Description Input Unit

Site Elevation MASL

Ambient temp. ᵒC
Kiln feed tph
Loss on Ignition %
Clinker production tpd
Type 1 -
Fuel used

Type 2 -
Type 3 -
Type 4 -
Type 1 kcal/kg
Fuel NCV

Type 2 kcal/kg
Type 3 kcal/kg
Type 4 kcal/kg
Kiln firing rate kg/h
Calciner firing rate kg/h
Fuel consumption kcal/kg cl.
Type 1 %
Kiln fuel mix

Type 2 %
Type 3 %
Type 4 %
Type 1 %
Calciner fuel

Type 2 %
mix

Type 3 %
Type 4 %
Kiln inlet O2 %
Calciner outlet O2 %
Preheater outlet O2 %
Preheater dust loss %
Kiln burner primary air %
Calciner blower air %
Preheater outlet temp. ᵒC
Preheater outlet pressure mmwc
Preheater fan power kWh
Preheater type -
No. of cyclone stages -

Cooler vent system -

Undergrate spillage transport

Specific problem related to Cooler, also explan in the remarks column
Total Cooler downtime hrs
Snowmen formation issue Yes/No
Downtime due to Snowmen hrs
Red river formation Yes/No
High clinker exit temperature Yes/No
Material fall through Yes/No
High vent temperature Yes/No
Problems with vent system Yes/No
Leakage in seals Yes/No
Problems with clinker size Yes/No
Other problems Yes/No
Other problems Yes/No
Other problems Yes/No
Other requirement
Other requirement

Typical maintenance cost

Cost of power xxx/kWh

Cost of fuel xxx/t fuel
 Remarks (if any)

Design basis
at normal operating condition

is it validated earlier by drop test?

fill in if applicable

fill in if applicable

at normal operating condition

at normal operating condition
reported in plant

fill in if applicable

fill in if applicable

measured ?
provide % or acutal flow with units
provide % or acutal flow with units
during normal operating condition
during normal operating condition
during normal operating condition
ILC or SLC or …
4 or 5 or 6
Bag filter w. bleed air or ESP or Bag filter w.
Heat exchanger
Yes/No
r, also explan in the remarks column
CLINKER BREAKER JAM

fill in if applicable
state currency and period (eg. EUR/ton or
EUR/year)
pls state currency
pls state currency
Note: 1. Below data are to be measured during normal/stable operating condition of kiln system
2. Provide DCS mimics during measured period (for Cooler, Kiln and Preheater)
3. Provide fan design specification and fan curves of cooler fans and Cooler vent fan
4. Provide Heat and Mass balance (if performed recently / available)
Description Input Unit
Cooler supplier -
Cooler installed year
Cooler type -
Cooler size -
Width of Cooler m
Length of Cooler m
Total Cooler grate area m²
Fixed inlet Supplier & type -
Fixed inlet installed year
Fixed inlet grate area m²
Crusher type -
Cooler fan power consump. kWh/t
Total no. of cooler fans -
Grate area m²
Compartment -
Flow m³/min
471FN2

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
Speed rpm
Grate area m²
Compartment -
Flow m³/min
471FN3

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
Speed %
Grate area m²
Compartment -
471FN4

Flow m³/min
Inlet pressure mmwc
Power (Opr.) kWh
Speed %
Grate area m²
Compartment -
Flow m³/min
471FN5

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
471F
Speed %
Grate area m²
Compartment -
Flow m³/min
471FN6

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
Speed %
Grate area m²
Compartment -
Flow m³/min
471FN7

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
Speed %
Grate area
Compartment
Flow m³/min
471FNC

Outlet pressure
Inlet pressure mmwc
Power (Opr.) kWh
Drive type
Speed %
Grate area
Compartment
Flow m³/min
471FND

Outlet pressure
Inlet pressure mmwc
Power (Opr.) kWh
Drive type
Speed %
Grate area m²
Compartment -
Flow m³/min
471FN8

Outlet pressure mmwc

Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
Speed %
Grate area m²
Compartment -
Flow m³/min
471FN9

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
 471F
Speed %
Grate area m²
Compartment -
Flow m³/min
471FNA

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
Speed %
Grate area m²
Compartment -
Flow m³/min
471FNB

Outlet pressure Pa
Inlet pressure mmwc
Power (Opr.) kWh
Drive type -
Speed %
Tertiary air temp. ᵒC
Tertiary air temp. (range) ᵒC
Kiln hood temp. ᵒC
Kiln hood temp. (range) ᵒC
Cooler vent temp. ᵒC
Cooler vent temp. (range) ᵒC
Clinker exit temp. (Avg) ᵒC
Clinker exit temp. (max) ᵒC
Clinker exit temp. (min) ᵒC
Clinker density g/l
% > 25mm
Clinker granulometry
% < 15mm

Water injection m³/h

Cooler drive speed spm

Cooler drive speed spm
Clinker bed height mm
Calciner outlet temp. ᵒC
table operating condition of kiln system
er, Kiln and Preheater)
er fans and Cooler vent fan
/ available)
Remarks (if any)

PRESENT

Roller crusher / Hammer crusher

at meter or shaft

VFD or damper controlled

VFD or damper controlled

VFD or damper controlled

VFD or damper controlled

VFD or damper controlled

VFD or damper controlled

VFD or damper controlled

VFD or damper controlled

VFD or damper controlled

during normal operating condition

fluctuation range for 4hrs or 8 hrs
during normal operating condition
fluctuation range for 4hrs or 8 hrs

Average of 8 hrs period

Maximum of 8 hrs period
Minimum of 8 hrs period
Plant terminology litre weight

Sieve analysis

If used during measured period or normal

operating condition
during normal operating condition
range during operation (4 or 8 hrs period)
during normal operating condition
during normal operating condition