Heat Calculation by SG.

7/28/2019 Heat Calculation by SG.

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Clinker Weighing test result

11 September 1997 start Stop Total Ton/jam

Time (hour) 14.13 22.13 8

Kiln Feed totalizer (T) 813041 817186 4145 518.1

Kiln Coal totalizer (T) 11001.9 11120.5 118.6 14.8

ILC Calciner coal totalizer (T) 6312.82 6355.32 42.5 5.3SLC Calciner coal totalizer 12078 12230.3 152.3 19.0

Clinker weighing total (T) 2719.5 339.9

L min 8.542 kg air/kg Coal

GHV 5763 kcal/kg Coal

Fuel consumption Ton % ton/jam

Kiln (PW1) 118.6 37.8% 14.8

ILC Calciner (PW2) 42.5 13.6% 5.3

SLC Calciner (PW3) 152.3 48.6% 19.0

Total 313.4 100.0% 39.2

Fuel Consumption 664 kcal/kg Clinker (note:pfist

Combustion air 334632.9 kg air/jam

5577.2 kg air/min

0.984 kg air/kg clinker

Clinker Faktor 1.52 (note:the dust return is not weighed)

Material Balance

Pulvurized X kcal/kg terak

Coal Ash 19.67 %

0.1967 x kg

3.413E-05 x kg

Raw mix to clinker LOI 35.18

= (1 - 3.413* X*(10^-2))*100

100 - 35.18

= 1.542733724 - 5.266E-05 x

CO2 From raw mix total carbonat 77.22 %

= 0.524171552 - 1.789E-05 x

Free H2O in the raw mix H2O 0.5 %


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=( 1.542733724 - 5.26559E-05 x) *

= 0.007752431 - 2.64602E-07 x

Combined H2O in raw mix H2O 1.12 %

=( 1.542733724 - 5.26559E-05 x) *

= 0.017278618 - 5.89746E-07

Carbon from raw mix C 0.11 %

=( 1.542733724 - 5.26559E-05 x) *

= 0.001697007 - 5.79214E-08

Excess Air

% Excess Air = 79 * %O2

0.21 * (100 - % CO2) - %O2

Stage 1 ILC average exit gas analiysis

CO2 = 29

O2 = 3.5

Excess air = 24.2

Stage 1 SLC average exit gas analiysis

CO2 = 32

O2 = 3.5Excess air = 25.6

Dust in Exit Gas 10.5%

Dust rate 56.28 tph

kiln Feed 511.1 tph 508.5445

Total 567.38 tph 564.5431

CLK = KF * (efficiency) * (1 - H2O) * (1-LOI) + (Coal

335 = 567.4 * (efficiency) * (1 - 0.05) * (1-0.3518) +

327.6227335 = 365.936837 * Efficiency

Efficiency = 89.5%

Dust = 0.177 kg dust/kg clinker

Water from Coal


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Fine Coal H2O 2.29 %

LHV Fine Coal 5763 kcal/kg Coal

Fine Coal Consumption = x

5763

= 0.000174 x kg coal/kg terak

Dry Coal consumption = x + (1- 0.0229 )

5763

= 0.000169547 x kg coal Dry/kg terak

Water from Coal = x * 0.0229

5763

= 3.97362E-06 x kg air/kg terak

Combustion Air Rates:

L min 8.542 kg air/kg Coal

Air required = x * 8.542 kg air

5763 kg Coal

= 0.001482214 x kg air/kg Clk

= 8.3976694

Kiln Primary air

Flow 150.7 kg air/min (measurement pitot tube)

0.027 kg air/kg Clk

L min = 2110.585833 kg air/min

= 7.14% kebutuhan udara dari total combustion o

Kiln Coal Transport air

Flow 81.8 kg air/min

0.015 kg air/kg Clk


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ILC Calciner coal transport and primary air

