Kiln System Assessment Tool

Plant Saurastra cements limited

Existing option 1 option 1 A option-2 option-3 option-3 A option-4 option-4A
Kiln Length 60.96 60.96 60.96 60.96 60.96 60.96 60.96 60.96 m
Kiln ID 4.267 4.267 4.267 4.267 4.267 4.267 4.267 4.267 m
Bricks Thickness 0.22 0.22 0.22 0.22 0.22 0.22 0.22 0.22 m
Kiln ID (effective) 3.83 3.83 3.83 3.83 3.83 3.83 3.83 3.83 m
L/D 14.3 14.3 14.3 14.3 14.3 14.3 14.3 14.3
Production Rate 3991 4000 4000 4000 4200 4200 4500 4500 tpd
Kiln Slope 4 4 4 4 4 4 4 4 %
2.29 2.29 2.29 2.29 2.29 2.29 2.29 2.29 Degrees =ATAN(Slope%)*180/PI()
Kiln Speed 4 4.3 4.3 4.3 4.3 4.3 4.3 4.4 rpm
Heat consumption 3364.9 3167.186 3055.58 3272.94 3076.48 2969.305 3068.12 2963.62 kJ/kg_cli
Firing in main burner 31.0% 35.0% 35.0% 35.0% 35.0% 35.0% 35.0% 35.0%

Specific kiln volume load 5.7 5.70 5.70 5.70 5.99 5.99 6.42 6.42 t/dm3 for precalciner kiln
t/dm3 for SP with >= 4 stages
Specific burning zone area load 347 348 348 348 365 365 391 391 t/dm2 for precalciner kiln
t/dm2 for SP with >= 4 stages

Specific thermal burning zone load 3.6 3.8 3.7 4.0 3.9 3.8 4.2 4.0 Gcal/m2
Material residence time in the kiln 19.5 18.1 18.1 18.1 18.10 18.104 18.1 17.69 min for precalciner kilns
min for SP kilns
Kiln tube velocity
Material filling degree in the kiln 14.241 13.3 13.3 13.3 13.9 13.94 14.9 14.60 %
Kiln drive power (kW) 324.1 348.4 348.4 348.4 348.4 348.4 348.4 356.5 (kW)
Constants
Angle of repose of material 40 40 40 40 40 40 40 40 degrees (normally 35 - 40)
 700.8604

Recommended (not
>= <=
0 6
2.2
350
180

6
18 35 3612
40 60 4042
10
14 14

ally 35 - 40)
 Burner System Assessment Tool
Plant Saurastra cements limited
Existing option 1 option 1 A option-2 option-3
Kiln Length 60 60.96 60.96 60.96 60.96
Kiln ID 4 4.267 4.267 4.267 4.267
L/D 15.0 14.3 14.3 14.3 14.3
Production Rate 2965 4000 4000 4000 4200
LHV 6781 6850 6850 6850 6850
Heat consumption 3415.06 3167.186 3055.58 3272.94 3076.48
Firing in main burner 40.5% 34.0% 35.0% 31.0% 35.0%
PA % 6.7 8 8 8 8
Velocity at burner tip 160 160 160 160 160
Thermal Power 47.46 49.85 49.51 46.97 52.34
Thermal Power 40.82 42.87 42.58 40.40 45.01
Kiln Burner heat consumption 331 258 256 243 258

43.6106
option-3
60.96 43.86
4.267
14.3
4200
6850
3076.48
40.0%
8
160

59.82
51.45
7.5
294
 m Assessment Tool
mited
option-3 A option-4 option-4A
60.96 60.96 60.96 m
4.267 4.267 4.267 m
14.3 14.3 14.3
4200 4500 4500 tpd
6850 6850 6850
2971.98 3068.12 2963.62 kJ/kg_cli
35.0% 35.0% 35.0%
8 8 8 %
160 160 160 m/s Recommended (not
50.56 55.93 54.02 MW Refer design value
43.49 48.10 46.46 Kcal
249 257 248 Kcal/kg clk 220-260

