This document provides information for conducting a heat balance on a cement kiln system. It outlines the necessary inputs and outputs to the system including material flows, energy flows, and measurement procedures. Key steps in the heat balance include quantifying heat input from fuel combustion, heat outputs through exhaust gases, dust, evaporation, and radiation/convection losses, and ensuring total heat input equals total heat output. Measurement of gas flows, temperatures, material flows, and plant operating data are scheduled to collect the necessary input for calculating the heat balance.
This document provides information for conducting a heat balance on a cement kiln system. It outlines the necessary inputs and outputs to the system including material flows, energy flows, and measurement procedures. Key steps in the heat balance include quantifying heat input from fuel combustion, heat outputs through exhaust gases, dust, evaporation, and radiation/convection losses, and ensuring total heat input equals total heat output. Measurement of gas flows, temperatures, material flows, and plant operating data are scheduled to collect the necessary input for calculating the heat balance.
This document provides information for conducting a heat balance on a cement kiln system. It outlines the necessary inputs and outputs to the system including material flows, energy flows, and measurement procedures. Key steps in the heat balance include quantifying heat input from fuel combustion, heat outputs through exhaust gases, dust, evaporation, and radiation/convection losses, and ensuring total heat input equals total heat output. Measurement of gas flows, temperatures, material flows, and plant operating data are scheduled to collect the necessary input for calculating the heat balance.
This document provides information for conducting a heat balance on a cement kiln system. It outlines the necessary inputs and outputs to the system including material flows, energy flows, and measurement procedures. Key steps in the heat balance include quantifying heat input from fuel combustion, heat outputs through exhaust gases, dust, evaporation, and radiation/convection losses, and ensuring total heat input equals total heat output. Measurement of gas flows, temperatures, material flows, and plant operating data are scheduled to collect the necessary input for calculating the heat balance.
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HEAT BALANCE
Necessity
To Establish the Specific heat
consumption To Find out the areas of heat losses To Quantify the losses Taking Energy
Steps
to
Conserve
Thermal
Procedure
HEAT BALANCE
CALCULATION
ENERGY FLOWS
MATERIAL FLOWS
BOUNDARY
Boundary
HEAT BALANCE
Material Flow PH Exhaust
HEAT BALANCE Outputs Inputs
Raw meal
Fine Coal
Air
Cooling Air
Cooler Exhaust
Clinker
Energy Flow
HEAT BALANCE
PH Exhaust Raw meal
Input Loss
Radiation Fine Coal
Air Reaction Radiation Coolin g Air
Cooler Exhaust Radiation Clinke r
HEAT BALANCE Measurement Schedule Surface temperature of Preheater ,Kiln, & Cooler should be taken before and after trial Parallel measurement is required for Highly varying parameters like Gas flow, temperature, oxygen etc.
IMPORTANT AN UNINTERRUPTED LONG TRIAL PERIOD IS ALWAYS BENEFICIAL
Programme schedule Material Flow Measurement Frequency :- Every 1 Hours
