1 2, Table of Contents INTRODUCTION. BASICS OF HEAT TRANSFER. 2.1 Conduction... 2.2 Convection... 2, Radiation ...scesesese sesentnneeneineininen sevens DESCRIPTION OF KILN SYSTEM AND OF DATA ACQUISITION 3.1 Specification Of Kiln System. 3.1.1 Kiln. 3.1.2 Preheater 3.1.3. Clinker Cooler...... 3.14 Fans. 3.1.5 Waste heat utilization... 3.2 Description Of The Kiln Investigation COMPUTATION. 4.1 Specific Produetion Rate. 4.2 Raw Meal Requirement... 4.3. Mineral Components. 44 Kiln Ga8 casceneneee ce ee 4.5. Heat Supplied To The Kiln System. 4.5.1 Fuel. 45.2 Combustible Material in Raw Meal.... 45.3. Sensible Heat..... : 4.6 Heat Expenditure Of Kiln System..... 46.1 Theoretical Heat Requirement For Clinker Formation 4.6.2. Evaporation of Water. 4.6.3 Loss with Kiln Exhaust Gas..... 4.6.4 Loss Due to Incomplete Combustion... 4.6.5 Loss with Clinker... 4.6.6 Loss with Dust....... 4.6.7 Heat Due to Convection and Radiation... 4.7 Heat Balance Of The Kiln System...Sil SOC 48 Clinker Cooler «scene 4.8.1 Determination of Secondary ~ Primary — And False Air, Their Relation Ti 3 Combustion Air 4.8.2 Heat Received By Clinker Cooler 4.8.2.1 Heat received with clinker . 4.8.2.2 Heat received with cooler air 4.8.3 Heat Expenditure of Clinker Cooler. 4.8.4 Heat Balance of Clinker Cooler 26 4.8.5 Secondary Air Temperature... n 4.8.6 Loss of Cooler and Cooler Efficiency. 7 48.7 Heat Credit Due to Cooler Exhaust Gas Utilization in Drying Systems... 28 48.8 Electrical Drives: Specific Power Consumption ...n.e:enunnenennecnsnes 28 5 Diagrams And Tables. ee eet 29 6. EXAMPLES OF HEAT BALANCES OF VARIOUS KILN SYSTEMS... 40 7. Related Topics 43 7.1 Secondary Air Temperature And Specific Heat Consumption ren 43 7.2 Preheating Of Kiln Feed - Exhaust Gas Temperature 47 7.3 Radiation And Convection Losses...... 35HEAT BALANCE & HEAT TRANSFER SUMMARY nvestigations and measuring campaigns on kiln systems yield a large I quantity of operating data. One particular possibility to make an assessment of the system is to compute a heat balance. The heat balance must include all heat intakes and expenditures thai can occur, €.&. : + Heat of combustion of fuel (also burnable components in gaseous and solid flows). Heats) of formation. Heat of evaporation Sensible heats of gas and mass flows Radiation and convection. Frequently a best balance is made for the complete kiln system, but it is also possible to consider only a part of it as e.g, the cooler. The heat balance shows clearly how the proportions of heat are distributed over the different items and is therefore most suitable to detect anomalous operating conditions. As a next step it is often possible to decide which measures should be taken in order to achieve improvements By using theoretical thermodynamic considerations, it is also possible to obtain some general characteristics of kiln systems. For a suspension preheater kiln the following conclusions can be given + In order to get a low specific heat consumption the secondary air temperature should be increased by suitable measures whereas it is not preferable to increase the quantity of secondary air (as long as its temperature is not remarkably above 9000C). + A saving of say 100 ki/kg clinker on the kiln shell losses results in a fuel saving of approx. 150 ki/kg clinker.Sl SOE Genel Heat Balance & Heat Transfer 2/63 1. INTRODUCTION This paper treats some aspects of the heat economy of kiln systems irrespective of type of kilns although emphasis is put on preheater kilns. A first part (Paragraph 2, 3 and 4) is meant to give a basic guideline for establishing heat balances of kiln tables and figures. (Paragraph 5) contains heat balances of some kiln systems. The last part of this paper (Paragraph 6) deals with the major aspects with respect to heat economy mainly of preheater kilns. As several topics related to heat balances are already covered in other papers of the course they are not repeated here; the paper may therefore appear fragmented. On the oO other hand to treat this subject exhaustively would definitely not fit into the scope of this paper. ‘The fact that this paper is intended as a first approach only is once more stressed, By no means should a kiln investigation of this nature be restricted to the formul ind methods presented here especially if a high degree of sophistication is desired. To illuminate this point attention is e.g, drawn to the formulae given in paragraph 3.5.21 which serve for the calculation of heat of formation of clinker. These formulae are by no means the only information available and if desired a more refined approach may be chosen," acme Heat Balance & Heat Transfer. 3/63 2. BASICS OF HEAT TRANSFER 2.1 Conduction Heat transfer by conduction is accomplished in two ways. The fi molecule at higher temperature imparts heat to the adjacent molecules at lower st mechanism is that of molecular interaction, in which the greater motion of a temperature, This type of transfer s usually encountered in systems where a temperature gradient exits between solid, liquid or gas molecules. ‘The second mechanism of conduction heat transfer is by free electrons, this free eletron oO mechanism is significant mainly in pure-metallie solids; the concentration of free electrons varies considerably for alloys and becomes very low for nonmetallic solids. The ability of solids to conduct heat varies direetly the concentrations of free electrons thus it is not surprising that pure metals are the best heat conductors. ‘The basic equation used to describe this process: The Fourier rate equation: A Where: 4x = heat transfer rate in the x direction. (ovatts or Btu/ hr) oO A = area normal to the direction of heat flow. (m? or f) aT Gq the temperature gradient inthe x direction (K /m or f/f k= the thermal conductivity. (W/mK or Btu/hr. fi. °))Sl SOC cmc Heat Balance & Heut Transfer 4/63 2.2 Conveetion Heat transfer due to convection involves the energy exchange between a surface and an adjacent fluid. A distinction must be made between “forced convection” where the fluid is made to flow past a solid surface by an external agent as a fan or a pump; and “free ot natural convection” where the warmer (or cooler) fluid next to the solid boundary causes circulation because of the density difference resulting from the temperature variation throughout a region of the fluid. ‘The equation used to describe this process: ‘The Newton rate equation: ¢/ A =h. AT Where: O q =rate of convective heat transfer. (W or Btu / hr) A= the area normal to direction of heat flow. (m? or f) AT = temperature difference between surface and fluid. (K or °F) h = convective heat transfer coefficient. (W/ m2. K or Bau/hr fi? . °F) This equation is not a law but a definition of the coefficient “h” which in