Residence time in Kiln t =

Phy

1.77 (Phy)^1/2 L
________________
Alpha* D*N

=Angle of repose for lime stone

~ 36 Degree
= length of Kiln in meter

Alpha = Kiln inclination in %

D

= Effective diameter of Kiln in meter

= Rotation per minute rpm

Kiln

Kiln

Inlet

Outlet

Preheater Zone = 1 min

7.5m/sec
Mat velo Max

Precalcination Zone = 2 min

B
=

Calcination Zone = 10-12 min

Burning Zone = 6 8 min

Cooling Zone = 2 min

t = 20 -28
Minutes

4.5m/sec
Mat Velo Min

CLINKERISATION
12 CaO
Lime stone

3Cao.SiO2 (C3S)
Alite

2 SiO2
Silica oxide

2CaO SiO2 (C2S)

Belite

1450*C
2 Al2O3
Aluminium oxide

Fe2O3
Iron oxide

3 CaOAl2O3 (C3A)
Tricalcium Aluminate

4CaO.Al2O3.Fe2O3 (C4AF)
Tetra Calcium Alumino Ferrite

LIME SATURATION FACTOR

100* CaO
LSF =
(2.8 SiO2 + 1.18 Al2O3 + 0.65 Fe2O3)
0.66 > LSF < 1.2
=
=
AR = > 0.64

SILICA RATIO

SiO2
SR =
(Al2O3 + Fe2O3)
2.2 >
=

SR < 2.6
=

ALUMINA RATIO

Al2O3
AR =
Fe2O3
1.5 >
=

AR < 2.5
=

AR < 1.5 IS CALLED FERROCEMENTS

AR = 0.637 IS CALLED FERRARI CEMENT

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

KCal / Kg x 4.187 x 10^(-3) = MJ/Kg

KCal / Kg x 1.8 = Btu / lb

O = % OXYGEN

ultimate
analysis

COAL USED IN CEMENT INDUSTRY

LHV = 6500 7000 Kcal / Kg
ASH = 12~15 %
VOLATILE MATERIAL = 18~ 22 %
MOISTURE = UP TO 12 %

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

THERMAL EXPANSION OF SHELL

A = Alpha x

TxL

Skin Temperature
Diagram

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
A1= (T2a+T1)/2 - T
A1= (T2b+T1)/2 - T
Ambient temp = T

X L1
X L2

T2bb
T1
T2a

A = A1 +A2

L2

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

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.

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)

PH fan-1 Twin cyclones

IA

PH fan-2 Twin cyclones

IB

II
III
IV

Riser
Duct
KILN STRING

V
VI
V

950*C
T.A.Duct
SLC

PYRO STRING

KILN
I Girth gear

II

III

CEMENT MILL FORMULAS

MILL CRITICAL VELOCITY = 76 / (D)^1/2

MILL ACTUAL VELOCITY = 32 / (D)^1/2

Mill charging:

Theta
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 )

GRINDING MEDIA LOAD G

G = gm.Sy.Pi. (R)^2.L
4

G = 4620(R)^2.L
TAGGARTS FORMULA

Constants:

Sy = specific gravity of
ball 7.8-7.9 Ton / m3
gm = Bulk density of charge
4.5 Ton / m3
.
Pi = 22/7 or 3.14

POWER CONSUMPTION OF MILL = P

L= G/D=A-C

2.

B-A

P= 12G

SEPARATOR
B%fines/D
A %fines/F

Seperator efficiency
s

A % fines of separator feed

B % fines of Tailings/Reject
C % fines of finished Product
F TPH of separator feed
D TPH of Tailings/Reject
G TPH of finished Product

C%fine/G

Ball Mill

1.
n = C (A-B)
A(C-B))

3.
F = L(1+D)

L/D=3
L / D = 4.5

Two Compartment Mill

Three Compartment Mill

I Chamber Drag Peb Liners

Carman Lining

Classifying
Liners

Slegton
Magotteaux
Lining
Lining

FLS Lining

Important Conversions

1 Barrel = 42 Gallons = 159 litres = 5.615 Cuft

1 Kcal = 4.187 J

Characteristic
Blaine
3 Days(MPa)
7 Days
28 Days

KCal / Kg x 1.8 = Btu / lb

OPC-43(IS8112)

225
23
33
43

OPC-43(IS12269)

225
27
37
53

PPC- (IS1489)Part-1

300
16
22
33

H
70 *

L=H/2

Length of Dip Tube = Gas inlet height

Single Stream

ESP ELECTROSTATIC PRECIPITATOR

TOP VIEW

GASCONDITIONING TOWER SPRAY

SIDE VIEW

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
(Diameter)

4000 m
6400 m

4400 m
7000 m

Dip tube
(Diameter)

