWG

p0

mmHg
760

m
500
1000
1500
1800
2000
2500
h

mmHg
716.00
674.08
634.17
611.16
596.20
560.09

kg/m3

kg/m3

1.29

500
1000
1500
1800
2000
2500

kg/Nm3
1.29
1.23
1.17
1.11
1.08
1.06

1.23
1.17
1.11
1.08
1.06
1.01
m
kg
1.29
1.23
1.17
1.11
1.08
1.06

h
m
0

tpd
1400

%
100

1350
1302
1254
1226
1208
1119

96.44
92.97
89.59
87.60
86.29
79.95

DENSITATE ATMOSFERICA

0 *(1-0.225694*10-4*h)4.2553
4.26

AIR MASS

V
Nm 3
1

P0
tpd

KILN OUTPUT

h
m
0
500
1000
1500
1800
2000

P0 *(1-0.225694*10-4*h)3.1915

1400

INLET KILN DIAMETER

D

D0 /(1-0.225694*10-4*h)1.0638

P0

21.43*D3
D
3.5
4.0
4.5
5.0

pb/p0

Cs0
kcal/kg
820

P0
640
1000
1450
2100
h
m
500
1000

500
1000
1500
1800
2000
3000

Corectie
0.9421 1.061
0.8869 1.127
0.8344 1.198
0.8042 1.244
0.7845 1.275
0.7370 1.357
/0
0/
0.953
0.907
0.864
0.838
0.822
0.781
F
corection
1.00
1.05
1.10
1.16
1.19
1.22
P

D0

m
4

m
500
1000
1500
1800
2000

m
4.05
4.10
4.15
4.18
4.20

%
101.21
102.46
103.73
104.51
105.04

h1
1 km
580
920
1350
1900

h2
2km
540
840
1200
1750

h3
3km
480
760
1120
1550

h4
4km
440
680
1000
1410

(0/)0.75

pb/p0

1.0369
1.0756

1.0437
1.0910

Page 215

1.0495
1.1020
1.1578
1.1930
1.2172
1.2804

altitudine

Cs/Cs0

Cs0
850

QgN/QgoN

Cs0
850

P=

1500
1800
2000

1.1162
1.1415
1.1588

1.1423
1.1753
1.1982

h
m
500
1000
1500
1800
2000

(0/)0.5 Cs
1.0244
1.0498
1.0760
1.0923
1.1033

858
867
875
881
885

h
m
500
1000
1500
1800
2000

(0/)0.75

(0/)0.5

1.0369
1.0756
1.1162
1.1415
1.1588

1.0244
1.0498
1.0760
1.0923
1.1033

QgN/QgoN
1.011
1.023
1.036
1.044
1.049

1.030
1.062
1.095
1.116
1.130

101325*(1-2,5577-5*H)5,25588

Gain (or loss) of pressure (Open circuit

The gain (or this loss) of relative pressure will be taken into account for the evaluation of the pressure losses on the open circuits, suc
p=

H*(air0-air1)*9,81

With:
G = Gain or loss of pressure in mmCE
H = Difference of height in m
air0 = Density of the ambient air, expressed in kg/m3 (according to the level of altitude)

1.294

air1 = Density of the ambient air, expressed in kg/m3 (according to the level of altitude)

1.171

Page 216

1208
1000

altitudine

1600

p0

mmWG
10333

m
300
1000
1500
1800
2000
2500

mmWG
9,951
9,114
8,560
8,244
8,039
7,550

p0
Pa
101325

h
m
300
1000
1500
1800
2000
2500

p
Pa
100,129
99,536
99,181
98,945
98,358
101,325

1600

100

1543
1488
1433
1402
1381
1279

110.22
106.26
102.39
100.12
98.62
91.37

500
1000
1500
1800
2000
3000

Page 217

Corectie
0.9630 1.038
0.8821 1.134
0.8284 1.207
0.7978 1.253
0.7780 1.285
0.7307 1.369

altitudine

valuation of the pressure losses on the open circuits, such as for example a gas feeding.

Page 218

Celsius degree vs Farenheit degree

200

f(x) = 1.8x + 32
R = 1

180
160
140

oF

120
100
80
60
40
20
0
0

10

20

30

40

50
oC

60

70

80

90

100

temperatura

TEMPERATURE SCALE

K
C
R
F

K
X
x-273
5/4x+273
5/9*(x-32)+273

C
X-273
X
5/4x
5/9(x-32)

R
4/5x-273
4/5x
x
4/9(x-32)

F
9/5*(x-273)+32
9/5x+32
9/4x+32
x

TRANSFORMATION
Q0 =

Q
Q
m3/h
256,370

273/(273+t [o C])* b/760

t
C
90
o

h
m
0
500
1000
1500
1800
2000

b
mmHg
760
716
674
634
611
596

C
0 - 30
30-600
30-300

0.9
0.95
0.25

EMISIVITY
o

FONTA RUGOASA
OTEL NETED
MAT DE CONSTRUCTII
CIMENT
BETON
CLINKER
Temp oC
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600

Nm3/h
192,807
181,644
171,010
160,886
155,048
151,253

%
0.75
0.71
0.67
0.63
0.60
0.59

0.96
0.93

Color of the radiation

dark red ,just visible
dark red
dark red
cherry red
bright cherry red
orange red
bright orange to yellow
bright yellow
bright yellow to white
white
white to brilliant white
brillant white

Overall Heat Transfer Coefficient

Type

Q0

Fluid

Application

ENG.A.TOADER

temperatura
Fluid
-UType

Application
Gases at
atmospheric
pressure inside and
outside tubes
Gases at high
pressure inside and
outside tubes
Liquid outside
(inside) and gas at
Tubular, heating or cooling atmospheric
pressure inside
(outside) tubes
Gas at high pressure
inside and liquid
outside tubes
Liquids inside and
outside tubes
Steam outside and
liquid inside tubes
Steam outside and
cooling water inside
tubes
Tubular, condensation Organic vapors or
ammonia outside
and cooling water
inside tubes
steam outside and
high-viscous liquid
inside tubes, natural
circulation
steam outside and
low-viscous liquid
Tubular, evaporation
inside tubes, natural
circulation
steam outside and
liquid inside tubes,
forced circulation
Cooling of water
Cooling of liquid light
hydrocarbons
Cooling of tar
Cooling of air or flue
Air-cooled heat exchangers gas
Cooling of
hydrocarbon gas
Condensation of low
pressure steam
Condensation of
organic vapors
Plate heat exchanger
liquid to liquid
Spiral heat exchanger

liquid to liquid
condensing vapor to
liquid

W/(m .K)

Btu/(ft2.F.h)

Water

5 - 35

1-6

Water

150 - 500

25 - 90

Water

15 - 70

3 - 15

Water

200 - 400

35 - 70

Water

150 - 1200

25 - 200

Water

300 - 1200

50 - 200

Air

1500 - 4000

250 - 700

Air

300 - 1200

50 - 200

Steam

300 - 900

50 - 150

Steam

600 - 1700

100 - 300

Steam

900 - 3000

150 - 500

Steam

600 - 750

100 - 130

Steam

400 - 550

70 - 95

Steam

30 - 60

5 - 10

Steam

60 - 180

10 - 30

200 - 450

35 - 80

700 - 850

125 - 150

350 - 500

65 - 90

1000 - 4000

150 - 700

700 - 2500

125 - 500

900 - 3500

150 - 700
Building Element

Doors
Ht = U A dt (1)

where

Ht = heat loss (btu/hr, W)

Roofing

ENG.A.TOADER

temperatura

U = "U-value" (btu/hr ft2 oF, W/m2K)

Roofing

A = wall area (ft2, m2)

dt = temperature difference (oF, K)

U and R-values
Windows
U-value (or U-factor) is a measure of the rate of heat loss or gain through a construction of materials. The lower the
Walls
The U-value of a construction consisting of several layers can be expressed as
U = 1 / R (2)
where
R = "R-value" - the resistance to heat flow in each layer (hr sq.ft oF/btu)
The R-value of the single layer can be expressed as:
R = 1 / C = lt / K (3)
where
C = layer conductance (btu/hr ft2 oF)
K = layer conductivity (btu in/hr ft2 oF)
lt = thickness of layer (inches)

ENG.A.TOADER

temperatura

oC

Transmission
Surface

Fluid

0
10
20
30
40
50
60
70
80
90

oF
32
50
68
86
104
122
140
158
176
194

100

212

Overall Heat Transmission Coefficient

ENG.A.TOADER

temperatura
Transmission
Surface

Fluid
(Btu/ft2 hr oF)

(W/m2 K)

Cast Iron

Air or Gas

1.4

7.9

Mild Steel

Air or Gas

2.0

11.3

Copper

Air or Gas

2.3

13.1

Cast Iron

Water

40 - 50

230 - 280

Mild Steel

Water

60 - 70

340 - 400

Copper

Water

60 - 80

340 - 455

Cast Iron

Air

1.0

5.7

Mild Steel

Air

1.4

7.9

Cast Iron

Air

2.0

11.3

Mild Steel

Air

2.5

14.2

Copper

Air

3.0

17

Cast Iron

Water

160

910

Mild Steel

Water

185

1050

Copper

Water

205

1160

Stainless Steel

Water

120

680

1 Btu/ft2 hr oF = 5.678 W/m2 K = 4.882 kcal/h m2 oC - Unit Converter

Heat-Transfer Coefficient
Building Element
Single sheet metal

(Btu/hr ft2 oF)

(W/m2K)

1.2

6.8

1 inch - wood

0.65

3.7

2 inches - wood
metal uninsulated
1 inch wood uninsulated
2 inches wood un-insulated
1 inch wood - 1
inch insulation
2 inch wood - 1
inch insulation
2 inches concrete slab

0.45

2.6

1.5

8.5

0.5

2.8

0.3

1.7

0.2

1.1

0.15

0.9

0.3

1.7

ENG.A.TOADER

temperatura

2 inches concrete slab - 1

inch insulation
Vertical single
glazed window
Vertical double
glazed window
Vertical double
glazed window
with "Low-E"
coatings
Vertical double
glazed window
with "Low-E"
coatings and
heavy gas filling
Vertical double
glazed window
with 3 plastic
films ("Low-E"
coated) and
heavy gas filling
Horizontal single
glass
8 inches poured concrete
12 inches poured concrete

0.15

0.9

1.1

0.5

0.32

1.8

0.27

1.5

0.06

0.35

1.4

7.9

0.25

1.4

0.2

1.1

ENG.A.TOADER

densitati

DENSITATI UZUALE
kg/m3
FONTA
7250
OTEL
7800
APA
1000
Hg
13600
OIL
850-950
MATERIAL
1500
FAINA
1100
FAINA FLUID
750
CLINKER
1350-1450
CIMENT
1100
AIR
O2
N2
CO2
H2O
=

1=

1.29
1.43
1.25
1.96
0.8
T0

* ( Pb+Pst)