Programme Air Flow Measurement schedule Frequency :- Every 6 Hours
Location
Parameter
PH exhaust
Temperature C
Cooler fan Air
Cooler Vent air Primary firing air Secondary firing air
Flow in Kg/hr
Device / Method o
Thermo meter Thermocouple
Anemometer Pitot tube
Plant Data
HEAT BALANCE
Kiln Size diameter
3.8:50 25
Ambient temperature Wind speed
::-
1.1 47
Site elevation MSL
:-
m long o
Km/hr m/sec m from
Material Flow
HEAT BALANCE
A. Kiln feed for 24 hours
Counter
8488 Final reading : 4000 Initial reading: 4488
Difference
T T
Q:
187
Kiln feed Hourly rate ( Q / 24 ) :
74 TPH Raw meal Temperature Raw meal Moisture %
0.16
C %
HEAT BALANCE
Material Flow B. Clinker Production Total weighed ( W ) :
2817.6 117.4
Hourly rate ( W / 24 ) : Kg per Sec
32.61
C. Raw meal to Clinker factor
KF Average TPH RMKF = ----------------------------------Hourly Clinker Prod. Rate
T TPH Kg /Sec 187
= -------------117.4 = 1. 5928
Material Flow
HEAT BALANCE
D. Recirculation dust (6 hours)
Measured
(W) :
Hourly rate ( W / 6 ) :
45
7.50
T TPH
Dust in Preheater exit gas in kg /kg clinker
7.5*1000
Dust Hourly rate * 1000
= -- -------------117.4 * = ----------------------------------1000 Clinker Hourly rate * 1000 Kg dust / Kg clinker
0.064
HEAT BALANCE
Material Flow B. Fuel used Coal + Pet coke Net Colorific Value :Moisture ( % )
:-
Ash content ( % )
:-
Sulpher S ( % )
:-
Firing System
:-
Coal Consumed
:-
7797 0.33 1.92 4.15 Indirect X
Kcal/kg coal % % %
Kg /Kg Clinker
HEAT BALANCE
Material Flow Clinker Analysis SiO2 Al2O3 Fe2O3
= = =
CaO MgO K2 O Na2O So3
= = = = =
LOI
21.56 5.56 4.17 64.19 1.79 0.55
% % %
% % 0.26 % 1.59 % 0.15 %
Basis 1 Kg Clinker at Temperature 0
Clinker Temperature measure at cooler out let
HEAT BALANCE
Gas Flow Measurement
Primary air
Measuring Equipment Anemometer - Measure at fan open inlet Pitot tube - Measure at intermediate duct Data to be measured if Pitot tube 0.250 Dia of the duct : 0 .049 Area of the duct : 103.5 Velocity Pressure ( Vp ) :
40
Air temperature : Density of standard air : 1.29
m m2 mm Wc C kg/Nm3 o
HEAT BALANCE
Gas Flow Measurement
Pitot tube
It has two coaxial tubes, the inner one has an open
end and the outer one has a closed end. The outer tube has a small holes on its surface. The center tube (+) Shows Total Pressure (TP) The Outer tube (-) Shows Static pressure (SP) If we connect both tube with manometer it Shows Velocity pressure (VP) The measuring point should be in a straight duct with uniform flow (5*D before and 2*D after)
HEAT BALANCE
Gas Flow Measurement
Pitot tube
HEAT BALANCE
Gas Flow Measurement
Primary air
47
Barometric pressure = 10333 * 2.71828-0.0001255 * H
10272
= 1.29
mm Wc
10272
800
40 * 273 * b + SP --------- ---------------0 1.206 273+ T 10333
Density correction =
= 0.98
Velocity m/Sec
= Kp
103. 5
9.81
40. 2
1.206
VP * 2 * g ------------------
HEAT BALANCE
Gas Flow Measurement
Primary air Volume
= =
0.049
Area
* Velocity
1.970 1.970
Mass of the air Kg/sec
40.2
m3 / Sec 1.206
= Volume
2.38
m3 /sec
* Density
Kg/ Sec
Like that we have to take measurement and
calculate the mass of air in all points
Gas Flow - Input
HEAT BALANCE
A. Coal firing Air Flow
2.380 Kiln Primary air= 0.293 Kg / Sec @ 40 o C Calciner air = 2.673 Kg /Sec @ 40 o C 2.673 / 32.61 = Total air = Kg /Sec @ 40 o C 0.82
