Parameters Numeric Value

Altitude 950
Abient Temperature, °C 27
Water at Cooler Water Tank Temperature, °C 26.2
Kiln Feed, TPH 67
Kiln Feed Moisture, % 0.2
Coal Firing PC, TPH 5
Coal Firing to Kiln, TPH 2.65
Fine Coal Moisture, % 1.7
KF Temperature, °C 66
PC Coal Firing Temperature, °C 60
KC Firing Temperature, °C 59
PH Fan RPM 922
PH Fan Amps 770
K Inlet Temperature, °C 894.3
Kiln RPM 4
Kiln Amps 186
Kiln Filling, % 12
Bag House Fan RPM 900
Bag House Fan Amp 439
ESP Fan RPM 798
ESP Fan Amp 90
Coler Fan FN11, RPM 1283
Coler Fan FN11, Amp 82
Coler Fan FN12, RPM 1134
Coler Fan FN12, AMP 114
Cooler Fan 13, Amp 1174
Cooler Fan 13, RPM 77
Coler Fan FN14, RPM 1194
Coler Fan FN14, Amp 65
Coler Fan FN15, RPM 562
Coler Fan FN15, Amp 36
Coler Fan FN16, Damper O/P Position, % 25
PA Blower RPM 1255
PA Blower Amp 29
PH Return Dust, % 7
Clinker Temperature in to Cooler, °C 1450
Clinker Production, TPH 41.88 Clinker analysis (%)
Clinker Production, Kg 41875.00 CaO 62
Clinker Factor 1.6 Mgo 3.4
Coal Consumption, tpd 155.78 Al2O3 5
Clinker Production, tpd 1005 Sio2 20.4
GCV of Coal 5450 Iron 4.9
Kiln Feed, tph 67 SO3 0.5
PH Return Dust % 8.09 LOI 0.9
PH Return Dust, TPH 5.42
Cooler Water Spray, L/min 43
Ambient Temperaure, °C 27
Datum temperature, °C 0
KF Moisture, % 0.2
Fine Coal Moisture, % 1.7
Heat of Evaporation, Kcal/Kg 594.2
Kiln Feed Temperature, °C 79
Conveying Air Temperature, °C 60
Coal Dust Temperature, °C 55
Clinker Temp. from Kiln to Cooler, ◦C 1450
Secondary Air Temperature, ◦C 928.81
Coal Ash, % 24
KF LOI, % 34.4
Coal Feed, TPH 6.49
KF Moisture, Mass, Kg/kg-Clk 0.0032
Coal Moisture, Mass Kg/Kg-Clk 0.002635
Heat of Clinker
Formation,
Kcal/Kg-CLK

409.3664
406.2
 Cooler Heat Balance with Reference Temperature: 0 ◦C
M (Kg/Kg-Clinker) CP T ◦C Heat Kcal/Kg
Heat Input
Heat Input to Cooler by Clinker 1.000 0.264 1450 383.23
Heat input from Clinker Dust 0.050 0.264 1450 19.14
Heat input from Cooler Fans 2.844 0.242 27 18.58
Fan Energy 3.326 0.86 2.86
Total Heat Input 3.894 423.82
Heat Output
Cooler Vent Heat Loss 1.842 0.243 397 177.65
Heat Carried away by Secondary Air 0.502 0.269 928.81 125.50
Heat loss due to Secondary Air Dust 0.025 0.269 928.81 6.25
Heat Carried Away by Tertiary Air 0.500 0.255 624 79.36
Heat loss due to Tertiary Air Dust 0.025 0.255 624 3.97
Heat Carried Away by Clinker into DBC 1.000 0.194 147 28.51
Heat Losses due to Radiation 2.57
Total Heat Output 3.894 423.82

((Total Heat Recovered into the Kiln System)/(Heat input through Clinker into Cooler))*100%
Cooler Recuperation Efficiency, %
48.34
 0.50

ker into Cooler))*100%

 Heat Balance Sheet with Reference Temperature: 0 ◦C
M (Kg/Kg-
Heat Input Cp
Clk)
Combustion of Coal
Sensible Heat from Primary Air into Kiln 0.035 0.222
Sensible Heat from Conveying Air With Coal to PC 0.087 0.224
Sensible Heat from Conveying Air With Coal to Kiln 0.085 0.224
Sensible Heat from Coal Dust 0.155 0.283
Sensible Heat from kiln Feed 1.600 0.214
Sensible Heat from Grate Cooler: Cooling Air 2.844 0.222
Sensible Heat from False Air ingress 0.565 0.222
Total Heat Input

M (Kg/Kg-
Heat Output Cp
Clk)
Heat through PH Downcomer Exit gases 2.363 0.239
Heat through RMBH Return Dust @ = 8.086% of Kiln Feed 0.129 0.239
Heat to Evaporate Moisture Content in Kiln Feed 0.003
594.2
Heat to Evaporate Moisture Content in Coal 0.0026
Heat of Formation
Heat through Cooler Vent 1.842 0.254
Cooler Loss : Heat carried away by Clinker into Cooler 1.000 0.194
Radiation & Convection Losses
(i) Cooler Radiation & Convection Losses
(ii) Kiln Radiation & Convection Losses
(iii) Kiln O/L Hood Convection & Radiation Losses
(iv) TAD Convection & Radiation Losses
(v) Cyclones
(vi) Feed Pipes
(vii) Riser Ducts
(viii) PC
(ix) CV Furnace
(x) Mixing Chamber
(xi) Kiln Inlet Hood
Heat Loss Through Radiation
Total Heat Output

31.09
Temperature: 0 ◦C
Heat
Temperature, °C % of Heat
(Kcal/Kg-Clk)
858.52 94.25
27 0.21 0.02
60 1.17 0.13
60 1.15 0.13
55 2.42 0.27
79 27.02 2.97
27 17.03 1.87
27 3.39 0.37
910.90 100.0

Heat
Temperature, °C % of Heat
(Kcal/Kg-Clk)
323 182.36 20.02
323 9.98 1.10
1.90 0.21
594.2
1.57 0.17
409.37 44.94
397 185.78 20.40
147 28.51 3.13
osses
2.57 0.28
37.86 4.16
0.56 0.06
6.13 0.65
19.77 2.17
3.00 0.33
7.48 0.82
7.82 0.86
4.49 0.49
0.93 0.10
0.84 0.09
91.44 10.01
910.90 100.0

44.32
5.82
6.13
11.36
23.31
 Kiln BagHouse Return Dust, %

Production, Coal Feed K Feed, KF LOI, %, KF Moisture, NUM = (A-

Coal Ash, %, C
TPH, A Rate, TPH, B TPH , D E %, F (B*C)/100)

41.88 6.49 24 67 34.4 0.2 40.31725

DENO=(D*(1- Return
RD,=
E/100)*(1-F/ Dust % (1-
(NUM/DENO)
100)) RD)*100

43.864 0.919 8.086

S.No. Kg.-air/Kg.-clk.
A) Cooler Air Inputs :
1 Cooling Air from 06 Nos. Cooler Fans 2.84
B) Cooler Air Outputs :
1 Cooler Vent Air 1.842
Secondary + Tertiary Air 1.002
3 1. Tertiary Air (From TA duct) 0.500
2. Secodary Air 0.502
SUM 2.844

Combustion Air :
Secondary + Tertiary Air 1.002
Primary Air(Jet Air + Swrle Air) 0.035
C)
Conveying Air with fuel to KC &PC 0.172
Infiltration Air to System
SUM 1.209

S.No. Particulars Kg.-air/Kg.-clk.