general is a function of system geometry, fluid and flow properties and magnitude of AT.acme Heat Balance & Heat Transfer 3/63 2.3 Radiation Radiant heat transfer differs from conduction and convection in that no medium is required for its propagation, indeed energy transfer by radiation is maximum when the two surfaces exchanging heat are separated by perfect vacuum. The exact mechanism of radiant heat transfer is not completely understood, yet the remarkable fact is that a relatively complex process such as radiation heat transfer can be described by a reasonably simple analytical expression, oO The equation used to describe this process: The Stefan-Boltzmann Law: 7 =oor Where: 4g = rate of radiant energy emission. (W or Btu/ hr) A = area of the emitting surface. (nt or f) T= absolute temperature. (K or °R) = Stefan ~ Boltzmann const. (5.616 x 108 W/m? . K! or 0.1714 x 10® Bru’ hy fe °R')Sl OSOC acme Heat Balance & Heat Transfer 6/63 DESCRIPTION OF KILN SYSTEM AND OF DATA ACQUISITION 3.1 Specification Of Kiln System + Process + Manufacturer + Year of manufacture + Dimensions + Inclination + Internal heat exchanger = + Rotational speed O + Fuel (type) + Fuel supply system + Primary air supply + Primary air nozzle diameter + Kiln feed system + Dedueting system + Dust reintroduction 312 Preheater + Type Manufacturer + Year of manufacture O + Dimensions ker Cooler + Type + Manufacturer + Year of manufacture + Dimensions + Speed + Type of grate + Crusher typeSei OCT AcMc Hes Balance & Heat Transfer 7/63 3.1.4 Fans Of all fans the following information should be given : + Type + Manufacturer + Design parameters volume flow rate, pressure and temperature + Speed + Power 3.1.5 Waste heat utilization ‘The main data of the system should be given 3.2. Description Of The Kiln Investigation Under this heading all information pertinent to the exp iment is to be given, in particular: + Date + Duration of experiment + Interruptions due to kiln disturbances + Measuring techniques for fuel consumption, clinker rate, dust rates etc. + Sampling procedures of kiln feed, fuel clinker, dust gas + Frequency of sampling and performed analyses. + Information of the flow rate measurements and temperature measurements. 4. COMPUTATION 4.1 Specific Production Rate Production rate is calculated in relation to free kiln cross section and free kiln volume Production /24 h > — a tim d ross section, a a) 123 ‘ a Production 124 Hy jt volume, mSl SOC acne Heat Balance & Heat Transfer 8/63 4.2 Raw Meal Requirement For the computation of the raw meal requirement (raw meal factor) for the clinker burning the following has to be taken into consideration + ash from the fuel + dust losses, i.e. dust which is not reintroduced into the kiln system. ‘The raw meal quantity for the clinker buming this is calculated as follows clinker (free of LOD, aie kgJs + dust (free of LOD) i . kgs - ash (free of LOD, kgis rawmeal (freeOf LOD) cnnnnennne kgis _ 4.3. Mineral Components For the calculation of the theoretical heat requirement for clinker burning the main oxides as well as the following mineral components have to be determined * For calcination CaCO; - and MgCO; - contents for decomposition of clay content of kaolinite, montmerillonite and elite and other clay minerals * Time saturation * silica ratio * alumina ratio * clinker composition based on the Bogue formula Oo + 8 + Os + GA + CAF 44° Kiln Gas For the calculation of the kiln gas quantities, see paper on “Combustion Engineering”Sesustt| SEG oO oO acuc Heat Balance & Heut Transfer 9/63 4.5 Heat Supplied To The Kiln System Al heat losses occurring in the burning process have to be covered by heat input which consist of + combustion of fuel + combustion of combustible material in the kiln feed + heat received as sensible heat of fuel, raw meal, cooling air and combustion air. 45.1 Fuel The heat intake from the combustion of fuel is calculated by multiplying the specific fuel consumption k (relative to clinker) times the low heat value Hu (relative to 20°C). See also “Combustion Engineering” 4.5.2 Combustible Material in Raw Meal Combustible material in raw meal consists mainly of organic matter, the determination of which is, however, difficult, Usually the carbon content is determined and used for the heat released : que = 33.9 CeR Mivkg Clinker (qoe = 8100 CaR keal/kg Clinker ) where doe heat released by the organic material, MJ/kg Clinker (Koal/kg Clinker) Cr carbon content in raw meal (weight fraction) R raw meal factor, kg/kg clinkerSl OS0C ACHC Heat Batance & Heat Transfer 10/63 Besides organic components pyrite is sometimes encountered, its heat contribution i calculated as follows : dpe = 54 Spya-R Mike Cli (pyr = 8100 SpyaR Keal/kg Clinker) where aps: heat released by the burning of the pyrite Milkg Clinker (Keal /kg Clinker) Spor content of sulfur form pyrite in the raw meal O R raw meal factor The reference temperature of the heat balance may be set at 209C: all sensible heat quantities have to be evaluated as positive or negative with respect to this reference temperature. Positive heat inputs are the heat quantities, the temperature of which is above the reference temperature of 20°C. Negative heat inputs are thus the temperature of which is below the reference temperature The sensible heat is calculated by the following formulas : Q = mep, AT MW or oO Q = Vepy AT MW depending if mass flow rate or volume flow rate applies, where Q heat flow rate MW m mass flow rate kg/s a volume flow rate" Nn /s aT temperature difference, “C cp, specific heat Mi/kg'C, MyJ/Nm’ °C Values for the specific heat ep are found in the figures of paragraph 4. (Actually Nm is also a mass unit, it is maintained for its practicality 2oO ACM Heat Balance & Hleat Transfer 11/63 4.6 Heat Expenditure Of Kiln System 4.6.1 Theoretical Heat Requirement For Clinker Formation ‘The theoretical heat of formation of clinker according to H. Zur Strassen is calculated from the following quantities of heat + heat required to calcine the carbonates of the raw meal + heat for the dehydration of clay + heat from the exothermic effect of clinker formation + formation of all sulphates In these formulas the calculating units are based on the nonvolatile oxides of the raw meal-, dust-, ash- and clinker analyses. The following formulae calculate the theoretical heat requil ments for burning clinker from normal raw material consisting of limestone and clay or similar components : depending on how much is known of the raw material one of the following formulae (a to d) is chosen. 