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    Cooler Balance 1

    Uploaded by

    Tamer Fathy
    This document provides operational data from a cement plant collected on November 11, 2008. It includes information on clinker production rate, fuel consumption, cooling fan air flows and temperatures, combustion air flows, and cooler heat and mass balance calculations. The data is presented in metric units and includes parameters like clinker temperature entering and leaving the cooler, cooling air temperature and flow, and calculations of heat transfer and clinker cooling efficiency.

    Copyright:

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

    Cooler Balance 1

    Uploaded by

    Tamer Fathy
    213 views17 pages
    This document provides operational data from a cement plant collected on November 11, 2008. It includes information on clinker production rate, fuel consumption, cooling fan air flows and temperatures, combustion air flows, and cooler heat and mass balance calculations. The data is presented in metric units and includes parameters like clinker temperature entering and leaving the cooler, cooling air temperature and flow, and calculations of heat transfer and clinker cooling efficiency.

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    © © All Rights Reserved

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    This document provides operational data from a cement plant collected on November 11, 2008. It includes information on clinker production rate, fuel consumption, cooling fan air flows and temperatures, combustion air flows, and cooler heat and mass balance calculations. The data is presented in metric units and includes parameters like clinker temperature entering and leaving the cooler, cooling air temperature and flow, and calculations of heat transfer and clinker cooling efficiency.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    213 views17 pages

    Cooler Balance 1

    Uploaded by

    Tamer Fathy
    This document provides operational data from a cement plant collected on November 11, 2008. It includes information on clinker production rate, fuel consumption, cooling fan air flows and temperatures, combustion air flows, and cooler heat and mass balance calculations. The data is presented in metric units and includes parameters like clinker temperature entering and leaving the cooler, cooling air temperature and flow, and calculations of heat transfer and clinker cooling efficiency.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 17

    Data input

    Version 2 - 30.10.2002

    Arasmeta

    Plant:
    Cooler:
    Date:
    Start Time:
    Duration
    Altitude:
    Atmospheric pressure:
    Reference temperature:
    Clinker production rate:
    Clinker hot temperature:
    Clinker cold temperature:
    Dust from kiln to cooler:
    Dust from cooler to kiln:
    Fuel Consumption:
    Kiln Fuel Split
    Kiln Fuel Feedrate
    Calciner Fuel Feedrate
    Electrical energy:
    Cooler Water spray:
    Wall loss:

    Cooling fans:
    #1
    #2
    #3
    #4
    #5
    #6
    #7
    #8
    #9
    #10
    #11
    #12
    #13
    #14
    #15
    #16
    #17

    11-Nov-08
    10:00
    3
    .
    246
    32.5
    4800
    1450
    140
    0.00
    0.00
    750
    32
    9.0
    22.2
    2406107
    0.0
    30
    29.40

    hours
    m
    kPa
    C
    T/d
    C
    C
    kg/kg ck
    kg/kg ck
    kcal/kg n
    %
    tph
    tph
    kJ/h
    m/h
    C
    kJ/kg ck

    Name

    Flow

    Ps

    K10
    K11
    K12
    K13
    K14
    K15
    K16
    K17
    K18
    K19

    m/h
    13,603
    16,971
    16,992
    31,298
    41,478
    72,389
    67,181
    67,181
    72,711
    63,919

    C
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5

    kPa
    11.6
    13.1
    13.1
    4.8
    4.8
    4.3
    5.3
    5.3
    5.0
    4.5

    TA %
    PA %
    Theoretical air for Kiln
    Theoretical air for calciner
    TA % for calciner

    Data units:

    Air flows:
    Kiln Primary Air :
    Kiln Inleaks :
    Kiln Excess Air:
    Secondary air:
    Kiln Combustion Air
    Calciner Primary Air:
    Calciner Inleaks :
    Calciner Excess Air:
    Tertiary air:
    Calciner Combustion Air:
    Raw mill take-off:
    Coal mill take-off:
    Exhaust Inleaks:
    Vent air:

    Compartment
    grate area
    m
    2.28
    2.84
    3.13
    8.30
    12.40
    16.50
    16.50
    16.50
    16.50
    17.90

