kiln audit h&m balance calculation 2012

8/9/2019 Kiln Audit H&M Balance Calculation 2012

http://slidepdf.com/reader/full/kiln-audit-hm-balance-calculation-2012 1/24

The following colour code is used:

Blue on yellow Cells to fill in

Data input is carried out on 4 input sheets (Input Sheet 1 to 4).

Source: CTEC Heat Balance Tool 200 ! updated in 200"

#uthors: Bernhard $oec% & Cen% Es%in

Any error to report ? Suggestions for improvement ?Please contact your TC or the authors above.

#ll ri'hts o reproduction representation adaptation and translation relatin' to this report *elon' to +aar'e S#. +aar'e S# reser,es the ri'ht to e-ploit this report or not and to reeldistri*ute it to all o its current and uture su*sidiaries /orld/ide in an or /hether paper electronic or di'ital includin' ,ia internet and&or intranet. This report alon' /ith its contentis o a conidential nature. In particular it a not *e reproduced copied transitted pu*lished di,ul'ed and&or appropriated in /hole or in part or personal use or or use * a thirdpart /ithout prior consent ro the roduction rocess Departent e-cept or reproduction * or or ailiated +aar'e copanies.

JOB AID

Kiln Heat Balance Calculation Calciner _ Preheater

1 /18

PR PR T!"#!$ v1. # %an &!!"

Pyroprocessing

This tool is used or %iln audits3 *alance calculations and reportin' o the. This ,ersion is the oicial release 1 as di,isiontool. orer ,ersions distri*uted in CTEC area are replaced * this release 5 the chan'es and ipro,eents copared tothe #pril 200" ,ersion are docuented in the ne-t pa'e 6 re,ision.

# detailed trainin' on the tool is pro,ided in the process en'ineer trainin' roprocessin' 2 (%iln audit trainin'). To 'uide theuser coents are a,aila*le or ost input cells and iportant calculation cells.

This tool is usin' the updated #dd I7 unction therodnaic.-la ro 8anuar 2009 (1.*). ;ser should install the updatedadd5in prior to usin' the tool. The add in ile as /ell as an installation 'uide is attached *elo/. The ne/ add in ,ersion allo/sthe use o ne'ati,e teperatures an <Enthalp6ree< unction /ithout /ater e,aporation is ipleented.

There are no a%ros used or calculation to %eep the tool transparent. The onl a%ro used is to ensure the proper unctiono the add ins 5 the a%ro is deletin' an path to therodnaic unctions /hich i'ht occure /hen copin' ro anotherC.The add in unction still ha,e soe lo'ical chec%s /hich i'ht cause error assa'es durin' data input (unlo'ical data aslon' as the input is not copleted). 8ust a%no/led'e and continue /ith urther data input.

The cells are not protected to allo/ ollo/ up /ith the orula auditin' = ta%e care not to odi. Input is done onl on the

input pa'es and to *e custoised e-aple pa'es at the *ac%.

Suar laout o tool: 4 input sheets /here data entr is processed into aterial *alance /aste 'as calculation and inallheat *alance sheets. Balanced i'ures o perorance results are suari>ed in a inal sheet.The calculation and result sheets are created to *e directl copied into the audit report.

reheater and&or precalciner %ilns are supported * the tool (still separate line calciners /ith separated preheater strin'sneed anipulation * user). or /et lines and lon' dr lines a separate ,ersion is in use /ithin CTEC and a,aila*le asdi,ision tool soon.

lo/ sheet e-aple and e-aple or cclone speed calculations are added at the *ac% the are lin%ed to the input sheets othe heat *alance *ut are not used or heat *alance results the can *e custoised or the speciic application.



Kiln Heat Balance Tool _ Calciner Preheater

Revisions

Version Date Who CoentsDivision !"# $an%#& DPC CT'C Kiln Heat Balance Tool v" !"(") *ecoes the division tool version !

or pu*lication on Ceent ortal3s roprocessin' doain

CTEC 1626A 7o,50" Bernhard $oec% Ipro,eents & Correction since 161 #ll chan'es since the irst CTEC release 161 are docuented *elo/.

CTEC 161 #pr50" Cen% Es%in icial release /ithin CTEC 5 spread out in CTEC areaBernhard $oec%

CTEC test ,ersion 200 Cen% Es%in ;sed * CTEC process en'ineers since *e'in 200 5 irst use in %iln audit trainin' 5Bernhard $oec% Sept 200 5 irst sharin' /ithin the co*ustion C

+,-T ./ 0.D,/,C1T,.2- 3V'R-,.2 !"! T. V'R-,.2 !"(")4

1) /aste 'as calculation: +H as ired is corrected /ith 94%cal&$8 /ater instead o 9A *eore.

2) /aste 'as calculation and calciner /aste 'as calculation: correction o "" 5 a*ient air oisture /as not considered in ass section

) Chan'e o clin%er heat o oration. Dehdration o cla is considerin' the cristal /ater. CS is /ithout S su*straction.

