Formulas kiln - Presentation Transcript Kiln fuel feed rate = 6000 kgs/hr kgs/hr C.V = 600 Kcals!".#$" = %&#'6 K(/Kg of coal Thermal )nput = 6000 * %&#'6 K+s/,r = #6.#&6 +s/,r Kiln dia inside ining1 = .6 m C.2 3rea = .#"/"1!.6!.6 =#0.#& m% Thermal load on kiln = #6.#&6/#0.#$ =#6.0" (/hr.m% #. 4esidence time in Kiln 5t = #.& #.&& Ph Ph718#/% 9999999999999999 3lpha! :!; Ph7 =3ngle of repose for for lime stone < 6 :egree = length of of Kiln in meter 3lpha = Kiln inclination in : = >ffecti?e diameter of Kiln in meter ; = 4otation per minute rpm %. Kiln Kiln )nle )nlett @ut @utle lett 3 A C : > Pre Prehe heat ater er Bon Bonee = # min min 3 &. &.m/ m/se secc at at ?elo ?elo aD Precalcination Bone = % min A t = %0 -%$ = inutes Calcination Bone = #0#% min C Aurning Bone = 6 E $ min : ".m/sec Cooling Bone = % min F at Velo in . C); C );K> K>4) 4)23 23T) T)@; @; #% Ca@ Ca@ Ca Cao. o.2i 2i@% @% C2 C211 im imee sto stone ne 3lit 3litee % 2i@ 2i@% %% %Ca Ca@ @ 2i@% C%21 2ilica oDide Aelite #"0!C % 3l%@ Ca@3l%@ C31 3luminium oDide Tricalcium 3luminate Fe%@ "
[email protected]%@.Fe%@ C"3F1 )ron oDide Tetra Calcium 3lumino Ferrite ". )> )> 23T 23T4 43T 3T)@ )@; ; F3C F3CT@ T@4 4 #00! #00! Ca@ Ca@ 2 2F F = %. %.$ $ 2i@% 2i@% G #.#$ #.#$ 3l% 3l%@ @ G 0.6 Fe%@1 0.66 H 2F I #.% = = 34 = H 0.6" .
2)) 2))C3 C3 43T) 43T)@ @2 2i@ i@% % 24 24 = 3l% 3l%@ @ G Fe% Fe%@ @1 %.% %.% H 24 I %.6 %.6 = =
6. 3);3 43 43T)@ 3l 3l%@ 34 = Fe Fe%@ #. #. H 34 I %. %. = = 34 I #. #. )2 C3>: F>44@C>>;T2 34 = 0.6& )2 C3>: F>4434) C>>;T &. C3@4)F)C V3 V3> @F C@ C@3 ,V ,V = ,,V ,,V E 0. 0.#, E .6 .6 E 0.#'#@ ,V = @J ,>3T); V3> Kcal /Kg ,,V = ,), ,>3T); V3> Kcal /Kg = @)2T4> , = ,:4@>; @ = @*>; KCal / Kg D ".#$& D #08-1 = +/Kg ultimate anal7sis anal7sis KCal / Kg D #.$ = Atu / lL $. C@3 C@3 2>: 2>: ); ); C> C>>; >;T T );: );:2T 2T4 4 M ,V ,V = 60 600 0 E &00 &000 0 Kca Kcall / Kg Kg M 32, = #%<# M V@3T)> V@3T)> 3T>4)3 3T>4)3 = #$< %% M @)2T4> @)2T4> = P T@ #% '. : =:iameter in eter = ength in meter J>),T @F C);:4)C3 kiln1 2,> = J J = Pi D 1 D :1 D thk mm1 D &.$ etric Tons #0. #0. T,>4 >43 >*P3; *P3;2 2)@; )@; @F 2,> > 2ki 2kin Tem Temper perature ure :iag :iagra ram m 3 = 3lpha D TD = ength of Kiln1 2hell =# G % 3lpha for steel coefficient of