43.6106

43.86
 Cooler System Assessment Tool
Plant Saurastra cements limited
Existing option 1 option 1 A option-2 option-3 option-3 A
Kiln Length 60.96 60.96 60.96 60.96 60.96 60.96
Kiln ID (within bricks) 4.267 4.267 4.267 4.267 4.267 4.267
L/D 14.3 14.3 14.3 14.3 14.3 14.3
Production Rate 4000 4000 4000 4000 4200 4200

Cooler active grtae area 67 67 67 100 100 100

Heat consumption 805 758 731 783 736 711

Sp. Grate Area load 59.70 59.70 59.70 40.00 42.00 42.00

Deasign Sp. Air volume 1.6 1.8 1.8 1.8 1.8 1.8

49265 49265 49265 49265 49265

49265 49265 49265 49265 49265
31680 31680 31680 31680 31680
2810 2810 2810 2810 2810
48240 48240 48240 48240 48240
69600 69600 69600 69600 69600
76200 76200 76200 76200 76200
m Assessment Tool
ts limited
option-4 option-4A
60.96 60.96 m
4.267 4.267 m
14.3 14.3
4500 4500 tpd

100 100 m2

734 709 kcal/kg_cli

Recommended (not
>= <=
45.00 45.00 t/dm2 for precalciner kiln 0 45

1.8 1.8 Nm3/kg clk. 2

44755.546487
44755.546487
28780.182944
2552.7876917
43824.369482
63229.1898
69225.061247
227897.62289
1367.3857374
1.3673857374
 RM System Assessment Tool
Plant Saurastra cements limited
Existing Option-1A option 1 option 1 B option-2 option-3
2965 4000 4000 4000 4000 4200
Input Heat Required for RM 27,630,865 27,630,865 27,630,865 27,630,865 27,630,865 31,346,740
ILC preheater gas in Nm3/hr 191562 174333 266667 266667 174333 280000
ILC preheater gas temperature 320.0 376.0 330 300 426.0 330
SLC preheater gas in Nm3/hr 0.0 100833.3 0 0 100833.3 0
SLC preheater gas temperature 320.0 320.0 0.00 0.00 320.0 0.00
heat content in ILC gases 23110096.5 24712098.7 31262000.0 28420000.0 27998282.0 32825100.0
heat content in SLC gases 0.0 12024173.3 0.0 0.0 12024173.3 0.0
Total preheater gases input to RM 130145.3 203378.1 232043.0 254852.7 186945.0 263248.8
Total heat available in PH gases 23110096.5 36736272.0 31262000.0 28420000.0 40022455.3 32825100.0
extra heat content
extra preheater gases
wt. avg temperature 320.0 355.5 330.0 300.0 387.2 330.0
bypass in volume 61417.2 71788.6 34623.6 11814.0 88221.7 16751.2
bypass % in volume 32.06% 26.09% 12.98% 4.43% 32.06% 5.98%
by pass heat content 7323876.9 9509782.3 4257825.8 1320746.4 12728095.6 2059970.0
O2 % in to raw mill 6.0 6.0 6.0 6.0 6.0 6.0
O2 % @ Ph outlet 3.0 3.5 3.5 3.5 3.5 3.5
False % going to raw mill 0.20 0.17 0.17 0.17 0.17 0.17
false air quantity 26029.1 33896.3 38673.8 42475.4 31157.5 43874.8
heat in false air 287981.6 375024.1 427881.5 469941.9 344721.9 485424.2
Heat input to raw mill from PH 15700726.9 27255840.6 27202983.1 27160922.7 27286142.8 30861315.4
Total heat input from gases to RM (17+16) 15988708.4 27630864.7 27630864.7 27630864.7 27630865 31346739.6
Total heat needed for raw mill for drying of mositure
Heat in for WHRS boiler 4898020.811945 4944438.567479 2133682.33 599560.608 7035679.0209 1032292.48
979604.162389 988887.7134958 426736.466 119912.122 1407135.8042 206458.497
1139.074607429 1149.869434297 496.205193 139.432699 1636.2044235 240.06802
WHRS potential (MW) from PH 1.1 1.1 0.5 0.1 1.64 0.2
cooler vent flow 0.60 0.60 0.60 0.60 0.70 0.70
temperature from vent 420 420 420 420 300 300
temperature out from boiler 120 120 120 120 120 120
heat given to boiler 6954248.13125 9381785 9381785 9444750 6649104 6981559.2
WHRS potential from cooler(MW) 1.6 2.2 2.2 2.2 1.55 1.6