Pb

oil= 0.95-0.00063*t
oil= 8e-9*t3+1e-6t2-0.0011*t+0.9716

Page 226

+ C* (t - t1)

densitati

0
0.83
0.84
0.84
0.85
0.85
0.86
0.86
0.87
0.87
0.88
0.88
0.89
0.89
0.9
0.9
0.91
0.91
0.92
0.92
0.93
0.93
0.94
0.94
0.95
0.95
0.96
0.96
0.97
0.97
0.98
0.98
0.99
0.99
1

C
0.84
0.84
0.85
0.85
0.86
0.86
0.87
0.87
0.88
0.88
0.89
0.89
0.9
0.9
0.91
0.91
0.92
0.92
0.93
0.93
0.94
0.94
0.95
0.95
0.96
0.96
0.97
0.97
0.98
0.98
0.99
0.99
1
1

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Page 227

C
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120

0.76
0.77
0.77
0.78
0.78
0.79
0.79
0.8
0.81
0.81
0.82
0.82
0.83
0.83
0.84
0.84
0.85
0.85
0.86
0.86
0.87
0.87
0.88
0.88
0.89
0.89
0.9
0.9
0.91
0.91
0.92
0.92
0.93
0.93

transformari

Normal
DECI
CENTI
MILI
MICRO
NANO
PICO
FEMTO
ATTO
ZEPTO
Yocto

d
c
m

n
p
f
a
z
y

0.1
1.00E+00
1.00E+01
1.00E+02
1.00E+05
1.00E+08
1.00E+11
1.00E+14
1.00E+17
1.00E+20
1.00E+23

NORMAL
0

%
0

1PPM NO

1.34

1PPM NO2

2.05

mgNO/Nm3
mgNO2/Nm3

1PPM SO2
1PPM CO

2.86
1.25

PPM

mg/Nm3

la x % O2

Normal
DECA
HECTO
KILO
MEGA
GIGA
TERA
PETA
EXA
Zetta
Yotta

mgSO2/Nm3
mgCO/Nm3

(21-15)/(21-x)

mg/Nm3

Heat
Designation
heat loss per unit area
termal conductivity
heat transfer coefficient
specific heat

Unit
W/m2
W/Km
W/Km2
kj/kgK

Conversion factor
1.16
1.16
1.16
4.2

1 shT
1 lb

0.91
0.45

mt
kg

1 BTU
1 BTU

0.25
1.06

kcal
kJ

1BTU/shT

1/3600

kcal/kg

1oF

1.8* o C+32

1 in
1 ft

25.4
0.31

mm
m

1sq ft
1 cu.ft

0.09
0.03

m2
m3

Page 228

Unit
kcal/m2h
kcal/mhdeg.
kcal/m2hdeg.
kcal/kg o C

BTU/lb

transformari

Integer Exponents

an am = an+m (1)
an / am = an-m (2)
(an)m = anm (3)
(ab)m = am bm (4)
(a / b)m = am / bm (5)
Fractional Exponents
ap/q = (a1/q)p (6)

Page 229

transformari

da
h
k
M
G
T
P
E
Z
Y

1.00
1.00E-01
1.00E-02
1.00E-03
1.00E-06
1.00E-09
1.00E-12
1.00E-15
1.00E-18
1.00E-21
1.00E-24

la 6 % O2

0.56 kcal/kg

Page 230

8514.16

transformari

Page 231

air

CHEMICAL COMPOSITION OF AIR

O2
21
23

%
VOLUME
MASS

N2
79
77

EXCESS AIR

100- CO2-O2-CO

100-CO2-O2-CO-3.762*(O2-CO/2)

0.95*O2

+1
21-O2

FUEL
GAS
OIL
COAL
COCKS

MIN
1.0
1.2
1.2
1.3

MAX
1.2
1.4
1.4
1.5

FALSE AIR
21- O2(x)

Q FALSE AIR (Y) =

*Q (X)
21-O2(y)

Q FALSE AIR =

14,000*Area*sqrt(Pst)

water content in air at 18 o C and 75 % relative moisture

Dtermination des cpm
CO2
N2
H2O
O2
CO

0.2
0.25
0.44
0.22
0.25

Umiditatea aerului

kcal/kg/C
kcal/kg/C
kcal/kg/C
kcal/kg/C
kcal/kg/C

Masses volumique
CO2
N2
H2O
O2
CO

xd=

kg H2O/kg dry air

ps(tlu)
xd= 0.622*

VH2O=1.608*xd*Vdr

p/f-ps(tlu)

ps(tlu)=611.5+43.87*tlu+1.47*(tlu)2+2.564*10-2*(tlu)4+2.722*10-6*(tlu)5
f=umiditatea relativa a aerului [%]
ps(tlu)=presiunea de saturatie a aburului in Pa

Page 232
Vo2
p =

Vo2
=

air

Presiunea partiala
Vo2
pO2=

Vo2
=

Vaertot

1
1.01

Vn2+Vo2

Vtotal
Nm3/m3
9.72
9.82

Vexces
Nm3/m3
0
0.10

Vo2

Vn2

Nm3/m3
2.03
2.05

Nm3/m3
7.69
7.77

Specific heats and molar heat capacities for various substances at

20 C
Substance
Aluminum
Bismuth
Copper
Brass
Gold
Lead
Silver
Tungsten
Zinc
Mercury
Alcohol(ethyl)
Water
Ice (-10 C)
Granite
Glass

c in J/gm K
0.9000
0.1230
0.3860
0.3800
0.1260
0.1280
0.2330
0.1340
0.3870
0.1400
2.4000
4.1860
2.0500
0.7900
0.8400

c in cal/gm K or
Btu/lb F
0.2150
0.0294
0.0923
0.0920
0.0301
0.0305
0.0558
0.0321
0.0950
0.0330
0.5800
1.0000
0.4900
0.1900
0.2000

Page 233

Molar C
J/mol K
24.3
25.7
24.5
...
25.6
26.4
24.9
24.8
25.2
28.3
111.0
75.2
36.9
...
...

air

L COMPOSITION OF AIR

100- CO2-O2-CO
100-CO2-O2-CO-3.762*(O2-CO/2)
0.95*O2
+1
21-O2

21- O2(x)
*Q (X)
21-O2(y)

Pst [mmWG]
12.6 g/m3 dry air
Masses volumique
1.96
1.25
0.8
1.43
1.25

kg/Nm3
kg/Nm3
kg/Nm3
kg/Nm3
kg/Nm3

kg H2O/kg dry air

VH2O=1.608*xd*Vdry air

u+1.47*(tlu)2+2.564*10-2*(tlu)4+2.722*10-6*(tlu)5
p=presiunea mediului in Pa

Page 234

air

Vaer

Po2

Pn2

%
100
100

%
20.9
=

%
79.1

Page 235

pitot

Punctele de masura
SECTION CIRCULAR

a1
a2
a3
a4
a5
a6
a7
a8
a9
a10

D<300
2*2
0.85*D
0.15*D

300<D<700
2*4
0.93*D
0.75*D
0.25*D
0.07*D

700<D<1500
2*6
0.96*D
0.85*D
0.7*D
0.3*D
0.15*D
0.04*D

1500<D<2400
2*8
0.97*D
0.9*D
0.81*D
0.68*D
0.32*D
0.19*D
0.1*D
0.03*D

2400<D<3400
2*10
0.97*D
0.92*D
0.85*D
0.77*D
0.66*D
0.34*D
0.23*D
0.15*D
0.08*D
0.03*D

SECTION RECTANGLE
D=0.5*(H+B)
MEASUREMENT
Pd
Ps
Tg

DINAMIC PRESSURE (+/-)

cu gaurele laterale (-)
temperatura o C

( sqrt(Pd))2

Pd=

n
2*9.81*Pd*Tg*760
V= SQRT(
)
T0*0*(760-Ps)
Pd
Ps

Page 236

mmWS
mmHg

Pd*Tg
V=23.6*sqrt(

Pd,Ps

)
*(760-0.75*Ps)
hPa

energie

CONVERSION TABLES
FORCE
N
dyn
kP
MP
p

N
1
1
1
1
1

dyn
100,000.00
100,000.00
100,000.00
100,000.00
100,000.00

j=ws
1

kJ

kP
0.1
0.1
0.1
0.1
0.1

Mp
0
0
0
0
0

p
102
102
102
102
102

erg

kpm (kgfm)

ENERGY & WORK

j=Nm
kJ
GJ
erg
kpm
kWh
kcal
cal
eV
BTU
ftlbf
kgfm
CPh

W(J/sec)
kW(kJ/sec)
MW(MJ/s)
GW(GJ/s)
TW(TJ/s)

GJ
0

1
1
1
1
1
1
1
1.00E+00
1.0000
1
1
1

W(J/sec)
1
1,000
1,000,000
1,000,000,000
1,000,000,000,000

0
0
0
0
0
0
0
1.00E-06
0
0
0
0

0.1
0.1
0.1
0.1
0.1
0
0.1
0.1
1.02E-01
0.1
0.1
0.1
0.1

0
0
0
2.78E-07
0
2.78E-07
0
0
2.78E-07
0
0
0
0

MW
0
0
1
1000
1000000

GW(GJ/s)
0
0
0
1
1000

TW(TJ/s)
0
0
0
0
1

erg/s
10000000
10000000000
1.00E+13
1.00E+16
1.00E+19

0
0
0
0
0
0
0
1.00E-03
0
0
0
0

kW(kJ/sec)
0
1
1,000
1,000,000
1,000,000,000

kWh

1.E+07
1.E+07
1.E+07
1.00E+07
1.00E+07
10000800
10005720
1.00E+07
1.00E+07
10,000,000
10000000
10000000.03
1.E+07

Page 237

energie

erg/sec
kgfm/s
prony
poncelet
CP
cal/sec
kcal/h
Gcal/h
hp
BTU/h

0
9.81
98.07
980.67
735.5
153496.46
1.16
1,163,000
745.7
0.29

0
0.01
0.1
0.98
0.74
153.5
0.001
1,163
0.75
0

0
0
0
0
0
0.15
0
1.16
0
0

0
0
0
0
0
0
0
0
0
0

5.68

w/m2oK

4.88

kcal/m2oC

BTU/ft2hoF

0
0
0
0
0
0
0
0
0
0

1.00E+00
98066500
980665000
9806650000
7354990000
###
11630000
###
7457000000
2930710

POWER

W
kW
kpm/s
PS
HP
kcal/s
kcal/h

W=js
1
1,000
9.81
735.5
745.71
4187
1160

kW
0
1
0.01
0.74
0.75
4.19
1.16

kpm/s
kgfm/s
0.1
102
1
75
76.04
427
119

Page 238

PS
CP
0
1
0.01
1
1.01
5.69
1.58

HP
0
1
0.01
0.99
1
5.61
1.56

kcal/s
0
0
0
0.18
0.18
1
0.28

energie

TERA
GIGA
MEGA
KILO
HECTO
DEKA

T
G
M
k
h
da

DECI
CENTI
MILI
MIKRO
NANO
PICO
FEMTO
ATTO

d
c
m

n
p
f
a

PPM
%

1.00E+12
1.00E+09
1.00E+06
1.00E+03
1.00E+02
1.00E+01
1.00E+00
1.00E-01
1.00E-02
1.00E-03
1.00E-06
1.00E-09
1.00E-12
1.00E-15
1.00E-18

