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Cooler Balance 1

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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.

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

Cooler Balance 1

Uploaded by

Tamer Fathy
231 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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XLS, PDF, TXT or read online from Scribd

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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
231 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
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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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