Total potential (MW) 2.8 3.3 2.2 2.2 3.18 1.6

cooler mid flow 0.20 0.20 0.20 0.20 0.30 0.30

temperature from mid 630 630 630 630 473 473
temperature out from boiler 250 250 250 250 250 250
heat given to boiler 2895619 3906400 3987783.33 4069166.67 3510298.75 3685813.69
WHRS potential from cooler(MW) 0.7 0.9 0.9 0.9 0.82 0.86
ent Tool
ents limited
option-3 A option-4 option-4A
4200 4500 4500
31,346,740 32,394,807 32,394,807
280000 300000 300000 Nm3/hr
300 330 300 Deg C
0 0 0 Nm3/hr
0.00 0.00 0.00 Deg C
29841000.0 35169750.0 31972500.0 Kcal/hr
0.0 0.0 0.0 Kcal/hr
289126.0 272050.4 298792.8 Nm3/hr
29841000.0 35169750.0 31972500.0 Kcal/hr
0.000000000

300.0 330.0 300.0 Deg C

-9126.0 27949.6 1207.2 Nm3/hr 0.1490643454169
-3.26% 9.32% 0.40% % 1.4E+10
-1020236.0 3437083.8 134961.3 0.00000000
6.0 6.0 6.0 % 0.000000
3.5 3.5 3.5 % 0.00000000
0.17 0.17 0.17 %
48187.7 45341.7 49798.8 Nm3/hr 0
533141.0 501654.2 550966.4 Kcal/hr 0
30813598.5 31893152.6 31843840.4 Kcal/hr 0
31346739.6 32394806.8 32394806.8 Kcal/hr 0.00
0.0
-463142.16 1722391.9286844 61266.4595 Kcal/hr
-92628.432 344478.38573687 12253.2919 Kcal/hr 0.0
-107.70748 400.55626248473 14.2480138 kw
-0.1 0.4 0.014 MW >= <=
0.70 0.70 0.70
300 300 300
120 120 120
6981559.2 7480242 7480242
1.6 1.7 1.7

1.6 1.7 1.8

0.30 0.30 0.30

473 473 473
250 250 250
3685813.69 3949086.09375 3949086.09
0.86 0.918 0.918
DCBL A.P

Kiln % loading

Feed rate 300 tph

Clear Φ 3.827 m
Kiln rpm 4 rpm
Slope 4%
Raw meal/clinker factor 1.78
Kiln loading 14.43 %
Ratio Feed/rpm*100 0.75

Specific coal consumption

PC 13 tph
Main burner 5.10 tph
Kiln feed 300 tph
Coal CV 7800 kcal/kg
Spec consumption 838 kcal/kgclinker
Coal - Kiln 28 %
Coal - PC 72 %
R meal/clinker factor 1.78

Kiln thermal loading

Coal CV 6600 kcal/kg
Main burner coal 8.00 tph
Kiln thermal loading 5.34 MW/m2
4.59 million kcal/hr/m2

Volumetric loading
Feed rate 300 tph
Kiln length 62 m
Volumetric loading 6.27 tpd/m3

Kiln residence time

Kiln rpm 4.2 rpm

Kiln residence time (Duda) 21.6 min
Kiln residence time (Labhan) 19.8 min
 Pre heater gas
PH fan flow 191562.47 Nm3/hr CF 1.55 Clinker production
1.55 net Kiln feed 105319.27 kg/hr
Diameter
of duct in Temperature Pressure T&P
Location mm Area m2 Deg C mmwg Factor
PH down comer duct 2900 6.61 317 -490 0.4299
riser 2-1 3350 8.81 505 -376 0.3299
riser 3-2 3540 9.84 650 -300 0.2802
riser 4-3 3780 11.22 781 -210 0.2476
riser 5-4 3720 10.87 860 -145 0.2319
Kiln inlet 3.2*2.6 7.80 950 -16 0.2176