1.00E-12
1.00E-09
1.00E-06
1.00E-03
1.00E-02
1.00E-01
1.00E+01
1.00E+02
1.00E+03
1.00E+06
1.00E+09
1.00E+12
1.00E+15
1.00E+18

1,000,000
1.000000
100.000000

1,000,000
1
100

1.00

100
0
0.01

CONDUCTIVITATE termica
BTU/(fthoC)
BTU/(fthoC)
BTU/(fthoC)

1 kcal/(hmoC)
0.67 kcal/(hmoC)
0.58 kcal/(hmoC)

1.49 W/(moK)
0.9 W/(moK)
0.86 W/(moK)

1.73
1.05
1

1.000 tona echivalenta de petrol tep

10.500 Gcal

44.000 GJ

1.000 tona echivalenta de petrol tep

10.500 Gcal

44.000 GJ

1.000 tona echivalenta de petrol tep

10.500 Gcal

44.000 GJ

Page 239

energie

1.000 tona echivalenta de petrol tep

10.500 Gcal

44.000 GJ

1.000 tona echivalenta de petrol tep

10.500 Gcal

44.000 GJ

1
1
1
1
1

kW
kW
kW
kW
kW

1,000
3,600,000
3.6
860
3,413

J/s
J/s
MJ/h
Kcal/h
BTU/h

Page 240

energie

kcal
0
0
0
0.000239
0
0
0
0
0.000239
0
0
0
0

cal
0.24
0.24
0.24
0.2388
0.24
0.2388
0.2388
0.24
0.2388
0.24
0.24
0.24
0.24

eV
6.24E+018
6.24E+018
6.24E+018
6.24E+018
6.24E+018
6.24E+18
1
6.24E+018
6.24E+18
6.24E+018
6.24E+018
0
6.23E+18

kgfm/s
0.1
101.97
101,972
1.E+08
1.E+11

prony
0.01
10.2
10197.2
10197200
10197200000

poncelet
0
1.02
1019.72
1019720
1019720000

BTU

ftlbf

kgfm

0
0
0
0
0
0
0
0
0.0009
0
0
0
0

0.74
0.74
0.74
0.74
0.74
0.74
0.737
0.74
0.737
0.74
0.74
0.74
0.74

0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1

CP
0
1.36
1359.62
1359620
1359620000

cal/sec
0.24
238.85
238846
238846000
###

kcal/h
0.86
859.85
859845
859845000
###

Page 241

CPh(HPhr)
0
0
0
3.78E+07
0
3.78E-07
0
0
0
0
0
0
3.78E-07

Gcal/h
hp
0
0
0
1.34
0.86
1341.02
859.85
1341020
859850 1341020000

BTU/h
3.41
3412.14
3412140
3412140000
###

energie

0
1
10
100
75
15652.29
0.12
118593
76.04
0.03

0
0.1
1
10
7.5
1565.23
0.01
11859.3
7.6
0

0
0.01
0.1
1
0.75
156.52
0
1185.9
0.76
0

104,760,000

3471000000

33.13

kcal/h
0.86
860
8.43
632.53
641.31
3600.82
1000

BTU/h
3.41
3,412.00
33.47
2,509.53
2,544.37
14,286.04
3,957.92

ftpdl/s
23.73
23,730.00
232.79
17,453.42
17,695.75
99,357.51
27,526.80

0
0.01
0.13
1.33
1
208.7
0
1581.24
1.01
0

ftlbf/s
0.74
737.00
7.23
542.06
549.59
3,085.82
854.92

Page 242

0
2.34
23.42
234.23
175.67
36662
0.28
277778
178.11
0.07

0
8.43
84.32
843.22
632.42
131983.2
1
1000000
641.19
0.25

0
0
0
0
0
0.13
0
1
0
0

0
0.01
0.13
1.32
0.99
205.84
0
1559.61
1
0

0
33.46
334.62
3346.17
2509.63
523753.33
3.97
3968320
2544.43
1

energie

1.500 tona combustibil conventional

12.500 MWh

1.500 tona combustibil conventional

12.500 MWh

1.500 tona combustibil conventional

12.500 MWh

Page 243

energie

1.500 tona combustibil conventional

12.500 MWh

1.500 tona combustibil conventional

12.500 MWh

Page 244

atm
Pa
N/mm2
daPa
hPa
bar
mbar
at
torr
mmWG
kgf/m2
kgf/cm2
inchWG
Psi

atm
1
0.00000987
1.00000000
1.000000
1.000000
0.986923
1.000000
0.967867
1.000000
0.000581
1.000000
6.776378
1.000000
1

Pa
101,325.00
1
101,325
101,325.000000
101325.000000
100,000.00
101,325.000000
98,069.105691
101325.000000
58.852856
101325.000000
686616.650532
101325.000000
101,325

N/m2
101,325.00
1.00
101,325.00
101,325.000000
101,325.00
100,000.00
101,325.00
98,069.11
101,325.00
58.85
101,325.00
686616.650532
101325.000000
101,325

N/mm2
0.101325
0.000001
0.101325
0.101325
0.101325
0.100000
0.101325
0.098069
0.101325
0.000059
0.101325
0.686617
0.101325
0.1

daPa
10,132.50
0.10
10,132.50
10,132.50
10,132.50
10,000.00
10,132.50
9,806.91
10,132.50
5.89
10,132.50
68,661.67
10,132.50
10,132.50

hPa
1,013.25
0.01
1,013.25
1,013.25
1,013.25
1,000.00
1,013.25
980.69
1,013.25
0.59
1,013.25
6,866.17
1,013.25
1,013.25

bar
1.013250
0.000010
1.013250
1.013250
1.013250
1
1.013250
0.980691
1.013250
0.000589
1.013250
6.866167
1.013250
1.01

mbar
1013.250000
0.01000
1,013.25000
1,013.25000
1,013.25000
1,000.00000
1,013
980.69106
1,013.00000
0.58853
1,013.25000
6,866.16651
1,013.25000
1013.25

at
1.033200
0.0000102
1.033
1.033200
1.033200
1.019743
1.033200
1
1.033200
0.000600
1.033200
7.001355
1.033000
1.03

torr
760.000000
0.007501
760.000000
760.000000
760.000000
750.061683
760.000000
735.578784
760
0.441433
760.000000
5150.048403
760.000000
760

mmWG
10,330.00
0.10
10,330.00
10,330.00
10,330.00
10,194.92
10,330.00
9,998.06
10,330.00
6.00
10,330.00
70,000.00
10,330.00
10,330.00

kgf/m2
10,330
0
10,330
10330.00000
10330.00000
10,194.91735
10330.00000
9,998
10330.00000
6.00
10,330.00
70,000.00
10,330.00
10,330.00

kgf/cm2
Psi [lbf/in2]
inchWG
1.0330 406.692100
14.7
0.0000
0.004014 0.0001450
1.0330 406.692100
14.7
1.0330 406.692000
14.7
1.0330 406.692100
14.7
1.0195 401.373896
14.5
1.0330 406.692100
14.7
0.9998 393.623790
14.22
1.0330 406.692100
14.7
0.0006
0.236220
0.01
1.0330 406.692100
14.7
7 2755.900000
99.59
1.03300
406.69
14.7
1.03
406.69
14.7

Pump power
9,81 x

x Q x p

3600 x

N=

Q
p

kg/m3
m3/h
m WG
%
W

1000
200
10
0.7

0.5

0.7

7,778

Motor for Lifts , elevators and cranes

9,81 x
N=

Gxv

96.24

G
v

kp
m/s
%
W

375
0.6
0.5

0.5

0.7

0.5

0.7

4,415

Fan compressor motor

27,78 x
N=

Q
p

Q x p

m3/h
bar
%
W

30
10
0.7

11,906

Pump power
x Q x p
N=
3 600 000 000 x

Q
p

kg/m3
m3/h
Pa
%
kW

1000
200
98100
0.7

7.786

Motor for Lifts , elevators and cranes

96,2361 x
N=
1000x
G
v

kg
m/s
%
kW

Gxv

38.27
0.6
0.5

0.5

4.419

Fan compressor motor

27,78 x

Q x p

N=
100 000 000 x
Q
p

m3/h
Pa
%
kW

30
1,000,000
0.7

11.906

0.7

Climate/humidity table
AH=
Dew points=
Pv=RHxES

gWater/m3 dry

Relative humidity/Temp
50

RH
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar

Es=6,1078*107,5*Tc/(237,3+Tc)

45

40

35

30

25

20

15

10%
8.3
8.0
12.3
1233.8
6.5
4.0
9.6
958.4
5.1
1.0
7.4
737.7
4.0
-2.0
5.6
562.3
3.0
-6.0
4.2
424.4
2.3
-8.0
3.2
316.8
1.7
-12.0
2.3
233.9
1.3
-16.0
1.7

20%
16.6
19.0
24.7
2467.6
13.1
15.0
19.2
1916.7
10.2
11.0
14.7
1475.3
7.9
8.0
11.2
1124.7
6.1
3.0
8.5
848.7
4.6
0.0
6.3
633.7
3.5
-4.0
4.7
467.7
2.6
-7.0
3.4

30%
24.9
26.0
37.0
3701.4
19.6
22.0
28.7
2875.1
15.3
18.0
22.1
2213.0
11.9
14.0
16.9
1687.0
9.1
10.0
12.7
1273.1
6.9
5.0
9.5
950.5
5.2
1.0
7.0
701.6
3.9
-3.0
5.1

40%
33.2
32.0
49.3
4935.2
26.2
27.0
38.3
3833.4
20.5
23.0
29.5
2950.6
15.8
18.0
22.5
2249.4
12.1
14.0
17.0
1697.5
9.2
10.0
12.7
1267.3
6.9
5.0
9.4
935.5
5.1
1.0
6.8

50%
41.5
36.0
61.7
6169.0
32.7
32.0
47.9
4791.8
25.6
27.0
36.9
3688.3
19.8
21.0
28.1
2811.7
15.2
18.0
21.2
2121.8
11.5
13.0
15.8
1584.1
8.7
9.0
11.7
1169.3
6.4
4.0
8.5

60%
49.8
40.0
74.0
7402.8
39.3
36.0
57.5
5750.2
30.7
30.0
44.2
4425.9
23.8
25.0
33.7
3374.1
18.2
21.0
25.5
2546.2
13.8
16.0
19.0
1901.0
10.4
12.0
14.0
1403.2
7.7
7.0
10.2

70%
58.1
43.0
86.3
8636.7
45.8
38.0
67.1
6708.5
35.8
33.0
51.6
5163.6
27.7
28.0
39.4
3936.4
21.3
24.0
29.7
2970.6
16.1
19.0
22.2
2217.8
12.1
14.0
16.4
1637.1
9.0
9.0
11.9

