Kiln Performance & Efficiency

S. Description Symbol Formula Example

No.
1 Degree of filling DF 3.2 * P P 5500
3
Cement Manufacturer's Handbook, % Deff * n * s Deff 4.15
Kurt E. Peray P Clinker production, tpd n 3.8
Deff Burning zone effective diameter, mts S 4
n Kiln speed, rpm DF 16.20
s Kiln slope, % Target 14-16
2 Thermal loading TL Formula-1 F 10000
or Gcal/hr/m2 F * NCV NCV 27000
Burning zone loading A * 4179000 A 13.52
FLS - Kiln manual F Fuel rate in kiln, kg/hr TL 4.78
NCV Net calorific value of fuel, kJ/kg-fuel Target 4.0-5.0
A Burning zone cross-sectional area, m2

Formula-2 P 5500
P*H H 1190
A * 24 * 4179 A 13.52
P Clinker production, tpd TL 4.83
H Specific heat consumption in kiln, kJ/kg-clinker Target 4.0-5.0
A Burning zone cross-sectional area, m2
3 Volumetric loading VL P P 5500
FLS - Kiln manual tpd/m3 A*L A 13.52
P Clinker production, tpd L 68
A Burning zone cross-sectional area, m2 VL 5.98
L Kiln length, mts Target 5.0-5.5
4 Material residence time in kiln RTK 19 * L L 68
FLS - Kiln manual min Deff * n * s Deff 4.15
L Kiln length, mts n 3.8
Deff Burning zone effective diameter, mts S 4
n Kiln speed, rpm RTK 20.5
s Kiln slope, % Target 20-25
5 Clinker residence time in cooler RTC 15.805 * A * Ps A 100
Emperical Formula min P Ps 70
A Cooler grate cross-sectional area, m2 P 5500
Ps Static pressure at clinker droping area, mB RTC 20.1
P Clinker production, tpd Target 20-25
6 True CO2 in kiln exit gas TCO2 100 * ( CO2 + CO ) CO2 36.5
Cement Manufacturer's Handbook, vol% 100 + ( 1.89 * CO ) - ( 4.78 * O2 ) CO 0.002
Kurt E. Peray CO2 Kiln exit gas CO2, vol% O2 4.2
CO2 Kiln exit gas CO, vol% TCO2 45.7
O2 Kiln exit gas O2, vol% Target -
7 Excess air EA 79 * O2 O2 2.8
FLS - Kiln manual % 0.21 * ( 100 - CO2 ) - O2 CO2 26.5
O2 O2 content in gas, vol% EA 17.5
CO2 CO2 content in gas, vol% Target 10-15
-8 4 4
8 Radiation heat losses RHL 16.716 * 10 * ( T - t ) T 517
FLS - Kiln manual kJ/hr/m2 T Radiating body temperature, K t 305
t Ambient air temperature, K RHL 10496
Target -
-0.724 1.333
9 Convection heat losses CHL 335.7 * ( ( T + t ) / 2 ) *(T-t) T 443
FLS - Kiln manual kJ/hr/m2 T Radiating body temperature, K t 308
t Ambient air temperature, K CHL 3174
Target -
-0.351 0.805 -0.195
10 Forced convection heat losses FCHL 117.14 * ( ( T + t ) / 2 ) *v *D *(T-t) T 525
(when wind speed > 3.0 m/s) kJ/hr/m2 T Radiating body temperature, K t 302
FLS - Kiln manual t Ambient air temperature, K v 5
v Wind speed, m/s D 4.15
D Radiating body diameter, mts FCHL 8725
Target -
11 %Ash absorption in clinker %AA CC * Ash CC 26
Simple mathematical calculation % P Ash 15
 Kiln Performance & Efficiency
S. Description Symbol Formula Example
No.
CC Coal consumption, tph P 208
Ash Ash content in fuel (as fired basis), % %AA 1.88
P Clinker production, tph Target -
12 Raw Mix:Clinker ratio RMCK 100 - %AA %AA 1.74
(dust to kiln) - 100 - LOI LOI 35.58
Simple mathematical calculation %AA %Ash absorption, % RMCK 1.525
LOI Loss on ignition of raw mix, % Target -
13 Raw Mix:Clinker ratio RMCS ( 100 - %AA ) * 100 %AA 1.74
(dust to silo) - ( 100 - LOI ) * ( 100 - DL ) LOI 35.58
Simple mathematical calculation %AA %Ash absorption, % DL 8.5
LOI Loss on ignition of raw mix, % RMCS 1.667
DL Dust losses from preheater, % Target -
14 Heat of reaction HR [ ( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMCK ) CaCO3 75.1
or kJ/ + ( 222 * Al2O3 / ( 100 - LOI ) ) + ( 11.6 * CH2O * RMCK ) RMCK 1.53
Theoretical heat required to kg-clinker - ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) ) MgCO3 1.6
produce 1 kg of clinker - ( 1000 * ( K2O + Na2O ) / ( 100 - LOI ) ) LOI 34.5
or - ( 79 * C * RMCK ) - ( 32 * S * RMCK ) ] * 4.179 Al2O3 4.17
Clinkerisation heat CaCO3 CaCO3 content in kiln feed, % CH2O 1.05
(including Heat of combustibles) RMCK Kiln feed:Clinker ratio, - SiO2 13.47
FLS - Kiln manual MgCO3 MgCO3 content in kiln feed, % Fe2O3 2.41
LOI LOI content in kiln feed, % K2O 0.38
Al2O3 Al2O3 content in clinker, % Na2O 0.27
CH2O Water of crystalisation in kiln feed, % C 0.2
SiO2 SiO2 content in clinker, % S 0.04
Fe2O3 Fe2O3 content in clinker, % HR 1625
K2O K2O content in clinker, % Target -
Na2O Na2O content in clinker, %
C Carbon content in kiln feed, %
S Sulphur as pyrites in kiln feed, %
15 False air w.r.t. mix FAMO ( O2mix - O2gas ) * 100 O2mix 3.6
(based on O2 analysis) % 21 - O2gas O2gas 2.8
FLS - Communition Manual O2mix O2 content in mixture of gas, vol% FAMO 4.4
O2gas O2 content in unmixed gas, vol% Target 5-7
16 False air w.r.t. gas FAGO ( O2mix - O2gas ) * 100 O2mix 3.6
(based on O2 analysis) % 21 - O2mix O2gas 2.8
FLS - Communition Manual O2mix O2 content in mixture of gas, vol% FAGO 4.6
O2gas O2 content in unmixed gas, vol% Target 5-7
17 False air w.r.t. mix FAMC ( CO2gas - CO2mix ) * 100 CO2mix 32.1
(based on CO2 analysis) % CO2gas CO2gas 34.5
FLS - Communition Manual CO2mix CO2 content in mixture of gas, vol% FAMC 7.0
CO2gas CO2 content in unmixed gas, vol% Target 5-7
18 False air w.r.t. gas FAGC ( CO2gas - CO2mix ) * 100 CO2mix 32.1
(based on CO2 analysis) % CO2mix CO2gas 34.5
FLS - Communition Manual CO2mix CO2 content in mixture of gas, vol% FAMC 7.5
CO2gas CO2 content in unmixed gas, vol% Target 5-7