4.6.1.1Formulas without effect of alkalies 2) composition of clay and content of hydrate water is unknown: Q= 17.21 ap +27.13 me + 32.01 cg- 21.42 8-2.47F ki/kg clinker (Q= 4.11 ay + 6.48 me + 7.646 cg - 5.116 8-0.59f — keal/kg clinker ) b) Unknown composition of clay, known content of hydrate water Q=9.29 ap + 24.53 by + 27.13 me + 32.01 cg = 21.42 s- 2.47 f ki/kg clinker Q=2.22 ar + 5.86 by + 6.48 me + 7.646 06 - 5.116 8 - 0.59 F keal/kg clinker) c) Clay composition is known, content of hydrate water is not determined.Sl SOC a CMC Heat Balance & Heat Transfer 12/63 Q = 2.19 aq + 13.06 ay + 16.41 a 27.13 me + 32.01 ce- 21.42 s - 2.47 f ki/kg clinker Q= 5.30 ag 13.12 ay + 3.92 a) + 648 me + 7.646 cg = 5.116 8 - 0.59 fF keal/kg clinker) Known composition of clay, known content of hydrate water: Q= 13.98 ax + 6.24 ay + 7.62 a + 24.53 hy $27.13 mg + 32.01 og - 21.42 s-247f ki/kg clinker Q = 3.34 ax + 1.49 ay + 1.82 a, + 5.86 by + 6.48 mg + 7.646 cg - 5.1168 -0.59f kcal/kg clinker) oOSac SOC 3 O) acme Heat Balance & Heat Transfer 13/63 nenclature ar % Al,03 in clinker (from clay only) am % Al,O3 in clinker from montmorillonite aq % Al,O3 in clinker from kaolinite ay % Al,O3 in clinker from little hy % hydrate water relative to clinker from clay m % MgO in clinker (from MgCOs) © % CaO in clinker (from CaCOs) a % SiO, in clinker t % Fe,O3 + MagOy in clinker Q % theoretical heat required for burning clinker 4.6.1.2Formula effect of alkal ‘The heat gained by the formation of alkali sulphate is added to the heat requirement Q calculated above. ‘That is the following two formulae represent a refinement to the result of above formula. ‘The result of either of this formula (a, b) or else the average of both is added to the result obtained by applying one of the above formulas. a) Calculation based on sulphur balance : Qe - 83.74 (SUai+ SUsr-SUx) ki/kg cli (Q= - 20.0 (SUgi + SUsr-SUx) keal/kg eli) where SUci % 803 in clinker SUsr % SOs in dust of exit gas, relative to clinker = % SOs. s (s= dust loss relative to clinker) SUR % SO; in raw meal relative to clinker =%S03.R R raw meal factor, kg raw meal /kg CliSagi OSEG _ Acc Heat Balance & Heat Transfer 14/63 b) Calculation based on alkali balance (applicable if dust analysis is not known) Q= 108.02 (ng - nen) - 71.18 (ke - Kew) + 83.74 (SUg - SUca) ki/kg Cli) (Q= 25.8 (np ~ ac) ~ 17.0 (kg - koa) + 20.0 (SUr ~ SUci) ki/kg Cli) where np %Na;0 in raw meal relative to clinker oO Dew %Najo _inclinker ky %K20 in raw meal relative to clinker ken %K,0 _inclinker 4.6.2 Evaporation of Water This item represents the heat required to evaporate the free water at reference temperature. The heat of evaporation of water at reference temperature. The heat of evaporation of 1 kg water at 20°C amounts to 2.453 Myl/kg H,0 (586 kcal/kg HzO) Qiao = (Quo myn0 2.453 Mi/kg Cli myo 586 keal / kg Cli) Oo where Quo heat required for evaporation of water my, water content relative to clinker Care must be taken that the correct value for water content is used (with or without dust recirculation).xs SOG oO Oo Acne Heat Balance & Heat Transfer 15463 4.6.3 Loss with Kiln Exhaust Gas The basic equations for the calculation of sensible heat apply (see paragraph 3.5.1.3) The specific heat cpy or epy has to be calculated for the actual exhaust gas composition measured and/ or calculated (see also : “Combustion Engineering”. The values for the specific heat of the various gas components are found in figure 4 of para 4 of this chapter. Note The Orsat-analysis yields the gas composition of the dry gas only; the SO» - content is included in the CO>- content. To obtain the gas composition of the wet exhaust gas the dry gas fractions are multiplied by (I= Vigo) Vwi = (= Vino) Viki Where : Viy,0 Volume fraction of HO relative to wet exhaust gas; determined from measurement or from theoretical calculation. Vai Volume fraction of the gas component considered, relative to the dry exhaust gas: determined from Orsat-analysis or from theoretical calculation Vwi Volume fraction of the gas component considered, relative to the wet exhaust gas can also be calculated theoretically For theoretical calculation as well as Orsat -analysis and dew point calculation reference is made to “Combustion Engineering”. The heat loss by the kiln exhaust gases thus is : do = LA Vwi epy } (Me ~ 20) MI / Nm?sl SOC ACMC Hews Balance & Heat Transfer 16163 where 4 sensible heat of exhaust gas relative to Nm3 cpu specific heat of component i, determined from figure 4, parag 4 T, gas temperature, oc V, specific exhaust gas rate, Nm3/kg cli ©, _ sensible heat of exhaust gas relative to clinker To obtain the heat loss relative to clinker the above value is multiplied by the specific exhaust gas rate Ve Qa=4o- Vo Mi/kg cli The specific exhaust gas rate is determined either theoretically (see “Combustion Engineering”, and/or by measurement. 4.6.4 Loss Due to Incomplete Combustion Incomplete combustion entails losses in that the latent heat of the combustible gases is not utilized. For the calculation the lower heat value Hu of the combustible gases in question is used : Q = Df Vai -¥) Huy} MI / kg Cli ei where Q lose due to incomplete combustion Vg specific exhaust gas rate NM3 /kg clinker v; volume fraction of combustible gas considered (i) Hu lower heat volume of combustible gas considered (i). ‘The lower heat values of CO, Hy and CH, are Huco = 12.64 MJ/Nm3_——_ (3020 keal/Nm°) Huy, = 10.80MI/Nm3_—_ (2580 keal/Nm°)See OSCG oO acMe Heat Balance & Heat Transfer 17163 Huey, = 35.88 MI/Nm3 (8570 keal/Nm*) Note that y; is the fraction relative to wet gas since V;, denotes the total exhaust gas, ie. wet gas. In case dry gas analysis is available, adjustment as outlined in 3.6.3 applies. 4.6.5 Loss with Clinker ‘The amount of heat lost with clinker is calculated with the clinker temperature measured and the specific heat of clinker Qe = ep Teri - 20) MI/kg Cli oO Where Qei heat loss with clinker cep average specific heat from temperature 20 OC t0 Tex Tox clinker exit temperature Specific heat values of clinker are given in figure 5 4.6.6 Loss with Dust Heat losses due to dust occur with the dust of the exhaust gas and also with the dust of the cooler exhaust air if any. The dust temperatures can be assumed to be equal to the exhaust gas temperature or cooler exhaust air temperature respectively. Q = S. ep. (Te- 20) MiVkg Cli Where Qu heat loss due to dust S amount of dust relative to clinker, ke/kg Cli ep specific heat approximately that of CaCOs (see figure 3). The specific heat of clinker cooler dust is that of clinker (Figure 5).Sl BOC acMc Heat Balance & Heat Transfer 18/63 If the dust is not reintroduced but discarded the degree of calcination of dust has also to be considered : Qde = — $ 31.53 (CaOg- 1.274 COrg) MI/kg Cli (Que = 8 7.53 (CaOg- 1.274 COxy) Keal / kg Cli) Where Qee heat loss due to partial caclination CaO Ca0 in dust COxd CO) in dust 4.6.7 Heat Due to Convection and Radiation