MathCement

Module 1

MathCement _2000

Volume-1 : Cement plant process calculations Process calculation of plant sections Book 200 MC_V1_B201_Quarry_TOC MC_V1_B201_Quarry_1BIU MC_V1_B201_Quarry_1 MC_V1_B201_Quarry_2BIU MC_V1_B201_Quarry_2 Quarry Section Quarry Deposit Estimation Quarry Deposit Estimation Quarry - Excavator Quarry - Excavator

No of files

Part -1

MC_V1_B201_Quarry_3BIU_r3 Quarry - Dumper Calculations MC_V1_B201_Quarry_3_r3 Quarry - Dumper Calculations

MC_V1_B202_Crushing_TOC Crushing Section MC_V1_B202_Crushing_1BIU_ r5 Crusher and Auxiliaries Calculations MC_V1_B202_Crushing_1_r5 MC_V1_B202_Crushing_2BIU MC_V1_B202_Crushing_2 Crusher and Auxiliaries Calculations Single Rotor Hammer or Impact Crusher Calculations Single Rotor Hammer or Impact Crusher Calculations Calculation of power for existing crusher at different capacities application of Rittinger's law Calculation of power for existing crusher at different capacities application of Rittinger's law Calculation of power for existing crusher but to be used for different / changed material - application of Rittinger's law Calculation of power for existing crusher but to be used for different / changed material - application of Rittinger's law Calculation of throughput for Roll Crusher Calculation of throughput for Roll Crusher Double Rotor Hammer or Impact Crusher Calculations Double Rotor Hammer or Impact Crusher Calculations

12

MC_V1_B202_Crushing_3BIU

MC_V1_B202_Crushing_3

MC_V1_B202_Crushing_4BIU

MC_V1_B202_Crushing_4 MC_V1_B202_Crushing_5BIU MC_V1_B202_Crushing_5 MC_V1_B202_Crushing_6BIU MC_V1_B202_Crushing_6

MC_V1_B203_Preblending_TOC Pre-blending Section MC_V1_B203_Preblending_1BI Preblending and Stockpile Equipment U Calculations

Preblending and Stockpile Equipment MC_V1_B203_Preblending_1 Calculations MC_V1_B203_Preblending_2BI Stockpile capacities-Longitudinal with U trapizoidal cross section Stockpile capacities-Longitudinal with MC_V1_B203_Preblending_2 trapizoidal cross section MC_V1_B203_Preblending_3BI Stockpile capacities-Longitudinal with U triangular cross section Stockpile capacities-Longitudinal with MC_V1_B203_Preblending_3 triangular cross section MC_V1_B203_Preblending_4BI Stockpile capacities-Kidney shaped U windrows -triangular section MC_V1_B203_Preblending_4BI Stockpile capacities-Kidney shaped U windrows -triangular section

MC_V1_B204_Rawmill_TOC

Raw Mill Section Bond Work Index of the various material based on bond test mill result MC_V1_B204_RawMill_1_r4 dry basis Calculation of Power at Ball Mill Shaft for Raw Material,based on Bond's Work MC_V1_B204_RawMill_2BIU Index Calculation of power at Ball Mill shaft for Raw material, based on Bond's work MC_V1_B204_RawMill_2 index Raw Mill and Auxiliary Equipment MC_V1_B204_RawMill_3BIU Capacity Calculations Raw Mill and Auxiliary Equipment MC_V1_B204_RawMill_3 Capacity Calculations Raw Material Drying - Estimation of MC_V1_B204_RawMill_4BIU_r total moisture to be evaporated from 3 feed Raw Material Drying - Estimation of total moisture to be evaporated from MC_V1_B204_RawMill_4_r3 feed Raw Mill Heat Balance - Evaluation of MC_V1_B204_RawMill_5BIU Hot Gas Requirement for Drying Raw Mill Heat Balance - Evaluation of Hot MC_V1_B204_RawMill_5 Gas Requirement for Drying Calculation of Ball Mill Percentage MC_V1_B204_RawMill_6BIU Filling as per Measurement Calculation of Ball Mill Percentage MC_V1_B204_RawMill_6 Filling as per Measurement MC_V1_B204_RawMill_7BIU MC_V1_B204_RawMill_7 MC_V1_B204_RawMill_8BIU MC_V1_B204_RawMill_8 Calculation of Grinding Ball Size Calculation of Grinding Ball Size Specific Heat of Raw Material as a Function of Temperature Specific Heat of Raw Material as a Function of Temperature Estimation of specific power consumption, at mill shaft, based on the operating parameters of close circuit ball mill