2000 m
3200 m

2200 m
3500 m

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)

Tyre Assemblies three nos :

Material of construction = GS 24 Mn 5 (Normalized Cast Steel)

Dimensions = 5620 OD x 4581 ID x 775 (width)
Supporting Rollers Assemblies three nos :

Main Drive

Material of construction = CS 640 (Normalized Cast Steel)

Dimensions = 5620 OD x 4581 ID x 775 (width)
Tyre
Supporting Roller
Girth Gear

Pinion

Kiln
Shell

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
RWB-178

G.B
G.B

Motor

Pinion

Kiln Axis
Concord Alingnomatic
Geared Coupling

G.G

MID KILN
FEEDING

Degree Of Kiln filling & Kiln Cross Sectional loading:

Area of this segment (A1)

% of Filling or
Kilns Degree

=
Area of cross section of Kiln (A)

Centric Angle Theta

(Degree)

% of Kiln
filling

110

15.65

105

13.75

100

12.1

95

10.7

90

9.09

85

7.75

80

6.52

75

5.42

70

4.5

Theta

Segment
r = radius inside lining

A1 =

r^2

O Sin O

A = II r^2

Rotary Kiln Slope versus Load

Theta
%

4.5

4.0

3.5

3.0

2.0

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

% Kiln
Slope

Kiln diameter
(m)

up to 2.8 m

3 m to 3.4 m

> 3.4 m

Material velocity in kiln

1). Burning Zone = 4.5 mm / sec Lowest

2). Calcining Zone = 7.5 mm / sec Max

Rotary Kiln power input calculation :

H.P =

W x bd x td x N x F x 0.0000092

rd

W = Total vertical load on all roller shaft bearing,lb

bd = roller shaft bearing diameter , inches
rd = roller diameter , inches

Note :
This is Frictional
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

This is Load Horse

2
Horse Power

H.P = (D x Sin O) ^3 x N x L x K

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 =

Cement Monthly - Edelweiss

From: Arun Shourie [mailto:Arun.Shourie@edelcap.com]

Arun Shourie
Relation Manager - Insurance
Dir: +91 (22) 4086 3835 / +91 99200 29366

Burner pipe centering location and alignment

Burner Pipe
Location

40*
L
v
H

Dab

K%

Z Cos O

H = Z Sine O

2
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 %

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

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
100
Kg of Air

B
7000

SCF

10.478 SCF

Kg of Coal
a = % Moisture in coal ( as fired )
B = Heat value of coal ( Kcal / kg as fired )

% Loading of Kiln :

Cxfxt
dxV

Theoretical Flame
Temperature fuel oil :
T =

Q
Vg x Cp

Q = heating value of
oil , K cal / kg
C = Capacity of Kiln Ton / hr
f = Ton (Kg) dry feed / Ton ( kg) of Clinker
t = residence time
d = Bulk density of dry feed ton (Kg) / m^3
V = Internal volume of kiln in m^3

Vg = Volume of
combustion gases ,
Nm^3 / Kg
Cp = Specific heat of
combustion gases
=0.40 at 2000*C for
fuel class S

Rotary kiln Capacity

Martins Formula :
v
2.826
C =
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

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

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
ID ^ 5

Constant

V = Gas volume
ID = Inside Diameter of ducts /
cyclones respectively

Preheater cyclone sizing

D = 0.536

(V) ^ 2 x Vt
4

Vt = V0 273 + t + K
273

C
P

K = dust concentration in
Gas , grams / m^ 3

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

Small size high efficiency cyclone

H
70 *

L=H/2

Length of Dip Tube = Gas inlet height

Pressure drop across cyclone = 55 60 mbar

Single Stream

Theoretical Heat consumption Q for

clinker burning :zur Strassen formula :
Constituent Constituent
Name

Multiplication
Factor Y

Al2O3

5.92

MgO

1.05 6.48*MgO6.48
63.91
7.646

CaO

2.22

Heat Cons Net

kcal/kg

+ 13.1
+ 6.8
+ 488.7
+ 18.8

H2O

3.2

5.86

SiO2

22.68

5.11

Fe2O3

2.31

0.59

_ 117
_ 1.4

Net %

99.27

Net Kcal / Kg

= 409.0

+
527.4

_
118.4

Q = 2.22 Al203 + 6.48 MgO + 7.646 CaO + 5.86 H2O + 5.11 SiO2 + 0.59 Fe2O3

Thermal efficiency of cooler = E

E=

A-B

X 100

A
A = Heat loss of clinker leaving the kiln
B = Heat loss of the clinker cooler

Secondary Air Temperature = t =

3250 (347 K )
(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

Cooling of kiln Exit Gases (GCT)

Y=

Kg / min.Exit gas x 0.25 ( t 1 t 2) Kcal / min

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