4) alse air tertiar air related to tertiar air input at the calciner

) Correction o oisture 5 aterial *alance 79 and 9

A) aterial *alance C42: Chlorine added to total

) aterial *alance FA": corrected D4 (*pass dust) instead o D44") Input: or a preheater %i ln cells BABF1F10810 <7ot applica*le or preheater %iln< sentance added

9) Input C: preheater alse air in a preheater %iln is calculated usin' a separate eGuation and not lin%ed to aste Fas Calc. 11 <Tertiar air int

10) Input I1: no ,alue in case o preheater %iln

11) Heat ,alue o C in the e-it 'as considered as heat loss

12) aterial *alance: S Cl and uel #sh is ta%en ro as ired (/as ta%en ro input 2 *eore /ithout considerin' /et&dr)

1) aterial *alance C and " 555 correction o S25&TC and oisture calculation (dr 55 drJTC&S55/etJTC&S).

Correction o all dependend calculations /hich had *een CA *eore to C (calculated clin%er analse C2 ra/ i-...)

14) # ne/ input ield (input 1 5 % iln eed *alanced dr) is created to a,oid circular reerence in the aterial *alance 5 used to calculate the S2 eiss

1) aterial *alance: $iln eed S25 trapped is added to uel ash.

1A) Correction o aterial *alance *ased on %iln eed

1) TC and S lo/ in e-it 'as calculations (4 and K 4) are *ased on C aterial *alance

1") heat capacit or 'ases ro teperature 0LC to 50LC is added

19) enthalp or H2, /ithout heat o ,apori>ation is replaced:

enthalp6ree(< <! )

20) enthalp or %iln eed ilter dust and *pass dust are *ased on their cheical coposition21) enthalp or coal (dr) is *ased on ,olatile content

22) enthalp or oil is *ased on the densit

2) aterial *alance HA" corrected

24) Input 1 E2 deleted (*pass dust no/ * deault not included in clin%er /ei'hin')

2) Calculation o secondar air is corrected * usin' *lendteperature6ree. In ,ersion 1 ,ol M oisture had *een used in I22 instead o ass M.

2A) Corrction o *pass ipact in /aste 'as calculation 5 7A & 7" & 790.

2) Calculation o C2 and C2 ossil added input ields or M ossi l per uel added.

2") aste 'as calc and calciner e-it 'as: Correction o cell D and 5 use o calculated -'en in C11 instead o 209.

29) Sulide considered in +I chec% 5 input 1

0) aste 'as calculations K1 5 Sulide o-dation into S instead o S2 is considered dependin' on the trappin' coeicient e2 o-idation ro

1) aste 'as calcualtion neutral co*ustion air 5 -idation into S instead o S2 is considered.

2) Heat Calculation Cooler 5 2 and +10 5 chan'ed *ac% ro *lendteperature6ree to *lendteperature considerin' recalculated ener'ies in I21

(the *lendteperature6ree unction used *eore sho/ed in soe iteration cases an error).

) aterial *alance 5 S2 eissions not considered as output or the *ac% calculation o %iln eed or clin%er.

4) aste 'as calculation and calciner e-it 'as calculation (D100...) 5 a*ient oisture considered in the e-cess air o %iln and e-cess air o line. C

) *lendteperature6ree replaced * *lendteperature /ith recalcualted enthalp. (priar air and alse air in heat calculation %iln)

A) aste 'as calculation '4 5 a*ient oisture considered in the *pass e-cess air.

) aterial *alance DA 5 decar*onatisation ener' o *pass dust 5 ta%in' Ca ree in *pass dust as input i'ure

") aste 'as calculation and calciner e-it 'as calculation 5 CA is ta%in' directl the decar*onatisation C2 ro the aterial *alance 5 considerin'

9) Chan'e to the updated therodnaic.-la (1.* 5 8an 2009). Iproo,ed help and description o the add ins. Correction o *lendteperature6re

40) aterial Balance T2A & N2A and #C2A: ;se o ne/ Enthalp6ra/i- unction. Cheical analse is totalised to 100M to a,oid issin' Enthalp o



KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 1

Plant Name Rawang5 0alaysia Kiln Feed Preheater dust Bypass D

Name of the Kiln RK67 Flowrate wet, kg/h (8#### 9!(#

Kiln Type #"(! #

Date of measurement 0arch !65 (#!( Temperatures,°C )& 99;

Date of report Crystall ater, ! ! #"9

"m#ient temperature, °C 6#

"ltitude a#o$e sea le$el, m% 9# Kiln Feed Preheater dust Bypass D

"tmospheri' pressure, hPa !##8 *rr+,11 )"8! !("!!

"m#iente relati$e humidity, ! ;#< #"&& 6"&9

#"9! !"89

;#< Ca(, ! ;#"68 99"&6

#< )g(, ! #"98 #"98*atio hot meal/kk !"!& +( ,! 9#"6 69"&

Kiln inlet dust g/kg'k !;# 6&"6

#"!8 #"&!

s there a #y-pass in the kiln. #"#6 #"#9

olume ratio of gas e0tra'tion at the #y-pass, ! #"##< #"#)

Ti( ,!

