Mill Material Balance

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 8 5% 85 1 5% 15

L/S Clay

M2

Loss

kg/day kg/day 1%

0.01

Clay M1 M3

Component %

IN M1 15

= = = =

Loss M2 15*0.01 0.15 14.85

M3 SiO2 50

+ + +

OUT M3 M3

kg/day

Al2O3 13

CaCO3 6

Fe2O3 10

MgCO3 2

M5

Loss

1%

0.01

Inert 19

Crusher M4 M6

Component %

IN M4 85

= = = =

Loss M5 85*0.01 0.85 84.15

M6 SiO2 6

+ + + kg/day

Al2O3 2

CaCO3 48

Fe2O3 1

OUT M6 M6

MgCO3 1 .5

Inert 0

M8 Raw Mill M3 M6 Loss

M3 14.85

IN + +

M6 84.15 M8

OUT M8 M8 98.505

+ + + kg/day

Loss M7 0.495

Composition of M7 & M8 SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 12.474000 3.613500 41.283000 2.326500 1.559250

Component kg/day

Component %

= = = =

Concentration of Composition in Mixture SiO2 Al2O3 CaCO3 Fe2O3 12.60 3.6500 41.70 2.35

M7 0.5% 0.005

MgCO3 1.58

Inert 2.822

Inert 2.85

Exhaust Gases Kiln M8 M9 IN M8 98.505

= = kg/day

OUT M9

+ +

Exhaust Gases Exhaust Gases

Component kg/day

SiO2 12.4

Analysis of M8 Al2O3 CaCO3 3.60 41.08

Fe2O3 2.31

MgCO3 1.55

Component Mwt

Mwt of Component SiO2 Al2O3 CaCO3 60.06 101.94 100.09

Fe2O3 159.68

MgCO3 84.31

Component kmol/day

Moles of Component SiO2 Al2O3 CaCO3 0.206654 0.035270 0.410396

Fe2O3 MgCO3 0.014497 0.018402

Inert 2.81

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

1 2 3 4 5 6 7 8 9

5

Moles of Components By the Reaction CaCO3 1 0.410396 X1

MgCO3 1 0.018402 X2

CO2 Weigh of CO2

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

=

Y1

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

CaO 1 X1

+

CO2 1 Y1

=

0.410396

kmol/day

MgO 1 X2

+

CO2 1 Y2

=

Y2

=

= =

Y1

+ kmol/day * Mwt

1

2

0.018402 kmol/day

Y2

= =

0.428798 kmol/day 18.871412 kg/day

9

2CaO 2 Y3

+

SiO2 1 0.206654

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

Y3 X3

= =

0.413308 0.206654

kmol/day kmol/day

4CaO 4 Z4

+

Al2O3 1 Y4

+

Z4 Y4 X4

= = =

0.057988 0.014497 0.014497

kmol/day kmol/day kmol/day

5CaO 5 Z5

+

3Al2O3 3 Y5

Fe2O3 1 0.014497

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

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

= = =

+

0.020773 0.006924 0.034622

kmol/day kmol/day kmol/day

5CaO.3Al2O3 ----------1 X5 = 0.006924 = =

0.027698 0.020773

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) 0.143321 kmol/day Y7 = Z7 = 0.143321

= =

SiO2 kmol/day* (1/2.263+1) 0.063332 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 -0.266540 kmol/day

MgO

+

CaO Excess

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

2.807393 ########

+ kg/day

0.7419596

+

-14.94755

% Analysis of the clinker

Component C2S C3S C3A C4AF Inert Sum

kmol/day 0.063332 0.143321 0.020773 0.014497 -

Mwt 177.22 228.3 270.3 485.95 -

= = =

M9 45.205618 64.077029

kg/day kmol/day * Mwt 11.223780 32.720270 5.614988 7.044776 -11.398197 45.205618

% 24.8 72.4 12 15.6 -25.2 100.0

Check  M8 98.505 98.505

+ +

Exhaust Gases 18.871412

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

=

47.584861

kg/day

M10

=

2.379243

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 0.15

Clay M1

15

M``

=

X*M / 100

M1`` M2`` M3``

= = =

792393 7923.93 784469.1

M4

85

5%

0.05 14.85 M3

M5 0.85

Crusher

Loss

kg/day kg/day kg/day

Loss

5%

0.05 84.15 M6