Formulas kiln - Presentation Transcript

Kiln fuel feed rate = 6000 kgs/hr

C.V
= 6500 Kcals*4.184 = 27196 Kj/Kg of coal
Thermal Input
= 6000 X 27196 KJs/Hr
= 163.176 GJs/Hr
Kiln dia (inside Lining) = 3.6 m
C.S Area
= (3.14/4)*3.6*3.6
=10.17 m2
Thermal load on kiln = 163.176/10.18
=16.04 Gj/hr.m2
1.
Residence time in Kiln t = 1.77 (Phy)^1/2 L ________________
Alpha* D*N Phy =Angle of repose for lime stone ~ 36 Degree L = length of Kiln in
meter Alpha = Kiln inclination in % D = Effective diameter of Kiln in meter N =
Rotation per minute rpm
2.
Kiln Inlet Outlet A B C D E Preheater Zone = 1 min A 7.5m/sec Mat velo
Max Precalcination Zone = 2 min B t = 20 -28 = Minutes Calcination Zone = 1012 min C Burning Zone = 6 8 min D 4.5m/sec Cooling Zone = 2 min F Mat Velo
Min
3.
CLINKERISATION 12 CaO 3Cao.SiO2 (C3S) Lime stone Alite 2 SiO2 2CaO
SiO2 (C2S) Silica oxide Belite 1450*C 2 Al2O3 3 CaOAl2O3 (C3A) Aluminium
oxide Tricalcium Aluminate Fe2O3 4CaO.Al2O3.Fe2O3 (C4AF) Iron oxide Tetra
Calcium Alumino Ferrite
4.
LIME SATURATION FACTOR 100* CaO LSF = (2.8 SiO2 + 1.18 Al2O3 +
0.65 Fe2O3) 0.66 > LSF < 1.2 = = AR = > 0.64
5.

SILICA RATIO SiO2 SR = (Al2O3 + Fe2O3) 2.2 > SR < 2.6 = =

6.
ALUMINA RATIO Al2O3 AR = Fe2O3 1.5 > AR < 2.5 = = AR < 1.5 IS
CALLED FERROCEMENTS AR = 0.637 IS CALLED FERRARI CEMENT
7.
CALORIFIC VALUE OF COAL LHV = HHV 50.1H 5.6 M 0.191O
LHV = LOW HEATING VALUE Kcal /Kg HHV = HIGH HEATING VALUE
Kcal /Kg M = % MOISTURE H = % HYDROGEN O = % OXYGEN KCal / Kg x
4.187 x 10^(-3) = MJ/Kg ultimate analysis KCal / Kg x 1.8 = Btu / lb
8.
COAL USED IN CEMENT INDUSTRY LHV = 6500 7000 Kcal / Kg
ASH = 12~15 % VOLATILE MATERIAL = 18~ 22 % MOISTURE = UP TO 12 %
9.
D =Diameter in Meter L = Length in meter WEIGHT OF
CYLINDRICAL( kiln) SHELL = W W = Pi x (L) x (D) x thk (mm) x 7.85 Metric
Tons
10.
THERMAL EXPANSION OF SHELL Skin Temperature Diagram A =
Alpha x TxL L= Length of (Kiln) Shell =L1 + L2 Alpha for steel (coefficient of