Non Car#onated Ca( in Kiln Feed / Total Ca(, ! # T(C ,!

Non Car#onated )g( in Kiln Feed / Total )g(, ! #

ree li

Kiln feed dry - #a'k 'al'ulated, kg/h1 6#8)8# 0" +( 'he'k 0.00 4.0

Total 99.64 64.65

&2(, !

3i(2,!

"l2(

4,!

Fe2(

4,!

3(2 trapping ! of 3 -2

T(C #urnt in 'al'iner

C(2,!

K2( ,!

Na 2( ,!

3(4,!

P2(

5,!

Cl- , !

3-2 ,!

Precalciner

No



KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET

KILN FUELS on Burner PRECLCINER FU

Name of Fuel 3er$o Coal 3er$o Coal Bottom feed *i'e hus

Flowrate, kg/h fired 8)(; 8#; !(;# !#

"nalyse 6dry / wet7 dry dry dry dry

Car#on, ! ;)"8# ;)"8# !("&# 9!

&ydrogen, ! ;"&# ;"&# !"#; ;

3ulphur, ! #";# #";# #"!9 #

(0ygen, ! !;";# !;";# ;"!6 69

Nitrogen, ! #";# #";# #"() #

"sh, ! !&";# !&";# &"(& !)

Total, ! &8"# #"## #"## #"## #"## #"## &8"# &8" &&

+& 8k9/kg: (9!99 (9!99 ;(& !)#

!6"8! !6"8! ("#; !8

Temperatures,°C )# )# #

$olatiles,! 9# 9# !!

fossil 'ar#on, ! !##< !##< !##< !#

oil density, kg/dm;

"sh < "sh 2 "sh 4 "sh = "sh 5 "sh > "sh ? "sh @ "sh A

;!"8 ;!"8 6)"!6 &9

!)"9; !)"9; !6"6; #

"&8 "&8 !("9( #

Ca(, ! )"! #

)g(, ! 9"9 9"9 #";; #

(")) (")) !"9 (

("89 ("89 #"(9 #

Ti(, ! #"6 #"6 #"6& #

#"6) #"6) #"!)( #

Total, ! &9"( # # # # # &9"( #"8#! &&

Choose -uel Typeð

Cl-, !

&2(, !

3i(2, !

"l2(

4,!

Fe2(

4, !

K2(, !

Na 2(, !

P2(

5, !

Coal AF-sol. Gas Coal Coal Coal CoalCoal Coal AF-sol



KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 3

Preheater E#it $as =C l>h %all Losses ?$>?gc? K

as Flowrate Err:11 9)( Kiln &"6 $

Preheater ater ne'tion Err:11 # 0 Preheater !!; $

Tertiary "ir Du't !!"9 $

Preheater E0it 3tati' Pressure, hPa %89"&6 $

?

=C &ain 'urner 2@>h =C

Precalciner E#it $as Err:11 &!9 Transport air < (89) 6#

Transport air 2

Pre'al'iner E0it 3tati' Pressure,hPa %8"8 Transport air 4

Transport air =

$as (easure(ents C. A<

Kiln inlet,! 6dry7 ;"( #"#(9

Preheater outlet, ! 6dry7 6"); #"#8

Cal'iner (utlet, ! 6dry7 !"6 #"!; Precalciner 'urners 2@>h =C

Transport air < (86; 6#

&ain 'urner 2@>h =C < Transport air 2 !(9# 6#

Primary air < (86 6# Err:11 Transport air 4 69;; 6#

Primary air 2 Err:11 Transport air = 69;; 6#

Precalciner 'urners

Primary air < By)Pass 2@>h =C

Primary air 2 OO Extracted kiln inlet gas Err:11

Primary air 4

False air 2@>h =C < Preheater false air assessment for preca kiln Err:11

Kiln hood sealing Err:11 6# 9"#Kiln inlet sealing Err:11 6# 9"#

"irlift )8!6 ); Err:11

Preheater false air Err:11 6# Err:11

Tertiary air false air (9&& 6# Err:11

False air 'al'iner )##

26 >h

26 >h C

.(A<



KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 4 - COOLER

Cooler *ans

Fan < 6969( 6# "! 1. .09 3e'ondary air Err:11

Fan 2 ;8&!8 6# &"6 1.A 1A." Tertiary air Err:11

Fan 4 &;(! 6# !;") 1.0 1.9 )ill take off <

Fan = (86!! 6# "( 1.10 9.11 )ill take off 2

Fan 5 9#6;) 6# !("! 0.9 1.1A E0haust air measured

Fan > 6&(&; 6# !6") 0."0 A4." E0haust air 'al'ulated Err:11

Fan ? (8(6; 6# !;"! 0.2 9." &ot 'linker temperature, °C

Fan @ (898& 6# (!"( 0. 101.0 Cold 'linker temperature, °C

Fan A

Fan <

Fan <<

Fan <2

Fan <4

Fan <=

Total 1A4 101.0 0.9

all losses of 'ooler?$>?gc?