Flow 25.83 kg air/min

0.005 kg air/kg Clk



SLC Calciner coal transport and primary air

Flow 91 kg air/min

0.016 kg air/kg Clk



Remaining air requirement ILC/kiln String

=[( 0.001482214 x * (1 + 0.242 )) * (

= 0.000946553 x -0.046

Remaining air requirement ILC/kiln String

=[( 0.001482214 x * (1 + 0.256 )) * (

= 0.000905049 x -0.016

Combustion products from coal 9.349 kg gas/kg coal including w

= X kcal/kg terak 9.349 kg gas/kg c

5763 kcal/kg Coal

= 0.001622245 x kg gas/kg clk


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Extra air required to burn carbon in the kiln feed

C + Air

Lb 1 11.53

lb/lb clk 0.0017 0.019566492

---------- > Including 24.2 % Excess air in ILC 0.024308

---------- > Including 25.6 % Excess air in SLC 0.024585

Extra Product of Combustion for ILC

CO2 0.006 kg CO2/kg clk

N2 0.0187 Kg N2/kg Clk

Extra Product of Combustion for SLC

CO2 0.006 kg CO2/kg clk

N2 0.0189 Kg N2/kg Clk

Excess Air

ILC/kiln string = [( 37.8% + 13.6% ) *

5763

= 0.000184636 x + 0.0047 kg air/kg cl

SLC string = [ 48.6% * 8.542 *

5763

= 0.000184752 x + 0.0050 kg air/kg cl

Sistem surface losses

Radiation losses

Kiln Radiation loss 23


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Cooler and firing hood radiation loss 6

Preheater and tertiary air dust radiation loss 28

Cooler

Average clinker discharge temperature 124C

Heat of Cooler = 1 kg/kg clk * 124 *

= #NAME? kcal/kg clk

Radiation Loss 6 kcal/kg clk

Excess Air

Flow 388554 kg/hr @ 238 C

1.158726595 kg air/kg clk

CP #NAME?

Heat Of excess Air #NAME? kcal/kg clk

Hot air for the raw mill

Flow 122897 kg/hr @ 407 C

0.366497378 kg air/kg clk

CP #NAME?

Heat Of excess Air #NAME? kcal/kg clk

Total Cooler loss #NAME? kcal/kg clk


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r feeder calibration not correct)


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0.005025

0.0112

0.0011

sh)

(39.17*0.1967)


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f kiln fuel.


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f kiln fuel.

v

f ILC Calciner.

f SLC Calciner.

37.8% + 13.6% )] -0.027 -0.015 -0.005

kg air/kg clk

48.6% )] -0.016

kg air/kg clk

ter in Coal

oal


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CO2 + N2

3.666667 8.85504

0.006222 0.015027

kg air/kg clk

kg air/kg clk

8.542 * 0.242331 ] * x + ( 0.024308 -0.0196 )

0.256494 ] * x + ( 0.024585 - 0.0196 )

kcal/kg clk


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kcal/kg clk

kcal/kg clk

#NAME?


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System Heat Input C kcal/kg CFuel : Combustion Heat 1

Free heat w/ coal 80 0.000174 x 0.2932 0.004070102

Air : Primary 32 0.027 0.2377

Kiln Coal transport 32 0.015 0.2377ILC Coal transport 32 0.005 0.2377

SLC Coal transport 32 0.016 0.2377

Remaining ILC 32 0.0009466 x -0.04622 0.2377 0.007200951

Remaining SLC 32 0.000905 x -0.01628 0.2377 0.006885208

Extra for C - ILC 32 0.02431 0.2377

Extra for C - SLC 32 0.02459 0.2377

Cooler : Excess Air 32 1.15873 0.2377

Hot air for RM 32 0.3665 0.2377

Water from coal 80 3.974E-06 x 1.0000 0.00031789

Raw Feed 90 -5.266E-05 x 1.54273 #NAME? #NAME?

Returned dust 90 0.177 #NAME?

Sum Of heat inputs #NAME?