49

MC_V1_B204_RawMill_9BIU

MC_V1_B204_RawMill_9

Estimation of specific power consumption, at mill shaft, based on the operating parameters of close circuit ball mill

Calculation of mill power demand for MC_V1_B204_RawMill_10BIU_ desired output at specified feed and r3 product sizes, based on Bond Index. Calculation of mill power demand for desired output at specified feed and MC_V1_B204_RawMill_10_r4 product sizes, based on Bond Index. MC_V1_B204_RawMill_10_1BI Calculation of mill output for different U feed and product sizes Calculation of mill output for different MC_V1_B204_RawMill_10_1 feed and product sizes Calculation of Efficiency of Dynamic Air MC_V1_B204_RawMill_11BIU Separator Calculation of Efficiency of Dynamic Air MC_V1_B204_RawMill_11 Separator Average Piece Weight of Grinding MC_V1_B204_RawMill_12BIU Media Average Piece Weight of Grinding MC_V1_B204_RawMill_12 Media Ball Mill Critical Speed and Ball Charge MC_V1_B204_RawMill_13BIU Calculations Ball Mill Critical Speed and Ball Charge MC_V1_B204_RawMill_13 Calculations MC_V1_B204_RawMill_14BIU_ Vertical Roller Mill -- Calculation of r4 Power Vertical Roller Mill -- Calculation of MC_V1_B204_RawMill_14_r4 Power MC_V1_B204_RawMill_15BIU_ Radiation Loss in Raw Mill Heat r3 Balance Radiation Loss in Raw Mill Heat MC_V1_B204_RawMill_15_r3 Balance Calculation of false air coming into MC_V1_B204_RawMill_16BIU grinding mill system Calculation of false air coming into MC_V1_B204_RawMill_16 grinding mill system Calculation of water pressure at nozzle over material bed of Vertical Roller Mill with supply from overhead tank Calculation of water pressure at nozzle over material bed of Vertical Roller Mill with supply from overhead tank Calculation of retention time of material in a two compartment ball mill

MC_V1_B204_RawMill_17BIU

MC_V1_B204_RawMill_17

MC_V1_B204_RawMill_18BIU

Calculation of retention time of material in a two compartment ball mill Rosin-Rammler equation -calculation of MC_V1_B204_RawMill_19BIU_ predicted residue on sieve and variaton r1 calculations MC_V1_B204_RawMill_18

Rosin-Rammler equation -calculation of predicted residue on sieve and variaton MC_V1_B204_RawMill_19_r1 calculations Calculation of mean diameter of fine MC_V1_B204_RawMill_20BIU ground particles Calculation of mean diameter of fine MC_V1_B204_RawMill_20 ground particles MC_V1_B204_RawMill_21BIU_ Calculation of auxiliary drive rating of r1 Ball Mill for raw grinding Calculation of auxiliary drive rating of MC_V1_B204_RawMill_21_r1 Ball Mill for raw grinding MC_V1_B204_RawMill_22BIU_ Calculation of makeup charge or ball r2 mills Calculation of makeup charge or ball MC_V1_B204_RawMill_22_r2 mills MC_V1_B204_RawMill_23BIU_ Calculation of wear rate of grinding r1 balls in ball mills Calculation of wear rate of grinding MC_V1_B204_RawMill_23_r1 balls in ball mills Calculation of Recirculation Air in Raw MC_V1_B204_RawMill_24BIU Grinding Vertical Roller Mill Calculation of Recirculation Air in Raw MC_V1_B204_RawMill_24 Grinding Vertical Roller Mill

MC_V1_B205_Blending_TOC Blending and Storage Section Calculation of Blending & Storage Silos and Auxiliary Equipment Capacity for MC_V1_B205_Blending_1BIU Raw-meal preparation Calculation of Blending & Storage Silos and Auxiliary Equipment Capacity for MC_V1_B205_Blending_1 Raw-meal preparation MC_V1_B205_Blending_2BIU_r Calculation of Kiln Feed Raw-meal 3 Systems Calculation of Kiln Feed Raw-meal MC_V1_B205_Blending_2_r3 Systems Calculation of Kiln Feed Raw-meal MC_V1_B205_Blending_3BIU Quantity Calculation of Kiln Feed Raw-meal MC_V1_B205_Blending_3 Quantity MC_V1_B205_Blending_4BIU_r Calculation of blending factor by 2 methods of standard deviation Calculation of blending factor by MC_V1_B205_Blending_4_r2 methods of standard deviation

MC_V1_B206_Kilnfeed_TOC Kiln-feed Section MC_V1_B206_Kilnfeed_1BIU_r Locating feeding point of material into 3 Preheater Gas ducts Locating feeding point of material into MC_V1_B206_Kilnfeed_1_r3 Preheater Gas ducts Clinkerisation (kiln,preheater)Section