A) Air Inputs :
1 Cooling Air from 06 Nos. Cooler Fans 2.84
2 Primary Air(Jet Air + Swrle Air) 0.04
3 Kiln Coal Blower Air 0.09
4 PC Coal Blower Air 0.09
5 Calcination gas 0.59
6 False Air + excess air 0.57
SUM 4.21
B) Air Outputs :
1 Cooler Vent Air 1.84
3 Preheater Exit Air 2.36
SUM 4.21
 Temprature (Degree
For Air A B*10^-3
Celcius)
Cooler Fan 11 6.386 27 1.762
Cooler Fan 12 6.386 27 1.762
Cooler Fan 13 6.386 27 1.762
Cooler Fan 14 6.386 27 1.762
Cooler Fan 15 6.386 27 1.762
Cooler Fan 16 6.386 27 1.762
Secondary Air 6.386 939 1.762
False Air 6.386 27 1.762
PH Downcomer Duct 6.386 323 1.762
TA Duct 6.386 624 1.762
ESP I/L Duct 6.386 397 1.762
RMBH Fan I/L 6.386 165 1.762
Coal Conveying air to PC 6.386 60 1.762
Coal Conveying air to KC 6.386 60 1.762
Kiln Feed 6.386 70 1.762
Air 6.386 27 1.762
Clinker into Cooler 6.386 1450 1.762

Heat Capacity (Cp) = a+bT+cT^2, T in ◦C

Material a b(10^-6)
Kiln Feed 0.206 101
Coal 0.262 390
Clinker 0.186 54

Material a b(10^-6) c(10^-9)

Kiln Feed 0.206 101 -37
Coal 0.262 390 0
Clinker 0.186 54 0
Clinker Discharge from Kiln 0.186 54 0
 BT C (*10^-6) CT^2 Mol. Wt (kg) A+BT+CT^2 CP, Kcal/Kg. K
0.0476 0.2656 0.0002 29 6.4334 0.2218
0.0476 0.2656 0.0002 29 6.4334 0.2218
0.0476 0.2656 0.0002 29 6.4334 0.2218
0.0476 0.2656 0.0002 29 6.4334 0.2218
0.0476 0.2656 0.0002 29 6.4334 0.2218
0.0476 0.2656 0.0002 29 6.4334 0.2218
1.6545 0.2656 0.2342 29 7.8063 0.2692
0.0476 0.2656 0.0002 29 6.4334 0.2218
0.5691 0.2656 0.0277 29 6.9274 0.2389
1.0995 0.2656 0.1034 29 7.3821 0.2546
0.6995 0.2656 0.0419 29 7.0437 0.2429
0.2907 0.2656 0.0072 29 6.6695 0.2300
0.1057 0.2656 0.0010 29 6.4908 0.2238
0.1057 0.2656 0.0010 29 6.4908 0.2238
0.1233 0.2656 0.0013 29 6.5080 0.2244
0.0476 0.2656 0.0002 29 6.4334 0.2218
2.5549 0.2656 0.5584 29 8.3825 0.2891

^2, T in ◦C
c(10^-9)
-37
0
0

Temperature, ◦C bT cT^2 Cp, Kcal/Kg ◦C

79 0.0080 -0.0002 0.2137
55 0.0215 0.0000 0.2835
147 0.0079 0.0000 0.1939
1450 0.0783 0.0000 0.2643
 Barometir
X, m A = X/42000
950 0.023

Density of Hot Barometric Pressure,

Location
Gas, Kg/m^3 mmWG

PH Downcomer Duct 1.4 9166.17

TA Duct 1.29 9166.17
ESP I/L Duct 1.29 9166.17
RMBH Fan Inlet 1.29 9166.17

V. m/s = k*
Pitot Tube DP, Average,
{(2*DP*g)/Corrected Location
Constant, K mmH2O
Density)}^0.5
PH Downcomer Duct 0.849 10.04
TA Duct 0.849 9.85
ESP I/L Duct 0.849 6.27
RMBH Fan Inlet 0.849 15.85

Site Pressure inletStatic Pressure

Location
MMWG MMWG
Cooler Fan 11 9166.168 41
Cooler Fan 12 9166.168 19.6
Cooler Fan 13 9166.168 24
Cooler Fan 14 9166.168 53
Cooler Fan 15 9166.168 11
Cooler Fan 16 9166.168 1
 Barometirc Pressure Caculation
1-A = a a^5.25 = c c*10336, MMWG
0.977 0.887 9166.168 Barometric Pressure = 10336*
(1-x/42000)^5.25

Temperature
Static Pressure, Draft, Corrected Denisty
Measured using
mmH20 Kg/m^3
Thermocuple, °C Corrected Density, kg/m^3 = Density of
Hot Gas*{ (Pb-1000)-Pstatic} / {(273+T) *
447.00 323 0.540 Pb}
10.70 624 0.526
21.00 397 0.525
201.00 165 0.513

Corrected Density
g, m/s^2 Velcoty, m/S Area of Duct, Pi*D^2/4, m^2
Kg/m^3

9.81 0.540 16.2121 3.14

9.81 0.526 16.2814 0.68
9.81 0.525 12.9980 3.14
9.81 0.513 20.8927 3.63

Corrected Density,
Air Density, Kg/M^3 Temperature, °C
Kg/M^3
1.293 27 1.0481
1.293 27 1.0457
1.293 27 1.0462
1.293 27 1.0495
1.293 27 1.0447
1.293 27 1.0436
Volumetric Flow Temperature Kg Clinker
m3/hr Kg/hr Nm3/hr
Rate, m^3/s (°C) Produced/Hour

50.91 323 183261.20 98968.65 70691.89 41875.00

11.05 624 39795.13 20921.71 16218.38 41875.00
40.81 397 146929.29 77148.36 59804.93 41875.00
75.81 165 272925.13 140138.27 108634.32 41875.00
 Nm^3/Kg-
Kg-Air/ Kg-Clinker
Clinker

2.36 1.69
0.500 0.39
1.842 1.43
3.35 2.59
 ESP I/L Duct, DIA: 2000 MM RMBH Fan I/L Duct, DI
Draft (-)MMWG DP mmwg Temperat Draft (-)MMWG
21.00 7.00 7.00 6.00 ure (°C) 201.00
5 6 6 397
7 7 6
6 6 6
5 6 7
6 6 7
7 7 6
6 6 5
5 7 7
7 6 6
6 7 7
Avg (mmwg) 6.27

TA Duct, DIA: 930 MM PH Downcomer Duct, D

Draft (-)MMWG Temperat Draft (-)MMWG
10.70 9.50 11.00 9.00 ure (°C) 447.00
10.00 8.40 11.00 624
10.30 10.00 10.00
9.00 10.00 8.00
11.00 11.00 10.00
9.00 9.00 11.00
11.00 11.00 9.00
10.00 10.00 10.00
8.00 9.00 9.00
9.00 11.00 11.00
11.00 9.00 10.00
Avg (mmwg) 9.85
 RMBH Fan I/L Duct, DIA: 2150 MM
DP mmwg Temperat
16.00 14.00 18.00 ure (°C)
15 17 17 165
14 15 16
16 17 18
14 15 14
16 16 15
14 17 16
15 16 17
16 18 16
17 17 14
16 16 15
15.85