80%
66.4
45.0
98.7
9870.5
52.4
41.0
76.6
7666.9
40.9
36.0
59.0
5901.2
31.7
31.0
45.0
4498.8
24.3
26.0
33.9
3394.9
18.4
21.0
25.3
2534.6
13.8
16.0
18.7
1870.9
10.3
11.0
13.6

90%
74.7
48.0
111.0
11104.3
58.9
43.0
86.2
8625.2
46.0
38.0
66.4
6638.9
35.6
33.0
50.6
5061.1
27.3
28.0
38.2
3819.3
20.7
23.0
28.5
2851.4
15.6
18.0
21.0
2104.8
11.5
13.0
15.3

100%
83.0
50.0
123.4
12338.1
65.4
45.0
95.8
9583.6
51.1
40.0
73.7
7376.5
39.6
35.0
56.2
5623.4
30.4
30.0
42.4
4243.7
23.0
25.0
31.7
3168.3
17.3
20.0
23.4
2338.7
12.8
15.0
17.1

10

-5

-10

-15

-20

-25

Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal
AH
Dew point
Pv mbar
Pv Pascal

Pd
Pv
D= ---------- + ---------Rd*T
Rv*T

170.6
0.9
-19.0
1.2
122.8
0.7
-23.0
0.9
87.2
0.5
-26.0
0.6
61.1
0.3
-29.0
0.4
42.1
0.2
-34.0
0.3
28.6
0.2
-37.0
0.2
19.1
0.1
-42.0
0.1
12.5
0.1
-45.0
0.1
8.0

341.1
1.9
-11.0
2.5
245.6
1.4
-15.0
1.7
174.5
1.0
-19.0
1.2
122.2
0.7
-22.0
0.8
84.3
0.5
-26.0
0.6
57.2
0.3
-30.0
0.4
38.1
0.2
-35.0
0.2
24.9
0.1
-40.0
0.2
16.0

511.7
2.8
-7.0
3.7
368.5
2.0
-11.0
2.6
261.7
1.5
-14.0
1.8
183.3
1.0
-18.0
1.3
126.4
0.7
-22.0
0.9
85.7
0.5
-26.0
0.6
57.2
0.3
-32.0
0.4
37.4
0.2
-36.0
0.2
24.0

682.3
3.8
-3.0
4.9
491.3
2.7
-7.0
3.5
349.0
1.9
-11.0
2.4
244.4
1.4
-15.0
1.7
168.5
0.9
-19.0
1.1
114.3
0.6
-23.0
0.8
76.2
0.4
-29.0
0.5
49.9
0.2
-34.0
0.3
32.0

852.8
4.7
0.0
6.1
614.1
3.4
-5.0
4.4
436.2
2.4
-8.0
3.1
305.5
1.7
-13.0
2.1
210.6
1.2
-17.0
1.4
142.9
0.8
-21.0
1.0
95.3
0.4
-27.0
0.6
62.3
0.3
-32.0
0.4
40.0

1023.4
5.6
1.0
7.4
736.9
4.1
-2.0
5.2
523.5
2.9
-6.0
3.7
366.6
2.1
-11.0
2.5
252.8
1.4
-15.0
1.7
171.5
1.0
-19.0
1.1
114.3
0.5
-25.0
0.7
74.8
0.3
-30.0
0.5
48.0

1194.0
6.6
4.0
8.6
859.7
4.8
0.0
6.1
610.7
3.4
-4.0
4.3
427.7
2.4
-8.0
2.9
294.9
1.6
-13.0
2.0
200.0
1.1
-17.0
1.3
133.4
0.6
-24.0
0.9
87.3
0.4
-29.0
0.6
56.0

1364.5
7.5
6.0
9.8
982.6
5.4
2.0
7.0
698.0
3.9
-3.0
4.9
488.7
2.7
-7.0
3.4
337.0
1.9
-11.0
2.3
228.6
1.3
-16.0
1.5
152.4
0.7
-22.0
1.0
99.7
0.4
-27.0
0.6
64.0

1535.1
8.5
8.0
11.1
1105.4
6.1
3.0
7.9
785.2
4.4
-2.0
5.5
549.8
3.1
-6.0
3.8
379.1
2.1
-11.0
2.6
257.2
1.5
-15.0
1.7
171.5
0.8
-21.0
1.1
112.2
0.5
-26.0
0.7
72.0

1705.6
9.4
10.0
12.3
1228.2
6.8
5.0
8.7
872.5
4.8
0.0
6.1
610.9
3.4
-5.0
4.2
421.3
2.3
-10.0
2.9
285.8
1.6
-15.0
1.9
190.5
0.9
-20.0
1.2
124.7
0.6
-25.0
0.8
79.9

Pd
Pv
D= ---------- + ---------Rd*T
Rv*T
Rd
Rv
T

287.05
461.5
o
K

INPUT DATA
P
T

Pa
o
C
o
K
%

Relative humidity

101,325
15
288.15
100

CALCULATION
Pv
Pd

Pa
Pa

D0
Dwet

kg/Nm3
kg/m3

1,705.65
99,619.35

1.292
1.217

Pd=P-Pv

CONVERSION TABLE
1 km
1m
1m

0.62 mile
1.094 yd
3.281 ft

1 mile
1 yd
1 ft

1.609 km
0.914 m
0.305 m

1 mm

0.039 in

1 in

25.4 mm

1 km2

0.39 sqmile

1 sqmile

2.59 km2

1 m2

3.28 sqyd

1 sqyd

0.84 m2

10.75 sqft

1 sqft

0.09 m2

0.16 sqin

1 sqin

6.45 cm2

25000 m2

1 m2

0.01 ha

35.71 cuft

1 cuft

0.028 m3

1 dm3

0.04 cuft

1 cuft

28.3 dm3

1 dm3
1 dm3
1 cm3

0.22 Imp.Gal
0.27 US.Gal
0.06 cu.in

1 Imp.Gal
1 US.Gal
1 cu.in

4.55 dm3
3.79 dm3
16.4 cm3

1.2 US.Gal

1 US.Gal

0.83 Imp.Gal

1 m2

1 cm2
2.5 ha
1 m3

1 Imp.Gal
1t
1t
1 kg
1 kg
1 kg
1g

1.1 shT
0.98 longT
2.2 lb
0.02 cwt
0.01 bbl
0.04 oz

1 shT
1 longT
1 lb
1 cwt
1 bbl
1 oz

1 sh.t
1 longT
1 cwt
1 lb
1 lb
1 bbl(US)

2000 lb
2240 lb
112 lb
16 oz
7000 grain
376 lb

1 lb
1 lb
1 lb
1 oz
1 grain
1 lb

0.91 mt
1.02 t
0.45 kg
50.8 kg
170.5 kg
28.4 g

0 sh.t
0 longT
0.01 cwt
0.06 lb
0 lb
0 bbl(US)

1 sh.cwt
1 at
1 at
1 at
1 at
1 atm
1 atm
1 atm
1 atm
1 atm
1 mbar
1 kgf/m2
1 kgf/cm2
1 kgf/cm2
1 kgf/mm2
1 kgf/mm2
1 kg/cm2
Unit of power
1w
1w
1w
1w
1 kW
1 hk
1 hk
1 kcal/h
1 CP
1 CP
1 HP
Units of work,Energy
1J
1J
1J
1 KJ
1 kWh
1 kWh
1 kWh
1 kWh
1 kcal
1 kcal
1 PSh
1 PSh
1 PSh

1 kcal/kg
1 kcal/kg
1 kcal/kg

100 lb
1 kg/cm2
0.98 bar
98.1 kPa
10 mVS
1.03 kgf/cm2
760 torr
10333 mmWG
1,013 mbar
1,013 hPa
1019.74 mmWG
9.81 Pa
9,810 Pa
9.81 kPa
9,810,000 Pa
9.81 N/mm2
0.07 lb/sq.in

0.86 kcal/h
0 kcal/s
0.1 kpm/sec
0 PSh
1.36 hk
75 kpm/sec
0.99 hp
0 kcal/s
735.28 kW
0.99 HP
745.48 kW

0 kWh
4.19 cal
0.1 kpm
0.948 BTU
860 kcal
3412 BTU
367,000 kpm
3,600 KJ
4.19 KJ
3.968 BTU
0.74 kWh
632 kcal
2648 kJ

4.19 KJ/kg
1.80 BTU/lb
3,600 BTU/shT

1 lb
1 kg/cm2
1 bar
1 kPa
1 mVS
1 kgf/cm2
1 torr
1 mmWG
1 mbar
1 hPa
1 mmWG
1 Pa
1 Pa
1 kPa
1 Pa
1 N/mm2
1 lb/sq.in

1 kcal/h
1 kcal/s
1 kpm/sec
1 PSh
1 hk
1 kpm/sec
1 hp
1 kcal/s
1 kW
1 HP

1 kWh
1 cal
1 kpm
1 BTU
1 kcal
1 BTU
1 kpm
1 KJ
1 KJ
1 BTU
1 kWh
1 kcal
1 kJ

1 KJ/kg
1 BTU/lb
1 BTU/shT

0.01 sh.cwt
1.00 at
1.02 at
0.01 at
0.10 at
0.9681 atm
0.0013 atm
0 atm
0 atm
0 atm
0 mbar
0.1 kgf/m2
0 kgf/cm2
0.1 kgf/cm2
0 kgf/mm2
0.1 kgf/mm2
14.22 kg/cm2

1.16 w
4187.01 w
9.80 w
735.50 w
0.736 kw
0.013 hk
1.014 hk
3600 kcal/h
0.0014 CP
1.0139 CP

3,600,000 J
0.239 J
9.810 J
1.055 KJ
0 kWh
0 kWh
0 kWh
0 kWh
0.239 kcal
0.25 Kcal
1.359 PSh
0.002 PSh
0.000 PSh

0.239 kcal/kg
0.555 kcal/kg
0 kcal/kg

1 oC

1%

5/9*(F-32)

10,000 ppm

1 oF

1 ppm

32+9/5*C

0%

1 ppmNO
1 ppmNO2

1.34 mgNO/m3
3
2.05 mgNO2/m

1 mgNO/m3
3
1 mgNO2/m

0.746 ppmNO
0.488 ppmNO2

1 ppmSO2
1 ppmCO

3
2.86 mgSO2/m
1.25 mgCO/m3

3
1 mgSO2/m
1 mgCO/m3

0.350 ppmSO2
0.8 ppmCO

1 nod/h
1 nd/h
1 nd/h
1 nd/h
1 km/h
1 km/h
1 milla/h

1.85 km/h
1852 m/h
0.5144 m/s
2,025.36 yarzi/h
0.2778 m/s
16.6667 m/min
0.4470 m/s

1 ft/s
1 ft/min

0.31 m/s
0.005 m/s

1 kg/m3

0.06 lb/cuft

1 km/h
1 m/h
1 m/s
1 yarzi/h
1 m/s
1 m/min
1 m/s

1 m/s
1 m/s
0.07 lb/cuft

0.5400 nod/h
0.0005 nd/h
1.9439 nd/h
0.0005 nd/h
3.6000 km/h
0.0600 km/h
2.2371 milla/h