"ir leakage lea$ing 'ooler (9"##

False air entering 'ooler Coolin' air: 1.7P&%'cl

/lowrate526 >h

Teerature5=C

rate 1rea5(

26 >s>(

Cu" 1rea5(

/lowrate526 >h

Tee=

E0haust air waterine'tion

litres>h or?g>h

Tee=



KILN AUDIT HEAT BALANCE TOOL - MATERIAL BALANCE CAL

Kiln /uels Preca$iln eed Ser,o Coal 0 0 0 0 0 Ser,o Coal Botto e

lo/rate Qt&hR 2"0 ".A2 0 0 0 0 0 ".0 1.

0.21

Sulphur QMR 0.4 0.00 0.00 0.00 0.00 0.00 0.4 0.

#sh QMR 1A."1 0.00 0.00 0.00 0.00 0.00 1A."1 .

Cl QMR 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.

$iln eed #sh 1 #sh 2 #sh #sh 4 #sh #sh A #sh #sh "

A."1 1." 0 0 0 0 0 1." A.

0.99 1A.4 0 0 0 0 0 1A.4 1.

0.41 .9" 0 0 0 0 0 .9" 12.

Ca 0." 0 0 0 0 0 A

' 0.4" 4.4 0 0 0 0 0 4.4 0.

+I 40.0

9.0

0.1" 2.AA 0 0 0 0 0 2.AA 1.

0.0 2."4 0 0 0 0 0 2."4 0.

0.0A

Ti 0 0. 0 0 0 0 0 0. 0.

0 0.A 0 0 0 0 0 0.A 0.1

Cl 0

H2 QMR

Si2

#l2

e2

C2

$2

7a2

S

2



KILN AUDIT HEAT BALANCE TOOL - MATERIAL BALANCE RESULTS

t / h kg/kg'k t / h kg/kg'k Clinker )easured Cal'ulated

Kiln Feed 6dry7 0.4 1. 29.41 1.2 22.4" 1".2

0.4 1. 29.41 1.2 .4 4.A

0.9" 1. 2"0.00 1.2 4.4 ."1

Total Fuel "sh ". 0.29 ". 0.2 Ca( A.A9 A9.0

0.4 0.00 0.4 0.00 )g( 0.A4 0."

Total Fuel Cl 0.00 0.00 0.00 0.00 +( 0.00 0.00

A4.14 1."2 ".22 1."4 0.00 0.00

Clinker 199.4 1.00 1"4.0A 1.00 0.2 0.

Preheater Dust 41.2 0.21 41.2 0.2 0.0 0.14

Bypass Dust 0.00 0.00 0.00 0.00 0.2" 0.1

0.00 0.00 0.00 0.00 Ti( 0.12 0.12

DehydrationGDe'ar#onation 122."" 0.A2 112.44 0.A1 0.0 0.0

A4.14 1."2 ".22 1."4 Cl 0.00 0.00

99.91 9".AA

Kiln feed wet / 'linker 1. 1.2

*aw mi0 dry / 'linker 1.2 1.29

/actor ?iln feed > clin?er for roduction: 1.40

0aterial Balance Basedon Clin?er Weighing

0aterial BalanceBased on Kiln /eed

'leental Balance Based onClin?er Weighing

3i(2

Kiln Feed 6dry G T(C G 3 -27 "l2(

4

Kiln Feed 6wetGT(CG3-27 Fe2(

4

Total Fuel 3(4

C(2

K2(

Na 2(

3(4

3(2 in preheater e0it

P2(

5



ILN AUDIT HEAT BALANCE TOOL - THEORETICAL HEAT OF CLINKER FORMATION CALCU

Clin'er ypass

1sh Corr" Clin?er Coounds gr>?gc? 1lE/ 0.022 0eta?aolin 0.04

11A.1 Kaolin 0.04 0.091 Clin?er P

14.0

11.4 0.2A

Ca( A"."9 0.00 0.002 all 7P&%'c%

)g( 4.24 0.00 C.(FG 0.2" 0.0A FC.(

Delta 0.04" Free lime

%cal&%'c% %cal&%'c% 3ulphur / "lkali

<%=5 ! 'rystal water / kg 'l +3F fCa(

Dehydration 'lay 19. 3/*

4"2.A 0.00 Clinkerisation 11.9" 10".429

2. 0.00 CrystalliHation ." ."

las formation .0Total 'ndotheric 09." 0.00 Total 'Iotheric 11.A 111."1

Theoretical Heat Clin?er5 A?cal > ?gc? 410.24 9".01

Theoretical Heat Clin?er5 A?$>?gc? 11.A9

/or coarison: PerrayJs heat for clin?er foration which is *ased on clin?er analysis

9!#"(9 A?cal > ?gc?