PH Downcomer Duct, DIA: 2000 MM

DP MMWG Temperat
9.00 10.00 9.00 ure (°C)
10 9 11 323
12 11 9
10 9 9.5
10 10 9.6
9 9 9
11 12 11.6
9 11 10.4
11 9 9
10 11 11
9 9 10
Avg (mmwg) 10.04
 Garte
Clinker
Surface (Ta,K - Ta,
Productio Ts, °C Ta, °C Ts, K Ta K (Ta+Ts)/2
Area, K)
n, kg/hr
M^2
41875.00 192 81.76 27 354.76 300 327.38 54.76

Measure
60 56 77 78 76 86 89 86
55 52 64 65 68 65 67 72
78 68 74 76 81 76 73 80
72 86 89 87 89 86 78 75
54 132 58 61 94 99 96 70
Average Temperature, ◦C
 Total Surface
Convection Radiation
Losses
Ts, K ^4 Ta, K^4 A B Losses, Losses,
(Kcal/hr*m^2
Kcal/hr*m^2 Kcal/hr*m^2
)
15838601108.78 8100000000.00 0.02 207.65 251.95 309.54 561.49

Measured Cooler Ts, ◦C

91 73 64 88 90 92 56
68 59 65 70 68 65 64
81 86 69 99 101 77 68
88 66 68 74 78 61 58
76 65 693 82 86 73 71
Average Temperature, ◦C
Kcal/kg-
clinker

2.57

66 49 93
71 78 87
69 75 77
56 66 61
69 82 78
81.76
 kiln Surface Losses

Clinker Surface
(Ta,K - Ta,
Productio Length, m Area, Ts, °C Ta, °C Ts, Kelvin Ta, Kelvin (Ta+Ts)/2
K)
n, kg/hr M^2