linear expansion = 1.2x 10^ (-5) mm per Meter T= dT =( Average temp

Ambient temp) Degre centigrade L1 L2 A1= (T2a+T1)/2 - T X L1 T2bb A1=
(T2b+T1)/2 - T X L2 T1 Ambient temp = T T2a A = A1 +A2
11.
IMPOTANT PARAMETERS KILN SPECIFIC VOLUME LOADING = TPD/
m3 or Specific Kiln capacity ~ 2.3 t / m3 at Kiln circumferential speed = 50 cm /
sec KILN SPECIFIC THERMAL LOADING = Kcal / m2.hr Specific Kiln thermal
loading Qp = 1.4 x 10 ^ 6 x D Kcal / m2. hr Qp should not exceed 3.46 x 10^6
Kcal/m^2.hr COOLER SPECIFIC LOADING or Specific Cooler Capacity = TPD/
m2 = 38 -43 metric ton of clinker per m^2 .24 hr KILN % FILLING = 04 % Min 16% Max
12.
KILN CAPACITY ASSESMENT Capacity of ID fan. Preheater cyclone
design. Proclaimed Design & Volume. Kiln inclination & Volume. Kiln %
filling, Specific volume loading &.Thermal loading. Kiln Drive capacity. System
Design, Ducts, GCT, fan position & ESP.
13.
For Gears: Pitch Diameter = Module x No. of Teeth Blank Diameter =
Module x (No of Teeth+2) For Airslide Cloth Fabric Polyester 100%.
Min=140*C & Max = 260*C. Permeability = 400m3/hr-m2 or 6m3/min-m2. at
80mbar Tensile strength : WEFT = 1200 Kg/cm2 : WARP = 600 Kg/cm2 Air
Required = 2.5-3.0(Closed type), (2 Cone silo Bins),(1.5Open Type)
14.
PH fan-1 Twin cyclones PH fan-2 Twin cyclones IA IB II III IV Riser Duct
V KILN STRING VI V 950*C T.A.Duct SLC PYRO STRING KILN I Girth gear II
III
15.
CEMENT MILL FORMULAS MILL CRITICAL VELOCITY = 76 / (D)^1/2
MILL ACTUAL VELOCITY = 32 / (D)^1/2
16.
D Theta Mill charging: Theta H H = 0.16D MILL CROSS SECTION
Dynamic Angle of Repose = 35 degree 20 minutes with Horizontal (Theta ) OR
Dynamic Angle of Repose = 54 degree 40 minutes with Vertical (Theta )
17.
GRINDING MEDIA LOAD G G = gm.Sy.Pi. (R)^2.L 4 Constants: Sy =
specific gravity of G = 4620(R)^2.L ball 7.8-7.9 Ton / m3 gm = Bulk density of
charge TAGGARTS FORMULA 4.5 Ton / m3 . Pi = 22/7 or 3.14
18.
POWER CONSUMPTION OF MILL = P L= G/D=A-C 2. B-A P= 12G
SEPARATOR B%fines/D A %fines/F Seperator efficiency A % fines of separator
feed s B % fines of Tailings/Reject C%fine/G C % fines of finished Product F TPH
of separator feed D TPH of Tailings/Reject G TPH of finished Product Ball Mill 1.
n = C (A-B) 3. A(C-B)) F = L(1+D)
19.
L/D=3 Two Compartment Mill L / D = 4.5 Three Compartment Mill I
Chamber Drag Peb Liners Carman Lining Classifying Slegton Liners
Magotteaux Lining Lining FLS Lining

20.
Important Conversions 1 Barrel = 42 Gallons = 159 litres = 5.615 Cuft 1
Kcal = 4.187 J KCal / Kg x 1.8 = Btu / lb Characteristic OPC-43(IS8112) OPC43(IS12269) PPC- (IS1489)Part-1 Blaine 225 225 300 3 Days(MPa) 23 27 16 7
Days 33 37 22 28 Days 43 53 33
21.
22.
23.

