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Heat Balance

The document presents heat balance calculations for a cement plant before and after optimization work. It shows the heat inputs from raw materials and fuel used in the precalciner and kiln. The total heat input was reduced from 820.2 kcal/kg-cl to 777.8 kcal/kg-cl after optimization. The heat outputs include clinker production and exhaust gases from the preheater and cooler. Optimization resulted in lower exhaust gas outputs from the preheater and higher heat of formation, reducing total heat output from 820.2 kcal/kg-cl to 777.8 kcal/kg-cl.

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ayaskant751001
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245 views

Heat Balance

The document presents heat balance calculations for a cement plant before and after optimization work. It shows the heat inputs from raw materials and fuel used in the precalciner and kiln. The total heat input was reduced from 820.2 kcal/kg-cl to 777.8 kcal/kg-cl after optimization. The heat outputs include clinker production and exhaust gases from the preheater and cooler. Optimization resulted in lower exhaust gas outputs from the preheater and higher heat of formation, reducing total heat output from 820.2 kcal/kg-cl to 777.8 kcal/kg-cl.

Uploaded by

ayaskant751001
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
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BEFORE OPTIMIZATION WORK

HEAT BALANCE CALCULATIONS,


HEAT INPUTS
Stream

Raw meal (dry)


Raw meal (moisture)
Sensible heat of fuel to PC
Sensible heat of fuel to kiln
Conveying air w ith fuel to PC
Conveying air w ith fuel to kiln
Primary air to kiln
Air to cooler
Coal fired in Precalciner
Coal fired in Kiln
Total Calorific heat from fuel to system

PLANT : OCL India Lim ited, Rajgangpur, Orissa (11/9/9)

Flow
Nm3/kg-cl

0.02
0.01
0.02
2.3750

Flow
kg/kg-cl
1.58
0.00
0.13
0.05
0.03
0.02
0.03
3.07
0.13
0.05

Cp
Tem p.
Heat
kcal/kg OC
OC
kcal/kg-cl
0.21
1.00
0.29
0.29
0.24
0.24
0.24
0.24

55
55
65
65
65
65
65
35

Total heat in

% Heat
%

10.09
0.02
1.47
0.63
0.27
0.17
0.31
7.34
560.3
239.6
799.9
820.2

1.23
0.00
0.18
0.08
0.03
0.02
0.04
0.90
68
29

15.03
96.97
75.63
6.90
149.23
0.46
0.00
431.53
44.39
0.09

2
12
9
1
18
0
0
53
5
0.0

820.2

100

100

HEAT OUTPUTS
Clinker
Preheater-1 exhaust gas (Old PH tow er)
Preheater-2 exhaust gas (New PH tow er)
Preheater exhaust dust
Cooler exit w aste air
Evaporation heat from moisture in raw meal
Heat due to incomplete combustion
Heat of formation
Radiation & convection
Other losses

0.84
0.65
1.4962

1.00
1.18
0.91
0.09
1.93
0.001

0.19
0.24
0.24
0.21
0.25
1.00

Total heat out

106
365
368
365
336
55

AFTER OPTIMIZATION WORK

rissa (11/9/9)

HEAT BALANCE CALCULATIONS,


HEAT INPUTS

Heat
kcal/kg-cl

% Heat
%

10.09
0.02
1.47
0.63
0.27
0.17
0.31
7.34
560.3
239.6
799.9
820.2

1.23
0.00
0.18
0.08
0.03
0.02
0.04
0.90
68
29

PLANT : OCL India Lim ited, Rajgangpur, Orissa (19/12/9)

Stream

Raw meal (dry)


Raw meal (moisture)
Sensible heat of fuel to PC
Sensible heat of fuel to kiln
Conveying air w ith fuel to PC
Conveying air w ith fuel to kiln
Primary air to kiln
Air to cooler
Coal fired in Precalciner
Coal fired in Kiln
Total Calorific heat from fuel to system

Flow
Nm3/kg-cl

0.02
0.01
0.02
2.1081

Flow
Cp
Tem p.
Heat
% Heat
kg/kg-cl kcal/kg OC OC kcal/kg-cl
%
1.58
0.00
0.12
0.06
0.03
0.02
0.03
2.73
0.12
0.06

100

0.21
1.00
0.29
0.29
0.24
0.24
0.24
0.24

55
55
65
65
65
65
65
35

Total heat in

10.09
0.02
1.42
0.64
0.27
0.17
0.30
6.52
523.4
234.9
758.3
777.8

1.30
0.00
0.18
0.08
0.03
0.02
0.04
0.84
67
30

15.03
89.36
64.52
6.26
122.20
0.46
0.00
435.38
43.40
1.15

2
11
8
1
16
0
0
56
6
0.1

777.8

100

100

HEAT OUTPUTS
15.03
96.97
75.63
6.90
149.23
0.46
0.00
431.53
44.39
0.09

2
12
9
1
18
0
0
53
5
0.0

820.2

100

Clinker
Preheater-1 exhaust gas (Old PH tow er)
Preheater-2 exhaust gas (New PH tow er)
Preheater exhaust dust
Cooler exit w aste air
Evaporation heat from moisture in raw meal
Heat due to incomplete combustion
Heat of formation
Radiation & convection
Other losses

0.86
0.63
1.2719

1.00
1.20
0.89
0.09
1.64
0.001

0.19
0.24
0.24
0.21
0.25
1.00

106
335
328
335
325
55

Total heat out

ngpur, Orissa (19/12/9)

Tem p.
Heat
% Heat
OC kcal/kg-cl
%
55
55
65
65
65
65
65
35

in

106
335
328
335
325
55

out

10.09
0.02
1.42
0.64
0.27
0.17
0.30
6.52
523.4
234.9
758.3
777.8

1.30
0.00
0.18
0.08
0.03
0.02
0.04
0.84
67
30

15.03
89.36
64.52
6.26
122.20
0.46
0.00
435.38
43.40
1.15

2
11
8
1
16
0
0
56
6
0.1

777.8

100

100

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