Pre heater gas v

PH fan flow 191562.47124 Nm3/hr CF 1.50 Clinker production
1.55 net Kiln feed 105319.27 kg/hr
Diameter
of duct in Temperature Pressure T&P
Location mm Area m2 Deg C mmwg Factor
PH down comer duct 3250 8.30 426 -430 0.3721
Cyclone 1 entry 3.73 425 -310 0.3772
Cyclone 2 entry 6.65 616 -155 0.3008
Cyclone 3 entry 8.96 783 -97 0.2546
cyclone 4 entry 8.96 895 -40 0.2315
inlet chamber 7.80 950 -16 0.2216

cyclone-3 entry 16.34

 Pre heater gas velocities (ILC- Riser duct)
0.345
Clinker production 2965 TPD CaO
123542 kg/hr 44
CO2
contribution Net CO2
flow in M3/hr DOC Kg/hr CO2 (Nm3/hr) (Nm3/hr)
445647 0.00 0 0 0
580754 0.80 291 148 148
683645 7.50 2437 1241 1241
773564 14.00 2365 1204 1204
826110 90.00 27647 14075 14075
880316 100.00 3638 1852 1852
18519
0.27 0.2638
nm3/kgclk

Pre heater gas velocities (ILC- cyclone inlet)

0.345
Clinker production 2965 TPD CaO
123542 kg/hr 44
CO2
contribution net CO2
flow in M3/hr DOC Kg/hr CO2 (Nm3/hr) (Nm3/hr)
514788 0.00 0 0 0
507863 0.88 320 163 163
636930 7.77 2506 1276 1276
752268 14.85 2576 1311 1311
827422 92.28 28167 14340 14340
864358 100.00 2808 1430 1430
18519
0.27
nm3/kgclk
MSL 45
Barometric 10092 mmwg 1.96 kg/Nm3
%
CO2
contribution in Velocity m/s Velocity m/s flow
m3/hr Net air volume with out DOC with DOC Nm3/hr Nm3/kg cl
0 445647 18.74 18.74 191562 1.55
449 580306 18.302 18.3 191414 1.55
4428 678768 19.3 19.16 190196 1.54
4861 763826 19.15 18.91 189151 1.53
60697 816373 21.11 20.86 189304 1.53
8510 809881 31.35 28.84 176235 1.43

MSL 45
Barometric 10278 mmwg 1.96 kg/Nm3
%
CO2
contribution in Velocity m/s flow
m3/hr Net air volume with DOC Nm3/hr Nm3/kg cl
0 514788 17.24 191562 1.55
432 507432 18.89 191400 1.55
4243 632256 26.4 190157 1.54
5149 742445 23.02 189061 1.53
61937 817599 25.35 189288 1.53
6451 792598 28.23 175659 1.42
71760

39.655465116279
0.2671555788371
 Pre heater gas vel
PH fan flow 100662 Nm3/hr CF 1.50 Clinker production
0.60 net Kiln feed 112500 kg/hr
Diameter
of duct in Temperature Pressure T&P
Location mm Area m2 Deg C mmwg Factor
PH down comer duct 2500 4.91 320 -490 0.4360
riser 2-1 2561 5.15 464 -372 0.3550
riser 3-2 2695 5.70 670 -270 0.2803
riser 4-3 2695 5.70 824 -166 0.2435
riser 5-4 2695 5.70 890 -90 0.2314
Calciner 3872 11.77 895 -55 0.2312
144
206
154
66
Pre heater gas velo
PH fan flow 100662 Nm3/hr CF 1.50 Clinker production
0.60 net Kiln feed 250000 kg/hr
Diameter
of duct in Temperature Pressure T&P
Location mm Area m2 Deg C mmwg Factor
PH down comer duct 2500 4.91 318 -490 0.4374
cyclone 1 entry 4.65 335 -372 0.4303
cyclone 2 entry 4.53 464 -270 0.3587
cycclone 3 entry 4.85 670 -166 0.2832
cyclone 4 entry 4.85 824 -90 0.2453
cyclone 5 entry 5.60 895 -55 0.2312
17
129
206
154
re heater gas velocities (SLC Riser duct)
0.341
Clinker production 4000 TPD CaO
166667 kg/hr 43.5
CO2
contribution Net CO2
flow in M3/hr DOC Kg/hr CO2 (Nm3/hr) (Nm3/hr)
230895 0.00 0 0 0
283546 0.53 206 105 105
359103 4.94 1694 862 862
413451 8.31 1295 659 659
435056 21.12 4921 2505 2505
435431 93.27 27717 14111 14111
18242
0.27 0.11
nm3/kgclk 0.24