41875.00 0 to1 9.42 326.7 27 599.7 300 449.85 299.7

41875.00 1 to 2 9.42 254.6 27 527.6 300 413.8 227.6
41875.00 2 to 3 9.42 264.7 27 537.7 300 418.85 237.7
41875.00 3 to 4 9.42 269.8 27 542.8 300 421.4 242.8
41875.00 4 to 5 9.42 234 27 507 300 403.5 207
41875.00 5 to 6 9.42 215.8 27 488.8 300 394.4 188.8
41875.00 6 to 7 9.42 216.2 27 489.2 300 394.6 189.2
41875.00 7 to 8 9.42 206 27 479 300 389.5 179
41875.00 8 to 9 9.42 230.9 27 503.9 300 401.95 203.9
41875.00 9 to 10 9.42 228 27 501 300 400.5 201
41875.00 10 to 11 9.42 200.9 27 473.9 300 386.95 173.9
41875.00 11 to 12 9.42 195 27 468 300 384 168
41875.00 12 to 13 9.42 197.9 27 470.9 300 385.45 170.9
41875.00 13 to 14 9.42 202 27 475 300 387.5 175
41875.00 14 to 15 9.42 232 27 505 300 402.5 205
41875.00 15 to 16 9.42 246.5 27 519.5 300 409.75 219.5
41875.00 16 to 17 9.42 254.8 27 527.8 300 413.9 227.8
41875.00 17 to 18 9.42 262.9 27 535.9 300 417.95 235.9
41875.00 18 to 19 9.42 250.6 27 523.6 300 411.8 223.6
41875.00 19 to 20 9.42 272.6 27 545.6 300 422.8 245.6
41875.00 20 to 21 9.42 271.7 27 544.7 300 422.35 244.7
41875.00 21 to 22 9.42 256.6 27 529.6 300 414.8 229.6
41875.00 22 to 23 9.42 259.4 27 532.4 300 416.2 232.4
41875.00 23 to 24 9.42 233.7 27 506.7 300 403.35 206.7
41875.00 24 to 25 9.42 247.8 27 520.8 300 410.4 220.8
41875.00 25 to 26 9.42 266.9 27 539.9 300 419.95 239.9
41875.00 26 to 27 9.42 276.1 27 549.1 300 424.55 249.1
41875.00 27 to 28 9.42 281.8 27 554.8 300 427.4 254.8
41875.00 28 to 29 9.42 279.7 27 552.7 300 426.35 252.7
41875.00 29 to 30 9.42 273.8 27 546.8 300 423.4 246.8
41875.00 30 to 31 9.42 258.2 27 531.2 300 415.6 231.2
41875.00 31 to 32 9.42 250.6 27 523.6 300 411.8 223.6
41875.00 32 to 33 9.42 253.4 27 526.4 300 413.2 226.4
41875.00 33 to 34 9.42 245.1 27 518.1 300 409.05 218.1
41875.00 34 to 35 9.42 231.3 27 504.3 300 402.15 204.3
41875.00 35 to 36 9.42 223 27 496 300 398 196
41875.00 36 to 37 9.42 222 27 495 300 397.5 195
41875.00 37 to 38 9.42 226 27 499 300 399.5 199
41875.00 38 to 39 9.42 219.6 27 492.6 300 396.3 192.6
41875.00 39 to 40 9.42 212.9 27 485.9 300 392.95 185.9
41875.00 40 to 41 9.42 219.6 27 492.6 300 396.3 192.6
41875.00 41 to 42 9.42 190.4 27 463.4 300 381.7 163.4
41875.00 42 to 43 9.42 186.2 27 459.2 300 379.6 159.2
41875.00 43 to 44 9.42 177.4 27 450.4 300 375.2 150.4
41875.00 44 to 45 9.42 166.1 27 439.1 300 369.55 139.1
Kiln Total Surface Radiation Losses
kiln Surface Losses
Total
Convectio Radiation
Surface
n Losses, Losses, Kcal/kg-
Ts ^4 Ta^4 A B Losses
Kcal/hr* Kcal/hr* clinker
(Kcal/hr*
m^2 m^2
m^2)
129340994335.2 8100000000 0.0120 2001.813 1929.657 4849.64 6779.297 1.525
77485269430.3 8100000000 0.0127 1364.706 1397.528 2775.411 4172.939 0.939
83591120331.26 8100000000 0.0126 1445.835 1467.663 3019.645 4487.307 1.009
86807921141.79 8100000000 0.0126 1487.239 1503.072 3148.317 4651.388 1.046
66074188401 8100000000 0.0130 1202.931 1254.549 2318.968 3573.516 0.804
57085365879.19 8100000000 0.0132 1064.346 1128.501 1959.415 3087.916 0.695
57272454180.89 8100000000 0.0132 1067.346 1131.267 1966.898 3098.165 0.697
52643172481 8100000000 0.0133 991.504 1060.828 1781.727 2842.555 0.639
64472933869.34 8100000000 0.0130 1179.030 1233.054 2254.917 3487.971 0.785
63001502001 8100000000 0.0131 1156.780 1212.954 2196.06 3409.014 0.767
50436719885.06 8100000000 0.0134 954.110 1025.685 1693.469 2719.154 0.612
47971512576 8100000000 0.0135 911.300 985.1068 1594.861 2579.967 0.580
49171647745.18 8100000000 0.0134 932.281 1005.041 1642.866 2647.907 0.596
50906640625 8100000000 0.0134 962.145 1033.26 1712.266 2745.526 0.618
65037750625 8100000000 0.0130 1187.497 1240.68 2277.51 3518.19 0.791
72835349340.06 8100000000 0.0128 1300.493 1341.288 2589.414 3930.702 0.884
77602827185.67 8100000000 0.0127 1366.301 1398.917 2780.113 4179.03 0.940
82477412589.22 8100000000 0.0127 1431.292 1455.164 2975.097 4430.26 0.997
75162038716.44 8100000000 0.0128 1332.900 1369.753 2682.482 4052.235 0.912
88613001370.01 8100000000 0.0126 1510.093 1522.509 3220.52 4743.029 1.067
88029756609.65 8100000000 0.0126 1502.738 1516.261 3197.19 4713.452 1.060
78666876328.35 8100000000 0.0127 1380.679 1411.416 2822.675 4234.091 0.952
80343766444.06 8100000000 0.0127 1403.118 1430.86 2889.751 4320.611 0.972
65917938541.11 8100000000 0.0130 1200.612 1252.468 2312.718 3565.186 0.802
73567145001.37 8100000000 0.0128 1310.747 1350.313 2618.686 3968.999 0.893
84967591893.84 8100000000 0.0126 1463.660 1482.938 3074.704 4557.642 1.025
90908768546.86 8100000000 0.0125 1538.782 1546.801 3312.351 4859.151 1.093
94742711433.24 8100000000 0.0125 1585.788 1586.349 3465.708 5052.058 1.136
93316374705.74 8100000000 0.0125 1568.429 1571.781 3408.655 4980.436 1.120
89395163615.26 8100000000 0.0125 1519.914 1530.838 3251.807 4782.644 1.076
79621850241.43 8100000000 0.0127 1393.490 1422.527 2860.874 4283.401 0.964
75162038716.44 8100000000 0.0128 1332.900 1369.753 2682.482 4052.235 0.912
76782725241.24 8100000000 0.0128 1355.145 1389.195 2747.309 4136.504 0.931
72053381810.31 8100000000 0.0129 1289.472 1331.569 2558.135 3889.704 0.875
64677894355.88 8100000000 0.0130 1182.107 1235.827 2263.116 3498.943 0.787
60523872256 8100000000 0.0131 1118.666 1178.319 2096.955 3275.274 0.737
60037250625 8100000000 0.0131 1111.082 1171.396 2077.49 3248.886 0.731
62001498001 8100000000 0.0131 1141.497 1199.097 2156.06 3355.157 0.755
58881332550.66 8100000000 0.0132 1092.931 1154.785 2031.253 3186.038 0.717
55742648083.42 8100000000 0.0132 1042.657 1108.458 1905.706 3014.164 0.678
58881332550.66 8100000000 0.0132 1092.931 1154.785 2031.253 3186.038 0.717
46113078628.99 8100000000 0.0135 878.264 953.5339 1520.523 2474.057 0.557
 44463896402.33 8100000000 0.0136 848.368 924.7618 1454.556 2379.318 0.535
41152244515.23 8100000000 0.0137 786.574 864.6714 1322.09 2186.761 0.492
37175237213.62 8100000000 0.0138 708.965 787.9659 1163.009 1950.975 0.439
l Surface Radiation Losses 37.857
Err:509
 TAD Surfac
Clinker
Surface
TAD Portion Productio Length, m Ts, °C Ta, °C Ts, Kelvin Ta, Kelvin (Ta+Ts)/2
Area, M^2
n, kg/hr
41875.00 0 to1 2.9202 76 27 349 300 324.5
41875.00 1 to 2 2.9202 139.25 27 412.25 300 356.125
41875.00 2 to 3 2.9202 124.5 27 397.5 300 348.75
41875.00 3 to 4 2.9202 117.5 27 390.5 300 345.25
41875.00 4 to 5 2.9202 118.25 27 391.25 300 345.625
41875.00 5 to 6 2.9202 121.25 27 394.25 300 347.125
41875.00 6 to 7 2.9202 132.2 27 405.2 300 352.6000
41875.00 7 to 8 2.9202 112.8 27 385.8 300 342.9
41875.00 8 to 9 2.9202 111.8 27 384.8 300 342.4
41875.00 9 to 10 2.9202 133.4 27 406.4 300 353.2
41875.00 10 to 11 2.9202 149.6 27 422.6 300 361.3000
41875.00 11 to 12 2.9202 165.4 27 438.4 300 369.2
41875.00 12 to 13 2.9202 138.6 27 411.6 300 355.8000
41875.00 13 to 14 2.9202 120.2 27 393.2 300 346.6000
41875.00 14 to 15 2.9202 139.2 27 412.2 300 356.1000
41875.00 15 to 16 2.9202 94 27 367 300 333.5000
41875.00 16 to 17 2.9202 129.4 27 402.4 300 351.2000
41875.00 17 to 18 2.9202 186 27 459 300 379.5000
41875.00 18 to 19 2.9202 174.4 27 447.4 300 373.7
41875.00 19 to 20 2.9202 237.5 27 510.5 300 405.2500
Horizontal 41875.00 20 to 21 2.9202 276 27 549 300 424.5000
Portion TAD 41875.00 21 to 22 2.9202 189.5 27 462.5 300 381.2500
I/L 41875.00 22 to 23 2.9202 260 27 533 300 416.5
41875.00 23 to 24 2.9202 161 27 434 300 367.0000
41875.00 24 to 25 2.9202 154.5 27 427.5 300 363.75
41875.00 25 to 26 2.9202 164 27 437 300 368.5
41875.00 26 to 27 2.9202 144 27 417 300 358.5
41875.00 27 to 28 2.9202 154.5 27 427.5 300 363.75
41875.00 28 to 29 2.9202 89 27 362 300 331
41875.00 29 to 30 2.9202 147.5 27 420.5 300 360.25
41875.00 30 to 31 2.9202 171.5 27 444.5 300 372.25
41875.00 31 to 32 2.9202 123 27 396 300 348
41875.00 32 to 33 2.9202 181.5 27 454.5 300 377.25
41875.00 33 to 34 2.9202 191 27 464 300 382
41875.00 34 to 35 2.9202 71 27 344 300 322
41875.00 35 to 36 2.9202 118 27 391 300 345.5
41875.00 36 to 37 2.9202 167.5 27 440.5 300 370.25
41875.00 37 to 38 2.9202 106 27 379 300 339.5
41875.00 38 to 39 2.9202 128 27 401 300 350.5
41875.00 39 to 40 2.9202 108 27 381 300 340.5
 41875.00 40 to 41 2.9202 83 27 356 300 328
41 to
41875.00 1.4717808 81 27 354 300 327
41.504
41.504 to
41875.00 1.4484192 174 27 447 300 373.5
42
41875.00 42 to 43 2.9202 103 27 376 300 338
41875.00 43 to 44 2.9202 76 27 349 300 324.5
41875.00 44 t0 45 2.9202 79 27 352 300 326
41875.00 45 to 46 2.9202 81 27 354 300 327
41875.00 46 to 47 2.9202 91 27 364 300 332
41875.00 47 to 48 2.9202 135 27 408 300 354
41875.00 48 to 49 2.9202 76 27 349 300 324.5
41875.00 49 to 50 2.9202 110 27 383 300 341.5
41875.00
Vertical Portion of TAD 50 to 51 2.9202 112 27 385 300 342.5
41875.00 51 to 52 2.9202 94 27 367 300 333.5
41875.00 52 to 53 2.9202 112 27 385 300 342.5
41875.00 53 to 54 2.9202 48 27 321 300 310.5
41875.00 54 to 55 2.9202 156 27 429 300 364.5
41875.00 55 to 56 2.9202 114 27 387 300 343.5
41875.00 56 to 57 2.9202 147 27 420 300 360
41875.00 57 to 58 2.9202 112 27 385 300 342.5
41875.00 58 to 59 2.9202 68 27 341 300 320.5
41875.00 59 to 60 2.9202 163 27 436 300 368
41875.00 60 to 61 2.9202 109 27 382 300 341
41875.00 61 to 62 2.9202 82 27 355 300 327.5
41875.00 62 to 63 2.9202 87 27 360 300 330
Horizontal Portion at TAD O/L
41875.00 63 to 64 2.9202 60 27 333 300 316.5
64 to
41875.00 2.832594 94 27 367 300 333.5
64.97
TAD Surface Radiation Lo
 TAD Surface Losses
Convection
(Ta,K - Ta, Radiation Losses,
Ts ^4 Ta^4 A B Losses,
K) Kcal/hr*m^2
Kcal/hr*m^2
49 14835483601 8100000000 0.0152 179.0735 218.6702 269.4193
112.25 28883023743.8 8100000000 0.0142 540.6278 617.1859 831.3209
97.5 24965975039.1 8100000000 0.0144 448.0672 519.3267 674.6390
90.5 23253276345.1 8100000000 0.0145 405.7071 473.6762 606.1311
91.25 23432433986.8 8100000000 0.0145 410.1951 478.5398 613.2974
94.25 24159436918.1 8100000000 0.0145 428.2694 498.0616 642.3775
105.2000 26957384104 8100000000 0.0143 495.8462 570.1542 754.2954
85.8 22153833797.9 8100000000 0.0146 377.8666 443.3585 562.1534
84.8 21925032886.7 8100000000 0.0146 372.0075 436.9452 553.0013
106.4 27278142708.1 8100000000 0.0143 503.4000 578.1280 767.1257
122.6000 31894659557.4 8100000000 0.0141 608.0759 686.9722 951.7864
138.4 36938748893.6 8100000000 0.0138 714.7175 794.9041 1153.5500
111.6000 28701293140 8100000000 0.0142 536.4588 612.8314 824.0517
93.2000 23903089446.9 8100000000 0.0145 421.9213 491.2169 632.1236
112.2000 28869013910.1 8100000000 0.0142 540.3069 616.8508 830.7606
67.0000 18141126721 8100000000 0.0149 271.7426 325.3225 401.6451
102.4000 26219951751.6 8100000000 0.0144 478.3324 551.6024 724.7981
159.0000 44386483761 8100000000 0.0136 859.9285 937.5422 1451.4594
147.4 40066731808.9 8100000000 0.0137 777.3331 856.9948 1278.6693
210.5000 67917702405.1 8100000000 0.0129 1249.9569 1299.5152 2392.7081
249.0000 90842562801 8100000000 0.0125 1563.6290 1571.9113 3309.7025
162.5000 45755883789.1 8100000000 0.0135 885.2533 961.9431 1506.2354
233 80706559921 8100000000 0.0127 1431.1509 1458.6864 2904.2624
134.0000 35477982736 8100000000 0.0139 684.5902 764.6985 1095.1193
127.5 33399846914.1 8100000000 0.0140 640.6858 720.2802 1011.9939
137 36469158961 8100000000 0.0139 705.0964 785.2818 1134.7664
117 30237384321 8100000000 0.0141 571.3362 649.1116 885.4954
127.5 33399846914.1 8100000000 0.0140 640.6858 720.2802 1011.9939
62 17172529936 8100000000 0.0150 245.0519 294.9717 362.9012
120.5 31265400810.1 8100000000 0.0141 594.2316 672.7477 926.6160
144.5 39037955190.1 8100000000 0.0138 757.0139 836.9457 1237.5182
96 24591257856 8100000000 0.0145 438.9020 509.4974 659.6503
154.5 42671268185.1 8100000000 0.0136 827.6404 906.2330 1382.8507
164 46352367616 8100000000 0.0135 896.1627 972.4130 1530.0947
44 14003408896 8100000000 0.0153 155.1395 190.5077 236.1364
91 23372600161 8100000000 0.0145 408.6977 476.9178 610.9040
140.5 37651618620.1 8100000000 0.0138 729.2099 809.3565 1182.0647
79 20632736881 8100000000 0.0147 338.4830 400.0246 501.3095
101 25856961601 8100000000 0.0144 469.6349 542.3555 710.2785
81 21071715921 8100000000 0.0147 349.9537 412.7010 518.8686
 56 16062013696 8100000000 0.0151 213.9610 259.2506 318.4805
54 15704099856 8100000000 0.0151 203.8360 247.5290 304.1640

