Theoretical Calculations on Fuel Consumption

TP cement will be the basis of analysis since it has the most “wet mixture” due to its
composition. It has the highest percentage of wet additives (lst and poz).

Technical Data Sheet of Bunker Fuel from Shell:

W:\Common Folder\Maintenance\romel\HGG improvement\TDS_RFO.pdf

Sample Certificate of Analysis:s

W:\Common Folder\Maintenance\romel\HGG improvement\COA.pdf

Based on the sample COA, the lower heating value of their bunker fuel is approximately:
𝐵𝑇𝑈 𝐾𝐽
17249 = 40121.2
𝑙𝑏 𝑘𝑔

The table below shows the typical additive percentage of TP cement and the corresponding
moisture content per kg mass. The specific heat of the cement components are also stated in the table
as per the data gathered from the Mill Audit conducted by Fred and Jeffrey last 2016.

Cement TP Cement Typical Typical Moisture Specific Heat

Component Composition (%) Content (%) (KJ/kg.K)
Limestone 11.45 14.39 0.078
Pozzolan 18.95 16.38 0.833
Gypsum 7.63 20.476 1.123
Clinker 61.97 1.49 0.785
 The gathered data for the moisture content were from the 2016 trend (January-December). The
highest moisture for each additive type were the basis for the calculations. The tables below show the
moisture data for each additive type from January to December of 2016.

% Moisture of Gypsum - 2016 Trend

2016 Gypsum % Moisture

25

20
% MOISTURE

15

10

MONTH OF 2016

Moisture % Average
% Moisture of Limestone - 2016 Trend

2016 Limestone % Moisture

16

14

12

10
% MOISTURE

MONTH OF 2016

Moisture % Average
% Moisture of Pozzolan - 2016 Trend

2016 Pozzolan % Moisture

18
16
14
12
% MOISTURE

10
8
6
4
2
0

MONTH OF 2016

Moisture % Average
% Moisture of Pozzolan - 2016 Trend

2016 Clinker % Moisture

1.6
1.4
1.2
1
% MOISTURE

0.8
0.6
0.4
0.2
0
-0.2

MONTH OF 2016

Moisture % Average
Mill Heat Requirement

The figure below shows the schematic diagram of ball mill heat balance. The data gathered such
as the shell losses and reject temperature were based from the audit done by Jeff and Fred last June of
2016. As noticed, a gap still exists at the feed end part of the mill which serves as an inlet for false air.

Wall losses (8x105 KJ/hr) Reject @ 94oC

Mat’l in @ 30oC
Hot Air + Mat’l

Hot Air
BALL MILL

Mat’t out False Air

Power in – about 90% is

converted to heat

Heat Balance Diagram of the Ball Mill

The table below shows the typical composition of TP cement and the highest recorded moisture
of the raw materials from 2016 trend. The specific heat data were taken from the audit of Fred and Jeff.
These will be used to compute the theoretical heat requirement of the mill.

Raw Material TP – Composition (%) Moisture (%) Specific heat (KJ/kg.K)

Limestone 11.45 14.39 0.078
Pozzolan 18.95 16.38 0.833
Gypsum 7.63 20.476 1.123
Clinker 61.97 1.49 0.785
Limestone moisture
85 𝑡𝑝ℎ (0.1145)(0.1439)
𝑘𝑔
= 1400.5 𝑜𝑓 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒
ℎ𝑟

Pozzolan moisture
85 𝑡𝑝ℎ (0.1895)(0.1638)
𝑘𝑔
= 2638.4 𝑜𝑓 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒
ℎ𝑟

Gypsum moisture
85 𝑡𝑝ℎ (0.0763)(0.20476)
𝑘𝑔
= 1327.9 𝑜𝑓 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒
ℎ𝑟

Clinker moisture
85 𝑡𝑝ℎ (0.6197)(0.0149)
𝑘𝑔
= 1327.9 𝑜𝑓 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒
ℎ𝑟

Summary of material moisture:

Raw Material Moisture (kg/hr) Dry Material (kg/hr)

Limestone 1400 8332
Pozzolan 2638 13469
Gypsum 1328 5157.5
Clinker 785 51889.6
 The total amount of moisture from all the raw materials fed inside the mill is approximately
6151 kg/hr, considering 85 tph production. The required heating to evaporate the moisture is shown
below based on the initial material temperature of 30 oC,

𝒌𝑱
Latent heat of water: 𝟐𝟐𝟔𝟒. 𝟕
𝒌𝒈

𝑘𝑔 𝑘𝐽 𝑘𝑔 𝑘𝐽
6151 (4.187 ) (100 K − 30 𝐾) + 6151 (2264.7 )
ℎ𝑟 𝑘𝑔.𝐾 ℎ𝑟 𝑘𝑔

𝑘𝐽
= 15 735 177 𝑜𝑓 ℎ𝑒𝑎𝑡
ℎ𝑟
For the material heating, assuming material outlet temperature of 100oC and using the specific
heat of each material from the audit done last June of 2016, the required heat that has to be supplied to
heat the material is indicated in the calculation below,