e heater gas velocities (SLC cyclone inlet)

0.341
Clinker production 4000 TPD CaO
166667 kg/hr 43.5
CO2
contribution Net CO2
flow in M3/hr DOC Kg/hr CO2 (Nm3/hr) (Nm3/hr)
230117 0.00 0 0 0
233916 0.53 206 105 105
280656 4.94 1694 862 862
355410 8.31 1295 659 659
410367 21.12 8113 4130 4130
435431 93.27 35831 18241 18241
23998
0.27 0.14 0.00
nm3/kgclk
0.1098855703587
MSL 45
Barometric 10278 mmwg 1.96 kg/Nm3
%
CO2
contribution in Velocity m/s flow
m3/hr Net air volume with DOC Nm3/hr Nm3/kg cl
0 230895 13.07 100662 0.604
295 283251 15.27 100557 0.603
3077 355731 17.32 99717 0.598
2707 407372 19.84 99182 0.595
10828 428977 20.89 99255 0.596
61037 418524 9.87 96754 0.58
6079

MSL 45
Barometric 10278 mmwg 1.96 kg/Nm3
%
CO2
contribution in Velocity m/s flow
m3/hr Net air volume with DOC Nm3/hr Nm3/kg cl
0 230117 13.02 100662 0.604
243 233672 13.96 100557 0.603
2405 278008 17.05 99712 0.598
2327 350434 20.07 99253 0.596
16839 405392 23.22 99442 0.597
78905 413617 20.52 95619 0.574
4975
 0

ILC
Inlet Area Height(mm Width(mm) X1(m2) Diff Inlet Area(
Stage 1A& 2835 1474 4.18 0.45 3.73
Stage 2 2680 2480 6.65 0.00 6.65
Stage 3 2948 3040 8.96 0.00 8.96
Stage 4 2948 3040 8.96 0.00 8.96

new cy 3 3940 1830 7.21

3940 1689 2251

3230185
3.230185
Outlet Area(m2)
3.34
7.99
7.99
7.99
 1798
1048

SLC
Inlet Outlet
Inlet Area Height(mm Width(mm) X1(m2) Diff Area(m2) Area(m2)
Stage 1 2964 1798 5.33 0.68 4.65 5.31
Stage 2 2899 1793 5.20 0.67 4.53 5.15
Stage 3 3002 1857 5.57 0.73 4.85 5.70
Stage 4 3002 1857 5.57 0.73 4.85 5.70
Stage 5 3406 1857 6.32 0.73 5.60 5.70

590 609.5 642.50 642.50 642.50

442.25 417.75 435 435 435
1032.25 1027.25 1077.5 1077.5 1077.5
2153 2133 2232 2232 2232
1120.75 1105.75 1154.5 1154.5 1154.5