3i(2 -i.(

"l2(

4C

43, 8!:

Fe2(

4CaC

Cal. C

23, 8!:

'CCal. C

4", 8!:

C="F, 8!:

CaC(4De'ar#onisation

)gC(4 De'ar#onisation



Clin%er

199.4

0

Clin%er

22.4"

.4

4.4

A.A9

0.A4

0

0

0.2

0.0

0.2"

0.11A

0.0

0



lant +a*



KILN AUDIT HEAT BALANCE TOOL - FUEL SUMMARY

Kiln -ecific Heat Consution5 3-HC45 ?$>?gc? 68))

68))

Neutral Waste Gases

0ain Burner /uels Flowrate, kg/h LH, !k"/kg # as fired$ Nm%/kgck Nm%/&" 'atio o(er kiln )H*, +Ser,o Coal "A2 204AA 0.2

0.00

0.00

0.00

0.00

0.00

Preheater > Precalciner /uelsSer,o Coal "0 204AA 0.21

Botto eed 120 120 0.4

?ice hus% 1040 12A" 0.02

ood A91 4 0.0

TC "0 0.001120 0.00

-HC including T.C and -%(5 ?$>?gc?

S52



C

PR,01R /,R,2

Tpe o uel Ser,o Coal 0 0 0 0 0 Tpe o uel

Tpe o analse (dr & /et) dr 0 0 0 0 0 Tpe o analse (dr & /

Car*one A."0M 0.00M 0.00M 0.00M 0.00M 0.00M Car*one

Hdro'en .90M 0.00M 0.00M 0.00M 0.00M 0.00M Hdro'enSulphur 0.0M 0.00M 0.00M 0.00M 0.00M 0.00M Sulphur

-'en 1.0M 0.00M 0.00M 0.00M 0.00M 0.00M -'en

7itro'en 0.0M 0.00M 0.00M 0.00M 0.00M 0.00M 7itro'en

#sh 19.0M 0.00M 0.00M 0.00M 0.00M 0.00M #sh

+H Q%8&%'R 24144 0 0 0 0 0 +H Q%8&%'R

+H (%cal&%') AA 0 0 0 0 0 +H (%cal&%')

1."1M 0.00M 0.00M 0.00M 0.00M 0.00M

Total 9".0M 0.00M 0.00M 0.00M 0.00M 0.00M Total

+H calculated (%cal&%') " 0 0 0 0 0 +H calculated (%cal&%'

1nalyses as fired 1nalyses as firedCar*one 4".9AM 0.00M 0.00M 0.00M 0.00M 0.00M Car*one

Hdro'en .09M 0.00M 0.00M 0.00M 0.00M 0.00M Hdro'en

Sulphur 0.4M 0.00M 0.00M 0.00M 0.00M 0.00M Sulphur

-'en 1.AM 0.00M 0.00M 0.00M 0.00M 0.00M -'en


#sh 1A."1M 0.00M 0.00M 0.00M 0.00M 0.00M #sh

1."1M 0.00M 0.00M 0.00M 0.00M 0.00M

+H Q%8&%'R 204A 0 0 0 0 0 +H Q%8&%'R

+H (%cal&%') 4""" 0 0 0 0 0 +H (%cal&%')

2eutral co*ustion air Total 2eutral co*ustion a

7P & %' uel Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 'rr:;!! 7P & %' uel

7P & %'c% Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 'rr:;!! 7P & %'c%

7P & h Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 'rr:;!! 7P & h

2eutral waste gases 2eutral waste gaVolue Volue

lo/rate (7P&%' uel) Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 lo/rate (7P&%' uel)0.91 0.00 0.00 0.00 0.00 0.00

Err:11 Err:11 Err:11 Err:11 Err:11 Err:11

0.00 0.00 0.00 0.00 0.00 0.00





0ass 0ass

lo/rate (%'&%' uel) Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 lo/rate (%'&%' uel)

1.9 0.00 0.00 0.00 0.00 0.00


0.01 0.00 0.00 0.000 0.00 0.00





uel eed rate (%'&h) "A2.0 0.0 0.0 0.0 0.0 0.0 uel eed rate (%'&h)

Total 32@>?gc?4 Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 Total 32@>?gc?4

%8&%'c% "" 0 0 0 0 0 %8&%'c%

7P&8 Err:11 7P&8

M 22.9M 0.0M 0.0M 0.0M 0.0M 0.0M M

heat cons. includin' TCS: "A.4 92 %cal&%'c% $iln e-cess air a,ail. (7

$iln production (%'.c%&h) 19940 7eutral co*ustion air

%8&%'c% total uel consuption 658); /hich 22.9M in %iln ?atio <ra/ i- & clin%er

0.1

?atio <hot eal & c%< 1.19 (in real ass)

B%P1-- 'Itra

P.,2T 1ir

7eutral Includin' Includin' Includin' B5pass or

$I+7 ENIT %iln 0.00M .20M 0.0M 0.00M e-tracted

Volue waste gases C dr e-traction *pass Volue

lo/rate (7P&%'c%) 'rr:;!! 'rr:;!! 'rr:;!! 'rr:;!! 'rr:;!! 'rr:;!! lo/rate (7P&%'c%)

H2 H

2

H2 H

2

C2

C2

H2 H

2

S2

S2

72

72

M C2

M C2

MH2 MH

2

M72

M72

C2

C2

H2 H

2

S2

S2

72 72

M C2

M C2

MH2 MH

2

M72

M72

decar*onatisation 7P C2 & %' cli

MH2 in ra/ i- (cristall /ater)

C2hoteal

2 dr



KILN AUDIT HEAT BALANCE TOOL - COOLER HEAT CALCULATIONS SUPPORT SHEE

?g>h ?cal>h ?$>h T=C ?g>h ?cal>h ?