Kg/Kg Clinker = B. Cooler Air flow rate6.19 Fan 1 flow = 9.78 kg / sec Fan 2 flow = 18.40 Kg / Sec Fan 3 flow = 20.60 Kg /Sec Fan 4 flow = 20.60 Kg / Sec Fan 5 flow = 77.29 Kg /Sec Total flow = 77.29/32.61 Kg /Sec @ 25 =
Gas Flow Out put
HEAT BALANCE
71.09
PH Exhaust mass Sec Temperature Air kg /Kg clinker
Heat of formation Heat in Preheater exit Loss through Gases Loss through dust Evaporation of raw meal moisture Evaporation of Coal moisture Loss due to Incomplete combustion Heat in discharge Clinker Heat in Cooler Exit Gas Radiation & Convection Losses
Heat Input
HEAT BALANCE
Coal combustion Heat in raw meal Heat in cooler Cooling air Heat in Primary air Sensible heat
Heat Balance
Total Heat input = Total Heat Output
HEAT BALANCE
Mean Specific Heats Between 0 and ToC
Specific Heat = A + B * T * 10-6 + C * T2 * 10-9 A
CO2
0.196
118
-43
H2 O
0.443
39
28
N2
0.244
22
O2
0.218
30
Air
0.237
23
Raw Meal
0.206
101
-37
Clinker
0.186
54
Coal
0.262
390
20
C 100
Evaporation of water at
HEAT BALANCE THEORATICAL HEAT OF FORMATION OF CLINKER + 64.29 Hf = + 7.646 * ---% CaO 491.56 + 1.79 + 6.48 * ---% Mgo 11.59 + 5.57% Al o + 2.2 * ---2
Wd *0.0230 Shd * ( Td 0 269 4 5 Tr ) = 3.97 Kcal / Kg Clinker Wd = Weight of dust in Kg/Kg clinker Shd = Specific heat of dust in Kcal / Kg C Td
= Temperature of Dust in
Tr =0.20 Reference Temperature in -6 Shd = A 6 + 101 B *269T *10 +-37 C ) = Kcal / Kg o C 0.2305
C2 (20 269 * T * 10-9
HEAT BALANCE
Heat Loss in PH Gases
Exit Gas composition
O2 = 2.8% ; CO2 = 26.3% ; CO =0.03 %
Balance assume as N2 = 100 (2.8+26.3+0.03) = 70.87 % The volume of one gram-molecular weight (Atomic weight) of any gas is 22.4 liters. Weight of the Gas element CO2 = (12.011 + (2*16))/22.4 = 1.9647 kg / Nm3 O2 = (2*16)/22.4 Nm3 CO = (12.011+16)/22.4 Kg/Nm3 N2 = (14.0067*2)/22.4 Nm3
= 1.42857 Kg / = 1.2505 = 1.2505 Kg /
HEAT BALANCE
Heat Loss in PH Gases
Total Weight of the Gas
CO2 = 1.9647 * 0.263
O2
= 0. 516
= 1.42857 * 0.028 = 0.04
CO = 1.2505 * 0.0003 0.000375 N2 = 1.2505 * 0.7087 Total weight per Nm3 1.442275
Wg *0.2402 Shg *269 ( Td 0 9 Tr ) = Kcal / Kg Clinker 140.85
HEAT BALANCE
Heat Loss in Raw meal moisture
0.0016
1.5928
Total Moisture =0.00254
Raw meal kg/kg clinker * % moisture = Kg water / Kg clinker 0.00254
597
1.52 Heat of Evaporation of Raw meal Moisture = Water Kg/kg clinker * Heat of evaporation Heat Loss in Fine coal moisture = Kcal / Kg clinker 0.0033 X Total Moisture = Fine coal kg/kg clinker * % 0.0033 X moisture = Kg water / Kg clinker 0.0033 X
597
Heat of Evaporation of Fine coal Moisture 1.97 X
HEAT BALANCE
Heat Loss in Incomplete combustion
The heat loss for in complete burning of Carbon
Is 2417 Kcal/kg of CO. % Weight of CO Gas = 0.026 wt % Amount of PH exhaust waste gases = 71.09 kg/sec Amount of CO = 71.09 *(0.026 /100) =0.01848 kg Kg/sec of CO Gas per kg of clinker= 0.01848 / 32.61 = 0.0005668 kg/kg Clinker Heat Loss in incomplete combustion = 0.0005688 * 2417 = 1.37
HEAT BALANCE
Heat Loss in Cooler Exhaust air
Heat loss in Air Tr )
1.22 = Wg
* Shg 0.2443
= 94.57
0.23
Shg = A 7 + B *316T 23 = Kcal / Kg 0.2443
*( 316
Td 0
Kcal / Kg Clinker
*10-6 o
Heat Loss in Clinker discharge
Heat loss in Air Tr ) 0.18
=1.0 Wm = 23.10
* Shg 0.1925
*( 120
Td 0
Kcal / Kg Clinker
Shcg = A 6 + 54 B *120T *10-6 = Kcal / Kg o C 0.1925
HEAT BALANCE Surface Losses Radiation Q = 4 * 10
( TS4 _ Ta4)
where,
Q - Heat in Kcal / hr m2 TS - Surface temperature in Kelvin's Ta - Ambient temperature in Kelvin's