0.63142
 Calciner residence time
cone dia 1 3.04 3.04 3.04
cone dia 2 6.54 6.54 6.54
cone hieght 1.357 1.357 1.357
volume of cone 25.53 25.53 25.53
cylinder diameter 6.54 6.54 6.54
height of cylinder 7.45 7.45 7.45
volume of cylinder 1 250.14 250.14 250.14
paralleogram diameter-1 6.54 6.54 6.54
height of paralleogram 1.1 1.1 1.1
paralleogram diameter-2 5.27 5.27 5.27
volume of parallelogram 37.91 37.91 37.91

cylinder diameter 5.27 5.27 5.27

height of cylinder 1.7 1.7 1.7

volume of cylinder 2 37.06 37.06 37.06

height of cone-2 3.27 3.27 3.27

diameter 1of cone-2 5.27 5.27 5.27

diameter 2 of cone -2 6.54 6.54 6.54
volume of cone-2 89.85 89.85 89.85
height of part-3 cylinder 7.2 7.2 7.2
diameter of part-3 cylinder 6.54 6.54 6.54
volume of part-3 cylinder 241.745 241.745 241.745
total volume 682.240 682.240 682.240
Clinker Production 4000 4000 4200
Gas flow at Ph outlet 173948 183056 183056
O2 at Ph outlet 3.1 3.1 3.1
O2 at calciner outlet 2 2 2
False air % 6.145 6.145 6.145
gas flow at calciner outlet w/o false air 163258 171807 171807
Barometric pressure 10278 10278 10278
denisty at Ph outlet 1.45 1.45 1.45
Density at calciner outlet 1.420 1.420 1.420
Gas flow at calciner in Nm3 166750 175481 175481
calcinet outlet temp 895 895 895
calciner outlet pressure 70 70 70
gas flow at cacliner outlet 722363 760187 760187
gas flow at cacliner outlet 201 211 211
residence time 3.40 3.23 3.23
e
3.04 m
6.54 m
1.357 m
25.53 m3
6.54 m
7.45 m
250.14 m3
6.54 m
1.1 m
5.27 m
37.91 M3

5.27 m O2 2.0
1.7 m CO2 25
37.06 m3 CO
3.27 m H2O 2.8
5.27 m N2 70.2
6.54 m Gas density 1.420
89.85 m3
7.2 m
6.54 m
241.745 m3 8
682.240 m3
4200 TPD
183056 Nm3/hr
3.1 %
2
6.145 %
171807 Nm3/hr
10278 mmWG
1.45 kg/nm3
1.420 kg/nm3
175481 Nm3/hr
895 Deg C
79.2 mmWG
760872 m3/hr
211 m3/sec
3.23 sec
 22.077

kg/nm3
 Calciner residence time
cone dia 1 3.872 3.872
cone dia 2 1.672 1.672

cone hieght 1.493 1.493

volume of cone 9.48 9.48

cylinder diameter 3.872 3.872

height of cylinder 40.8 40.8

volume of cylinder 1 480.18 480.18

total volume 872.740

Clinker Production 2965 4200 4200

Gas flow at Ph outlet 191562 105933 105933
O2 at Ph outlet 2.5 3.1 3.1
O2 at calciner outlet 0 2 2
false air 25.00 6.15 6.15
gas flow at calciner outlet w/o false air 143671.85 99423.15 99423.15
Barometric pressure 10092 10278 10278
Density of gases at Ph outlet 1.40 1.45 1.45
Density of gases at calciner 1.33 1.33 1.33
gas flow at calciner outlet 150770 108074 108074
calcinet outlet temp 835 895 895
calciner outlet pressure -180 -70 -70
gas flow at cacliner outlet 615703 461847 461847
gas flow at cacliner outlet 171 128 128
Residence time 5.10 0.00 0.00
 3.872 m
1.672 m

1.493 m O2 0.0
9.48 m3 CO2 10
3.872 m CO 6.00
40.8 m H2O 14.0
480.18 m3 N2 76.0
m3 Gas density 1.334 kg/Nm3
4200 TPD
105933 Nm3/hr
3.1 %
2 %
6.15 %
99423.15 Nm3/hr
10278 mmWG
1.45 kg/nm3
1.33 kg/nm3
108074 Nm3/hr
895 Deg C
-70 mmWG
461847 m3/hr
128 m3/sec
0.00 sec
Clinker Production 4000 4200
1. Primary air flow 11579 11579 kg/hr