Fan < Err:11 Err:11 Err:11 0 3e'ondary air, T°C measured Err:11 Err:11

Fan 2 Err:11 Err:11 Err:11 0 3e'ondary air, T°C 'al'ulated Err:11 Err:11

Fan 4 Err:11 Err:11 Err:11 0 Tertiary "ir Err:11 Err:11

Fan = Err:11 Err:11 Err:11 0 )ill take off < Err:11 Err:11

Fan 5 Err:11 Err:11 Err:11 0 )ill take off 2 Err:11 Err:11

Fan > Err:11 Err:11 Err:11 0 E0haust air measured Err:11 0

Fan ? Err:11 Err:11 Err:11 0 E0haust air 'al'ulated Err:11 Err:11

Fan @ Err:11 Err:11 Err:11 0 all losses 114A9 4

Fan A Err:11 Err:11 Err:11 aporisation &eat Err:11

Fan < Err:11 Err:11 Err:11 Cold 'linker 19940 Err:11

Fan << Err:11 Err:11 Err:11

Fan <2 Err:11 Err:11 Err:11 'nergy recalculations for T=C ?cal>h

Fan <4 Err:11 Err:11 Err:11 Total Cooling Fans Err:11

Fan <= Err:11 Err:11 Err:11 Secondary Air Err:11

Total Cooling fans Err:11 Err:11 Err:11 Err:11

?g>h ?cal>h ?

"ir leakage lea$ing 'ooler Err:11 Err:11

False air entering 'ooler Err:11 Err:11

&ot 'linker 19940 Err:11 Err:11

E0haust air water in% 0 Err:11 Err:11 Err:11ater ine'tion $olume, Nm4/h



KILN AUDIT HEAT BALANCE TOOL - KILN HEAT CALCULA

/uel sensi*le heat calculations

PR,01R /,R,2

1 2 1 1 1

Ser,o Coal Ser,o

%'&h /et "A2.00 0.00 0.00 0.00 0.00 0.00

%'&h dr 4."9 0.00 0.00 0.00 0.00 0.00

1191.11 0.00 0.00 0.00 0.00 0.00

enthalp uel Err:11 Err:11 Err:11 Err:11 Err:11 Err:11

LC A0.00 0.00 0.00 0.00 0.00 0.00

%cal&h uel Err:11 Err:11 Err:11 Err:11 Err:11 Err:11

%8&h uel Err:11 Err:11 Err:11 Err:11 Err:11 Err:11




Huidity calculations /alse air heat calculations

Err:11 %'&h

#ir oisture * ass M Err:11 $iln hood sealin'

#ir oisture * ,olue M Err:11 $iln inlet sealin'

#irlit

Err:11 reheater alse air

T# duct alse air

Total

?ecalculated ener' or i-ed

Priary air heat calculations Water inuts

Main burner %'&h LC %cal&h %8&h %'&h

riar 1 Err:11 0 Err:11 Err:11


Transport 1 Err:11 0 Err:11 Err:11 reheaterTransport 2 Err:11 0 Err:11 Err:11 Cooler

Transport Err:11 0 Err:11 Err:11 Total inected /ater

Transport 4 Err:11 0 Err:11 Err:11

Preca burners By%Pass

riar 1 Err:11 0 Err:11 Err:11 as Composition %'&h


riar Err:11 0 Err:11 Err:11



Transport Err:11 0 Err:11 Err:11

Transport 4 Err:11 0 Err:11 Err:11 Total B5ass Fas

Total priar air Err:11 *rr+,11 Err:11 Err:11 B5pass Dust

?ecalculated ener' or i-ed TLC Err:11

' 2

en a p2

ca 2

2

#*solute huidit %'H2&%' dr air

et olecular /ei'ht '&'ole /et air

$iln eed total H2

C2

H2

S2

72

2



Co

PR,01R /,R,2

Tpe o uel Ser,o Coal 0 0 0 0 0 Tpe o uel

Tpe o analse (dr & /et) dr 0 0 0 0 0 Tpe o analse (dr & /et

Car*one A."0M 0.00M 0.00M 0.00M 0.00M 0.00M Car*one

Hdro'en .90M 0.00M 0.00M 0.00M 0.00M 0.00M Hdro'enSulphur 0.0M 0.00M 0.00M 0.00M 0.00M 0.00M Sulphur

-'en 1.0M 0.00M 0.00M 0.00M 0.00M 0.00M -'en


#sh 19.0M 0.00M 0.00M 0.00M 0.00M 0.00M #sh

+H Q%8&%'R 24144 0 0 0 0 0 +H Q%8&%'R

+H (%cal&%') AA 0 0 0 0 0 +H (%cal&%')