System Heat Input C kcal/kg CCombustion Product (Coal) 348 0.0016222 x 0.2579 0.145595223

Combustion Product (Carbon in mix)

CO2 - ILC 348 0.006 0.2319

N2 - ILC 348 0.0187 0.2517

CO2 - SLC 348 0.006 0.2319N2 - SLC 348 0.019 0.2517

Excess Air In exit gas - ILC 348 0.0001846 x 0.0047 0.2450 0.015742344

Excess Air In exit gas - ILC 348 0.0001848 x 0.00502 0.2450 0.01575218

CO2 from Raw Feed 348 -1.789E-05 x 0.52417 0.2319 -0.00144354

Vapor from free H2O In feed 348 0.00775 788

Vapor from comb H2O In feed 348 0.01728 0.4600

Dust 348 0.177 0.2367

Radiation : Kiln

Preheater

Cooler loss : Heat in Clinker 124 1 0.1927

Radiation

Hot air for mill 407 0.3665 0.2464

Excess Air 238 1.15873 0.2425

Heat of reaction

Sum Of heat inputs 0.17564621

#NAME? x + #NAME?

0.17565 x 665.394721

k

k

kg/kg

kg/kg


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#NAME? x = #NAME?

x = #NAME?


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Summary

System Heat Input Cx Fuel : Combustion Heat

x Free heat w/ coal 80

0.2051346 Air : Primary 32

0.1113471 Kiln Coal transport 320.0351601 ILC Coal transport 32

0.1238703 SLC Coal transport 32

x -0.3516419 Remaining ILC 32

x -0.1238703 Remaining SLC 32

0.1849249 Extra for C - ILC 32

0.187033 Extra for C - SLC 32

8.8150728 Cooler : Excess Air 32

2.7881479 Hot air for RM 32

x Water from coal 80

x + #NAME? Raw Feed 90

#NAME? Returned dust 90

x + #NAME? Sum Of heat inputs

System Heat Input Cx Combustion Product (Coal) 348

Combustion Product (Carbon in mix)

0.5020577 CO2 - ILC 348

1.6349262 N2 - ILC 348

0.5020577 CO2 - SLC 3481.6535638 N2 - SLC 348

x 0.4042731 Excess Air In exit gas - ILC 348

x 0.4278995 Excess Air In exit gas - ILC 348

x 42.293343 CO2 from Raw Feed 348

6.1089155 Vapor from free H2O In feed 348

2.7657381 Vapor from comb H2O In feed 348

14.590608 Dust 348

23 Radiation : Kiln

28 Preheater

23.894304 Cooler loss : Heat in Clinker 124

6 Radiation

36.748299 Hot air for mill 407

66.868735 Excess Air 238

410 Heat of reaction

x 665.39472 Sum Of heat inputs

=

al/kg

al/kg


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Kcal/kg


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kg/kg kcal/kg C kcal/kg

#NAME?

#NAME? 0.2932 #NAME?

0.027 0.237736 0.205135

0.015 0.237736 0.1113470.005 0.237736 0.03516

0.016 0.237736 0.12387

#NAME? 0.237736 #NAME?

#NAME? 0.237736 #NAME?

0.024308 0.237736 0.184925

0.024585 0.237736 0.187033

1.158727 0.237736 8.815073

0.366497 0.237736 2.788148

#NAME? 1 #NAME?

#NAME? #NAME? #NAME?

0.177 #NAME? #NAME?

#NAME?

kg/kg kcal/kg C kcal/kg

#NAME? 0.2579 #NAME?

0.006 0.231857 0.502058

0.019 0.251656 1.634926

0.006 0.231857 0.5020580.019 0.251656 1.653564

#NAME? 0.245004 #NAME?

#NAME? 0.245004 #NAME?

#NAME? 0.231857 #NAME?

0.007752 788 6.108915

0.017279 0.459963 2.765738

0.177156 0.236667 14.59061

23

28

1 0.192696 23.8943

6

0.366497 0.246361 36.7483

1.158727 0.242474 66.86874

410

#NAME?


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Heat Calculation by SG.

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