The heat loss by convection and radiation is calculated based on surface temperature and heat transfer coefficient by the following formula : Q =A (To-T) MW (kcal /h) Where h overall heat transfer coefficient MW k h=h, +h, (Kea y my? °C (also designed with o) he _ heat transfer coefficient for convection hh heat transfer coefficient for radiation A arcam? To surface temperature °K* (0K = OC +273) Ta surrounding temperature ‘The evaluation of the losses is rather difficult, because the heat transfer coefficient for radiation and convection are difficult to determine. The surface temperature of the kiln shell is measured with contact or radiation pyrometer, * For the calculation of heat transfer by radiation theabsolute temperature enters the formulaKates SEG Oo O ACHC Heat Balance & Heat Transfer 19/63 If a radiation pyrometer is used the temperature may not be obtained due to the emissivity of the surface; if the emissivity is known or estimated the true surface temperature can be obtained (see figure 6). 4.6.7.1 Radiation Heat Transfer Coefficient ‘The heat transfer coefficient for radiation can either be taken from figure 7 or 8 (for ¢ = 4) of para 4 or it can be calculated with the following formula Jo T, U 100 with ¢ = ce f 1)! J se m? °C (keal / m* h °C) 100 where Co stefan-Botrzmann constant = 5.67 Wim? °K°(4.88 keal/m? °K*h ) £, emissivity of surface 0 109 (2) or k K Ruge ls (tT % h = 013 Jf #8 PY | lo Ly 2 T, For graphical evaluation of the free convection heat transfer coefficient see figure 9 O b) Forced convection To calculate the heat transfer coefficient for forced convection one of the following formulas applies, depending on the magnitude of the Reynolds number . 40'000 < Re < 400'000 : Nu = 0.0239 Re-805 h = 0,0239 Re0-805 Re > 400'000 Nu = 0.00672 Reo.g05 R h= 0.0672 — Re0-905 D Nomenciature No 2 a cg, D’gBAT ne pr Cpe 3600 b re WD vgait SEE ACMC Heat Balance & Heat Transfer 21/63 D diameter of kiln m 2 thermal conductivity MW/m°C, or (keal/mh°C) acceleration due to gravity mis" B coefficient of expansion VK y kinematic viscosity m/s cp specific heat ki/kg°C, or (keal/kg °C) viscosity kg. sim w velocity of wind mis oO 4.7 Heat Balance Of The Kiln System When a heat balance is carriedout it should be clearly defined how the boundary for the balance will be chosen. Preferably the boundary limit should be marked on the corresponding flow sheet or sketch by a special, non-interrupted line. This procedure helps to avoid errors and misunderstandings since it allows a quick survey of the complete balance situation, In the heat balance receivables (input) and expenditures (output) are tabulated. In general, these items will not balance hence a rest amount of heat will remain, this should not deviate more than 3% of the total receivable.Xgl SEC acMc Heat Balance & Heat Transfer 22/63 The table below comprises the items as calculated in the preceding paras. Heat balance of Kiln system relative in 20°C : Receivable Input Keal/Kg Clinker % Fuel Sensible heat combustion, raw meal Sensible heat combustible matter Combustion air Sensible heat of all air received ‘secondary, primary air... ) Total receivables 100 % Expenditures Output Keal /Kg clinker % ‘Theoretical heat required for clinker burning evaporation of water of kiln feed exhaust gas losses losses with dust of exhaust air losses due to incomplete combustion losses due to clinker exit temperature cooler exhaust air losses losses due to dust of cooler air losses due to radiation and convection rest ‘Total expenditures 100 % oOACM Heat Balance & Heat Transfer 23/63 4.8 Clinker Cooler 4.8.1 Determination of Secondary — Primary ~ And False Air, Their Relation To Combustion Air CG VU Designation : Aa air actually supplied to kiln Asin primary air Mee secondary air Atae false air Ae air supplied to cooler Nex cooler exhaust air Alek cooler air leakageSil SEC acme ‘Heat Balance & Heut Transfer 24/63 For the determination of the percentage of primary-, secondary- and false air the following air quantities to be measured or calculated: 1. Primary air: can usually be measured 2. False air estimated or calculated approximately 3.Airtokiln: can only be calculated 4. Air leakage: has to be estimated Note that a certain air quantity may escape with clinker discharge; either to clinker dust transport below grate or at clinker crusher. Alternatively, cooler dedusting may include Oo air sources other than from cooler. Ad2 The false air leakage can approximately be calculated from the area A and the pressure difference Ap between kiln hood and surrounding, by applying the following formula: Ame = | ZAP m? / sec p where Ane false air, m’ / sec A “Jeaking” area at kiln seal, m? Ap pressure difference, Pa (N/m? ) Pp density of air ( see table 1, para 4 ) Note that the above formula yields the volume flow m/s ; to obtain Nm’ / s barometric pressure and temperature have to be considered. To obtain the false air quantity relative to clinker the air flow rate Nm’ / s is divided by the clinker rate in kg /s.Sl SOE acme cy ) Heat Balance & Heat Transfer 25/63 4.8.2. Heat Received By Clinker Cooler 4.8.2.1 Heat received with clinker The heat received by the cooler is the sensible heat of the hot clinker leaving the kiln: Qen = open (Ten ~ 20) KI /kg clinker where Qu heat received Cpeu average specific heat of clinker between 20°C and Tex ( see figure 5) ‘Ton clinker temperature at kiln exit 4,8.2.2Heat received with cooler ‘The heat received with cooler air is the sensible heat: Qco =Aco - cpa (Ta -20) KJ/kg clinker where Qco sensible heat of cooler air, relative to clinker Aco cooler air, relative to clinker Ta ambient temperature 48.3 Heat Expenditure of Clinker Cooler Expenditures may consist of: Qeii heat of clinker leaving cooler (calculation similar as in 3.8.2 ) Qcoex _heat of cooler exhaust air and / or bleeding air (calculation similar as in 3.6.3 ). Qee heat Joss by radiation and convection (calculation similar as in 3.6.7 )Atl ASC ACM neal Heat Balance & Heat Transfer 26/63 Qs heat of secondary air * (calculation similar as in 3.5.3 ) * The direct measurement of the secondary air quantity is impossible: it has to be calculated from a cooler air balance ( see 3.8.1 ). The measurement of the secondary air temperature is difficult and requires special instrumentation. ‘The heat quantity of the secondary air may be calculated from the heat balance of the clinker cooler: Qsee = CQ'CHL + Qeo )- (Qeoex * QCHi + Qe ) Ki / kg clinker Furthermore addition items if any have also to be inserted i.e., cooler blood air for material drying, gas conditioning, heating purposes, etc. 4.8.4 Heat Balance of Clinker Cooler Similar to 3.7 the receivables and expenditures are tabulated: Heat balance clinker cooler at 20°C: Receivables Kiikg clinker % O hot clinker cooler air Total receivable 100 Expenditures cooler exhaust loss with clinker loss by radiation and convection heat of secondary air heat utilization total expenditures 100AcMC Heat Balance & Heat Transfer 27/63 4.8.5 Secondary Air Temperature ‘The secondary air temperature can be calculated from heat quantity of secondary air. secondary air quantity and specific heat of the secondary air: Q Hate] Tee = —2e— + 20°C ‘ epg: Agee where Tres secondary air temperature Que sensible heat of secondary air. KI / kg clinker Avec Specific secondary air. Nm3 / kg clinker cpa Specific heat of secondary air ( see figure 4 ) 4.8.6 Loss of Cooler and Cooler Efficiency The efficiency of the clinker cooler is dependent on: + Type of cooler dimensions and throughput + cooler air quantity and circulated air if any + secondary air quantity and primary air if bleeded from cooler. + granulometry of clinker + recuperated heat, used for various purposes. In order to compare different cooler efficiencies with each other the above items have to in mind. The cooler efficiency usually stated is calculated as follows: EOL Mae PEPE ee ra where Nevoier cooler efficiency Que heat quantity of secondary air Qa heat quantity of hot clinker ( as received from kiln )0 SOG ens Heut Balance & Heat Transfer 28/63 Note that occasionally the efficiency of cooler is defined differently and may then be somewhat receivable, It is for this reason that the losses of the cooler are often indicated instead: Losses of cooler: Quex losses with cooler exhaust air Qese losses by radiation and convection Qi; losses with clinker Qu heat utilization ( where applicable ) total losses 4.8.7 Heat Credit Due to Cooler Exhaust Gas Utilization in Drying Systems If the cooler exhaust air or part of it is utilized for drying of raw materials, slag, coal, gas conditioning, heating purposes or what the case may be, part of the heat can be credited to the kiln system and / or the cooler system. However, only the heat quantity which otherwise would have to be spent ( i.e. by the drying system ) should be credited to the kiln system 4.8.8 Electrical Drives: Specific Power Consumption It is also desirable - on the occasion of the kiln measurement - to collect data of the electrical power consumption. The specific power consumption kWh/ t should be given of the following equipment of the system: + Kiln system including ( preferably itemized ) kiln drive, exhaust fan and cooler + kiln feed + Firing system Fans, other than exhaust fan Dust handling system Other auxiliary equipment of the kiln system. + +Lap-cll SEC a Heat Balunce & Heat Transfer 29/63 5. Diagrams And Tables Figure 1 Average specific heat of coal 2 Average specific heat of fuel oil 3 Average specific heat of raw meal components 4 Average specific heat of gases and vapours 5 Average specific heat of linker 6 Relation between emissivity and true and apparent surface temperature 7 Heat transfer coefficient hy and hef at various constants C, oO g SwwYounding temperature 20°C, Heat transfer coefficient hy and hof at C = 4 and various 9 surrounding temperatures. Heat transfer coefficient of air at free turbulent flow on a vertical plate Table 1 Properties of air 2 data of water vapourAa OSOC one, 7 Heat Balance & Heat Transfer 30/63 0 DD 0 D 0D % 8% 1 HO 2000 coal temperature °C —= Figure 1: Average specific heat of coal keal ' iid 0 20 40 60 60 100 120 140 fuel temperature, *C Figure 2: Average specific heat of fuel oll oOACMC Heat Balance & Heat Transfer 31163 rence temperature 420°C 100 200 300 400 6a 700 660 900 Temperature °C ——~ Figure 3: Average specific heat of raw meal componentsSl SOC Ache Heat Balance & Heat Transfer 32/63 eo 1500 Temperature Figure 4: Average specific heat of gases and vapoursacme Heat Balance & Heat Transfer 33/63 Serpeiif BOG fanuiia 4o Wey suiveds aBe1eny sanyeradusa 19 4UH 9 006 909 OL 009 OOS OOF OIE OO oo “EET aunyeseduiay aouasayos 6 aunBiy | 20 84/194acuc Sal SOC Heat Balance & Heat Trensfer 34/83 ) temperature indicatad on radiation pyrametee Figure 6: Relation between emissivity € and true apparent surface temperatureSs SOC acme Heat Balance & Heat Transfer 35/63 200 300 400 Surace temperature °C Mert free convection ceeticient (ineans there is no wind at alll) Figure 7: Heat transfer coefficient hy and hc¢ at various constants C, surrounding temperature 20 °CSeat SOC soe Heat Balance & Heat Transfer 36/63 Figure 8: Heat transfer coefficient hy + nef at C= 4 and various surrounding temperaturesACMC Heat Balance & Heat Transfer 37/63 oO Figure 9: Heat transfer coefficient of air at free turbulent Flow on @ vertical plateLp uA SOE este Heat Balance & Heat Transfer 38/63 V thermal concwetity OF Prandtl number 2 Synamis viscosity & Z te kestnykew|Reatefminerd | kev? sow) aa dow | 1203 2017 rae 8 | ones ones | 320 2 | oan oan inductively A ot air in function of preasute and temperature Bpreceard] Tempers ie 3 a oy ey oe | 0 109 {- | | oom | oss oes | aos gone | ons a8! Gyname waconty gyaa tAeP and xinemaile vsconty D «t/e Table 1: Properties of air 9ACMC Heut Balance & Heat Transfer 39/63 heed hs E HE Data of water vapour Table 2:Zp SOC owe Heat Balance & Heat Transfer 40/63 6. EXAMPLES OF HEAT BALANCES OF VARIOUS KILN SYSTEMS Kiln systems cannot only be judged based on these heat balances. The heat consumption of kiln system may depend on many factors, Main factors are : + kiln size, i.e. production rate + dust circulation in the kiln system + heat loss due to radiation and convection + secondary air temperature + operating conditions of kiln Furthermore the related kiln system has also to be taken into account. Consider a grate preheater kiln ( Lepol-kiln ): lis specific heat consumption may almost be as low as that of a 4-stage preheater kiln However, the grate preheater kiln, the semi-dry type, requires that additional heat is spent for material drying, whereas the exhaust gas of the 4-stage preheater kiln may be utilized to dry up to 7.5 % water content of the raw material. The table 3 gives heat balances of three different kiln systems. The wet kiln has a O production capacity of approximately 3000 t /d, In general grate preheater kilns of the semi-dry type have a heat consumption slightly higher than the 4-stage preheater kilns. The heat balance of the 4-stage preheater kiln is typical the 2000-3000 t / d range. In order to give some idea of the influence of the kiln size on specific heat consumption figure 9a which applies for 4-stage preheater kilns - is given.VU Heat Balance & Heat Transfer 41/63 ACMC ‘Table 3: Heat Balances of Wet, Grate Preheater and Preheater Kilns | Wet Process TLEPOL Dry Preheater 1, Heat introduced: Ki/kgel]| % | Kivkgei [| % | Ki/kgeli | % FUEL from sensible heat 25 04 - - 1B 04 from combustion 5560 | 967 | 3295 | 962 | 3120 | 97.19 RAW MEAL from sensible heat 25 04 92 27 54 7 * from sensible heat ne 102" - - - - of water in slug COMBUSTION AIR from sensible heat of all 67 12 38 Ma - - the air supplied (prim. sec.) ‘Total receivables 3750__| 100 [3425 | 100 | 3187 100 2. Heat spent Theoretical heat required to} 1760 | 306 | 1760 | si4 | 1760 | 552 bburn finker Evaporation of water fiom) 2370 | 41.2 | 507 14.8 13 04 the raw meal Exhaust gas losses 54 | 13.1 314 92 636 20.0 Losses due to incomplete] — - 7 - - - combustion Losses due to clinker exit] 59 10 50 1s 683 20 temperature Losses due to cooler exhaust] 100 | 1.7 276 81 423 133 ‘gases Losses due to dust 28 4 a 06 8 03 Losses due to radiation and] 540 | 9.4 452 132 | 297 93 convection Water cooling ( Recupol inlet | —- 2 12 7 - chute ) Rest 142 | 25 4 o. 13 o4 ‘Total expenditures 5750_| 100 | 3425 {| 100 | 3187 100A. A OSEC ACM inal Heat Balance & Heat Transfer 42/63 . 