3.28 ft/s
196.72 ft/min
1.20 kg/m3

Quantity
Length (L)
Mass (M)

Velocity (v)

1
Volume Flow (Q)

1
1
1

Pressure (P)
Speed (n)
Electric Current (l)
Electromotive Force (V)
Power (W)
Density (p)
Power Factor (cos )
Efficiency (n)

Alternate
Unit
metre (m)
foot (ft)
kilogram (kg)
pound (lb)
metre per
foot per
second (m/s) minute (fpm)
cubic metre per cubic foot per
second (m/s) minute (cfm)
litre per second
(l/s)
per hour
(m/hr)
Pascal (Pa or
inch water
N/m)
gauge (in.wg)
millimetre of
water
(mm.H2O)
revs per second
revs per
(rps)
minute (rpm)
ampere (A)
volt (V)
horse power
watt (W or J/s)
(hp)
kg per cubic
cubic foot
metre (kg/m)
(lb/ft)
W : VA
QP / W
Preferred Unit

1000
1

Conversion
Factor
3.28
2.20
172.41
2,118.64
2.12
3.60
0.00
9.81
0.01667
1.34
0.06

AIR AND HEAT

Volume
Q0

Volume at 0oC and 10333 mmWG,760 torr,1013.3 mbar

Nm3

Volume at t oC and b (mmWG,torr,mbar)

Am3

Q0
Nm
10,000

t
C
200

p
mmWG
21,666

Q
Am3
36,329

t
C
200

p
mbar
2,125

C
Atmospheric air
kiln gases
aux furnace gases
water vapour
raw materials
clinker
o

1.96

CO2
%
0

kg/Nm3
0
1.29
1.4
1.3
0.8

1.43

Q0
Nm3
10,000

Specific gravity
kg/m3
kg/m3
90
100
0.97
0.95
1.05
1.02
0.98
0.95
0.6
0.59

O2
%
21

kgwater/kg dry air

0.05
kgwater/kg dry gases 30 % CO2
0.05

Q
Am3
36,329

1.25

t dew point
40.01
t dew point
42.64

Specific heat
cal/(goC)
0-200
0.24
0.25
0.26
0.48
0.21
0.19
N2
%
79

0
mixt
1.29 kg/Nm3dry

Calculation of false air

False air in the mill inlet lowers the temperature and thereby the drying capacity.
False air at the outlet does not directly influences drying but increase the load on fans and filter
False air is expresed in percente of unmixed gases at the inlet
The amount of false air through the mill and cyclones may be calculated from the contents of O2
and CO2 in the gases when atmospheric air is reckoned to contain 0 % CO2 and 21 % O2
In the following calculation the therm "gas" signifies the unmixed gases and the therm "mixture"
the mixture of false air and gases.
CO2 (gas)- CO2(mixture)
X CO2 =

X 100
CO2(mixture)
O2 (mixture)- O2(gas)

X O2 =

X 100
21- O2(mixture)

Inlet mill
outlet mill
outlet cyclone

CO2
19.7
17.2
12.3

O2
8.2
10
12.8

X CO2 =

14.53

X O2 =

16.36

False air through mill

15.45

X CO2 =

60.16

False air through mill and cyclones

58.13

X O2 =

56.10

VARIOUS CALCULATION
1

The theoretical power consumption E(kW) for fans and centrifugal pumps, when
transporting Q m3/h against of P mmWG may be calculated as

0
2

motor

eq

%
95

%
70

Q
P
mmWG
m3/h
500,000
700

%
75
55
70
95

Practical efficiencies for pumps

centrifugal pumps for water
centrifugal pumps for slury
fans for air gases
electric motors

E
kW
1,432

Quantity of air through orifice diaphragm

K

Q
m3/h
=

Heat transmission from radiator to air is approx

For fast or forced convection

Grinding with

Loss of heat from mill surfaces to be

kWh

8
10

kcal/(hoCm2)
kcal/(hoCm2)

produce a heating coresponding to 4 oC

600 kcal/(hm2)

Fan Power Consumption

The ideal power consumption of a fan (without losses) can be expressed as

Pi = dp q (1)
where
Pi = ideal power consumption (W)

dp = total pressure increase in the fan (Pa)

q = air volume flow delivered by the fan (m3/s)
The ideal power consumptions for fans at different air volumes and pressure
increases are expressed in the chart below:
Fan Efficiency
T
h
e
f
a
n
e
f
f
i
c
i
e
n
c
y
i
s

f = dp q / P (2)
where
f = fan efficiency (values between 0 - 1)
dp = total pressure (Pa)
q = air volume delivered by the fan (m3/s)
P = power used by the fan (W, Nm/s)

The power used by the fan can be expressed as:

t
h
e

P = dp q / f (3)

r
a
tThe
i
o
b
e
t
w
e
e
n
p
o
w
e
r
t
r
a
n
s
f
e
r
r
e
d
t
o
t
h
e

power used by the fan can also be expressed as:

P = dp q / (f b m) (4)
where
b = belt efficiency
m = motor efficiency

ding to 4 oC

Typical motor and belt efficiencies:

Motor 1kW - 0.4
Motor 10 kW - 0.87
Motor 100 kW - 0.92
Belt 1 kW - 0.78
Belt 10 kW - 0.88
Belt 100 kW - 0.93

kW
1
10
100

0.4
0.87
0.92

0.78
0.88
0.93

0.93
0.88

0.9

0.92

0.87
0.80.78
Column L
Column M

0.7

0.6

0.5

0.4

0.4

0.3
0

10

20

30

40

50

60

70

80

90

100

fuel

CHEMICAL COMPOSITION OF FUEL

COKE

Qi
kcal/kg
A
7767
B
7356
C
6022
D
5735
E
5777
5668
5556
F
5493
5360
5300
5226
G
5069
H
4436
I
3635
3277
J
3250
2653
1750
1700
ANVELOPE
7000
7500
OIL
CH4
C2H6
C3H8
C4H10
C5H12
CnHn

W
%
1.00
5.70
1.00
5.30
1.00
1.00
1.00
5.40
1.00
2.00
6.30
10.50
20.50
1.00
1.00
10.00
1.00
40.00
38.50

9600 1.00
8550

A
%
2.62
2.49
17.29
16.50
22.27
16.44
22.20
21.28
22.22
22.00
21.00
14.87
13.20
33.00
66.00
30.00
54.50
40.00
20.80

C
%
73.53
69.92
59.91
57.31
54.73
62.98
61.51
52.29
57.59
57.00
58.23
56.96
50.60
33.00
22.60
30.00
29.40
13.70
1.70
70.00
88.30

H
%
5.40
5.14
4.00
3.90
3.90
4.93
4.07
3.79
4.04
4.00
3.85
4.46
3.90
5.50
5.61
5.00
2.40
3.40
0.50
7.00
7.30

0.15 86.10 11.70

75.00 25.00

N
%
16.83
16.00
15.30
14.60
17.23
2.49
1.08
16.46
1.01
1.00
1.02
2.25
2.00
5.50
0.50
5.00
0.70
0.30
0.50

O
S
%
%
0.00 0.62
0.59
0.53 1.87
0.50 1.80
0.80
11.28 0.88
7.99 2.15
0.77
11.11 3.03
11.00 3.00
7.56 2.04
10.20 0.80
9.06 0.70
18.70 3.30
3.46 0.83
17.00 3.00
12.00 0.00
2.10 0.50
8.50 0.00
1.30
2.10

0.70 0.70

total minL
CO2
% Nm3/kg Nm3/kg
100.00 8.00
1.373
99.84 7.61
1.306
99.90 6.44
1.119
99.91 6.18
1.070
99.93 5.93
1.022
100.00 6.57
1.176
100.00 6.36
1.149
99.99 5.68
0.977
100.00 5.93
1.076
100.00 5.87
1.065
100.00 6.02
1.088
100.04 5.94
1.064
99.96 5.26
0.945
100.00 3.89
0.616
100.00 3.42
0.422
100.00 3.53
0.560
100.00 2.85
0.549
100.00 2.07
0.256
70.50 0.00
0.032
8.13
1.307
9.87
1.649
10.75
9.52
16.65
23.80
30.90
38.80
21.40

Page 264

1.608
1.000
2.00
3.00
4.00
5.00
3.00

H2O
Nm3/kg
0.618
0.647
0.461
0.503
0.450
0.565
0.469
0.492
0.465
0.473
0.510
0.631
0.692
0.629
0.641
0.685
0.281
0.879
0.535
0.784
0.818

SO2
Nm3/kg
0.004
0.004
0.013
0.013
0.006
0.006
0.015
0.005
0.021
0.021
0.014
0.006
0.005
0.023
0.006
0.021
0.000
0.004
0.000
0.009
0.015

N2
Nm3/kg
6.452
6.136
5.207
4.997
4.824
5.207
5.032
4.622
4.690
4.643
4.763
4.710
4.171
3.114
2.704
2.831
2.260
1.639
0.005
6.424
7.794

Vg
Nm3/kg
8.447
8.094
6.800
6.583
6.301
6.955
6.664
6.096
6.253
6.202
6.375
6.410
5.813
4.383
3.773
4.098
3.090
2.777
0.572
8.526
10.276

1.324
2.000
3.00
4.00
5.00
6.00
3.00

0.000
0.000

8.498
7.521
13.20
18.80
24.40
30.10
16.90

11.430
10.521
18.20
25.80
33.40
41.10
22.90

t
oC

Sheet12

SCHIMBATOR DE CALDURA SI PYROCLON S

Preheater no Production
t/d
1324
1425
1528
1630
1832
1934
2036
2139
2340
2442
2544
2646
2848
2950
3052
3354
3456
3558
3660
3962
4084
4166
4368
4490
4572

1100

D1(up)
inside
mm
1300
1425
1550
1675
1800
1925
2050
2175
2300
2425
2550
2675
2800
2925
3050
3305
3430
3550
3680
3925
4050
4175
4300
4425
4550

D2(down)
inside
mm
2400
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
5200
5400
5600
5800
6000
6250
6450
6550
6850
7000
7250

Briks
mm
190
190
190
190
190
190
190
190
190
190
190
190
190
190
190
190
190
190
190
230
230
230
230
230
230

K-C4
a
920
1010
1100
1190
1280
1370
1460
1550
1640
1730
1820
1910
2000
2090
2180
2270
2380
2450
2540
2600
2720
2720
2000
2910
3000

Page 265

Diameters Immersion pipes [mm]

C4
C4-C3
C3
d
a
c
910
920
790
1000
1010
870
1000
1100
950
1180
1190
1030
1270
1280
1110
1360
1370
1190
1450
1460
1270
1540
1550
1350
1630
1640
1430
1720
1730
1510
1810
1820
1590
1900
1910
1670
1990
2000
1750
2060
2090
1830
2170
2180
1910
2260
2270
1990
2350
2380
2070
2440
2450
2150
2530
2540
2230
2520
2600
2310
2710
2720
2390
2800
2720
2470
2890
2000
2550
2980
2910
2880
3070
3000
2710

