QUESTIONNAIRE FOR PYROPROCESSING

MODIFICATION
COMPANY NAME
LOCATION AND
ADDRESS
1

Plant Altitude (M)

Relative Humidity (%)
Ambient Temperature Range (oC)

Describe Kiln System and specify type

Long, wet
4-stage SP
4-STAGE SP
5-stage Precalciner
6-Stage Precalciner
Others
Existing clinker production
DESIGN
3000

MTPD

Long, dry
4-stage Precalciner
4-stage W/riser duct
Burning

NORMAL
4400

MAXIMUM
MTPD

4500

MTPD

Existing fuel consumption

NORMAL
810

MAXIMUM
kcal/kg

820

kcal/kg

PREHEATER
5

How many strings are there in your preheater? :- ONE

How many stages are there in your preheater? :-FOUR

What are the different vessel diameters?

Stage 1 (Top)
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6 (Bottom)

String One
6300 MM
7400 MM
8200MM
8200MM
---------

String Two

Please enclose a sketch of Cyclone and provide dimensions as per Annexure I.

What are the inlet and outlet areas of each vessel?

String One (m2)
Stage 1 (Top)
Stage 2
Stage 3

String Two
(m2)

IN 10.57662 M2
OUT 7.0225 M2
IN 12.1104 M2
OUT 10.75 M2
IN 14.4648 M2
OUT 12.1922 M2

Stage 4
Stage 5
Stage 6 (Bottom)
8

IN 18.29 M2
OUT 12.1922M2
------This data is essential and please fill completely.

Are there any crisscrossing? If yes, please explain

NO

Type of Precalciner
Size : Diameter (m) x Height (m)
% Calciner Achieved :
LOI of Raw Meal to Kiln:
% of fuel fired in Precalciner
Quantity of fuel fired in Precalciner (TPH):

:- 8.2M DIA. X 11.36M

:- 90%
:- 35%
:- 60-65%
:- 15-20 (TPH)

10

If system does not have a calciner, is there any firing in the riser duct?
N.A.
If yes, what percentage?

11

Please provide a pressure and temperature profile across the preheater in each stage.
Preferably attach a sketch showing exactly the measurement points.

12

A.

Preheater Fan (provide fan characteristic curves) String I

Static Pressure (mmWG or in WG)

Design
802 MMWG

Operating
800 MMWG

Volume (am3/Hr or ACFM)

712800 M3/HR

730000 M3/HR

Temperature (oC or oF)

390C

390C

Fan Drive Type

Fan Drive kW (Design & Absorbed)

Fan Drive Max. Amps

COUPLING
GEARED GC109 TRULINE
2500KW
252 AMP

2350KW
230AMP.

Fan Drive Normal Amps

230 AMP.

230AMP.

Normal Fan Damper & Speed

100% DAMPER
991 RPM
VARIABLE
SPEED

Specify as Damper Controlled or

Variable Speed

12

3.15 M. for
68.14 M. Length

100% DAMPER
920RPM

3.15 x 3.81
oblong dia for 38
M. from bottom
& remaining
30.14 M. length
duct dia is 3.15
M.

B.

Down comer duct diameter

C.

Preheater Fan (provide fan characteristic curves) String II N.A.

Design
Static Pressure (mmWG or in WG)
Volume (am3/Hr or ACFM)
Temperature (oC or oF)
Fan Drive Type
Fan Drive kW (Design & Absorbed)
Fan Drive Max. Amps
Fan Drive Normal Amps

Operating

Normal Fan Damper & Speed

Specify as Damper Controlled or
Variable Speed
Down comer duct diameter

FUEL FIRED IN PRE CALCINER

13

Give typical analysis and heating values for each. Please specify as low heat value
or high heat value.
(As fired)
(As fired)
Solid Fuel
Fuel
Indonesian Coal
Type
%
Type
Volatile Matter
40%
%
%C
Fixed Carbon
%
%H
Sulphur
0.75
%
%O
Water
TOTAL 18.0% %
%H2O
Ash

14%

%S

HHV (dry basis)

6050

kcal/kg

%Ash

LHV

kcal/kg

NCV
kcal/kg
NOTE: If more than one type of fuel is fired simultaneously, please specify fuel
split. Ultimate analysis is important and please fill all the data.
B

Maximum and minimum raw coal moisture content

MAXIMUM MOISTURE CONTENT 12-15 % MINIMUM MOISTURE CONTENT
9-10%

Do you use waste derived fuels (fires, solvents, etc.,)? If so please specify type and
give typical analysis and heating value for each.
Do you use waste derived fuels (fires, solvents, etc.,)? If so please specify type and
give typical analysis and heating value for each.

N.A.
D

If solid fuels are burned, what type of firing system exists for kiln and calciner?
(e.g. Direct, Indirect, Semi direct, FK pump). Provide sketch if possible..
INDIRECT WITH F.K.PUMP

15-20
Capacity of Pre calciner Firing System (TPH)
Type of Fuel Metering System

IMPACT SANKHYO FLOW

METER

14

Is there a tertiary duct from cooler / kiln hood to precalciner

T.A.DUCT FROM COOLER

Yes
No
Yes

Tertiary Air Duct Take off

No

Kiln Hood
TAKE OFF FROM COOLER

Cooler
What size is the duct?