5 Kiln diashever, m Figure 9a: Relation of Kiln Capacity m, Specific Heat Consumption q and Kiln Diameter of a Conventional 4-stage Preheater Kiln Since the following factors - theoretical heat of clinker burning, bumability of material, moduli, degree of dust formation, type of fuel used, type of cooler used - influence both specific heat consumption as well as output, a range rather than a single curve has to be considered. OoSul OSEE acme Oo Heat Balance & Heat Trunsfer 43/63 7. Related Topics 7.1 Secondary Air Temperature And Specific Heat Consumption It is obvious that the efficiency of the clinker cooler as well as the secondary air temperature have a remarkable influence on the specific heat consumption of the kiln. In a kiln system with comparatively high specific heat consumption the combustion air quantity is also large. Therefore, the full amount of cooler air could be introduced into the kiln as secondary air, Other parameters such as type of cooler, radiation and convection are also effective, In a kiln system having low specific heat consumption the required combustion air is also low (can be as low as 0.8 Nm? / kg clinker ), consequently with the often applied grate-coolers not all cooler air is required for the combustion. To illustrate this consider the following hypothetical ca + Clinker is fo be cooled from 1350 °C to 70°C yielding a heat quantity of 1.378 MI/ kg clinker ( 329 keal / kg clinker ). + Assume for this consideration no heat losses (radiation, convection) of the cooler: + Assume the cooling of the clinker is achieved with air of 30°C ( in some cooler systems water evaporation is also applied for additional cooling ). + Depending of the quality of the cooler - from a thermodynamic point of view - a different secondary air temperature can be achieved and hence the amount of cooler air varies accordingly yielding curve | of figure 10 + It can be seen from this curve that even at a secondary air temperature of 900 “C the resulting cooler air quantity is larger than what is required by an economic kiln, If oil firing is assumed to require say an excess air factor of 1,05 and 5% primary air than the secondary air required for combustion is obtained as shown on curve 2 of figure 10.Sl OSOE acme Heat Balance & Heat Transfer 44/63 The heat losses due to radiation and convection are not considered in figure 10. Curve 3 shows a range of secondary air temperature attained in practice, this depends on clinker properties, type of cooler and its specific loading. The relation between secondary air temperature and specific heat consumption is shown in Fig. 11 The specific heat consumption decreases with increasing secondary air temperature. Again the actual relationship may depend on several parameters, not only on the specific heat consumption itself but also on the excess air factor n of the firing. The relationship presented in Fig. 11 is calculated for a typical 4-stage-preheater kiln,Zapucl SEG seve tea Balance & Hea Torso 4583 oO setae if v200 fe Figure 10: Relation of air quantity and secondary air temperature and specific heat consumption 1on of kiln neat lly attained wth ol O eet Figure 11: Relation between secondary air temperature and specitic heat consumption (calculated tor typleal 4.stage preheater kilnZap tt SEC sew Heat Balance & Heat Transfer 46/63 As can be seen from the figure 11, the savings in specific fuel consumption is substantial if it is possible to inerease the secondary air temperature, Furthermore it is shown that at high secondary air temperature increasing the excess air factor by increasing the secondary air quantity the specific fuel consumption is also decreased. However, at secondary air temperatures below 900 OC the difference is marginal and would be more than off-set by other disadvantages. Increasing the air quantity will ensure loss and increased gas quantity will result in a higher specific power consumption of the exhaust fan, In case the exhaust fan is at its capacity limit a decrease of the production would result. Cooler Design Considerations: Various facts contribute to the limitation of the thermodynamic quality of the clinker coolers, such as: + Coolers are designed as cross flow heat exchanger and therefore limitations are set to the efficiency. (4 different new type cooler, working as counter current type heat exchanger, was developed some years ago ). + The granulometry of the clinker in most installations is farfromideal. Large lumps of clinker take long for cooling down due tothe heat conductivity required for heat flow. ‘The wide band of granule size sets severe limitation to an adequate cooler design. oO + The operation is often the limiting factor for not achieving better cooler efficiency. Reference is made to the lifters of planetary coolers as well as to the grate plates of the grate type cooler. + Finally it has to be kept in mind that thermodynamic considerations are only one f2 of the overall operating cost. On a grate cooler best efficiencies are achieved if the clinker bed thickness is at a maximum. This however necessitates that stronger blowers are installed to overcome the larger pressure drop; higher specific power consumption will resultSates SLT rile Heat Balance & Heat Transfer 47/63 7.2. Preheating Of Feed - Exhaust Gas Temperature If the heat balances of preheaters kilns or precalciner kilns - the kiln systems considered are that of the state of the art of today -are critically examined ( sec table 3 ), it is noted that the loss of the exhaust gas amounts to up to and even exceeding approx. 