L H 70 * L=H/2 Length of Dip Tube = Gas inlet height Single Stream

ESP ELECTROSTATIC PRECIPITATOR
TOP VIEW GASCONDITIONING TOWER SPRAY SIDE VIEW

24.
Kiln Data : 4.4 meter Diameter x 60 meter length Inclination = 3.5% Shell
thicknesses = 25 mm , 28 mm , 35 mm , 65 mm Kiln speed = 3.5 to 5.25 RPM
Preheater : Type : 6440 / PR 7044 VI Stage Desc Kiln string Pyro string I Cyclone
Twin 4000 m 4400 m (Diameter) 6400 m 7000 m Dip tube 2000 m 2200 m
(Diameter) 3200 m 3500 m
25.
Girth Gear : Module = 39 No of Teeth = 148 Material of construction = CS
640 (Normalized Cast Steel) Dimensions = 550 mm (width) Pinion : Module = 39
No of Teeth = 28 Material of construction = 30 Cr Ni Mo V8 (Normalized
CastSteel) Dimensions = 600 mm (width)
26.
Tyre Assemblies three nos : Material of construction = GS 24 Mn 5
(Normalized Cast Steel) Dimensions = 5620 OD x 4581 ID x 775 (width) Main
Drive Supporting Rollers Assemblies three nos : Material of construction = CS
640 (Normalized Cast Steel) Dimensions = 5620 OD x 4581 ID x 775 (width) Tyre
Kiln Supporting Roller Shell Girth Gear Pinion
27.
Kiln Main Drive : Gear box = SDN 800 Ratio = 54.35:1 RWN-500 Motor
KW = 710 Aux G.B SDA 250 54.35: 1 Input RPM = 100 - 1000 Motor 30 KW ;
1500 RPM Motor G.B G.B Motor RWB-178 Pinion Kiln Axis Concord
Alingnomatic Geared Coupling G.G
28.
MID KILN FEEDING
29.
Degree Of Kiln filling & Kiln Cross Sectional loading: % of Filling or Area
of this segment (A1) = Kilns Degree Area of cross section of Kiln (A) Theta
Centric Angle Theta % of Kiln (Degree) filling 110 15.65 105 13.75 100 12.1
Segment 95 10.7 r = radius inside lining 90 9.09 85 7.75 r^2 A1 = O Sin O 80
6.52 2 75 5.42 70 4.5 A = II r^2
30.
Rotary Kiln Slope versus Load Theta 4.5 4.0 3.5 3.0 2.0 % 9 10 11 12 13
Note : In practical Kiln operation the kiln load should not exceed 13%,since
higher Kiln loads impair the heat tranfer Thumb rule by Bohman Material
velocity in kiln % Kiln Kiln diameter 1). Burning Zone = 4.5 mm / sec Lowest
Slope (m) 5 up to 2.8 m 4 3 m to 3.4 m 2). Calcining Zone = 7.5 mm / sec Max 3 >
3.4 m
31.
Rotary Kiln power input calculation : W x bd x td x N x F x 0.0000092 1
H.P = rd W = Total vertical load on all roller shaft bearing,lb bd = roller shaft

bearing diameter , inches Note : This is Frictional rd = roller diameter , inches 1

