Residence time in Kiln t =

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

Phy

=Angle of repose for lime stone ~ 36 Degree = length of Kiln in meter

Alpha = Kiln inclination in % D N = Effective diameter of Kiln in meter = Rotation per minute rpm

Kiln Inlet

Kiln Outlet

Preheater Zone = 1 min

7.5m/sec Mat velo Max

Precalcination Zone = 2 min

B = t = 20 -28 Minutes

Calcination Zone = 10-12 min

Burning Zone = 6 8 min

4.5m/sec Mat Velo Min

Cooling Zone = 2 min

CLINKERISATION
12 CaO Lime stone 3Cao.SiO2 (C3S) Alite

2 SiO2 Silica oxide

2CaO SiO2 (C2S) Belite

1450*C 2 Al2O3 Aluminium oxide 3 CaOAl2O3 (C3A) Tricalcium Aluminate

Fe2O3 Iron oxide

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 O = % OXYGEN

KCal / Kg x 4.187 x 10^(-3) = MJ/Kg KCal / Kg x 1.8 = Btu / lb

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

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 A1= (T2a+T1)/2 - T A1= (T2b+T1)/2 - T Ambient temp = T X L1 X L2
T2a T1

L2
T2bb

A = A1 +A2

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 IB

PH fan-2 Twin cyclones

II III IV

Riser Duct V KILN STRING 950*C T.A.Duct SLC

VI V

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 = 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
Constants:

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

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
SEPARATOR B%fines/D

P= 12G
Seperator efficiency
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

A %fines/F

s C%fine/G

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

Ball Mill

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 KCal / Kg x 1.8 = Btu / lb

Characteristic Blaine 3 Days(MPa) 7 Days 28 Days

OPC-43(IS8112)

OPC-43(IS12269)

PPC- (IS1489)Part-1

225 23 33 43

225 27 37 53

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 I Cyclone Twin (Diameter) Dip tube (Diameter)

Kiln string 4000 m 6400 m 2000 m 3200 m

Pyro string 4400 m 7000 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 Kiln Shell

Pinion

Kiln Main Drive : RWN-500 Aux G.B SDA 250 54.35: 1 Motor 30 KW ; 1500 RPM

Gear box = SDN 800 Ratio = 54.35:1 Motor KW = 710 Input RPM = 100 - 1000

Motor RWB-178

G.B G.B Pinion Motor

Kiln Axis Concord Alingnomatic Geared Coupling G.G

MID KILN FEEDING

Degree Of Kiln filling & Kiln Cross Sectional loading:

% of Filling or Kilns Degree

Area of this segment (A1)

=
Area of cross section of Kiln (A)
Theta

Centric Angle Theta (Degree) 110 105 100 95 90 85 80 75 70

% of Kiln filling 15.65 13.75 12.1 10.7 9.09 7.75 6.52 5.42 4.5

Segment
r = radius inside lining

A1 =

r^2 2

O Sin O

A = II r^2

Rotary Kiln Slope versus Load

Theta
%

4.5 9

4.0 10

3.5 11

3.0 12

2.0 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 5 4 3 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 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 Note : This is Frictional Horse Power 1

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:[email protected]]

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 2

V
X K%

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 % Depth of material bed in Kiln = Y % 5 6 7 8 9 10 11 12 13 14 15

9.75

11

12.2

13.4

14.5

15.6

16.7

17.7

1.8.8

19.8

Z Cos O

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

B 7000

SCF

10.478 SCF

% Loading of Kiln :

Theoretical Flame Temperature fuel oil : T = Q Vg x Cp

Q = heating value of oil , K cal / kg

Cxfxt dxV

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 : 2.826 v 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

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

C P

Vt = V0 273 + t + K
273

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 Al2O3 MgO CaO H2O SiO2 Fe2O3 Net % X % 5.92 Multiplication Factor Y 2.22 Heat Cons Net kcal/kg

1.05 6.48*MgO6.48 63.91 7.646 3.2 22.68 2.31 99.27 5.86 5.11 0.59 Net Kcal / Kg

+ 13.1 + 6.8 + 488.7 + 18.8

_ 117 _ 1.4 = 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 A A = Heat loss of clinker leaving the kiln B = Heat loss of the clinker cooler X 100

Secondary Air Temperature = t =

K = Heat loss of the cooler , Kcal/Kg clinker

3250 (347 K ) (X.n)

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