Dia 2650 mm OD x 67322 mm length

Type of Damper in Tertiary Air Duct : No

Pressure drop in Tertiary Air Duct (mmWg)

15

Drawings to be enclosed for Preheater modification

1) GA of Preheater building
2) Floor plans of Preheater building with openings

KILN
16

Kiln Dimensions

A)

Length (m)

67.07M

Kiln Speed (rpm)

Diameter (m)

4.572M

Kiln Slope (%)

Year Commissioned

1982

Kiln Drive HP

B)

Installed Power

522

KW

C)

Operating Power

337

KW

D)

Drive details
Main Gear

Number of teeth
Face Width
Helix angle

Min.
Operating
Max.

0.40
4.0
4.0

4.0%
700HP

UNIT
NO.
MM
DEGREE

256
775
6 18 RH

Pinion

Normal pressure angle

Tooth hardness
Normal module or diametrical pitch

DEGREE
BHN
MM

25
200-220
1.0/25.4

Quantity
Number of teeth
Face Width
Helix angle
Normal pressure angle
Tooth hardness
Normal module or diametrical pitch
Bearing Size

NO
NO
MM
DEGREE
DEGREE
HB
MM

Bearing centerline to centerline

dimension

MM

1.0
19
787.4
6 18 LH
25
310-360
25.4
23152CA/C3
/W33
1621.66

Low Speed
Coupling

UNIT
Manufacturer
Size
Rating

CONCORD
GC-D-2014C
KW

Main Reducer
Manufacturer
Size of model
Ratio
Power rating
Service factor

KW

FLENDER
SZN 710(SPL)
20.628:1
745.7
2.4

High Speed
Coupling
Manufacturer

WELLMAN
BIBBY
432-B
2.4 HP/RPM

Size
Rating
Main Motor
Full Speed rpm
Full power rating
Auxiliary Drive
Clutch or
Decoupling
Device

n-1
KW

1150
525

KW

MARLON CO.
USA
CESU-12M,
SIZE - 75
29.8

Manufacturer
Size
Rating
Servicing factor

Auxiliary Reducer

Manufacturer
Size or model
Ratio
Power rating
Service factor

KW

FALK
CORPORATION
75 CB3-12A
39.28:1
29.8
1.22

Backstop
Manufacturer
Size
Rating

N-m

MARLAND USA
CEBMAG-5C-W
245 AT CAM
SHAFT

Service factor
Auxiliary Motor
Speed
Power

RPM
KW

1460
29.8

E) REFRACTORY
Calcination
R-63 & HA60
220MM

Type
Thickness

Sintering
HA-70
220MM

Cooling
S-65 ALMAG-85
220MM

F) THRUST ASSEMBLY:
Type

: VERTICAL THRUST ROLLER 26 x 8 SIZE

G) THRUST ASSEMBLY:
Feed End
: VERTICAL THRUST ROLLER 26 x 8 SIZE
Discharge End
: VERTICAL THRUST ROLLER 26 x 8 SIZE
FUEL FIRED IN KILN
17

Give typical analysis and heating values for each. Please specify as low heat value
or high heat value.
(As fired)
(As fired)
Solid Fuel
Fuel
Type
INDONESIAN %
Type
Volatile Matter
40
%
%C
Fixed Carbon
%
%H
Sulphur
0.75
%
%O
Water
TOTAL 18%
%
%H2O
Ash
6.7%
%
%S
HHV (dry basis) 6050
kcal/kg
%Ash
LHV
kcal/kg
NCV
kcal/kg
NOTE: If more than one type of fuel is fired simultaneously, please specify fuel
split. Ultimate analysis is important and please fill all the data.

Do you use waste derived fuels (fires, solvents, etc.,)? If so please specify type and
give typical analysis and heating value for each.
NO

18

If solid fuels are burned, what type of firing system exists for kiln?
(e..g. Direct, Indirect, Semi direct, FK pump). Provide sketch if possible.
INDIRECT WITH F.K.PUMPS

Type of Kiln Burner

Capacity of Kiln Burner
Design NCV of fuel
% of Fuel fired in Kiln
Quantity of fuel fired (TPH)

40
6000
35-40%
7-8(TPH)

What is percentage of kiln primary air?

M.KCal./Hr.
K.Cal./Kg.

12%

volume
m3/Hr or
ACFM
3
Primary air fan capacity 13000. m /Hr. 32*C mmWG
19

a)
b)
c)
d)
e)
f)

Drawings:

General Arrangement drawing of Kiln

General Arrangement drawing of Kiln hood Layout
General Arrangement drawing of Fire hood
General Arrangement drawing of Feed end seal arrangement
General Arrangement drawing of Discharge end seal Arrangement
General Combined Arrangement drawing of Cooler, Kiln & Pre heater

20

OPERATING DATA
Kiln inlet

Pressure
20-40 mmWG

Temperature
1050-1100 oC

Kiln hood

5-7 mmWG

850 900 oC

COOLER
21

Cooler Dimensions
Make:
Type:
Size: