Material Balance (Cement Plant)

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 85% 85 15% 15

L/S Clay

M2

Loss

kg/day kg/day 5%

0.05

Clay M1 M3

Component %

IN M1 15

= = = =

Loss M2 15*0.05 0.75 14.25

M3 SiO2 70.69

+ + +

OUT M3 M3

kg/day

Al2O3 14.91

CaCO3 4.5

Fe2O3 6

MgCO3 1.5

M5

Loss

5%

0.05

Inert 2.4

Crusher M4 M6

Component %

IN M4 85

= = = =

Loss M5 85*0.05 4.25 80.75

M6 SiO2 1.88

+ + + kg/day

Al2O3 1.2

CaCO3 94.45

Fe2O3 0.57

OUT M6 M6

MgCO3 1.95

Inert 0

M8 Raw Mill M3 M6 Loss

M3 14.25

IN + +

M6 80.75 M8

OUT M8 M8 94.525

+ + + kg/day

Loss M7 0.475

Composition of M7 & M8 SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 11.591425 3.093675 76.909625 1.315275 1.788375

Component kg/day

Component %

= = = =

Concentration of Composition in Mixture SiO2 Al2O3 CaCO3 Fe2O3 12.20 3.2565 80.96 1.38

M7 0.5% 0.005

MgCO3 1.88

Inert 0.342

Inert 0.36

Exhaust Gases Kiln M8 M9 IN M8 94.525

= = kg/day

OUT M9

+ +

Component kg/day

SiO2 11.5

Analysis of M8 Al2O3 CaCO3 3.08 76.53

Component Mwt

SiO2 60.06

Mwt of Component Al2O3 CaCO3 101.94 100.09

Component kmol/day

Exhaust Gases Exhaust Gases

Fe2O3 1.31

MgCO3 1.78

Fe2O3 159.68

MgCO3 84.31

Moles of Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 0.192032 0.030196 0.764563 0.008196 0.021106

Inert 0.34

Component %

C2S 20

Component Mwt

C2S 172.22

Analysis of M9 C3S C3A 60 12

C3S 228.30

C3A 270.18

C4AF 8

C4AF 485.95

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

1 2 3 4 5 6 7 8 9

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

Moles of Components By the Reaction CaCO3 1 0.764563 X1

MgCO3 1 0.021106 X2

CO2 Weigh of CO2

----------------------

=

Y1

----------------------

=

Y2

= =

Y1

CaO 1 X1 =

MgO 1 X2 =

+

CO2 1 Y1

1

0.764563 kmol/day

+

CO2 1 Y2

2

0.021106 kmol/day

+ Y2 kmol/day * Mwt

= =

0.785668 kmol/day 34.577271 kg/day

9

2CaO 2 Y3

+

SiO2 1 0.192032

----------------------

Y3 X3

= =

0.384065 0.192032

kmol/day kmol/day

4CaO 4 Z4

+

Al2O3 1 Y4

+

Z4 Y4 X4

= = =

0.032783 0.008196 0.008196

kmol/day kmol/day kmol/day

5CaO 5 Z5

+

3Al2O3 3 Y5

Fe2O3 1 0.008196

----------------------

2Ca.SiO2 1 X3

----------

6

4CaO.Al2O3.Fe2O3 1 X4

5CaO.3Al2O3 1 X5

5

3(3CaO.3Al2O3) 3 X6

7

Y5 = Total moles of Al2O3 - Y4 Y5 X5 Z5

4CaO 4 Y6 Y6 X6

= = =

+

0.022001 0.007334 0.036668

kmol/day kmol/day kmol/day

5CaO.3Al2O3 ----------1 X5 = 0.007334 = =

0.029334 0.022001

kmol/day kmol/day

CaO 1 Z7

+

2CaO.SiO2 1 Y7

-----------

3CaO.SiO2 1 X7

From outlet % Analysis

Weigh Ratio Mwt Mole Ratio

C3S 3CaO.SiO2 60% 3 228.3 0.013141 2.263 X7 X7 X7

2CaO.SiO2 Excess 2CaO.SiO2 Excess

=

Inerts in MgO CaO Excess

----------------------------

Amount of Inerts

= =

weigh ratio / mwt Divided by 0.005806

= = =

SiO2 kmol/day *2.263 / (2.263+1) 0.133181 kmol/day Y7 = Z7 = 0.133181

= =

SiO2 kmol/day* (1/2.263+1) 0.058851 kmol/day

The amount of CaO excess The amount of CaO excess The amount of CaO excess

Amount of Inerts

C2S 2CaO.SiO2 20% 1 172.22 0.005807 1

Inert in

= = =

+

Outlet Reactant CaCo3 Y3+Z4+Z5+Y6+Z7 0.148532 kmol/day

MgO

+

CaO Excess

Analysis of inlet Moles of component * Mwt CaO Excess * Mwt

0.340290 9.520970

+ kg/day

0.8509874

+

8.329693

% Analysis of the clinker

Component C2S C3S C3A C4AF Inert Sum

kmol/day 0.058851 0.133181 0.022001 0.008196 -

Mwt 177.22 228.3 270.3 485.95 -

= = =

M9 60.285304 94.862575

kg/day kmol/day * Mwt 10.429662 30.405208 5.946735 3.982729 9.520970 60.285304

% 17.3 50.4 10 6.6 15.8 100.0

Check M8 94.525 94.525

+ +

Exhaust Gases 34.577271

M9 Cement Mill M10 5%

0.05

+

M10

M11

From the Mill: Balance: M9

=

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 Working Days 1000000

ton/year

100 X

kg/day kg/day

X

=

1000000 300

ton/year day/year

=

3333333.3

kg/day

------------63.1 ------------- 3333333.3

kg/day kg/day

Basis

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 0.75

Clay

Loss

M1

15

M``

=

X*M / 100

M1`` M2`` M3``

= = =

792393 39619.65 752773.4

kg/day kg/day kg/day

M5 4.25

Loss

Crusher M4

85

5%

0.05 14.25 M3

5%

0.05 80.75 M6