147 39923636481 8100000000 0.0137 774.5224 854.2272 1272.9455

76 19987173376 8100000000 0.0148 321.4582 381.1243 475.4869
49 14835483601 8100000000 0.0152 179.0735 218.6702 269.4193
52 15352201216 8100000000 0.0152 193.8351 235.9069 290.0880
54 15704099856 8100000000 0.0151 203.8360 247.5290 304.1640
64 17555190016 8100000000 0.0150 255.6454 307.0518 378.2076
108 27710263296 8100000000 0.0143 513.5159 588.7803 784.4105
49 14835483601 8100000000 0.0152 179.0735 218.6702 269.4193
83 21517662721 8100000000 0.0146 361.5190 425.4358 536.7065
85 21970650625 8100000000 0.0146 373.1775 438.2268 554.8260
67 18141126721 8100000000 0.0149 271.7426 325.3225 401.6451
85 21970650625 8100000000 0.0146 373.1775 438.2268 554.8260
21 10617447681 8100000000 0.0157 57.8786 72.9699 100.6979
129 33871089681 8100000000 0.0140 650.7529 730.5078 1030.8436
87 22430753361 8100000000 0.0146 384.9277 451.0721 573.2301
120 31116960000 8100000000 0.0141 590.9471 669.3656 920.6784
85 21970650625 8100000000 0.0146 373.1775 438.2268 554.8260
41 13521270961 8100000000 0.0153 141.2020 173.9799 216.8508
136 36136489216 8100000000 0.0139 698.2442 778.4152 1121.4596
82 21293813776 8100000000 0.0147 355.7246 419.0612 527.7526
55 15882300625 8100000000 0.0151 208.8832 253.3776 311.2920
60 16796160000 8100000000 0.0150 234.5717 282.9758 347.8464
33 12296370321 8100000000 0.0155 105.7253 131.4578 167.8548
67 18141126721 8100000000 0.0149 271.7426 325.3225 401.6451

