Material out = Material in + Generation - Consumption - Accumulation

Accumulation = 0 (Steady State)

Generation & Consumption = 0 (No Chemical Reaction)

Material out = Material in

Dry Basis 100 kg/day

L/S 85% 85 kg/day
Clay 15% 15 kg/day

M2 Loss 5% 0.05
Clay
M1
M3

IN = Loss + OUT
M1 = M2 + M3
15 = 15*0.05 + M3
0.75
M3 = 14.25 kg/day

Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert

% 70.69 14.91 4.5 6 1.5 2.4

M5 Loss 5% 0.05
Crusher
M4
M6

IN = Loss + OUT
M4 = M5 + M6
85 = 85*0.05 + M6
4.25
M6 = 80.75 kg/day

Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert

% 1.88 1.2 94.45 0.57 1.95 0
 M8
Raw Mill
M3
M6 M7
Loss 0.5%
0.005

IN = OUT + Loss
M3 + M6 = M8 + M7
14.25 + 80.75 = M8 + 0.475
M8 = 94.525 kg/day

Composition of M7 & M8
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert
kg/day 11.591425 3.093675 76.909625 1.315275 1.788375 0.342

Concentration of Composition in Mixture

Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert
% 12.20 3.2565 80.96 1.38 1.88 0.36

Exhaust Gases
Kiln
M8
M9

IN = OUT + Exhaust Gases

M8 = M9 + Exhaust Gases
94.525 kg/day

Analysis of M8
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert
kg/day 11.5 3.08 76.53 1.31 1.78 0.34

Mwt of Component
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3
Mwt 60.06 101.94 100.09 159.68 84.31

Moles of Component
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3
kmol/day 0.192032 0.030196 0.764563 0.008196 0.021106
 Analysis of M9
Component C2S C3S C3A C4AF
% 20 60 12 8

Component C2S C3S C3A C4AF

Mwt 172.22 228.30 270.18 485.95

Reaction In Kiln
CaCO3 -------------- CaO + CO2 1
MgCO3 ------------- MgO + CO2 2
CaO + Al2O3 ------------- CaO.Al2O3 3
4CaO + 2Al2O3 + CaO.Al2O3 ----------------- 5CaO.3Al2O3 4
5CaO + 3Al2O3 --------------- 5CaO.3Al2O3 5
2CaO + SiO2 -------------- 2CaO.SiO2 6
4CaO + 5CaO.3Al2O3 -------------- 3(3CaO.Al2O3) 7
CaO + 2CaO.SiO2 -------------- 3CaO.SiO2 8
4CaO + Al2O3 + Fe2O3 -------------- 4CaO.Al2O3.Fe2O3 9

3 + 4 ------------- 5

Moles of Components By the Reaction

CaCO3 ---------------------- CaO + CO2 1

1 1 1
0.764563 X1 Y1

X1 = Y1 = 0.764563 kmol/day

MgCO3 ---------------------- MgO + CO2 2

1 1 1
0.021106 X2 Y2

X2 = Y2 = 0.021106 kmol/day

CO2 = Y1 + Y2 = 0.785668 kmol/day

Weigh of CO2 = kmol/day * Mwt = 34.577271 kg/day
 2CaO + SiO2 ---------------------- 2Ca.SiO2 6
2 1 1
Y3 0.192032 X3

Y3 = 0.384065 kmol/day
X3 = 0.192032 kmol/day

9 4CaO + Al2O3 + Fe2O3 ---------- 4CaO.Al2O3.Fe2O3

4 1 1 1
Z4 Y4 0.008196 X4

Z4 = 0.032783 kmol/day
Y4 = 0.008196 kmol/day
X4 = 0.008196 kmol/day

5CaO + 3Al2O3 ---------------------- 5CaO.3Al2O3 5

5 3 1
Z5 Y5 X5

Y5 = Total moles of Al2O3 - Y4

Y5 = 0.022001 kmol/day
X5 = 0.007334 kmol/day
Z5 = 0.036668 kmol/day

4CaO + 5CaO.3Al2O3 ----------- 3(3CaO.3Al2O3) 7

4 1 3
Y6 X5 = 0.007334 X6

Y6 = 0.029334 kmol/day
X6 = 0.022001 kmol/day
 CaO + 2CaO.SiO2 ----------- 3CaO.SiO2
1 1 1
Z7 Y7 X7

From outlet % Analysis

C3S C2S
3CaO.SiO2 2CaO.SiO2
60% 20%
Weigh Ratio 3 1
Mwt 228.3 172.22
Mole Ratio 0.013141 0.005807 weigh ratio / mwt
2.263 1 Divided by 0.005806

X7 = SiO2 kmol/day *2.263 / (2.263+1)

X7 = 0.133181 kmol/day
X7 = Y7 = Z7 = 0.133181

2CaO.SiO2 Excess = SiO2 kmol/day* (1/2.263+1)

2CaO.SiO2 Excess = 0.058851 kmol/day

The amount of CaO excess = Outlet - Reactant

The amount of CaO excess = CaCo3 - Y3+Z4+Z5+Y6+Z7
The amount of CaO excess = 0.148532 kmol/day

Amount of Inerts = Inert in + MgO + CaO Excess

Inerts in ---------- Analysis of inlet

MgO ---------- Moles of component * Mwt
CaO Excess ---------- CaO Excess * Mwt

Amount of Inerts = 0.340290 + 0.8509874 + 8.329693

= 9.520970 kg/day
 % Analysis of the clinker

kg/day
Component kmol/day Mwt kmol/day * Mwt %
C2S 0.058851 177.22 10.429662 17.3
C3S 0.133181 228.3 30.405208 50.4
C3A 0.022001 270.3 5.946735 10
C4AF 0.008196 485.95 3.982729 6.6
Inert - - 9.520970 15.8
Sum - - 60.285304 100.0

Check
M8 = M9 + Exhaust Gases
94.525 = 60.285304 + 34.577271
94.525 = 94.862575

M9
Cement Mill
M10
5% 0.05 M11

From the Mill:

Balance:

M9 + M10 = M11

M.B of CaSO4:
0.0*M9 + M10 = 0.05M11

M.B of Clinker:
0.0 + M9 = 0.95M11 = 60.285304 kg/day

M11 = M9 / 0.95 = 60.285304 / 0.95

M11 = 63.458215 kg/day

M10 = 3.172911 kg/day

 Real Quantities
Converted Balance
Annual Production 1000000 ton/year
Working Days 300 day/year

1000000 ton/year = 3333333.3 kg/day

Basis
100 kg/day ------------- 63.1 kg/day
X kg/day ------------- 3333333.3 kg/day

X = 5282620.2 kg/day

M`` = X*M / 100

M`` : Real quantities
X : the amount of clay and lime stone which produce 1000000 ton/day

M2 Loss 5% 0.05
Clay 0.75
M1 15 14.25
M3

M`` = X*M / 100

M1`` = 792393 kg/day

M2`` = 39619.65 kg/day
M3`` = 752773.4 kg/day

M5 Loss 5% 0.05
Crusher 4.25
M4 85 80.75
M6