1."1M 0.00M 0.00M 0.00M 0.00M 0.00M

Total 9".0M 0.00M 0.00M 0.00M 0.00M 0.00M Total

+H calculated (%cal&%') " 0 0 0 0 0 +H calculated (%cal&%')

1nalyses as fired 1nalyses as firedCar*one 4".9AM 0.00M 0.00M 0.00M 0.00M 0.00M Car*one

Hdro'en .09M 0.00M 0.00M 0.00M 0.00M 0.00M Hdro'en

Sulphur 0.4M 0.00M 0.00M 0.00M 0.00M 0.00M Sulphur-'en 1.AM 0.00M 0.00M 0.00M 0.00M 0.00M -'en


#sh 1A."1M 0.00M 0.00M 0.00M 0.00M 0.00M #sh

1."1M 0.00M 0.00M 0.00M 0.00M 0.00M

+H Q%8&%'R 204AA 0 0 0 0 0 +H Q%8&%'R

+H (%cal&%') 4""" 0 0 0 0 0 +H (%cal&%')

2eutral co*ustion air Total 2eutral co*ustion air

7P & %' uel Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 'rr:;!! 7P & %' uel

7P & %'c% Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 'rr:;!! 7P & %'c%

7P & h Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 'rr:;!! 7P & h

2eutral waste gases 2eutral waste gasVolue Volue

lo/rate (7P&%' uel) Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 lo/rate (7P&%' uel)

0.91 0.00 0.00 0.00 0.00 0.00


0.00 0.00 0.00 0.00 0.00 0.00





0ass 0ass

lo/rate (%'&%' uel) Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 lo/rate (%'&%' uel)

1.9 0.00 0.00 0.00 0.00 0.00


0.01 0.00 0.00 0.000 0.00 0.00





uel eed rate (%'&h) "A2.0 0.0 0.0 0.0 0.0 0.0 uel eed rate (%'&h)

Total 32@>?gc?4 Err:11 Err:11 Err:11 Err:11 Err:11 Err:11 Total 32@>?gc?4

%8&%'c% "" 0 0 0 0 0 %8&%'c%

7P&8 Err:11 7P&8

M 22.9M 0.0M 0.0M 0.0M 0.0M 0.0M M

heat cons. includin' TCS: "A. 92 %cal&%'c% $iln e-cess air a,ail. (7

$iln production (%'.c%&h) 19940 7eutral co*ustion air pr

%8&%'c% total uel consuption 658)) /hich 22.9M in %iln ?atio <ra/ i- & clin%er< (

0.11.09M

?atio <hot eal & c%< 1.19 (in real ass) %'&h %iln eed (oist)

B%P1-- 'Itra

P.,2T 1ir

7eutral Includin' Includin' Includin' B5pass or

$I+7 ENIT %iln 0.00M .20M 0.0M 0.00M e-tracted

Volue waste gases C dr e-traction *pass Volue

lo/rate (7P&%'c%) 'rr:;!! 'rr:;!! 'rr:;!! 'rr:;!! 'rr:;!! 'rr:;!! lo/rate (7P&%'c%)

H2 H

2

H2 H

2

C2

C2

H2 H

2

S2

S2

72

72

M C2

M C2

MH2 MH

2

M72

M72

C2

C2

H2 H

2

S2

S2

72

72

M C2

M C2

MH2 MH

2

M72

M72

decar*onatisation 7P C2 & %' cliMH

2 in ra/ i- (cristall /ater) MH

2 (oisture) in %iln e

C2hoteal

2 dr



Com

KILN AUDIT HEAT BALANCE TOOL - COOLER BALANCE AN

Cooler input ?g>h T=C 26>?gc? ?$>?gc? <

Cooling fans Err:11 Err:11 1. Err:11 Err:11 3e'ondary air

&ot Clinker 19940 140 Err:11 Err:11 Tertiary air

E0haust air water ine'tion 0 0 Err:11 Err:11 Err:11 )ill take off <

False air Err:11 0.00 0.00 Err:11 )ill take off 2

E0haust air

Cold 'linker

all losses

ap% &eat

"ir leakageTotal Err:11 Err:11 Err:11 Err:11 Total

.ut % ,n Err:11 Err:11 Err:11

Recovery 'fficiency5 L 'rr:;!! 1ir +oad5 26

Cooling 'fficiency5 M 'rr:;!!