C2
c
790
870
950
1030
1110
1190
1270
1350
1430
1510
1590
1670
1750
1830
1910
1990
2070
2150
2230
2310
2390
2470
2550
2880
2710

C2-C1
b
790
870
950
1030
1110
1190
1270
1350
1430
1510
1590
1670
1750
1830
1910
1990
2070
2150
2230
2310
2390
2470
2550
2880
2710

KCHARGE

LIMITS REGARDING KILN CHARGE

KILN

Max
4.2
3.8
11.34
60
680
2.30
1565

Min
4.2
3.8
11.34
60
680
1.80
1225

Average
4.2
3.8
11.34
60
680
2.05
1395

tpd
rpm
rph
%
%
m
sq.m
m
m3

1395
1.7
102
63.75
3.5
3.8
11.34
60
680
0.15

1395
1.5
90
56.25
3.5
3.8
11.34
60
680
0.15

1395
1.3
78
48.75
3.5
3.8
11.34
60
680
0.15

1395
1.1
66
41.25
3.5
3.8
11.34
60
680
0.15

1395
0.9
54
33.75
3.5
3.8
11.34
60
680
0.15

38.48

43.61

50.32

59.47

72.68

4.98

5.64

6.51

7.70

9.41

rad
deg
%
m

1.27
72.68
5.00
0.37

1.32
75.74
5.61
0.40

1.40
80.06
6.56
0.45

1.48
84.74
7.69
0.50

1.60
91.75
9.58
0.58

kiln inner diameter

kiln inlet opening

m
m

3.80
2.31

largest arrow height

angle of mat.in kiln

rad
deg

0.75
0.61
1.84
105.25

D
Di
S
L
V
Volumetric load
P

m
m
sq.m
m
m3
tpd/m3
tpd

KILN CHARGE
P
production
n
speed
max.speed
max.speed

kiln inclination
Di
kiln inner diameter
S
inside surface
L
length
V
volume
K
DURATION IN THE KILN
=

K*L
[min]
Di*n*

THEORETICAL DEGREE OF FILLING

P/24/60/1.1*100
=
V

angle of mat.in kiln

largest arrow height

MAX FILING DEGREE

Di
di
Hmax
1-Hmax/r

100
max=

100*sin( )
-

max=

A.Toader

13.88

%
2*

360
%

03/06/2013

CLINKER LOAD FOR KILN WITH CALCINER FLS

3.80
3.70

Clinker load [tpd/m3]

3.60
3.50
3.40
3.30
3.20
3.10
3.00
1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

5,500

6,000

6,500

7,000

7,500

Nominal output [t/d]

ing.A.Toader

03/06/2013

FLS CYCLONES STAGE 1 & 2,3,4

9.50
9.00
8.50

CYCLONES DIAMETER [m]

8.00
7.50
7.00
6.50
6.00
5.50
5.00
4.50
4.00
3.50
3.00

1,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 2,600 2,800 3,000 3,200 3,400
NOM INAL OUTPUT [tpd]

ing. A.Toader

03/06/2013

Sheet14

FLS DIMENSIONING ILC

Nominal output
t/d
Kiln tube diameter
m
Effective length
m
L/d
Volume
m3
Clinker load
tpd/m3
Precalciner
Diameter m
Height m
Volume
m3
Folax clinker cooler type
Number of strings
Number of cyclones
Top stage
Stages 2-3-4

1,050
3.45
47
13.62
343
3.06

1,200
3.6
49
13.61
394
3.05

1,450
3.75
53
14.13
467
3.11

1,850
3.95
58
14.68
574
3.22

2,200
4.15
60
14.46
662
3.32

2,700
4.35
66
15.17
808
3.34

3,200
4.55
68
14.95
919
3.48

4.75
15
223
620
1

5
15
249
620s
1

5.5
15
306
720s
1

6
15
369
820s
1

6.6
15
453
824s
1

7.2
15.7
570
928s
1

7.6
16.6
676
1030s
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

2
1

4,000
4.75
75
15.79
1,114
3.59
2
6.3
15
820
1034s
2
4
2

4,800
5
80
16.00
1,329
3.61
2
6.9
15
995
1038s
2
4
2

4
2

5,600
5.25
83
15.81
1,533
3.65
2
7.2
15.7
1,140
1142s
2
4
2

4
2

6,800
5.5
89
16.18
1,817
3.74
2
7.6
16.6
1,351
1247s
2
4
2

4
2

Top stage dia

3.5 3.6 3.6 3.8 4.0 4.2 4.4 4.8 5.0 5.3 5.5 5.8 6.0 6.3

4.8

5.0

5.3

5.5

5.8

6.0

6.3

Area

m2

9.35 ### ### ### ### ### ### ### ### ### ### ### 28.27 31.17

17.72

19.63

21.65

23.76

25.97

28.27

31.17

Stages 2-3-4 dia

5.0 5.3 5.5 5.8 6.0 6.3 6.6 6.9 7.2 7.6 8.0 8.4 8.8 9.2

6.9

7.2

7.6

8.0

8.4

8.8

9.2

Area

m2

### ### ### ### ### ### ### ### ### ### ### ### 56.05 61.48

33.68

36.83

41.26

45.94

50.87

56.05

61.48

Page 269

Sheet14

c1

6,800
5.5
89
16.18
1,817
3.74
2
7.6
16.6
1,351
1247s
2

C4

min

max

min

max

3.50
3.60
4.00
4.40
5.00
5.50
6.00

3.60
3.80
4.20
4.80
5.30
5.80
6.30

5.00
5.50
6.00
6.60
7.20
8.00
8.80

5
5.8
6.3
6.9
7.6
8.4
9.2

1,050
1200
1450
1850
2200
2700
3200
4000
4800
5600
6800

3.06
3.05
3.11
3.22
3.32
3.34
3.48
3.59
3.61
3.65
3.74

4
2

1,000
1,500

1
3.7
4.5

2
4.23
5.12

6.6

2,000
2,500

5.17
5.65

5.9

6.6

7.0

6.56

7.34

7.82

3,000
3,500
1400
1800

6.27
6.73
4.32
4.80

7.2

8.0

8.5

7.72
4.96
5.52

8.62
5.50
6.10

9.17
5.82
6.46

34.21

9.7
68.63

Page 270

3
4.74
5.76

4 ct
5.03
6.1

1.95
2.39
2.74
3.04
3.33
3.58
2.23
2.47

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

Table no. 1

LINE 2 & 3
PREHEATER TOWER
3300 t/d

0.54
0.98

1.17

STAGE
No
Dext
Dint
S
1.56 Hcilindric
0.74 Hconic

1
4
3,930
3,800
11.34
6,125
2,900
9,025
109

2
2
6,110
5,670
25.24
3,300
5,960
9,260
157

3
2
6,110
5,670
25.24
3,300
5,960
9,260
157

4
2
6,110
5,670
25.24
3,300
5,960
9,260
157

1,896
2,330
4.42

2,300
2,695
6.20

2,300
2,695
6.20

2,300
2,695
6.20

1,900
2.83

2,510
4.95

2,510
4.95

2,510
4.95

2,400

1,500

1,620

500

recom UZIN 95

3,400

2,700

550

550

Real 95 K2 & K3
98 K2
97 K3

2,330
3,930
3,930

0
2,050
1,700

1,620
1,420
1,620

0
500
500

mm
mm
m2
mm
mm
Htotal
mm
2
Usefull surface
m /cyclon
Inlet gases
mm
a
1.23 b
S1
m2
Outlet gases
d
mm
S2
m2
H immersion pipe
mm
design

03/06/2013

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

03/06/2013

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

LINE 1
PREHEATER TOWER
STAGE
NO
Dext
mm
Dint
mm
S
m2
Hcilindric
mm
Hconic
mm
Htotal
mm
USEFULL SURFACEm2/No
Inlet gases
mm
a
b
S1
m2
Outlet gases
d
mm
S2
m2
H immersion pipe
mm
design

1
4
5,360
5,359
22.54
3,725
8,464

2
2
7,010
6,590
34.09
8,084
6,133

LINE 3000
PREHEATER TOWER
3
1
9,700
9,400
69.36
4,084
8,803

4
2
7,010
6,590
34.09
8,084
6,133

12,189 14,217 12,887 14,217

22.55 34.09 69.36 34.09

1,171 2,304 2,868 2,304
1,730 3,786 4,350 3,786
2.03 8.72 12.48 8.72
2,490 3,680 5,160 3,680
4.87 4.95 4.95 4.95
3,000 4,000

190

3,300

STAGE
NO
Dext
mm
Dint
mm
S
m2
Hcilindric
mm
Hconic
mm
Htotal
mm
USEFULL SURFACE m2/No
Inlet gases
mm
a
b
S1 m2
Outlet gases
d mm
S2 m2
H immersion pipe
mm
design

recom

recom

Real 95

Real 95

LINE 800
03/06/2013

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

PREHEATER TOWER
STAGE
NO
Dext
mm
Dint
mm
S
m2
Hcilindric
mm
Hconic
mm
Htotal
mm
USEFULL SURFACE m2/No
Inlet gases
mm
a
b
S1 m2
Outlet gases
d mm
S2 m2
H immersion pipe
mm
design
recom
Real 95

03/06/2013

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

LINE 3000
PREHEATER TOWER
1
2
3
4
4
2
2
2
4,850 6,900 6,900 6,900
4,520 6,440 6,440 6,440
16.04 32.56 32.56 32.56
4,380 5,500 5,500 5,500
6,900 5,780 5,780 5,780
11,280 11,280 11,280 11,280
142.65 349.33 373.36 384.75
1,075 2,310 2,310 2,310
2,150 2,310 2,310 2,310
2.31 5.34 5.34 5.34
1,700 2,690 2,690 2,690
2.27 5.68 5.68 5.68
2,850 2,100

500

LINE 800
03/06/2013

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

PREHEATER TOWER
1
2
3,100
2,720
5.81
2,200
4,900
7,100

2
1
4,800
4,400
15.20
2,187
4,158
6,345

3
2
3,600
3,220
8.14
2,200
4,150
6,350

4
1
5,000
4,500
15.90
2,950
6,900
9,850

744
800
930 1,250
1,410 1,600 1,570 2,250
1.05 1.28 1.46 2.81
1,000 1,750 1,360 2,020
0.79 2.40 1.45 3.20
1,770 1,860 1,650 2,500

03/06/2013

TURCIA

STAGE
No

1
2
Dext
mm
3,180
Dint
mm
2,800
2
S
m
6.15
Hcilindric
mm
4,956
Hconic
mm
2,347
Htotal mm
7,303
2
Usefull surface m /cyclon 75
Inlet gases mm
a
1,404
b
1,713
2
S1
m
2.40
Outlet gases
d
mm
1,237
S2
m2
1.20
H immersion pipe mm
1,777
STAGE
No

1
2
Dext
mm
4,704
Dint
mm
4,324
2
S
14.68
m
Hcilindric
mm
7,331
Hconic
mm
3,471
Htotal mm 10,802
Usefull surface m2/cyclon 152
Inlet gases mm
a
1,404
b
1,713
2
S1
2.40
m
Outlet gases
d
mm
1,237
2
S2
m
1.20
H immersion pipe mm
design
1,777

A.Toader

2
1
5,180
4,800
18.09
2,798
5,053
7,851
121

3
1
5,180
4,800
18.09
2,798
5,053
7,851
121

4
1
5,180
4,800
18.09
2,798
5,053
7,851
121

1,564
1,830
2.86

1,564
1,830
2.86

1,564
1,830
2.86

1,750
2.40
1,020

1,750
2.40
1,104

1,990
3.11
340

2
1
5,336
4,956
19.28
2,882
5,205
8,087
127

3
1
5,881
5,501
23.75
3,176
5,737
8,913
148

4
1
6,196
5,816
26.55
3,346
6,044
9,390
161

1,564
1,830
2.86

1,564
1,830
2.86

1,564
1,830
2.86

1,750
2.40

1,750
2.40

1,990
3.11

1,020

1,104

340

ct
1
2,609
2,229
3.90

03/06/2013

I.N.C. CEPROCIM S.A.