linear eDpansion = #.%D #08 -1 mm per eter T= dT = 3?erage temp E 3mLient temp1 :egre centigrade # % 3#= T%aGT#1/% - T * # T%LL 3#= T%LGT#1/% - T * % T# 3mLient temp = T T%a 3 = 3# G3% ##. )P@T3;T P343>T>42 K); 2P>C)F)C V@> @3:); = TP:/ m or 2pecific Kiln capacit7 < %. t / m at Kiln circumferential speed = 0 cm / sec K); 2P>C)F)C T,>43 @3:); = Kcal / m%.hr 2pecific Kiln thermal loading Np = #." D #0 8 6 D : Kcal / m%. hr Np should not eDceed ."6 D #086 Kcal/m8%.hr C@@>4 2P>C)F)C @3:); or 2pecific Cooler Capacit7 = TP:/ m% = $ -" metric ton of clinker per m8% .%" hr K); F)); = 0" in #6 aD #%. K); C3P3C)T 322>2>;T MCapacit7 of ): fan. MPreheater c7clone design. MProclaimed :esign O Volume. MKiln inclination O Volume. MKiln filling 2pecific ?olume loading O.Thermal loading. MKiln :ri?e capacit7. M27stem :esign :ucts CT fan position O >2P. #. For earsQ Pitch :iameter = odule D ;o. of Teeth Alank :iameter = odule D ;o of TeethG%1 For 3irslide Cloth M FaLric Pol7ester #00. M in=#"0!C O aD = %60!C. M PermeaLilit7 = "00m/hr-m% or 6m/min-m%. at $0mLar M Tensile strength Q J>FT = #%00 Kg/cm% Q J34P = 600 Kg/cm% M 3ir 4eRuired = %.-.0Closed t7pe1 % Cone silo Ains1#.@pen T7pe1 #". P, fan-# TSin c7clones P, fan-% TSin c7clones )3 )A )) ))) )V 4iser :uct V K); 2T4); V) V '0!C T.3.:uct 2C P4@ 2T4); K); ) irth gear )) ))) #. C>>;T ) F@432 ) C4)T)C3 V>@C)T = &6 / :18#/% ) 3CT3 V>@C)T = % / :18#/% #6. : Theta ill chargingQ Theta , , = 0.#6: ) C4@22 2>CT)@; :7namic 3ngle of 4epose = degree %0 minutes Sith ,oriUontal Theta 1 @4 :7namic 3ngle of 4epose = " degree "0 minutes Sith Vertical Theta 1 #&. 4);:); >:)3 @3: 5 = gm.27.Pi. 418%. " ConstantsQ 27 = specific gra?it7 of = "6%0418%. Lall &.$-&.' Ton / m gm = Aulk densit7 of charge T334T2 F@43 ". Ton / m . Pi = %%/& or .#" #$. P@J>4 C@;2PT)@; @F ) = P = /:=3-C %. A-3 P= #% 2>P343T@4 Afines/: 3 fines/F 2eperator efficienc7 3 fines of separator feed s A fines of Tailings/4e(ect Cfine/ C fines of finished Product F TP, of separator feed : TP, of Tailings/4e(ect TP, of finished Product Aall ill #. n = C 3-A1 . 3C-A11 F = #G:1 #'. /:= TSo Compartment ill / : = ". Three Compartment ill ) E ChamLer :rag PeL iners Carman ining Classif7ing 2legton E iners agotteauD ining ining F2 ining
%0. )mportant Con?ersions # Aarrel = "% allons = #' litres = .6# Cuft # Kcal = ".#$& + KCal / Kg D #.$ = Atu / lL Characteristic @PC-")2$##%1 @PC")2#%%6'1 PPC- )2#"$'1Part-# Alaine %% %% 00 :a7sPa1 % %& #6 & :a7s & %% %$ :a7s " %#. %%. %.
, &0 ! =,/% ength of :ip TuLe = as inlet height 2ingle 2tream >2P >>CT4@2T3T)C P4>C)P)T3T@4 T@P V)>J 32C@;:)T)@;); T@J>4 2P43 2):> V)>J
%". Kiln :ata Q "." meter :iameter D 60 meter length )nclination = . 2hell thicknesses = % mm %$ mm mm 6 mm Kiln speed = . to .% 4P Preheater Q T7pe Q 6""0 / P4 &0"" V) 2tage :esc Kiln string P7ro string ) C7clone TSin "000 m ""00 m :iameter1 6"00 m &000 m :ip tuLe %000 m %%00 m :iameter1 %00 m 00 m %. irth ear Q odule = ' ;o of Teeth = #"$ aterial of construction = C2 6"0 ;ormaliUed Cast 2teel1 :imensions = 0 mm Sidth1 Pinion Q odule = ' ;o of Teeth = %$ aterial of construction = 0 Cr ;i o V$ ;ormaliUed Cast2teel1 :imensions = 600 mm Sidth1 %6. T7re 3ssemLlies three nos Q aterial of construction = 2 %" n ;ormaliUed Cast 2teel1 :imensions = 6%0 @: D "$# ): D && Sidth1 ain :ri?e 2upporting 4ollers 3ssemLlies three nos Q aterial of construction = C2 6"0 ;ormaliUed Cast 2teel1 :imensions = 6%0 @: D "$# ): D && Sidth1 T7re Kiln 2upporting 4oller 2hell irth ear Pinion %&. Kiln ain :ri?e Q ear LoD = 2:; $00 4atio = ".Q# 4J;-00 otor KJ = � 3uD .A 2:3 %0 ".Q # )nput 4P = #00 - #000 otor 0 KJ W #00 4P otor .A .A otor 4JA-#&$ Pinion Kiln 3Dis Concord 3lingnomatic eared Coupling . %$. ): K); F>>:); %'. :egree @f Kiln filling O Kiln Cross 2ectional loadingQ of Filling or 3rea of this segment 3#1 = Kilns :egree 3rea of cross section of Kiln 31 Theta Centric 3ngle Theta of Kiln :egree1 filling ##0 #.6 #0 #.& #00 #%.# 2egment ' #0.& r = radius inside lining '0 '.0' $ &.& r8% 3# = @ E 2in @ $0 6.% % & ."% &0 ". 3 = )) r8% 0. 4otar7 Kiln 2lope ?ersus oad Theta ". ".0 . .0 %.0 ' #0 ## #% # ;ote Q )n practical Kiln operation the kiln load should not eDceed #since higher Kiln loads impair the heat tranfer ThumL rule L7 Aohman aterial ?elocit7 in kiln Kiln Kiln diameter #1. Aurning Bone = ". mm / sec oSest 2lope m1 up to %.$ m " m to ." m %1. Calcining Bone = &. mm / sec aD H ." m #. 4otar7 Kiln poSer input calculation Q J D Ld D td D ; D F D 0.00000'% # ,.P = rd J = Total ?ertical load on all roller shaft LearinglL Ld = roller shaft
Learing diameter inches ;ote Q This is Frictional rd = roller diameter inches # ,orse PoSer td = tire or riding rind diameter inches ; = rpm of Kiln shell P = Coefficient or friction of roller Learings 0.0#$ for oil luL Learings O 0.06 for grease luL Learings %. This is oad ,orse % ,orse PoSer ,.P = : D 2in @1 8 D ; D D K % : = Kiln dia .inside lining ft 2in @ = read from diagram depending on oad ; = rpm of Kiln shell = length of kiln in ft K = 0.000&6 Total poSer = # G % . Cement onthl7 >delSeiss FromQ 3run 2hourie XmailtoQ3run.2hourieYedelcap.comZ 3run 2hourie 4elation anager - )nsurance :irQ G'# %%1 "0$6 $ / G'# ''%00 %'66 ". Aurner pipe centering location and alignment Aurner Pipe ocation "0! ? , d : . = V B Cos @ :EaEL * K = B % , = B 2ine @ Kiln :iameter = : Kiln lining thickness = a Kiln Coating thickness = L 3ngle of 4epose of kiln load = @ = "0! sa7 Kiln oad = K Value from taLle LeloS :epth of Led in Kiln = To Le measured Kiln load = K 6 & $ ' #0 ## #% # #" # :epth of material Led in Kiln = '.& ## #%.% #." #". #.6 #6.