TAD Surface Radiation Losses

 Total Surface
Losses Kcal/kg-clinker
(Kcal/hr*m^2)
488.0896 0.0340
1448.5068 0.1010
1193.9657 0.0833
1079.8072 0.0753
1091.8372 0.0761
1140.4390 0.0795
1324.4496 0.0924
1005.5119 0.0701
989.9465 0.0690
1345.2537 0.0938
1638.7586 0.1143
1948.4540 0.1359
1436.8832 0.1002
1123.3405 0.0783
1447.6114 0.1010
726.9676 0.0507
1276.4005 0.0890
2389.0015 0.1666
2135.6641 0.1489
3692.2232 0.2575
4881.6138 0.3404
2468.1784 0.1721
4362.9488 0.3043
1859.8178 0.1297
1732.2741 0.1208
1920.0482 0.1339
1534.6070 0.1070
1732.2741 0.1208
657.8729 0.0459
1599.3637 0.1115
2074.4639 0.1447
1169.1477 0.0815
2289.0837 0.1596
2502.5077 0.1745
426.6441 0.0298
1087.8218 0.0759
1991.4213 0.1389
901.3341 0.0629
1252.6339 0.0874
931.5696 0.0650
577.7311 0.0403
551.6930 0.0194

2127.1726 0.0736
856.6112 0.0597
488.0896 0.0340
525.9950 0.0367
551.6930 0.0385
685.2594 0.0478
1373.1908 0.0958
488.0896 0.0340
962.1423 0.0671
993.0528 0.0693
726.9676 0.0507
993.0528 0.0693
173.6678 0.0121
1761.3514 0.1228
1024.3022 0.0714
1590.0440 0.1109
993.0528 0.0693
390.8308 0.0273
1899.8748 0.1325
946.8138 0.0660
564.6696 0.0394
630.8222 0.0440
299.3126 0.0209
726.9676 0.0492

6.1252
 TAD Portion Length, m Measured Surface Temperature, ◦C
0 to1 76
1 to 2 79
2 to 3 81
3 to 4 86
4 to 5 108
5 to 6 117
6 to 7 76 177
7 to 8 79 85
8 to 9 81 98
9 to 10 86 160
10 to 11 116 209
11 to 12 108 256
12 to 13 117 187
13 to 14 95 186
14 to 15 177 170
15 to 16 92 78
16 to 17 87 225
17 to 18 406 124
18 to 19 404 132
19 to 20 402 73
Horizontal 20 to 21 396 156
Portion TAD I/L 21 to 22 236 143
22 to 23 394 126
23 to 24 244 78
24 to 25 141 168
25 to 26 246 82
26 to 27 212 76
27 to 28 156 153
28 to 29 94 84
29 to 30 209 86
30 to 31 256 87
31 to 32 186 60
32 to 33 187 176
33 to 34 202 180
34 to 35 116 26
35 to 36 108 128
36 to 37 202 133
37 to 38 95 117
38 to 39 93 163
39 to 40 75 141
40 to 41 53 113
41 to 41.504 78 84
41.504 to 42 174
 42 to 43 103
43 to 44 76
44 t0 45 79
45 to 46 81
46 to 47 91
47 to 48 135
48 to 49 76
49 to 50 110
50 to 51 112
Vertical Portion of TAD
51 to 52 94
52 to 53 112
53 to 54 48
54 to 55 156
55 to 56 114
56 to 57 147
57 to 58 112
58 to 59 68
59 to 60 163
60 to 61 109
61 to 62 82
62 to 63 87
Horizontal Portion at TAD O/L
63 to 64 60
64 to 64.97 94
e Temperature, ◦C Avg. Ts, ◦C
76.00
216 112 150 139.25
164 82 171 124.50
144 76 164 117.50
123 94 148 118.25
168 74 126 121.25
198 76 134 132.20
228 86 86 112.80
214 89 77 111.80
196 98 127 133.40
205 92 126 149.60
208 131 124 165.40
126 125 138 138.60
137 111 72 120.20
115 118 116 139.20
96 123 81 94.00
150 109 76 129.40
154 118 128 186.00
132 98 106 174.40
237.50
276.00
189.50
260.00
161.00
154.50
164.00
144.00
154.50
89.00
147.50
171.50
123.00
181.50
191.00
71.00
118.00
167.50
106.00
128.00
108.00
83.00
81.00
174.00
103.00
76.00
79.00
81.00
91.00
135.00
76.00
110.00
112.00
94.00
112.00
48.00
156.00
114.00
147.00
112.00
68.00
163.00
109.00
82.00
87.00
60.00
94.00
Length, m Ts °C
0 to1 357 248 332 335 342 338
1 to 2 354 245 236 242 237 248
2 to 3 254 246 235 266 249 272
3 to 4 248 242 239 294 285 276
4 to 5 248 221 232 234 237 242
5 to 6 222 218 217 221 215 210
6 to 7 210 214 222 226 216 209
7 to 8 210 215 198 202 208 210
8 to 9 242 202 238 235 232 228
9 to 10 243 201 228 232 235 230
10 to 11 212 180 208 214 164 199
11 to 12 208 160 175 201 205 199
12 to 13 199 174 202 206 205 201
13 to 14 209 188 206 203 205 199
14 to 15 242 218 222 236 222 230
15 to 16 245 253 249 251 242 239
16 to 17 240 243 253 247 251 266
17 to 18 264 258 272 266 265 269
18 to 19 246 255 247 253 249 251
19 to 20 280 230 275 283 205 290
20 to 21 272 281 250 236 279 286
21 to 22 284 286 287 250 201 232
22 to 23 292 296 293 223 242 317
23 to 24 216 219 222 248 242 245
24 to 25 232 244 260 264 242 245
25 to 26 282 256 262 258 280 266
26 to 27 290 272 284 276 262 286
27 to 28 284 282 290 293 246 296
28 to 29 282 268 264 258 242 364
29 to 30 268 282 269 273 280 285
30 to 31 248 252 250 253 275 264
31 to 32 240 252 250 244 247 253
32 to 33 236 253 254 242 285 248
33 to 34 236 253 244 242 271 243
34 to 35 230 232 236 239 235 225
35 to 36 243 228 236 232 235 240
36 to 37 238 222 232 179 235 233
37 to 38 216 242 238 236 218 222
38 to 39 232 224 216 219 222 218
39 to 40 221 204 222 224 201 192
40 to 41 232 218 216 219 217 220
41 to 42 196 186 188 190 192 189
42 to 43 189 175 189 186 188 187
43 to 44 181 160 178 182 180 182
44 to 45 171 160 169 172 168 165
°C AVG, Ts °C
329 324 330 332 326.7
235 243 257 249 254.6
284 278 275 288 264.7
300 292 289 233 269.8
229 230 233 234 234
208 213 215 219 215.8
215 214 220 216 216.2
202 208 206 201 206
233 236 230 233 230.9
226 232 228 225 228
202 206 210 214 200.9
195 206 203 198 195
198 196 200 198 197.9
202 203 200 205 202
242 228 239 241 232
243 245 250 248 246.5
264 250 264 270 254.8
256 266 252 261 262.9
250 247 256 252 250.6
296 299 285 283 272.6
227 302 298 286 271.7
279 286 233 228 256.6
238 236 225 232 259.4
232 236 237 240 233.7
240 252 250 249 247.8
271 273 255 266 266.9
276 264 280 271 276.1
280 278 284 285 281.8
275 281 284 279 279.7
272 275 270 264 273.8
263 256 258 263 258.2
246 248 254 272 250.6
260 256 249 251 253.4
239 242 249 232 245.1
228 231 227 230 231.3
180 231 233 172 223
238 235 234 174 222
225 218 221 224 226
215 219 214 217 219.6
194 223 225 223 212.9
218 221 219 216 219.6
191 193 190 189 190.4
186 188 189 185 186.2
179 180 174 178 177.4
168 166 159 163 166.1
 Clinker
Surface Area,
Cyclones Production Ts, ◦C Ta, ◦C
m^2
kg/hr
Cyclone -1 115.37 41875.00 119.72 27
Cyclone -2 105.69 41875.00 130.72 27
Cyclone -3 119.8 41875.00 127.33 27
Cyclone -4 131.93 41875.00 148.94 27
Cyclone -5 126.42 41875.00 146.00 27
Cyclones Total Heat Loss