RELATIONSHIP BETWEEN SPECIFIC KILN LOADING AND INLET CALCINING DEGREE OF THE KILN INLET
4.25
4.00
3.75

Kiln load [tpd/m3]

3.50
3.25
3.00
2.75
2.50
2.25
2.00
1.75
1.50
20

30

40

50

60

Calcining degree [%]

Eng. A. Toader

70

80

90

100

dia
diaint
s
l
l/dia
v
load
n
s
k
t
t1
f
f1

A.Toader

Campulung
800 1000

Turcia
1000 950 1400 2443

Fieni
3000 3800

Syria 1
1600 1800

Syria Tartous
Qaim
Egypt
Alsons
1600 1800 2400 3000 3200 3400 3700 4000

4.0
3.6
10.18
64
16
651
1.23
1.4
3
0.145
45
61
3.83
5.23

4.2
3.8
11.34
60
14
680
1.47
1.4
3
0.145
40
55
4.07
5.56

5.8
5.4
22.90
97
17
2,222
1.35
2.0
3
0.150
32
45
2.98
4.21

4.6
4.2
13.85
75
16
1,039
1.54
2.0
3
0.150
32
45
3.38
4.77

4.6
4.2
13.85
69
15
956
1.67
2.0
3
0.150
29
41
3.38
4.77

4.2
3.8
11.34
57
14
646
1.55
1.4
3
0.145
38
52
4.07
5.56

4.2
3.8
11.34
60
14
680
1.40
1.1
3
0.145
51
69
4.93
6.73

4.2
3.8
11.34
60
14
680
2.06
1.6
3
0.145
35
48
4.99
6.81

4.2
3.8
11.34
60
14
680
3.59
3.2
3
0.145
17
24
4.35
5.95

5.8
5.4
22.90
97
17
2,222
1.71
2.0
3
0.150
32
45
3.78
5.33

4.6
4.2
13.85
75
16
1,039
1.73
2.0
3
0.150
32
45
3.80
5.37

4.6
4.2
13.85
69
15
956
1.88
2.0
3
0.150
29
41
3.80
5.37

4.6
4.2
13.85
69
15
956
2.51
2.0
3
0.150
29
41
5.07
7.16

4.6
4.2
13.85
74
16
1,025
2.93
3.2
3
0.145
19
27
3.96
5.41

4.4
4.0
12.57
70
16
880
3.64
3.2
4
0.145
17
23
4.19
5.72

4.8
4.4
15.21
64
13
973
3.49
3.2
4
0.145
14
19
3.35
4.57

4.8
4.4
15.21
64
13
973
3.80
3.2
4
0.145
12
16
3.19
4.35

4.75
4.4
14.86
75
16
1,115
3.59
2.2
4
0.145
24
32
5.93
8.09

03/06/2013

(AVERAGE-XI)/S

ELIMINAREA UNUI REZULTAT

2.9
2.8
2.7
2.6
2.5
2.4
2.3
2.2
2.1
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0

f(x) = 0.4 ln(x) + 1.02

R = 1

10

20

30

40

50

NUMAR PROBE

60

70

80

90

100

STATISTICA
ELIMINAREA UNUI REZULTAT

average(x)-xi
ti=
s

>>tttt

n
3
4
5
6
7
8
9
10
15
20
25
30
35
40
45
50
60
70
80
90
100

tt
1.38
1.53
1.64
1.73
1.8
1.86
1.92
1.95
2.13
2.24
2.32
2.39
2.44
2.49
2.53
2.57
2.63
2.69
2.73
2.77
2.8

1.45
1.57
1.66
1.73
1.79
1.84
1.89
1.93
2.09
2.20
2.29
2.37
2.43
2.48
2.53
2.57
2.64
2.70
2.75
2.80
2.84

15

1.25

25
35
45
50
65
85
100

1.65
2
2.5
2.75
3.5
4.25
5

CARBUNI
Temperatura de mocnire
t cea mai mica a unei suprafete orizontale fierbinti care determina aparitia pct. de jar pe un strat de 5 mm grosime depus prin cadere libera

Temperatura minima de aprindere

t cea mai mica a unei surse care determina aprinderea prafului aflat in suspensiende aer
Concentratia minima de explozie
Cantitatea cea mai mica de pulbere raportata la volumul de umiditate care in amestec cu O2 din aer in contact cu o sursa de aprindere avand t superficiala
> decat t min de aprindere a pulberii se aprinde iar arderea se propaga in intreg amaestecul pulbere
Temperatura de autoaprindere
la o incalzire programata se urmaresc modificarile de masa si de entalpie precum si cantitatile de gaze produse

indicatie

UM

Filipesti

umiditate
Ash per umed
Ash per uscat
Vol. Per umed
Vol. Per uscat

%
%
%
%
%

6.13
58.36
62.16
22.85
24.34

T mocnire
T min aprindere
Con explozie
T autoaprindere

oC
g/m3

Schitu
Golesti
12.48
37.6
43.14
28.85
58.21

Cocs
I
0.51
3.21
3.22
8.56
8.89

Cocs
II
0.51
3.26
3.27
9.33
9.69

230
435
112

400
645
1000
325

400
645
1000
325

505
139
110

Gazul metan se aprinde in amestec cu aerul in proportie de 5 - 15 % la Taprindere =735 oC la 1 at

Volatile matter1)
Class

General description

A.TOADER

Class

(weight %)

101

< 6.1

102

3.1 - 9.0

Anthracites

201

9.1 - 13.5

Dry steam coals

202

13.6 - 15.0

203

15.1 - 17.0

204

17.1 - 19.5

206

19.1 - 19.5

301

19.6 - 32.0

305

19.6 - 32.0

306

19.6 - 32.0

401

32.1 - 36.0

402

> 36.0

501

32.1 - 36.0

502

> 36.0

601

32.1 - 36.0

602

> 36.0

701

32.1

General description

Cooking steams coals

Heat altered low volatile Low volatile

steam coals
steam coals
Prime cooking coals
Mainly heat altered
coals

Medium
volatile coals

Very strongly coking

coals
Strongly coking coals
Medium coking coals

702

> 36.0

Weakly coking coals

801

32.1 - 36.0

802

> 36.0

Very weakly coking

coals

901

32.1 - 36.0

902

> 36.0

Non-coking coals

High volatile
coals

A.TOADER

A.TOADER

H2
CO
metan

etan
propan
acetilena
H2S

Concentratie
%
28.5
23.55
61.9
2
4
8
1.9
8.15
1.25
10
45
55
1
12
60

Tauto
oC
550
650
641
850
810
800
594
540
588
500
335
335
373
290
487

TEMPERATURA DE APRINDERE SI DIMENSIUNILE PARTICULELOR

TEMPERATURE [deg C]

TEMPERATURA DE AUTOAPRINDERE PENTRU DIVERSE GAZE

480
460
440
420
400
380
360
340
320
300
0

50 100 150 200 250 300 350 400 450

PARTICLE SIZE [M ICRON]

the minimum temperature required to ignite a gas or vapor in air without a spark or flame being present
Temperature auto
Fuel or Chemical

(oC)

(oF)

Acetaldehyde

175

347

Acetone

465

869

Acetylene

305

581

Benzene

560

1040

Bituminous coal

300

572

Butane

420

788

Carbon
Carbon - bi
sulfide
Carbon
monoxide

700

1292

Charcoal

300
609

1128
660

A.TOADER

Coal-tar oil

580

1076

Coke

700

1292

Cyclohexane

245

473

Diethyl ether

160

320

Ethane

515

859

Ethylene

490

914

Ehtyl Alcohol

365

689

Fuel Oil No.1

210

410

Fuel Oil No.2

256

494

Fuel Oil No.4

Heavy
hydrocarbons

262

505

750

1382

Hydrogen

500

932

Gasoline

280

536

Gun Cotton

430

Kerosine

210

410

Isobutane

462

864

Isobutene

465

869

Isooctane

447

837

Isopentane
Isopropyl
Alcohol

420

788

399

750

Light gas
Light
hydrocarbons
Methane
(Natural Gas)

600

1112

650

1202

580

1076

Methyl Alcohol

385

725

Naphtha

550

1022

Neoheaxane

425

797

Neopentane

450

842

Nitro-glycerine

490

n-Butane

405

761

n-Heptane

215

419

A.TOADER

n-Hexane

225

437

n-Octane

220

428

n-Pentane

260

500

n-Pentene

298

569

Oak Wood - dry

900

Peat

227

440

Petroleum

400

752

Pine Wood - dry

Phosphorous,
amorphus
Phosphorous,
transparent

800
500
120

Production gas

750

1382

Propane

480

842

Propylene

458

856

p-Xylene

530

986

Rifle Powder

550

Toluene
Semi anthracite
coal

530

849

400

752

Styrene

490

914

Wood

300

572

Xylene

463

867

A.TOADER

TEMPERATURA DE APRINDERE SI DIMENSIUNILE PARTICULELOR

30
100
200
400

370
412
440
462

A.TOADER

A.TOADER

A.TOADER

Compressive strengths as % of value of cement vs kiln dust ratio

130

120

Compressive strength [%]

110

100

Column M
Column O
Column Q
Column S
Column U

90

80

70

60

50

40
0

10

Kiln dust ratio [%]

15

20

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

OPERATING CHARACTERISTICS OF KILN SYSTEM

KILN
Capacity
Heat consumption
Heat exchange devices

Long wet
tpd
300-3600
kcal/kg 1200-1400

Feedstock
Feedstock mass content of water
Waste gas upstream of precipitator

Specific waste gas volume

Waste gas analyses

CO2
O2
CO

Waste gas temperature

Water dewpoint
Dust
Dust content in crude gas (dry at standard condition)
Mass proportion of dust < 10 m
Dust precipitator
Separator

Long dry
300-3000
850-950

Lepol Preheater
300-3300
720-900

chains
lift shovels
crosses
chamber insertion
dry raw meal
0.5-15.0
waste gas
without
recycling
waste gas
recycling
with water
injection
2.5-3.0
2.2-2.8
20-17
24-19
6 - 10
4-7
<0.1
<0.1
130-180
150-200
45-75
45-60

grate-type
preheater of
various types

S.P.
300-5000
720-900

chains
crosses
chamber
preheater
raw slurry
32-40

m3/kg
%
%
%
o
C
o
C

3.2 - 4.2
25-18
4-8
<0.1
130-180
65-75

g/m3
%

3 - 22
20 - 60

35-150
70 - 90

15-25
70-90

1.5-12
10 - 45

35-150
80-99

20-50
85-99

E.S.P.