20 % of the expenditures of the kiln system. If compared to the total losses ( expenditures other than the theoretical heat required for clinker burning ) the exhaust gas loss is by far the largest contribution and may be responsible for more than 50 % of the losses, When compared to the heat balance of the grate preheater kiln ( table 3 ) or even the wet kiln ( table 3 ) it is noted that these kiln systems have both lower exhaust gas temperature and lower exhaust gas losses ( at least if water evaporation is not included ). The question therefore, arises why these losses are not decreased in case of the preheater- and precaleiner kilns, A kiln system represents a thermodynamic system the main function being that of the heat transfer of the heat of the fuel to the kiln feed in an optimal manner to produce the desired product. The heat transfer rate is generally calculated as follows: q=A*h*AT heat transferred kiln gas {also flame) to the material surface where heat transfer tekes place heat transfer coefficient temperature difference between kiln gas and ma- terial surface, AHeat Balance & Heat Transfer 48/63 To increase the heat transfer, q the factor on the right hand side has to be increased. The heat transfer coefficient depends on the properties of the ges, on the properties of surface and largely on the gas velocity. However the properties can not be changed at all. Increasing the velocity is, however, limited by dust formation as well as other parameters. The temperature difference between kiln gas and material can be increased by increasing the gas temperature this entails however, a higher specific heat consumption and is therefore not desirable ( compare also the T-I-diagram figure 13 for reference ). ‘The surface A in a kiln - for rough considerations - consists of the surface of the material oO bed and to a certain degree also the contact surface between material and kiln lining. In order to increase the effective surface prior to the introduction of suspension preheater Kilns, chains, crosses and “heat exchangers" of various design are installed. step of improvement was achieved when the grate preheater was introduced. By passing the kiln gas through a material bed the surface effective for heat transfer is considerably increased as compared to that of the inside the kiln. However, the actual surface of a raw meal is still considerably larger than that of pallets. (For comparison consider the specific surface ( Blaine value ) of cement. ) Advantage can be taken of this fact by suspending the raw meal directly in the kiln gas for better heat transfer. The sizes of the raw meal particles and the particle size distribution of the raw meal do, however, exclude counter current in its proper sense as well as a fluidized bed (when counter current is referred to in this context this applies to the mechanism of two phase flow where “clouds” of particle form which then are able to move towards the gas stream ). For this reason, most of the widely applied raw meal preheater systems are designed in such a way that: ¢ Each stage works as concurrent heat exchanger in which the raw meal is carried by the gas ( suspension preheater ) + The stages of the preheater system are arranged so as to work in counter current.Sega OSOE Acme 3 Oo Heat Balance & Heat Transfer 49/63 As under specific conditions it is possible to obtain a certain "counter current" between raw meal and gas. This effect is applied in raw meal preheater systems ( e.g. the GEPOL of Polysius or other systems ). In the following considerations this paper is confined however, to preheater systems consisting of stages working as concurrent heat exchangers. As the effective surface of the suspended raw meal is extremely high, the heat transfer mechanism is completed ( completed = zero temperature difference ) in very short time. Figure 12 shows the progress of heat transfer for 20 fractions as well as the raw meal as a whole in a typical preheater stage. In the figure the heat transfer is calculated under the assumption that the raw meal is completely and uniformly suspended in the gas, at time 0 to be noted: Fraction No. (zero ). The influence of the particle size on the heat transfer i 2 with average particle size of 150 y has assumed gas temperature after 2.5. 10 seconds whereas the fraction No. 20 with average particle size of 150 4. takes 0.35 seconds. If the bulk of the raw meal is considered, heat transfer is practically ( i.e. temperature difference reduced to only few degrees ) completed in one tenth of a second. The mechanism of uniformly suspending the raw meal over the gas stream will of course take somewhat longer time. In order to fully comprehend the gas temperature profile of a 4-stage preheater kiln, consider the temperature - enthalpy - diagram (T-I diagram ) as shown in figure 13.ACMC Heat Balance & Heat Transfer 50/63 oO ae ft oa Ze sso} 2 L _——— Ww Figure 12: Heat trarust SOC acme Heat Balance & Heat Transfer 51/63 Kiln Exit ) T Ckcat /ug ct} Figure 19: Temperature ~enthalpy — diagram of a 4~ stage preheater kiln4h SEC ene Heut Balance & Heat Transfer 52/63 ‘The I-T curve applies to the material only; this represents approximately the temperature - enthalpy bahaviour of a typical raw meal. Note that time and location in kiln are not proportional to the enthalpy scale gas tems corresponding to materia enthal In the kiln itself the temperature difference between gas and material is comparatively large to ensure the necessary heat transfer rate. Note that more than 50 % of the total heat is transferred to the material in the kiln, In the preheater section the presentation of the I- T-diagram needs some explanations: as was outlined above the heat transfer in the cyclone stage is completed in rather short time resulting in equal temperatures after each stage. Consider stage 1 ( the upper most stage of the preheater ): - see also figure 14 - the gas coming from stage 2 has a temperature of 500 OC , the raw meal fed to this stage has 65 OC ( assumed temperature of feed ). The resulting temperature at the exit of the stage depends on the quantities of the gas stream as well as on the material stream as seen from the heat balance of the stage: Qeas = — Qmeal + Qloss or Mus CParsie AC gos-Mgas - CPgas - AT g = Mmeal - CPmeal - ATm + Qloss 8 In the sample considered the resulting temperature is 320 °C.anc SEG acme Heat Balance & Heat Transfer 53/63 Similarly the T-I-curves can be constructed for the remaining cyclone stages From these considerations, it now follows that the exhaust gas temperature depends on + number of cyclone stages + gas quantity + gas temperature of transition chamber + dust load of gas at various stages ( dust recirculation ) Increasing the number of stages will result in a lower exhaust gas temperature and hence decreased losses. At the same time, the pressure drop will however increase entailing higher specific power consumption. As in almost all cases the exhaust gas can be utilized for raw material drying the question as to the installation of a 5-stage preheater rarely arises.Anti @S00 sce Heat Balance & Heat Transfer 54/63 kiln feed exhaust fan by pass installation kiln inlet — abi Figure 14: Schematic of a 4~stage preheateracu Heat Balance & Heat Transfer 35/63 Figure 15: Influence of number of stages on specilic heat consumption Figure 15 shows the influence of the number of stages on the heat economy if the kiln shell as well as kiln inlet temperatures are assumed constant and with limited influence of dust. It can be seen that an additional ( Sth ) stage will lower the specific heat consumption by 71 KJ / kg clinker. Note that a 2 stage preheater kiln is designed with a much longer kiln, therefore, the data of figure 15 do not apply to this kiln, 7.3 Radiation And Convection Losses Losses due to radiation and convection of the kiln equipment are less importance than exhaust gas and cooler exit air losses nevertheless some consideration may be of interest. In para 3.6.7 these losses were calculated as follows: Q=h*A(T—-T.) MWHeat Balance & Heat Transfer 56/63 ie. the heat losses were calculated on the basis of the surface and surrounding temperatures, area A, and heat transfer coefficient. For decreasing the heat losses the surface temperature of kiln, preheater and cooler and / or the heat transfer coefficient have to be lowered. ‘The heat transfer coefficient of radiation could for instance theoretically be reduced by decreasing the emissivity. The surface temperature may depend on several factors, as can be seen if the heat transmission thorough the kiln shell is considered: oe t A(T, -T, ) MW (keal’h) Oo Vasa rk, + RO Q heat transferred through unit considered A. surface area of unit considered T, inside temperature ( kiln gas ) T, ambient temperature hy inside heat transfer coefficient h, outside heat transfer coefficient d; thickness of various materials such as coating lining, : kiln shell Oo K; _ heat conductivities of the various materials. Once Q is determined the surface temperature can be calculated by adapting above equation correspondingly: 1 + 3d, 1k, Q A(T, - T, )MW (keal/h) I where : T, is surface temperature .AA SOC acme, O Heat Balance & Heat Transfer 57/63 Similarly, if the inner surface temperature ( inside the kiln ) is assumed, the equation is: Q= 4+ ait-t) dd,/k, From the above equations it follows that Q decreases as the term hj is decreased or the term dj / kj is increased which could theoretically done by the following: + Increase thickness of coating + Increase thickness of brick lining + Insert additional layer of insulating brick + Decrease hy As concerns the sintering zone of the kiln the following can be noted: + Decreasing hy would result in a higher surface temperature T,, which most probably may not be desirable from a shell strength point of view. + increasing the thickness of lining or / and adding of insulating layer will cause the inner surface temperature to increase. This would strongly influence the coating formation such as to drastically reduce it. Thereby, the insulating effect of the coating would be lost and the originally applied improvement of insulation would be balanced off again. Furthermore, the loss of coating would have a severe negative influence on the li ing life. For these reasons, such measures cannot be recommended and are in general not applied. + In the contrary, it is often desirable to install blowers, which give an increased cooling effect on the kiln which results in improved coating formation.Heat Balance & Heat Transfer 58/63 Aa, nest joss thru waits, kcal Aig CH Figure 16: Influence of heat loss on specific oO heat consumption Note that change in heat loss was assumed uniformly over kiln and preheater respectively. ‘The influence of the hot sections ( i.e. sintering zone ) is more pronounced than are the cooler sections. ( i.c. calcining zone ); the figure gives, however, an indication of the situation: A saving of 10 keal / kg clinker on the kiln shell losses would result in a saving “in specific heat consumption of 15 keal / kg clinker ( i.e. loss factor 1.5 ) on the other hand on the preheater reduction of the losses by 10 kcal / kg clinker would only contribute to saving of 1] keal / kg clinker (loss factor 1.1).Zajac SEE acuc Heat Balance & Heat Transfer 59/63 Heat Intake kcal/kg clinker Ll §.H. of raw meal 18 1.2 S.H. of air of airlift 0.2 13 S.H. of fuel 5 14 §.H. of combustion air -0.2 LS S.H. of cooling air 3 16 S.H. of quench air -0.2 1.7 S.H. of cooling tower water 0 18 S.H. combustion heat 881 Total intakes 900.8 Heat Expenditure kcal/kg clinker E.1 Clinker Heat of Formation 409 E.2 H.L. Due to Evap. Of water 3 E.3_ HLL. Kiln Exhaust gas 208 E4 HLL. Due to CO in kiln gas 5 E.5 HLL. With dust in kiln gas 7 E.6 HLL. By-Pass Gas 55 O E.7 H.L With With By-Pass dust 7 E8 HL With Clinker al E.9 HL Due to cooler gas 129 E.10 H.L Due to Evapouration of Cond. Tower 0.1 E.11 H.L Due to radiation & convection 66 Total Expenditures 9001 Rest = 900.8-900.1=0.7 <<<8% OoACMC Heat Balance & Heat Transfer 60/63 (eZ) nodog ) Ow isn (99) sop ssog-kg (LD) 220M, ‘amor uo) (ey) sD sopoauyadedACHE Heat Balance & Heat Transfer 61/63 BY-PASS PERCENTAGE, Vol. of kiln gases : = combustion gases Vc + CO> expelled from raw meal + Excess air 1) Combustion gases Ve = 0.28xm' | xHu Now Ah 2) Vco2 exp. From RM = 0.2226xmvrxtitration No _ Nm Kier aig h Key, h 3) Excess air = [0.25xm pxHtut Viv} Nm® _ [Nm h MI h © Vol of kiln gases = VY... + Venn +Vic4 Vol. of bypass gases Vop Nm hh 20)-C,.,, lg ~ 20) EG, 20) —Cy Cn — 20) Where Voy = Quinch air fan vol.rate cemp. of gases after quinching temp. of gases before quinching tg =amb.temp. CC, =sp-heat at temp.(from curve) MIN im = fuel rateKgffh Hu = low cal. Value =40 MI/Kgf Jeal.= 4.187 MI =1061 m.Cl= clinker flow rateSl SOC Wi Iv 7 % ene, Vi V com Vio Vex Vi Bypass Gas - = V comb V' coz * Vex. combustion Ni im hh = 0.28xmsx Hu 61026 Nm’ ACMC Heat Balance & Heat Transfer 62/63 gas volume rate resulted from 0.28 x (6.125 x 0.8816 x 1000) x 40.36268 = COp gas volume rate resulted fom decarbonation of raw meal in the kiln only = 2841 cs Excess air 0,% 0.2226 x mq x titration Nosh = 2 Avice: +(0.25xmexttu)] Nmi/a 21-0,% 3.15 21-3. = 9992 = ig 254! +(0.256.125x0.8816,1000140.36268)] Nm/h 61026 + 2541 +9992 = 73559 Nm'/h Vor Quench air volume rate Nm/h (w?)xvx3600x 29 ao) 4 @i+1) Zo x30.08x3600x- 62°036 273 __ (10265 ~145) (Q73+24) 10330 Nm oOSensi SOC Acme Heat Balance & Heat Transfer 63463 oO By heat balance of the quenching chamber. (ig ~20) v = v Bee ae - (5 20)-C,, (1, - 20) = —1-35(453=20)— 1 3124-20) _ 1,68(1072 — 20) — 1.575(453 — 20) = 33.152 Nm/b Vw 9 Bypass ratio = x100 = BIZ Ls99 73559 = 45.07% ve ie + ow?