    112.9

    (Enter M for metric,


    U for US)

    Flow
    Nm/h
    6298
    530
    10068
    56229
    52989
    5000
    1339
    2357
    119869
    133920
    6060
    0
    220339

    27.5
    9.4
    36.9

    Airflow
    %
    11.9
    1
    19.00

    T
    C
    60
    33

    3.7
    1
    1.76

    60

    BE O2

    4.00%
    0.1908

    CALCINER

    0.37%
    0.0176

    900

    1012

    365
    30
    250

    For Coal Ball mill

    11297.80
    2.3
    5.1
    8.3
    16.6
    29.0
    45.5
    62.0
    78.5
    95.0
    112.9
    112.9
    112.9
    112.9
    112.9
    112.9
    112.9
    112.9

    866.976 Nm3/hr

    Primary

    3.09%
    6.85%
    75079.31
    137925.3
    3.6%

    Transport

    1073.71
    2038.84
    866.976
    3979.526
    5146

    Swirl
    Axial
    Cooling
    nm3/hr
    kg/hr

    2318
    5000
    7318
    9462

    kiln
    calciner
    Nm3/hr
    kg/hr

    75%
    25%

    32

    Kiln Coal Blower


    Area
    0.25 m2
    Velocity

    2.61
    2.1
    2.08
    2.47
    3.9
    3.93
    3.38
    2.59
    2.8825 m/s

    Air Volume for Coal Blower

    2594.25 m3/hr
    2318.266 Nm3/hr

    Axial
    Area
    Velocity

    0.7744 m2
    1.03
    1.5
    1.1
    0.7
    0.65
    0.65
    0.49
    0.8
    1.04
    0.731333 m/s

    Air Volume for Coal Blower

    Swirl
    Area
    Velocity

    0.64 m2
    0.49
    0.46
    0.45
    0.44

    0.57
    0.57
    0.49
    0.3
    0.48
    0.6

    2038.84 m3/hr
    2038.84 Nm3/hr

    0.54
    0.69
    0.65
    0.59
    0.62
    0.42
    0.41
    0.45
    0.47
    0.53
    0.45
    0.41
    0.45
    0.77
    0.61
    0.53
    0.5215 m/s
    1201.536 m3/hr
    1073.713 Nm3/hr

    Metric units

    Fan name
    K10
    K11
    K12
    K13
    K14
    K15
    K16
    K17
    K18
    K19

    Total
    cooling
    air:

    reference temperature:
    altitude:
    atmospheric pressure:
    m/h
    13,603
    16,971
    16,992
    31,298
    41,478
    72,389
    67,181
    67,181
    72,711
    63,919
    0
    0
    0
    0
    0
    0
    0

    T(C)
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    32.5
    0.0
    0.0
    0.0
    0.0
    0.0
    0.0
    0.0

    463,722

    21.7

    Ps (kPa)
    11.55
    13.05
    13.07
    4.81
    4.79
    4.26
    5.27
    5.27
    4.96
    4.50
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00

    11-Nov-08
    33C
    246.0 m
    Err:511

    Nm/h
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    0
    0
    0
    0
    0
    0
    0

    kg/h
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511

    kJ/h
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511

    Err:511

    Err:511

    Err:511

    Cooler heat & mass balance

    Arasmeta

    Version 2 - 30.10.2002

    Clinker (T/d):
    Clinker (kg/h):

    4800
    200000

    IN

    Volume

    Volume

    Nm/h

    Nm/kg ck

    kg/kg ck

    kg/h

    Cooling air
    Hot clinker
    Total

    Err:511

    Err:511
    Err:511

    Err:511
    200,000
    Err:511

    33
    1,450

    Err:511

    Err:511
    1.00
    Err:511

    OUT
    Secondary air
    Tertiary air
    Raw mill take-off
    Coal mill take-off
    Vent air
    Water spray
    Cold clinker
    Wall loss
    Total

    Err:511
    Err:511
    119,869
    0
    6,060
    220,339

    Err:511
    Err:511
    0.60
    0.00
    0.03
    1.10

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

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

    1.00

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    0
    200,000

    Difference:

    r:
    h:

    Mass

    Mass

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511 (recovery ratio)


    Err:511 (cooling efficiency)

    Temp.