Horse Power td = tire or riding rind diameter , inches N = rpm of Kiln shell P =
Coefficient or friction of roller bearings , 0.018 for oil lub bearings & 0.06 for
grease lub bearings
32.
This is Load Horse 2 Horse Power H.P = (D x Sin O) ^3 x N x L x K 2 D =
Kiln dia .inside lining , ft Sin O = read from diagram depending on %Load N =
rpm of Kiln shell L = length of kiln in ft K = 0.00076 Total power = 1 + 2
33.
Cement
Monthly
Edelweiss
From:
Arun
Shourie
[mailto:Arun.Shourie@edelcap.com] Arun Shourie Relation Manager - Insurance
Dir: +91 (22) 4086 3835 / +91 99200 29366
34.
Burner pipe centering location and alignment Burner Pipe Location 40* L
vHdD
35.
= V Z Cos O Dab X K% = Z 2 H = Z Sine O Kiln Diameter = D Kiln
lining thickness = a Kiln Coating thickness = b Angle of Repose of kiln load = O =
40* say Kiln Load = K % Value from table below Depth of bed in Kiln = Y % To be
measured Kiln load = K % 5 6 7 8 9 10 11 12 13 14 15 Depth of material bed in Kiln
= Y % 9.75 11 12.2 13.4 14.5 15.6 16.7 17.7 1.8.8 19.8 21
36.
Standard Coal Factor : SCF To determine the approximate combustion air
needed to burn a given unit wt of coal, formula given below can be used when no
ultimate analysis is available. The combustion air requirement include here 5% of
excess air 100 - a B = SCF 100 7000 Kg of Air = 10.478 SCF Kg of Coal a = %
Moisture in coal ( as fired ) B = Heat value of coal ( Kcal / kg as fired )
37.
% Loading of Kiln : Theoretical Flame Temperature fuel oil : Cxfxt Q T = L
= Vg x Cp dxV Q = heating value of oil , K cal / kg C = Capacity of Kiln Ton / hr
Vg = Volume of combustion gases , f = Ton (Kg) dry feed / Ton ( kg) of Clinker
Nm^3 / Kg t = residence time Cp = Specific heat of d = Bulk density of dry feed
ton (Kg) / m^3 combustion gases =0.40 at 2000*C for V = Internal volume of
kiln in m^3 fuel class S
38.
Rotary kiln Capacity Martins Formula : C = 2.826 v X D^3 Vg C = Kiln
Capacity Ton / Hr V = Gas Velocity in gas discharge end , m / sec Vg = specific
gas volume , m^3 / kg clinker D = Kiln Diameter on Bricks, m
39.
Heat capacity of Rotary kiln 1 Q = 1.1 x 10 ^ 6 x D ^3 (Kcal / hr) D = Mean
inside Kiln Diameter on Bricks, m 2 Kiln Thermal loading at cross section of
burning zone = Qp = = Q / Fp Fp = 0.785 x D^2 Inside cross-section of the kiln
burning zone m^2 where D is kiln shell diameter Q p = 1.4 x 10 ^ 6 x D Kcal /
m^2.hr Qp should not exceed 3.46 x 10 ^ 6 kcal / m2.hr
40.
Heat transfer in cyclones preheater: The rule is that the sizes of the gas
ducts and of the cyclone should be in accordance with the formula: V^2 =

Constant ID ^ 5 V = Gas volume ID = Inside Diameter of ducts / cyclones

respectively
41.
Preheater cyclone sizing (V) ^ 2 x Vt C D = 0.536 4 P Vt = V0 273 + t + K K
= dust concentration in Gas , grams / m^ 3 273 D = cyclone Diameter , m V = Gas
volume passimg cyclone , m ^ 3 / Sec Vt = sp. gr. of gas at aver. Temp , Kg / m ^
3 C = Coefficient for pressure drop = 110 P = Pressure drop in cyclone in mm WG
42.
Small size high efficiency cyclone L H 70 * L=H/2 Length of Dip Tube =
Gas inlet height Single Stream Pressure drop across cyclone = 55 60 mbar
43.
Theoretical Heat consumption Q for clinker burning :zur Strassen
formula : Constituent Constituent Multiplication Heat Cons Net Name X %
Factor Y kcal/kg Al2O3 5.92 2.22 + 13.1 + MgO 1.05 6.48*MgO6.48 + 6.8 527.4
CaO 63.91 7.646 + 488.7 H2O 3.2 5.86 + 18.8 _ SiO2 22.68 5.11 _ 117 118.4
Fe2O3 2.31 0.59 _ 1.4 Net % 99.27 Net Kcal / Kg = 409.0 Q = 2.22 Al203 + 6.48
MgO + 7.646 CaO + 5.86 H2O + 5.11 SiO2 + 0.59 Fe2O3
44.
Thermal efficiency of cooler = E A-B X 100 E= A A = Heat loss of clinker
leaving the kiln B = Heat loss of the clinker cooler 3250 (347 K ) Secondary Air
Temperature = t = (X.n) K = Heat loss of the cooler , Kcal/Kg clinker X = Specific
Heat consumption of the kiln , Kcal / Kg clinker n = Excess Air number = 1.1
Cooler fans designed for Specific Volume of 3 3.15 st.m^3/Kg clinker
45.
Cooling of kiln Exit Gases (GCT) Kg / min.Exit gas x 0.25 ( t 1 t 2) Kcal /
min Y= H t2 H t3 t1 = Temperature of Kiln exit gases t2 = Temperature of gas
to be achieved or maitained t3 = temperature of water (15*C) H t2 = Heat content
of water at t2 H t3 = Heat content of water at t3 Y = Kg Water Spray / min