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Flow Measurements

This document discusses calculating gas quantities for a cement production process. It provides details on: 1) Calculating air required for combustion of fuel oil used in the kiln, which is found to be 154,301 Nm3/hr. 2) Calculating smoke gas quantity from the kiln and preheater, found to be 186,567 Nm3/hr total. 3) Breaking this total gas quantity down into components from the kiln (54,308.9 Nm3/hr) and preheater (111,375 Nm3/hr).

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Hazem Diab
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1K views19 pages

Flow Measurements

This document discusses calculating gas quantities for a cement production process. It provides details on: 1) Calculating air required for combustion of fuel oil used in the kiln, which is found to be 154,301 Nm3/hr. 2) Calculating smoke gas quantity from the kiln and preheater, found to be 186,567 Nm3/hr total. 3) Breaking this total gas quantity down into components from the kiln (54,308.9 Nm3/hr) and preheater (111,375 Nm3/hr).

Uploaded by

Hazem Diab
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Gas Quantities Of Dry Pyroprocess

Example: Cement factory, with nominal production of : 1 million ton/year.

The kiln will be fired with liquid fuel oil ( mazout ),


and the fuel consumption is 950 kcal/kg clinker. the lower calorific value of the oil is 9600 kcal/kg fuel

Calculate the following :


1- Air quantity required for combustion. 2- Smoke gas quantity in both kiln, preheater.

Solution :
1 Million ton/year = 3300 ton clinker / day Fuel Consumption = 950 kcal/kg clinker Lower calorific value of mazout = 9,600 cal/kg fuel The production = 3,300 * 1,000 / 24 = 137,500 kg clinker /hr

Total heat consumption = 137,500 * 950 =130,625,000 kcal/hr


The amount of mazout = 130,625,000 / 9600 = 1,3606.8 kg Oil/hr Air required for combustion = : Lo = [ (9600 - 1115) / 808 ] = 10.5 Nm3/kg oil

where :

Lo = the required combustion air.


Hu = lower heat value ( 9600 Kcal/kg for fuel oil ) Lo = [ (9600 - 1115) / 808 ] = 10.5 Nm3/Kg oil. Excess air for safe combustion is required say 8%

1.08 x 10.5 = 11.34 Nm3/Kg fuel. That means per hour: 11.34 x 13606.8 = 154,301 Nm3 air / hr.

The calcinations process asks for the smoke or exit gas quantity

Vo = [ ( 1.25 Hu - 3025 ) / 808 ] Nm3/Kg oil (fuel).


where Vo = The produced smoke gas volume. Vo = [ ( 1.25 x 9600 - 3025 ) / 808 ] = 11.11 Nm3/Kg fuel. = 11.11 x 13606.8 = 151,139.9 Nm3 / hr. ------------ ( 1 )

Unfortunately the cement process is a chemical , physical

process & by the declination the bounds CO2 will be volatiled


The atom weight of the elements in calcium carbonate CaCo3 Calcium Ca = 40 Carbon C = 12 Oxygen O = 16

There fore CaCo3 = 40 + 12 + 3 x 16 = 40 + 12 + 48 = 100 .


The decalcined carbonate is called Quick Lime or burnt lime and its formula is :

CaO = 40 + 16 = 56

From 100 carbonate remain 100 - 56 = 44 are volatiled and escape jointly the smoke or exit gas.

False Air : (Kiln)


Assuming 0.5 % O2 at the kiln up stream.

O2 % 0.5 The false air = 21 O % = = 2.5 % 21 0.5 2 Total false air = [ ( 2.5 / 100 ) x 151139.9 ] = 3778.5 Nm3 / hr. ------------- ( 2 )
Assuming calcinations in kiln is 15 % , and L.O.I ( Loss In Ignition ) 35 % Kg Co2 Kg clinker.

Total volatiled Co2 in kiln = ( 35 % / 1.977 ) x 15% x 137500 Kg clinker / hr.

= 3651.4 Nm3 Co2 / hr. --------------------------------------- ( 3 )

We have 35 - 40 % firing in kiln . from the total firing,


and 60 65 % firing in preheater from the total firing.

Kiln smoke gases


= [ ( 40 /100 ) x 151139.9 ] = 60456 Nm3 / hr. --------------------- ( 4 ) Total kiln gases =(2)+(3)+(4) = 3778.5 + 3651.4 + 60456 67885.9 Nm3/ hr.

If we have by-pass 20 % The by-pass gases = [ 67885.9 x ( 20 / 100 ) ]

13577 Nm3 / hr.


Total kiln gases excluding by pass gases = 67885.9 - 13577 = 54308.9 Nm3 / hr. ----------- ( 5 )

Total smoke gases in preheater


= [ ( 60/100 ) x 151139.9] = 90684 Nm3 / hr. ------- ( 6 )
Assuming calcinations in preheater is 85 % and L.O.I = 35 %

False Air : (Preheater)


Assuming O2 content after preheater is 5 %

O2 % - 2 0.5 The false air = = = 2.5 % 21 O2 % 21 0.5

Total volatiled Co2 in preheater =


= [ ( 35% / 1.977 ) x 85% x 137500 ] kg clinker / hr = 20691 Nm3 / hr. --------------------------------- ( 7 )

Total smoke gases in preheater + CO2 = 90684 + 20691 = 111375 Nm3/hr Total false air in preheater : = [ ( ( 5 - 2 ) / ( 21 - 5 ) ) / ( 90684 + 20691 ) ] = [ ( 3 / 16 ) x 11375 ] 20883 Nm3 / hr. -------- ( 8 )

Total gases after preheater

=5+6+7+8 = 54308.9 + 90684 + 20691 + 20883 = 186,567 Nm3 / hr.

Determination of the Gas Conditions in the main duct

Static Pressure as Under pressure

Static Pressure as Over pressure

Selection of a suitable Sampling position

Determination of
measuring points in Circular

ducts

Prandtl tube

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