E.S.P.

E.S.P.

E.S.P.

E.S.P.

E.S.P.

granules
11 - 22

1.8-2.2
29-20
4 - 10
<0.1
90-150
50-65

cyclone or chamber
preheater of various
types
dry raw meal
0.5-1.0
waste gas without
recycling waste gas
recycling
with water
injection
2.1-2.5
1.7-2.0
22-14
33-20
8 - 13
3-9
<0.1
<0.1
90-150
120-200
45-60
50-65

Tab 1

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

Chemical analysis of cement, kiln dust

SiO2
Al2O3
Fe2O3
CaO
MgO
SO3
Na2O
K2O
TiO2
P2O5
Cl
LOI
Total
Na2O+0.658K2O
Ins Res
FL
Blaine
LSF
SM
AM
MSO3
SD
Alkali
Chloride
Sulfate
CaCO3
Compressive str 28
0
10
15
20

A
B
C
D
E
Fieni
cement
EPdust
cement
EPdust
cement
EPdust
cement
EPdust
cement
EPdust
cement
EPdust
20.16
14.70
21.10
15.50
21.12
14.00
21.44
16.50
24.06
15.4
21.78
10.28
4.75
3.31
4.90
3.84
4.42
2.85
3.93
3.71
4.20
2.65
4.76
3.43
2.51
2.04
2.57
2.13
2.05
1.51
2.74
1.79
2.68
1.51
3.07
2.99
63.85
49.30
63.33
51.70
62.66
41.70
64.59
44.50
63.02
41.9
65.78
44.32
1.46
1.03
2.08
1.59
3.95
2.73
1.81
1.43
2.29
1.35
1.21
1.01
3.93
3.07
2.78
11.10
2.78
5.55
3.48
5.67
2.51
0.25
1.00
0.41
0.10
0.23
0.15
0.22
0.16
0.27
0.13
0.31
0.15
0.23
0.65
0.25
0.47
2.60
0.83
2.50
0.93
3.60
0.35
3.5
0.39
4.90
0.73
0.83
0.21
0.24
0.21
0.23
0.12
0.29
0.14
0.07
0.05
0.03
0.31
0.08
0.00
0.24
0.26
0.29
0.15
0.35
2.13
23.43
1.05
10.50
1.74
27.81
1.47
21.33
0.71
34.06
0.54
35.96
99.64
99.95
99.08
99.34
100.05
100.31
100.48
98.89
100.21
102.60
99.81
99.62
0.41
1.94
0.70
1.87
0.77
2.64
0.36
2.61
0.41
3.45
1.13
0.80
0.45
11.62
0.20
9.82
0.23
14.86
0.37
12.02
0.43
14.58
0.25
0.78
10.43
0.93
21.72
0.88
4.31
0.93
7.46
0.60
3.00
0.33
4,410
5,108
3,984
4,894
4,376
5,659
4,170
7179
3,127
4385
3,500
4800
100.3
106.3
95.19
104.83
95.4
95.8
97.2
86.0
85.1
88.7
95.9
127.4
2.78
2.75
2.82
2.60
3.26
3.21
3.21
3.00
3.50
3.70
2.78
1.60
1.89
1.62
1.91
1.80
2.16
1.89
1.43
2.07
1.57
1.75
1.55
1.15
7.43
744

1.37
122
low <2
low <0.3
low<5
50.76
100
95.7
95.4
86.2

3.09
309

5.24
461
low <2
low <0.3
high >10
33.50

2.79
1.80
279
163
moderate (2-3)
low <0.3
moderate (5-10)
51.79

7.47
1.77
748
168
moderate (2-3)
low <0.3
moderate (5-10)
47.08

100
117
101
107

100
90
89
93

100
87
81
69

4.78
478

0.06
6
high>3
high>0.3
low<5
58.99

0.68
69

0.40
40
low <2
low <0.3
low<5
69.21

100
48
56
65

Tab 1

NATIONAL INSTITUTE FOR CEMENT CEPROCIM S.A.

SIBLINE
cement
EPdust
21.2
9.83
5.38
2.92
3.73
1.77
65.42
45.64
1.69
0.4
0.77
0.37
0.53
0.31
0.28
0.2
0.7
0.22
0.62
0.39
0
0
0
37.6
100.32
99.65
0.71
0.44

96.0
2.33
1.44

142.1
2.10
1.65

0.84
84

0.65
65
low <2
low <0.3
low<5
73.14

Tab 1

OUTPUT
500
660
700
750
800
850
900
950
1000
1050

CS
62.5
82.5
87.5
93.8
100.0
106.3
112.5
118.8
125.0
131.3

918
898
880
864
850
838
816
807

104
102
100
98
97
95
93
92

116
107
102
100
98
97
95
93
91

134
113
109
105
101
98
95
94
93
93

THE CORRELATION BETWEEN CLINKER OUTPUT AND HEAT CONSUMPTION

140

Heat consumption [%]

135
130
125
120
115
110
105
100
95
90
60

70

80

90

100

110

OUTPUT [%]

120

130

140

3000
3200
3800

93.8
100.0
118.8

865.0
830.0
800.0

104.2
100.0
96.4

ALSONS

Clinker

V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
V11
V12
V13
V14

tpd
4,000

kg/h
166,667

Dext
m
4.80

Di
m
4.40

L
m
75.00

S
m2
15.2

V
m3
1,140

Q
m3/h
17,100
16,000
14,900
25,100
18,400
30,600
23,100
38,500
26,800
46,500
30,300
36,300
35,200
54,900

P
mbar
120
100
100
100
90
90
85
85
80
80
50
45
40
35

M
kW
75
75
55
110
55
110
75
132
75
160
55
75
75
110

SPEED
rpm
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800

m3/kgcl

###

2.48

Dedusting fan for grate cooler

Q
P
m3/h
mbar
VD
400,000
16

T
C
284

Q
Nm3/h
196,050

Nm3/kg
1.18

ID

360

284,645

1.71

660,000

67

Burning instalation
kiln
fuel
oil
coal

Normal
t/h
5.5
8.4

Max
t/h
6.3
13.1

115
156

RSP
fuel
oil
coal

Normal
t/h
7.9
12.6

Max
t/h
8.5
15.8

108
125

KILN

kcal/h/m2
3,979,576
5,171,869

load
tpd/m3
3.51

M
kW
600.00

load
kWh/t
3.6

D FINENESS OF FUEL AS FUNCTION OF THE VOLATILE CONTENT FOR ROTARY KILN AN

16
14
Column C
Column D

Residue [%]

12
10
8
6
4
2
0

10

12

Volatile content [%]

14

16

18

20

Transport of grinding material through grates

Dry

width of slots
1st partition
2nd partition
outlet grate

wet

width of slots
1st partition
2nd partition
outlet grate
wash drum periferal
grate
inclined grate

open circuit
closed circuit
approx

6 mm
8-12 mm
5 t/dm2/h

normally

6 mm
8 m3/dm2/h
9 m3/dm2/h
10 m3/dm2/h
3 m3/dm2/h
2.5 m3/dm2/h

pres
CALCULUL PIERDERILOR DE PRESIUNE PE CICLOANE
p=

k*Vik*Vok
C1
C2
C3
C4

C1
C2
C3
C4

Vik
19
18.12
17.84
18.21

mmWG
0.350
0.230
0.215
0.315

AL QAIM Irak
Vok
Vai
18.13
2.8
16.85
2.98
16.93
3.4
17.98
3.63

p
117
70
65
103

Vik
19.03
12.56
13.55
14.78

Page 301

ALSONS Filipine
Vok
Vai
18.98
3.59
16.76
4.08
16.08
4.47
17.77
4.55

p
126
48
46
83

0
2
4
8
14
20

0
1.5
3
6
9.7
13.5

The unit of Sound Power Level (Lw) is the Decibel (dB)

Sound Power (Watts)

25 to 40,000,000
100000
10000
1000
100
10
1
0.1
0.01
0.001
0.0001
0.00001
0.000001
0.0000001
0.00000001
0.000000001

Sound Power Level (dB)

195
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30

Sound Pressure Level (LP) is also measured on a logarithmic scale but the unit is
the Decibel (dB) re 2 x 10-5 Pa

Sound Pressure
(Pascals)
200.0
63.0

Sound Pressure
Level (dB)
140
130

20.0
6-Mar

120
110

2.0
0.63
0.2
0.063
0.02

100
90
80
70
60

0.0063
0.002
0.00063
0.0002
0.0002

50
40
30
20
0

Environment
Concert halls, opera halls, studios for sound reproduction, live
theatres (-500 seats)
Bedrooms in private homes, live theatres (+500 seats),
cathedrals and large churches, television studios, large conference
and lecture rooms (50 people)
Living rooms in private homes, board rooms, top management
offices, conference and lecture rooms (20-50 people), multipurpose halls, churches (medium and small, libraries, bedrooms in
hotels, etc., banqueting rooms, operating theatres, cinemas,
hospital private rooms, large courtrooms

Public rooms in hotels, etc., ballrooms, hospital open wards,

middle management and small offices, small conference and
lecture rooms (20 people), school classrooms, small courtrooms,
museums, libraries, banking halls, small restaurants, cocktail
bars, quality shops
Toilets and washrooms, large open offices, drawing offices,
reception areas (offices), halls, corridors, lobbies in hotels,
hospitals, etc., laboratories, recreation rooms, post offices, large
restaurants, bars and night clubs, department stores, shops,
gymnasia
Kitchens in hotels, hospitals, etc., laundry rooms, computer
rooms, accounting machine rooms, cafeterias, canteens,
supermarkets, swimming pools, covered garages in hotels, offices,
etc., bowling alleys

0
1
2
4
7
9.5

is the Decibel (dB) re 10-12 Watts.

Source

Saturn Rocket
Ram Jet
TurboJet engine 3200kg thrust
4 propeller airliner
75 piece orchestra
Large chipping hammer
Blaring radio
Car on motorway
Axial ventilating fan (2500 m/h)
Voice - shouting
Voice - conversational level

Voice - very soft whisper

measured on a logarithmic scale but the unit is

Typical Environments
off
Pneumatic chipping and riveting
(operator's position)
Boiler shop (maximum levels)
Automatic punch press (operator's
position)
Automatic lathe shop
Construction site - pneumatic drilling
Kerbside of busy street
room)
Restaurant

Conversational speech at 1m
Whispered conversation at 2m
studios
Normal threshold of hearing
NR criterion

20
25

30

35
40
45