Feed Pipes
Feed Pipe - 1 8.92 41875.00 104.56 27
Feed Pipe - 2 10.68 41875.00 118.78 27
Feed Pipe - 3 11.86 41875.00 116.06 27
Feed Pipe - 4 26.75 41875.00 131.72 27
Feed Pipe - 5 37.18 41875.00 145.67 27
Total Feed Pipes

Riser Ducts
RD 2 -1 69.23 41875.00 104.8333 27
RD 3 -2 72.46 41875.00 104.89 27
RD 4 -3 76.013 41875.00 117.33 27
RD 5 -4 79.756 41875.00 132.56 27
Total Riser Ducts Heat Loss

CV Furnace 59.49 41875.00 217.81 27

Mixing Chamber 37.154 41875.00 115.33 27

PC 185.1773 41875.00 156.33 27

Kiln Inlet Hood 16.7104 41875.00 172.89 27

Kiln O/l Hood 23.5746 41875.00 112.40 27

Kiln O/l Hood

Kiln I/L Hood
Ts, K Ta K (Ta+Ts)/2 (Ts,K - Ta, K) Ts, K ^4 Ta, K^4 A

392.72 300 346.36 92.72 23787122341.4792 8100000000.00 0.01

403.72 300 351.86111 103.7222 26566272335.4435 8100000000 0.01
400.33 300 350.16667 100.3333 25685440059.2716 8100000000 0.01
421.94 300 360.97222 121.9444 31697214031.7847 8100000000 0.01
419.00 300 359.5 119 30821664721.0000 8100000000 0.01

377.56 300 338.77778 77.5556 20319988619.2983 8100000000 0.01

391.78 300 345.88889 91.7778 23559127041.7583 8100000000 0.01
389.06 300 344.52778 89.0556 22911128703.2853 8100000000 0.01
404.72 300 352.36111 104.7222 26830465277.7837 8100000000 0.01
418.67 300 359.33333 118.6667 30723701620.9383 8100000000 0.01

377.83 300 338.91667 77.8333 20379854495.0008 8100000000 0.01

377.89 300 338.94444 77.8889 20391843525.9261 8100000000 0.01
390.33 300 345.16667 90.3333 23213603457.7901 8100000000 0.01
405.56 300 352.77778 105.5556 27052127152.8730 8100000000 0.01

490.81 300 395.40278 190.8056 58028037081.0118 8100000000 0.01

388.33 300 344.16667 88.3333 22741477785.4938 8100000000 0.01

429.33 300 364.66667 129.3333 33976483890.5679 8100000000 0.01

445.89 300 372.94444 145.8889 39528160216.5159 8100000000 0.01

385.40 300 342.70139 85.4028 22062735678.4607 8100000000 0.01

 Radiation
Convection Losses, Total Surface Losses
B Losses, Kcal/kg-clinker
Kcal/hr*m^2 (Kcal/hr*m^2)
Kcal/hr*m^2
419.04 488.11 627.48 1115.59 3.07
486.58 560.35 738.65 1299.00 3.28
465.51 537.96 703.42 1241.38 3.55
603.75 682.53 943.89 1626.42 5.12
584.39 662.61 908.87 1571.47 4.74
19.77

330.26 390.91 488.80 879.71 0.19

413.36 481.97 618.37 1100.33 0.28
397.10 464.33 592.45 1056.77 0.30
492.85 566.98 749.22 1316.20 0.84
582.21 660.36 904.95 1565.30 1.39
3.00

331.84 392.66 491.19 883.85 1.46

332.15 393.01 491.67 884.68 1.53
404.71 472.60 604.54 1077.14 1.96
498.08 572.52 758.09 1330.60 2.53
7.48

1096.55 1160.51 1997.12 3157.63 4.49

392.81 459.66 585.66 1045.32 0.93

653.00 732.78 1035.06 1767.84 7.82

766.73 846.54 1257.13 2103.67 0.84

375.54 440.81 558.51 999.32 0.56

 Kiln Inlet Hood Shell Temperatu
148 194 178 188 191 179 190 184
Average Kiln Inlet Hood Shell Temperature, ◦C

Kiln Outlet Hood Shell Temperat

98 112 116 122 92 89 100 116
118 116 141 96 94 82 151 143
69 118 119 118 124 126 125 134
125 98 104 119 134 126 124 134
Average Kiln Inlet Hood Shell Temperature, ◦C

CV Furnace Shell Temperature

244 236 238 235 250 245 238 228
153 148 212 184 196 215 213 198
Average CV Furnace Shell Temperature, ◦C

PC Shell Temperature, ◦C
148 139 144 193 188 192 174 189
154 193 151 148 157 148 147 152
Average PC Shell Temperature, ◦C

Mixing Chamber, ◦C
132 136 140 135 112 118 126 110
Average CV PC Shell Temperature, ◦C

Riser Duct 2 -1 Shell Temperatu

99 115 116 115 118 120 111 109
Average Shell Temperature, ◦C

Riser Duct 3-2 Shell Temperatu

102 108 103 105 99 108 98 106
Average Shell Temperature, ◦C

Riser Duct 4-3 Shell Temperatu

118 103 106 96 131 125 121 118
Average Shell Temperature, ◦C

Riser Duct 5-4 Shell Temperatu

110 155 118 120 116 128 130 125
Average Shell Temperature, ◦C

Cyclone - 1 Shell Temperature

117 115 114 116 115 132 129 133
Average Shell Temperature, ◦C

Cyclone - 2 Shell Temperature

135 125 222 120 124 132 126 129
 Average Shell Temperature, ◦C

Cyclone - 3 Shell Temperature

122 127 125 135 138 142 138 135
Average Shell Temperature, ◦C

Cyclone - 4 Shell Temperature

160 149 165 158 136 140 149 145
Average Shell Temperature, ◦C

Cyclone - 5 Shell Temperature

148 146 157 161 153 148 138 129
Average Shell Temperature, ◦C

Feed Pipe - 1 Shell Temperatur

108 110 111 108 110 111 109 108
Average Shell Temperature, ◦C

Feed Pipe - 2 Shell Temperatur

134 128 142 127 134 130 143 126
Average Shell Temperature, ◦C

Feed Pipe - 3 Shell Temperatur

112 118 112 126 119 118 96 136
Average Shell Temperature, ◦C

Feed Pipe - 4 Shell Temperatur

130 126 127 135 136 132 134 133
Average Shell Temperature, ◦C

Feed Pipe - 5 Shell Temperatur

154 142 154 151 148 147 148 152
Average Shell Temperature, ◦C
 Kiln Inlet Hood Shell Temperature, ◦C
176 186 202 198 179 187 96 112 160 164
Hood Shell Temperature, ◦C 172.89

