Pyro Process Production Counters readings

during Performance Guarantee Test

Date : 15.09.10 at 9.00hrs to 18.09.10 14.00hrs

Kiln Running Hours 72 Hrs

Total Kiln Feed Consumption 22348 MT

kg Kiln
feed/kg
Kiln Feed - Clinker factor 1.65 clinker

Clinker Production 13544 MT

Kiln Coal Consumption 797.05 MT

PC Coal Consumption 1060.2 MT

Net Calorific Value of coal 5109 Kcal/kg coal

Sp.Fuel Consumption 701 KCal/Kg clinker

performance of at different-2 kiln feed to clk factor

% Coal Ash
12.74 12.74 12.74 12.74

LOI 35.50 35.50 35.50 35.50

Dust loss 8.00 6.00 4.00 3.00

factor 1.65 1.62 1.59 1.57

Total KF Consumpton 22348.00 22348.00 22348.00 22348.00

Total Clk Prod. 13544.24 13812.11 14090.79 14234.39

Clk Prod.(TPD) 4514.75 4604.04 4697 4745

Total Coal Consumption 1857.25 1857.25 1857.25 1857.25

CV Of Coal On fired Basis 5109.00 5109.00 5109.00 5109.00

Sp.Heat consumption 700.57 686.98 673.40 666.60

Sp.Electrical Energy Cons. 13.20 12.94 12.69 12.56

Date 16th Sep, 2010 Total power for 17th Sep, 2010 Total power for

Time 0:00 24:00:00 24:00 hrs 0:00 24:00:00 23:00 hrs

Preheater Fan 955111 983416 28305 983416 1009482 26066

Kiln main drive 423812 430918 7106 430918 437319 6401

Cooler Fans including vent Fans 1797604 1819925 22321 1819925 1838909 18984
Cooler drives including cooler
breaker 2577 2470

Baghouse fan 5253 5125

Kiln Feed 8245

7732

Kiln Aux 1889

1814

Coal Firing 5491

5272

Compressor 3319 3216

3600 3350
Clinker Transport

Total power 88106 80429.625

Production 4515 4230

Specific power consumption 19.51 19.02

RAWMEAL TO CLINKER FACTOR CALCULATIONS
UINT
1 CLI KKER PRDN RAT = 188.1 TPH 4515 TPD
2 Coal %ASH = 12.74 %
3 C.V = 5109 KCALS / KG
4 RAWMEAL % MOIST = 0.5 %
5 RAWMEAL LOI = 35.5 %
6 ESP DUST LOI = 32 %
PH DUST LOSS = 8 %
7 PH DUST LOSS = 22.8 TPH
8 STACK DUST CONCN= 0.03 GM / NM3
9 STACK AIR VOLUME = 386000 NM3 / HR
10 SPECIFIC HEAT CO = 700 KCALS / KG OF CLINKER

(8)x(9)
11 DUST LOSS THRO C = ----------
1000

= 12 KG / HR

BY PASS DUST ( @ 48= TPH

11 TOTAL DUST LOSS = 0.01 TPH

-10
12 SPECIFIC COAL CO = -----------
-3

= 0.137 KG COAL/ KG OF CLIN.

(2)x(12)
13 SPECIFIC ASH AB = -----------
-100

= 0.0175 KG ASH / KG OF CILN.

(1-(13))
14 RAWMEAL TO CLINK = -----------
(1-((5)/100))

= 1.52 0.66
(7)+((11))
15 PH DUST LOSS(COR = ----------------------
(1 - ((5)-(6)/100))

= 23.6 TPH
 (14)X(1)+(15)
16 KILN FEED TO CL = -----------
-1

= 1.65 0.606
 PYRO PROCESSING SYSTEM PERFORMANCE GUARANTEE TEST RESULTS

Buyer DALMIA CEMENT (BHARAT) LTD. ARIYALUR, TN

Location ARIYALUR, TN, INDIA
CONTRACT NO. DCBL/PLANT2/PYRO/06-07/001 DTD 21.03.2007
Equipment FIVE STAGE ILC PREHEATER, KILN 4.35 X 67, SF 4X5 COOLER

The PG Test for Pyro processing system was conducted from 15.09.10 - 18.09.10 for 72 hours duration.
The guaranteed and achieved values are mentioned below.

Parameter Unit Guaranteed Value Achieved value

Clinker Capacity MTPD 4500 4515
Sp. Heat Consumption Kcal/kg Clinker 708 701
Specific Power Consumption Kwh/Ton Clinker @ meter 15.3 13.20
Accuracy of Fine coal feedrate % +/- 1% +/-1%
Clinker Temperature Deg C 65+ambient 112 (76 + ambient)
Note :
Equipment included in specific power guarantee are Preheater Fan, Kiln main drive, Cooler Fans, Cooler drives, Hammer crusher & Cooer Vent Fan.

For DCBL For FLS