Limestone heat required

𝑘𝑔 𝑘𝐽
8332 (0.078 ) (100𝐾 − 30𝐾)
ℎ𝑟 𝑘𝑔. 𝐾
𝑘𝐽
= 45 492.7 𝑜𝑓 ℎ𝑒𝑎𝑡
ℎ𝑟

Pozzolan heat required

𝑘𝑔 𝑘𝐽
13 469 (0.833 ) (100𝐾 − 30𝐾)
ℎ𝑟 𝑘𝑔. 𝐾
𝑘𝐽
= 785 383.2 𝑜𝑓 ℎ𝑒𝑎𝑡
ℎ𝑟

Gypsum moisture
𝑘𝑔 𝑘𝐽
5 157.5 (1.123 ) (100𝐾 − 30𝐾)
ℎ𝑟 𝑘𝑔. 𝐾
𝑘𝐽
= 405 431.1 𝑜𝑓 ℎ𝑒𝑎𝑡
ℎ𝑟

Clinker moisture
𝑘𝑔 𝑘𝐽
51889.6 (0.785 ) (100𝐾 − 30𝐾)
ℎ𝑟 𝑘𝑔. 𝐾
𝑘𝐽
= 2 851 336.3 𝑜𝑓 ℎ𝑒𝑎𝑡
ℎ𝑟
 𝑘𝐽
The heat required for material heating is approximately 4 087 643 ℎ𝑟. Adding up the heat
required for moisture vaporization and material heating,
𝑘𝐽 𝑘𝐽
15 735 177 + 800 000
ℎ𝑟 ℎ𝑟
𝑘𝐽
= 19 822 820
ℎ𝑟

Heat losses accounting

𝑘𝐽
As per the audit conducted, the mill shell heat loss is approximately 800 000 ℎ𝑟 and assuming
that 10% of the heat is lost at the HGG piping to the ball mill (encircled red), the total losses will
approximately be,
𝑘𝐽 𝑘𝐽
800 000 + (0.1) (19 822 820 )
ℎ𝑟 ℎ𝑟
𝑘𝐽
= 2 782 282
ℎ𝑟

Actual 3D Model of the Existing HGG System

Total heat requirement

Putting together all the heat requirements of the material and the losses, the gross total heat
requirement is approximately,
𝑘𝐽 𝑘𝐽
19 822 820 + 2 782 282
ℎ𝑟 ℎ𝑟
𝒌𝑱
= 𝟐𝟐 𝟔𝟎𝟓 𝟏𝟎𝟐
𝒉𝒓
The ball mill power input is 2200 KW and about 90% of that energy is converted into heat, the
approximate energy that is being converted to heat is indicated below,
𝑘𝐽 3600𝑠
2 200 . 𝑥(0.9)
𝑠 ℎ𝑟
𝑘𝐽
= 7 128 000
ℎ𝑟
The circulating load that is fed back to the ball mill can be considered dry and about 10% of its
energy is usable heat. The maximum circulating load for TP cement is 150% of the feed. The specific heat
of the rejects as per the mill audit conducted is 0.748 kJ/kg with a temperature of 94oC

𝑘𝑔 𝑘𝑔
𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑙𝑜𝑎𝑑: 85000 (1.5) = 127 500
ℎ𝑟 ℎ𝑟

Usable heat
𝑘𝑔 𝑘𝐽
127 500 (0.748 )(94 𝐶)(0.1)
ℎ𝑟 𝑘𝑔. 𝐶
𝑘𝐽
= 896 478
ℎ𝑟

Subtracting the energy converted to heat of the mill and the approximate usable heat of the
rejects from the separator to the gross total heat requirement, we get the net total heat requirement of
the system.

Net heat requirement

𝑘𝐽 𝑘𝐽 𝑘𝐽
22 605 102 − 7 128 000 − 896 478
ℎ𝑟 ℎ𝑟 ℎ𝑟
𝒌𝑱
= 𝟏𝟒 𝟓𝟖𝟎 𝟔𝟐𝟒
𝒉𝒓
 A heat of approximately 14.5x106 kJ/hr has to be supplied by the HGG system to the ball mill to
vaporize the moisture of the materials and heat the materials to the desirable temperature of 100oC.

When using a bunker oil with maximum viscosity of 230 Cst at 50oC (ASTM Standard), the
required injection viscosity of the fuel is 17 Cst – 30 Cst. The fuel should achieve a heating of 98 oC - 109 o
to attain the required viscosity for injection.

Fuel Consumption Calculation

Density of Bunker oil: 0.9841 kg/L

Density Correction:
𝑘𝑔
0.9841 [1 − (98C − 15C)(0.00064)]
𝐿
𝑘𝑔
= 0.9318
𝐿

The heating value as per the latest Certificate of Analysis is about,

𝐵𝑇𝑈 𝑘𝐽
17 212 = 40 035
𝑙𝑏 𝑘𝑔

Heating value per liter of fuel,

𝑘𝐽 𝑘𝑔
40 035 (0.9318 )
𝑘𝑔 𝐿𝑖
𝑘𝐽
= 37 304.6
𝐿

Solving for the fuel consumption per hour,

𝑘𝐽 𝑘𝐽
14 575 819 / (37 304 )
ℎ𝑟 𝐿𝑖
𝐿𝑖 𝑘𝑔
= 390 𝑜𝑟 364
ℎ𝑟 ℎ𝑟

Theoretically, the fuel that must be supplied to the burner is about 390 Li/hr or 364 kg/hr to
achieve moisture vaporization and attain required temperature of 100 oC.