Kiln Outlet Hood Shell Temperature, ◦C

96 94 82 151 141 143 116 121 123 122
116 121 123 122 117 96 97 87 84 78
136 64 118 74 86 100 104 164 153 96
112 104 98 132 124 111 88 74 125 117
Hood Shell Temperature, ◦C 112.40

CV Furnace Shell Temperature, ◦C

236 223 231 218 224 229 225 227 219 232
212 227 222 195 215 189 211 216 231 226
ace Shell Temperature, ◦C 217.81

PC Shell Temperature, ◦C
156 173 182 164 158 136 147 139 133 156
128 155 149 148 136 156 149 152 143 151
Shell Temperature, ◦C 156.33

Mixing Chamber, ◦C
116 86 78 79 84 160 144 98 92 130
C Shell Temperature, ◦C 115.33

Riser Duct 2 -1 Shell Temperature, ◦C

90 93 91 88 94 106 103 105 108 106
hell Temperature, ◦C 104.8333

Riser Duct 3-2 Shell Temperature, ◦C

112 109 110 112 94 107 104 98 101 112
hell Temperature, ◦C 104.89

Riser Duct 4-3 Shell Temperature, ◦C

120 124 125 128 122 118 127 120 108 102
hell Temperature, ◦C 117.33

Riser Duct 5-4 Shell Temperature, ◦C

130 125 148 153 126 132 128 135 155 152
hell Temperature, ◦C 132.56

Cyclone - 1 Shell Temperature, ◦C

137 113 109 135 128 111 110 99 107 135
hell Temperature, ◦C 119.72

Cyclone - 2 Shell Temperature, ◦C

126 117 118 122 120 123 138 132 118 126
hell Temperature, ◦C 130.72

Cyclone - 3 Shell Temperature, ◦C

127 133 122 126 129 142 136 98 92 125
hell Temperature, ◦C 127.33

Cyclone - 4 Shell Temperature, ◦C

157 160 146 140 148 161 136 139 153 139
hell Temperature, ◦C 148.94

Cyclone - 5 Shell Temperature, ◦C

131 136 152 153 144 160 136 135 144 157
hell Temperature, ◦C 146.00

Feed Pipe - 1 Shell Temperature, ◦C

99 107 109 113 99 103 98 104 88 87
hell Temperature, ◦C 104.56

Feed Pipe - 2 Shell Temperature, ◦C

128 136 145 96 88 128 74 115 88 76
hell Temperature, ◦C 118.78

Feed Pipe - 3 Shell Temperature, ◦C

138 129 115 138 133 121 114 84 76 104
hell Temperature, ◦C 116.06

Feed Pipe - 4 Shell Temperature, ◦C

132 155 148 150 159 141 109 103 109 112
hell Temperature, ◦C 131.72

Feed Pipe - 5 Shell Temperature, ◦C

155 149 142 143 148 152 124 154 121 138
hell Temperature, ◦C 145.67
 Flow Rate Flow Rate Clinker Production
Fan No. Dia, M Area M^2 Fan Flow M/s
(m^3/s) (m^3/hr) (67 TPH), KG
11 0.48 0.181 24.98 4.5183 16265.9216 41875.00
12 0.7 0.385 16.10 6.1929 22294.314 41875.00
13 0.6 0.283 21.80 6.1607 22178.448 41875.00
14 0.64 0.322 24.52 7.8835 28380.5212 41875.00
15 0.64 0.322 16.20 5.2092 18753.0318 41875.00
16 0.64 0.322 5.09 1.6366 5891.82566 41875.00
Total 113764.062 41875.00

Cooler Outlet Clinker Temperature

e^(-Vair/0.77)=Tco-Tam/Tci-Tamb
 1.10989010989011

m^3/Kg- Flow Rate

Nm^3/kg-Clinker Kg-Air/Kg-Clinker Fan No.
Clinker (Nm^3/hr)
0.3884 12579.98579 0.3004 0.407 11 12
0.5324 17242.31555 0.4118 0.557 26.3 16.5
0.5296 17152.70534 0.4096 0.554 25.5 16
0.6777 21949.359 0.5242 0.711 26.2 16.9
0.4478 14503.50489 0.3464 0.468 25 17.3
0.1407 4556.709717 0.1088 0.147 25.5 16.5
m/s
2.7168 87984.58028 2.1011 2.844 26.3 16.3
28 16.6
27 16.5
28 16.2

Temperature 26 16.3

m/Tci-Tamb Avg, m/s 24.98182 16.10

Fan No.
13 14 15 16
21.8 26 16 4.8
23.5 25 17.7 5.2
22.5 26 15.8 4.4
23.5 25 16.9 5.4
23 26 17.4 5.1
22 23 16.9 4.9
23 27.7 16 4.8
21.5 26 17.2 5.7
23.5 25 14.2 5.4
22.5 26 15.11 5.2
21.80 24.52 16.20 5.09
 KC & PC Coal Firing Blowers
Fan Flow Flow Rate Flow Rate
Fan No. Amps RPM Area M^2
M/s (m^3/s) (m^3/hr)

1100 BL-2 0.265 2.9 0.7692 2768.949

1100 BL - 3 0.265 2.95 0.7824 2816.6895

Total 5585.6385

PA Blower
Fan Flow Flow Rate Flow Rate
Fan No. Amps RPM Area M^2
M/s (m^3/s) (m^3/hr)

500 BL-1 24 900 0.265 1.19 0.316 1136.117

oal Firing Blowers
Clinker
m^3/Kg- Flow Rate Nm^3/kg- Kg-Air/Kg-
Production
Clinker (Nm^3/hr) Clinker Clinker
(67TPH), KG

41875.00 0.0661 2141.4919 0.0511 0.0855

41875.00 0.0673 2178.4142 0.0520 0.0870

41875.00 0.1334 4319.9060 0.1334 0.1725

A Blower
Clinker m/s
m^3/Kg- Flow Rate Nm^3/kg- Kg-Air/Kg-
Production
Clinker (Nm^3/hr) Clinker Clinker
(67 TPH), KG
41875.000 0.027 878.667 0.021 0.035

Avg, m/s
1100 BL-2, KC Firing 1100 BL-3 PC Firing
500 BL-1 PA Blower
Blower Blower
3.1 3.1 1.05
3.05 2.95 1.15
2.8 3 1.15
2.85 3.1 1.8
m/s
3.5 2.85 0.75

2.4 2.95 1.2

2.8 2.9 1.3
2.75 3 1.25
2.8 2.85 1.2
2.95 2.8 1.05
2.9 2.95 Avg, m/s 1.19
 Cyclone T&P Profile
Temperature, Static Pressure,
Location
◦C MMWG
Cy-5 Riser Duct 836 209
Cy-4 Riser Duct 760 253
Cy-3 Riser Duct 637 287
Cy-2 Riser Duct 423 326
Cy-1 Riser Duct 338 401
Calciner O/L 850 145

Gas Composition
Gas Composition, Downcomer
Cyclone -1 O/L Calciner O/L Kiln I/L
% Duct
O2 3 3.6 6.95 3.5
CO2 16.3 18.8 11.6 15.8
CO2, PPM 156 426 1068 185
Nox, PPM 434 489 352 454
RMBH Fan I/L
Duct
12
8.2
136
218