2. Primary air flow at 55 Deg C 10759 10759 M3/hr

3. coal flow rate 17.5 17.5 TPH

4. coal CV 7800 7800 kcal/kg

5. stiochiometric air flow 53.46 53.46 kg/s

7. primary air flow kg/s 3.216 3.216 kg/s

8. primary % 6.016 6.016 %

9. axial air area 0.0077 0.0077 m2

air going to axial channel 5380 5380 m3/hr

11. air going to radial air 5379.5 5379.5 m3/hr

12 area of radial air 0.032 0.032 m2

13. velocity of axial air 194.07 194.07 m/s

14. velocity of radial air 46.70 46.70 m/s

coal conveying air 2950 2950 m3/hr

coal conveying air area 0.064 0.064 m2
coal conveying velocity 12.80 12.80 m/s

flame momentum

flame momentum of axial air %m/s

1167.5 1167.5
flame momentum of radial air %m/s
280.9 280.9

flame momentum of coal conveying air %m/s

77.0 77.0
Total flame momentum 1525.5 1525.5 %m/s
 Pyro
A Process Parameters UOM
1 Kiln Throughput TPD

2 Kiln feed rate TPH

3 Kiln speed RPM

4 Cooling Air (specific air) Nm3/Kg Cl

5 Cooling Air M3/hr.

6 RABH fan flow(specific air) Nm3/Kg Cl

7 RABH fan flow M3/hr.
8 TAD specific air flow Nm3/Kg Cl

9 Primary Air(specific air). Nm3/Kg Cl

10 Primary Air M3/hr.

11 Cooler vent specific air flow. Nm3/Kg Cl
12 Cooler vent fan M3/hr.

13 Cooler vent temp deg.C

14 PH fan specific air flow Nm3/Kg Cl

15 PH fan flow M3/hr.

16 PH fan inlet temp deg.C

17 PH fan inlet pressure mbar
18 Cooler active grtae area m2

19 Cooler width m

20 Sp. Grate Area load t/d/m2

21 TAD velocity* m/sec

22 Calciner residence time m/sec

23 Volumetric loading tpd/m3
24 Thermal loading Gcal/hr.m2

25 Clinker temp deg.C

26 Clinker heat kcal/kg.clk

27 Cooler exhaust gas heat kcal/kg.clk

28 cooler exhaust fan power KW

29 cooler exhaust fan specific power KW/MT Clk
30 Cooler fans power KW
31 Cooler fans specific power KW/MT Clk

32 Specific cooler grate aeration (air flux) Nm3/m2.sec

33 cooler hydraulic motor power KW

34 cooler hydraulic Pressure (Grate I) Bar
35 cooler hydraulic Pressure (Grate II) Bar

36 Cooler grate speed I stoke/min

37 Cooler grate speed II stoke/min

38 PH fan power KW

39 PH fan specific power KW/MT Clk

40 RABH fan power KW

41 RABH fan specific power KW/MT Clk

42 Thermal energy consumption. Kcal/kg Clk.

43 Cooler recupeartion efficiency %

B Modification/Retrofitting

1 Existing Kiln feed dosing TPH

2 Air Slide/ conveying system TPH

3 Kiln feed bucket elevator TPH

4 Air Slide/ conveying system TPH

5 Fuel dosing system TPH

6 Fuel conveying system TPH
7 Burner Capacity MW
8 Burner PA fan
9 PH fan ILC KW/mbar/m3/hr
10 PH fan SLC

11 Kiln Main drive kW

12 All Cooler fans KW/mbar/m3/hr

13 Grate Speed SPM
14 Cooler ESP
15 Cooler ESP fan
16 Pan conveyor
17 Postioning of chute.
18 LS Crusher
19 Transport system (crusher to stacker)
20 Stacker
21 Reclaimer
22 Transport system (Reclaimer to hopper)
23 Raw mill
24 Raw mill system
25 Coal crusher
26 Transport system (crusher to hopper)
27 Coal mill
28 Coal mill system
29 RABH
30 RABH fan

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 Pyro-system
Current Option 1 Option 2
Remarks