Recovery /actor5 ? 'rr:;!! Err:511 Cooler +oss5

Err:11 7&%'c% Err:11 7&%'c% 0.00 7&%'c% 0.00 7&%'c%

Err:11 LC 901 LC 0 LC 0 LC

19940 %'&h Err:11 7&%'c%

140 LC A0 LC

1. 7&%'c% 19940 %'&h

Err:11 LC 22 LC

Cooler +oad5

1verage Blow

0.00

0.00

0.20

0.40

0.A0

0."0

1.00

1.20

1.40

1.A0

1."0

2.00

B

B l o w

i n g

D e n s i t y 5

2

6 > s >

(

Hot Clin?er í

éTertiary air ì

0ill ta?e off 7! ì0ill ta?e off 7(

'Ihaust air î

ColdClin?er î Cooling fans ì

ë-econdary air



ate+

0iln+

Comment+

KILN AUDIT HEAT BALANCE TOOL - KILN SYSTEM HEAT B

Syste( In S+g,h "-C N(.,+gc+ +/,+gc+ heat0 content +

Kiln Feed 0" A9 Err:11 Err:511 Preheater E0it as E

A4 A9 Err:11 Err:511 Gas Composition

Total Fuel 990 Err:11 Err:11 Err:11 E

3ensi#le &eat ""A0" Err:11 Err:511 Err:11 E

Com#ustion ""A0" Err:11 "A.A Err:511 Err:11

299 Err:11 Err:11 Err:511 Err:11 E

T(C Com#ustion 0 A9 Err:11 0.00 Err:511 Err:11 E

0 A9 Err:11 0.00 Err:511 C( Err:11 E

Total False "ir Err:11 Err:11 Err:11 Err:11 Err:511 &eat +oss C( Preheater E0it E

Total Primary "ir Err:11 Err:11 0.11 Err:11 Err:511 Cooler E0haust "ir E

Total Cooling "ir of Cooler Err:11 Err:11 1. Err:11 Err:511 Cooler E0haust n% ater ap%

Total ater ne'tion 0 Err:11 Err:11 Err:11 Err:511 Cooler )ill Take (ff < E

Cooler )ill Take (ff 2 E

Clinker 1

Clinker Formation &eat

Preheater Dust

By-Pass as

By-Pass Dust

Heat Consution 3fuels only5 no T.C5-(%4: 68)) %8&%'c% By-Pass De'ar#onisation &eat

ater aporiHation &eat

all +osses Tertiary "ir Du't

Preheater

Kiln

Cooler

"otal Heat In 'rr:;!!

"otal Heat !ut

&2(

C(2

&2(

3(2 6ppm7

&2( N

2

(2

3-2 Com#ustion



ate+ 12&0&1"99

0iln+ ?$O

Comment+

KILN AUDIT HEAT BALANCE TOOL - RESULTS SUMMARY TABLE

&ain Para(eter Unit uit Result Co((ents

KilnNPreheater

*linker Production Qt&dR 4"9 +oad is hi'h due to upraded %iln ro 4000 tpd to 000 tpd

*linkerisation Factor Q5R 1.

Preheater Exit ust Q'&7PR Err:11

-op *.clone Efficienc. QMR "A.

)pecific Heat *onsumption Q%8&%'c%R "AA er hi'h SC due to lo/ . Kuart> in aterial streas to *e conired

+ Heat nput on &ain 0urner1 QMR 22.9 Too lo/. Hi'h hi'h load at due to dual eed sste.

2F )u3stitution 'ate QMR ".40 7ot includin' SBE and $i*erl Clar% in shale strea

-hermal Load !0urning 4one$ .4

)pecific Preheater Gas Flow Q7&%'c%R Err:11 Due to hi'h heat consuption

)pecific Preheater Gas Flow Q#&%'c%R Err:11

Preheater Exit Gas 5x.gen !wet$ QMR Err:11

False air Preheater and *alciner Q7&%'c%R Err:11 Hi'h. ill repair on shut do/n

Preheater Exit Gas -emperature QLCR 4A2 Hi'h due to dual eed sste

*alcination egree QMR 100.00 5

6iln 'esidence -ime Qin.R 2"

*57 total Q%'&%' clR 0.9

*57 fossil total Q%'&%' clR 0.9

6iln Loading QMR A.2"

QMR 1 Hi'h illin'. To *e optii>ed

Cooler

)econdar. 2ir olume Q7&%'c%R Err:11 +o/.

)econdar. 2ir -emperature QLCR Err:11

-ertiar. 2ir olume Q7&%'c%R Err:11 Hi'h

Q&2R

Burnin' >one illin' de'ree(uller orula)



-ertiar. 2ir -emperature QLCR 901

*ooling 2ir Q7&%'c%R 1.

*linker Exit -emperature QLCR 22

'eco(er. Efficienc. QMR Err:11

6 Factor Q5R 1.20

*ooler Load 4.4Qt&d&2R



G! S"##$ - S%&# 1 E'(%

reheater e-it 'as: Err:11 7P&h #*solute ressure:

Teperature: 9)( LC

ressure: %89"&6 halo/ in actual: Err:511 #P&h

7u*er o cclones: 9

Diaeter o sta'e e-it: !"

#rea per sta'e: 2.2 U

Total area: 9.0" U

Fas Speed: Err:11 &s



100" ha



C)*(+#, R#!($#+*# T(#

Calciner e-it 'as: Err:11 7P&h #*solute ressure: 100" ha

Teperature: &!9 LC

ressure: %8"8 halo/ in actual: Err:511 #P&h

Calciner olue: 9# P

'as ,olue: Err:11 #P&s

residence tie: Err:11 sec

kiln audit h&m balance calculation 2012

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