MC_V1_B207_Clinker_TOC

49

Calculation of Kiln and Auxiliary MC_V1_B207_Clinker_1BIU_r3 Equipment Capacities. Calculation of Kiln and Auxiliary MC_V1_B207_Clinker_1_r3 Equipment Capacities. MC_V1_B207_Clinker_2BIU_r3 Leakages through Kiln Air Seals MC_V1_B207_Clinker_2_r3 Leakages through Kiln Air Seals Calculation of Specific Heats of Clinker as a Function of Clinker Temperature Calculation of Specific Heats of Clinker as a Function of Clinker Temperature Kiln Retention Time and Related Parameters Kiln Retention Time and Related Parameters

MC_V1_B207_Clinker_3BIU

MC_V1_B207_Clinker_3 MC_V1_B207_Clinker_4BIU MC_V1_B207_Clinker_4

MC_V1_B207_Clinker_5BIU_r3 Kiln sinter zone cooling fans MC_V1_B207_Clinker_5_r3 Kiln sinter zone cooling fans Calculation of nose ring cooling air for MC_V1_B207_Clinker_6BIU_r3 kiln inlet Calculation of nose ring cooling air for MC_V1_B207_Clinker_6_r3 kiln inlet MC_V1_B207_Clinker_7BIU Kiln Tyre / Shell Ovality MC_V1_B207_Clinker_7 Kiln Tyre / Shell Ovality MC_V1_B207_Clinker_8BIU_r4 Kiln Capacity check MC_V1_B207_Clinker_8_r4 Kiln Capacity check Degree of Decarbonation of Raw Meal MC_V1_B207_Clinker_9BIU -Definition and calculation Degree of Decarbonation of Raw Meal MC_V1_B207_Clinker_9 -Definition and calculation Degree of Decarbonation of Raw Meal Calculation on Operating Data Degree of Decarbonation of Raw Meal Calculation on Operating Data Reaction Enthalpy -Decarbonation and Clinkerisation Reaction Enthalpy -Decarbonation and Clinkerisation Theoretical Heat of Clinker Formation Calculation Theoretical Heat of Clinker Formation Calculation Calculation of kiln mass under operating conditions Calculation of kiln mass under operating conditions Calculation of Kiln Torque under Operating Conditions Calculation of Kiln Torque under Operating Conditions

MC_V1_B207_Clinker_10BIU

MC_V1_B207_Clinker_10 MC_V1_B207_Clinker_11BIU MC_V1_B207_Clinker_11 MC_V1_B207_Clinker_12BIU MC_V1_B207_Clinker_12 MC_V1_B207_Clinker_13BIU MC_V1_B207_Clinker_13 MC_V1_B207_Clinker_14BIU

MC_V1_B207_Clinker_14 MC_V1_B207_Clinker_15BIU_r 3 Calculation for Kiln Hydraulic Thruster MC_V1_B207_Clinker_15_r3 Calculation for Kiln Hydraulic Thruster

MC_V1_B207_Clinker_16TXT MC_V1_B207_Clinker_17BIU MC_V1_B207_Clinker_17 MC_V1_B207_Clinker_18BIU MC_V1_B207_Clinker_18 MC_V1_B207_Clinker_19BIU MC_V1_B207_Clinker_19 MC_V1_B207_Clinker_20BIU MC_V1_B207_Clinker_20 MC_V1_B207_Clinker_21BIU MC_V1_B207_Clinker_21 MC_V1_B207_Clinker_22BIU MC_V1_B207_Clinker_22

Kiln Hydraulic Thruster - A Note Kiln Drive Specification Kiln Drive Specification Calculation of expansion of Kiln in hot condition Calculation of expansion of Kiln in hot condition Calculation of Temerature Profile of Kiln Shell in hot condition Calculation of Temerature Profile of Kiln Shell in hot condition Calcination Function Calcination Function Calculation of false air infiltration into kiln preheater system Calculation of false air infiltration into kiln preheater system Calculation of Alkali Bypass System Calculation of Alkali Bypass System Calculation of Range of Bypass Quantity of Gases from Kiln to Limit Alkali concentration in Clinker Calculation of Range of Bypass Quantity of Gases from Kiln to Limit Alkali concentration in Clinker Correlation Between Central Chord Angle or Charge Angle and Degree of Filling of Kiln Correlation Between Central Chord Angle or Charge Angle and Degree of Filling of Kiln Calculation of fresh cooling air and water to reduce the temperature of kiln (alkali) bypass gases before release to atmosphere Calculation of fresh cooling air and water to reduce the temperature of kiln (alkali) bypass gases before release to atmosphere