& #&.& #.$.$ #'.$ %# 6. 2tandard Coal Factor Q 2CF To determine the approDimate comLustion air needed to Lurn a gi?en unit St of coal formula gi?en LeloS can Le used Shen no ultimate anal7sis is a?ailaLle. The comLustion air reRuirement include here of eDcess air #00 - a A = 2CF #00 &000 Kg of 3ir = #0."&$ 2CF Kg of Coal a = oisture in coal as fired 1 A = ,eat ?alue of coal Kcal / kg as fired 1 &. oading of Kiln Q Theoretical Flame Temperature fuel oil Q CDfDt N T = = Vg D Cp dDV N = heating ?alue of oil K cal / kg C = Capacit7 of Kiln Ton / hr Vg = Volume of comLustion gases f = Ton Kg1 dr7 feed / Ton kg1 of Clinker ;m8 / Kg t = residence time Cp = 2pecific heat of d = Aulk densit7 of dr7 feed ton Kg1 / m8 comLustion gases =0."0 at %000!C for V = )nternal ?olume of kiln in m8 fuel class 52 $. 4otar7 kiln Capacit7 artins Formula Q C = %.$%6 ? * :8 Vg C = Kiln Capacit7 Ton / ,r V = as Velocit7 in gas discharge end m / sec Vg = specific gas ?olume m8 / kg clinker : = Kiln :iameter on Aricks m '. ,eat capacit7 of 4otar7 kiln # N = #.# D #0 8 6 D : 8 Kcal / hr1 : = ean inside Kiln :iameter on Aricks m % Kiln Thermal loading at cross section of Lurning Uone = Np = = N / Fp Fp = 0.&$ D :8% )nside cross-section of the kiln Lurning Uone m8% Shere : is kiln shell diameter N p = #." D #0 8 6 D : Kcal / m8%.hr Np should not eDceed ."6 D #0 8 6 kcal / m%.hr "0. ,eat transfer in c7clones preheaterQ The rule is that the siUes of the gas ducts and of the c7clone should Le in accordance Sith the formulaQ V8% =
Constant ): 8 V = as ?olume ): = )nside :iameter of ducts / c7clones respecti?el7 "#. Preheater c7clone siUing V1 8 % D Vt C : = 0.6 " P Vt = V0 %& G t G K K = dust concentration in as grams / m8 %& : = c7clone :iameter m V = as ?olume passimg c7clone m 8 / 2ec Vt = sp. gr. of gas at a?er. Temp Kg / m 8 C = Coefficient for pressure drop = ##0 P = Pressure drop in c7clone in mm J "%. 2mall siUe high efficienc7 c7clone , &0 ! =,/% ength of :ip TuLe = as inlet height 2ingle 2tream Pressure drop across c7clone = E 60 mLar ". Theoretical ,eat consumption N for clinker Lurning QUur 2trassen formula Q Constituent Constituent ultiplication ,eat Cons ;et ;ame * Factor kcal/kg 3l%@ .'% %.%% G #.# G g@ #.0 6."$!g@6."$ G 6.$ %&." Ca@ 6.'# &.6"6 G "$$.& ,%@ .% .$6 G #$.$ 9 2i@% %%.6$ .## 9 ##& ##$." Fe%@ %.# 0.' 9 #." ;et ''.%& ;et Kcal / Kg = "0'.0 N = %.%% 3l%0 G 6."$ g@ G &.6"6 Ca@ G .$6 ,%@ G .## 2i@% G 0.' Fe%@ "". Thermal efficienc7 of cooler = > 3-A * #00 >= 3 3 = ,eat loss of clinker lea?ing the kiln A = ,eat loss of the clinker cooler %0 "& E K 1 2econdar7 3ir Temperature = t = *.n1 K = ,eat loss of the cooler Kcal/Kg clinker * = 2pecific ,eat consumption of the kiln Kcal / Kg clinker n = >Dcess 3ir numLer = #.# Cooler fans designed for 2pecific Volume of E .# st.m8/Kg clinker ". Cooling of kiln >Dit ases CT1 Kg / min.>Dit gas D 0.% t # E t %1 Kcal / min = , t% E , t t# = Temperature of Kiln eDit gases t% = Temperature of gas to Le achie?ed or maitained t = temperature of Sater #!C1 , t% = ,eat content of Sater at t% , t = ,eat content of Sater at t = Kg Jater 2pra7 / min