    140

    k:
    Cooler loss:

    Tertiary air
    0.60 Nm/kgck

    Secondary air

    Err:511

    Err:511
    Err:511
    Err:511

    Clinker
    200,000
    1450C

    Grate surface
    Standard load

    113 m
    42.5 t/d/m

    Cooling air
    Err:511
    33C

    Scale of classification for recovery k factor


    k < 0,9
    poor
    0,9 < k < 1,2
    mediocre
    1,2 < k < 1,4
    good
    k > 1,4
    very good

    11-Nov-08

    Ref. temperature:

    33C

    Heat

    Heat

    Heat

    kJ/h

    kJ/kg(Nm) C

    kJ/kg ck

    Err:511
    Err:511
    Err:511

    Err:511
    Err:511

    Err:511
    Err:511
    Err:511

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    5,880,000
    Err:511

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

    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    0.0
    Err:511
    29.4
    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511

    Err:511
    Err:511 kJ/kgck

    Vent air
    1.10 Nm/kgck
    Err:511

    Water spray
    0 kg/h

    Clinker
    200,000
    140C

    Air distribution along clinker cooler


    4800
    Err:511
    Err:511
    112.85
    Err:511
    Area
    Compartment #1
    Compartment #2
    Compartment #3
    Compartment #4
    Compartment #5
    Compartment #6
    Compartment #7
    Compartment #8
    Compartment #9
    Compartment #10

    Total

    m
    2.28
    2.84
    3.13
    8.30
    12.40
    16.50
    16.50
    16.50
    16.50
    17.90
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00
    112.85

    T/d
    Nm/h
    Nm/kg ck
    m
    m/s/m
    Cumulative
    area
    m
    2.28
    5.12
    8.25
    16.55
    12.40
    33.05
    49.55
    66.05
    82.55
    100.45
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00

    Blowing
    density
    m/s/m
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    Err:511
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00
    0.00

    Blowing density along cooler


    1.00
    0.90
    0.80
    Blowing Density m3/s/m2

    Clinker production:
    Total air flow:
    Air load:
    Total cooling area:
    Average blowing density:

    0.70
    0.60
    0.50
    0.40
    0.30
    0.20
    0.10
    0.00
    0.00

    20.00

    40.00

    60.00

    80.00

    Cumulative Area m2

    10

    density along cooler

    0.00

    60.00

    80.00

    Cumulative Area m2

    100.00

    120.00

    Pressure Profile
    14.0

    12.0

    10.0

    Pressure kPa

    8.0

    6.0

    4.0

    2.0

    0.0
    0.0

    20.0

    40.0

    60.0

    80.0

    Cumulative Area m2

    100.0

    120.0

    140.0

    Fuel Mix w/w %


    Fuel Mix cv/cv %

    0.0
    0.0

    C
    H
    N
    O
    S
    TOT O2
    N2 COMB
    TOT WET
    DRY
    Absolute Humidity

    100.0
    100.0

    1.57
    0.22
    -0.06
    0.01
    1.74
    5.73
    7.56
    7.47
    1.2

    Blue Circle Technical Centre 05/07/2016

    0.0
    0.0

    Combustion Products
    2.16
    0.36
    0.01
    0.01

    8.27
    7.91
    %

    27.35

    0.0
    0.0

    26.17
    4.31

    0.13

    0.12

    72.52

    69.39

    Fuel Mix w/w %


    Fuel Mix cv/cv %

    0.0
    0.0

    C
    H
    N
    O
    S
    TOT O2
    N2 COMB
    TOT WET
    DRY
    Absolute Humidity

    100.0
    100.0

    1.57
    0.22
    -0.02
    0.01
    1.78
    5.86
    7.73
    7.64
    1.2

    Blue Circle Technical Centre 05/07/2016

    0.0
    0.0

    Combustion Products
    2.16
    0.36
    0.01
    0.01

    8.40
    8.04
    %

    26.90

    0.0
    0.0

    25.75
    4.27

    0.12

    0.12

    72.97

    69.86

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