MC_V1_B207_Clinker_23BIU

MC_V1_B207_Clinker_23

MC_V1_B207_Clinker_24BIU

MC_V1_B207_Clinker_24

MC_V1_B207_Clinker_25BIU

MC_V1_B207_Clinker_25

MC_V1_B208_ClCooling_TOC Clinker Cooling Section Calculation of Grate Cooler Drive MC_V1_B208_ClCooling_2BIU Power Calculation of Grate Cooler Drive MC_V1_B208_ClCooling_2 Power Calculation of Grate Cooler Recuperation Efficiency -T.A. Duct MC_V1_B208_ClCooling_3BIU Tapping from Cooler Calculation of Grate Cooler Recuperation Efficiency -T.A. Duct MC_V1_B208_ClCooling_3 Tapping from Cooler

Calculation of Grate Cooler Recuperation Efficiency -T.A. Duct MC_V1_B208_ClCooling_4BIU Tapping from Kiln Hood Calculation of Grate Cooler Recuperation Efficiency -T.A. Duct MC_V1_B208_ClCooling_4 Tapping from Kiln Hood Calculation of Grate Cooler Offset from MC_V1_B208_ClCooling_5BIU Kiln axis Calculation of Grate Cooler Offset from MC_V1_B208_ClCooling_5 Kiln axis MC_V1_B209_Clstore_TOC Clinker Storage Section Calculation of Clinker Transport Equipment Capacity and Clinker Stockpile Calculation of Clinker Transport Equipment Capacity and Clinker Stockpile 2

MC_V1_B209_Clstore_1BIU

MC_V1_B209_Clstore_1

MC_V1_B210_Cement_TOC MC_V1_B210_Cement_1BIU MC_V1_B210_Cement_1 MC_V1_B210_Cement_2BIU MC_V1_B210_Cement_2 MC_V1_B210_Cement_3BIU MC_V1_B210_Cement_3

Cement Grinding Section Calculation of Cement Mill and Auxiliary Equipment Calculation of Cement Mill and Auxiliary Equipment Calculation of Cement Grindability based on Ziesel Value Calculation of Cement Grindability based on Ziesel Value Cement Mill Heat Balance and Calculation of Hot Gas for Drying Cement Mill Heat Balance and Calculation of Hot Gas for Drying Calculation of Cement Mill Output as a function of Grinding Media Load Calculation of Cement Mill Output as a function of Grinding Media Load Estimation of grindability of Clinker based on the operating parameters Estimation of grindability of Clinker based on the operating parameters Calculation of Water Spray in the Mill for Cooling Calculation of Water Spray in the Mill for Cooling Sizing of Close Circuit Cement Mill Sizing of Close Circuit Cement Mill Cement Mill Output at Different Finenesses Cement Mill Output at Different Finenesses Cement Mill Cooling Air Cement Mill Cooling Air Mill Radiation Loss

26

MC_V1_B210_Cement_4BIU

MC_V1_B210_Cement_4 MC_V1_B210_Cement_5BIU MC_V1_B210_Cement_5 MC_V1_B210_Cement_6BIU MC_V1_B210_Cement_6 MC_V1_B210_Cement_7BIU MC_V1_B210_Cement_7 MC_V1_B210_Cement_8BIU MC_V1_B210_Cement_8 MC_V1_B210_Cement_9BIU MC_V1_B210_Cement_9 MC_V1_B210_Cement_10BIU

MC_V1_B210_Cement_10

Mill Radiation Loss Cement Mill Grinding Performance as a MC_V1_B210_Cement_11BIU Function of Surface Generated Cement Mill Grinding Performance as a MC_V1_B210_Cement_11 Function of Surface Generated Expected Power Draw of Cement Mill MC_V1_B210_Cement_12BIU as a Function of Speed Expected Power Draw of Cement Mill MC_V1_B210_Cement_12 as a Function of Speed MC_V1_B210_Cement_13BIU_ Clinker grinding mill - calculation of r2 capacity and power Clinker grinding mill - calculation of MC_V1_B210_Cement_13_r2 capacity and power

Cement Storage and Dispatch MC_V1_B211_Cmtstore_TOC Section Calculation of Cement Transport and MC_V1_B211_Cmtstore_1BIU Silo and Auxiliary Equipment Calculation of Cement Transport and MC_V1_B211_Cmtstore_1 Silo and Auxiliary Equipment Evaluation of effect of weighing MC_V1_B211_Cmtstore_2BIU accuracy of packing m/c Evaluation of effect of weighing MC_V1_B211_Cmtstore_2 accuracy of packing m/c

End of Module - 1