Mod 7

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Importance…….. • Around 25% of the total production cost is spent for Heat

• Economy of the plant depends of its specific Heat consumption















Reduction in cooler Loss Secondary Second ary Air & TAD Temp raise Improved flame in kiln & better combustion in Calciner Less circulation of volatile matter Less formation of Build















Reduction in Specific #eat Consumption Reduction in Specific $ent %as % as lo'

Increased Ra'meal eed to (iln















Controllable arameters • Ra!meal • Combustibles • Air "istribution • #alse Air Intake















C&'E&'( • Introduction • Ra'meal *uality and roperties + #eat of reaction + Content of combustible materials + Content of free & combined moisture + Temperature of kiln feed

Combustibles, *uality & roperties

















Contents… • Air "istribution + rimary air















HEAT BALANCE Heat In put

Kcal /Kg Clinker

%

Heat through Coal Combustion

689.04

94.39

ensible heat in !a" meal

#$.06

3.43

ensible heat in uel

0 98

0 &3















Ra!meal +uality and roperties Influence on















Heat of Reaction……... • T!e t!eoritical amount of ener/y re0uired to convert t!e ra'meal into t!e correspondin/ mi1ture of clinker minerals • 2ner/y c!emically absorbed by t!e















• Heat of reaction HR/ !ill be normally in the ran0e of 15 , 324 *cals  *0 of clinker

• It is an inherent characteristic of a ra!mi) and it is not in the po!er of the operational staff to influence

















C89:('I9$E C89:('I9$E 8A' 8A'ERIA$















Effect of Combustible materials on Heat















peratin0 considerations



































































































































































































E)cesss Air in the *I$& E)ces • A certain e)cess air is maintained in the kiln inlet to a6oid C formation and reducin0 conditions in kiln • Increase in kiln draft increases the heat consumption but neutralised by the increased heat recuperation from the cooler • 'he amount of e)cess air durin0 operation is















Increased 21cess Air )ore !eat Loss in pre!eater #eat loss

Increased ID an Load 21cess "@ in Smoke %as )ovement of















'he influence of E)cess air on the heat consn and other parameters for H and I$C *iln

#or H kiln er % Increase in e)cess air in kiln

(p heat consn

#or Calciner kiln er % Increase in e)cess air in kiln

Independent of e)cess ;4.7 *cal  k0 clinker air up















or a specific !eat consumption of ;7 (Cals8(/ of clinker , , T!eo- Combustion air J 6-7K (/ of air8(/ of clinker J 7-6M m? 8 (/ of Clinker N67= 21cess air Combustion air J 6-6KK (/ of air 8(/ of clinker















#alse air intake……. • As it is a induced draft system, intake of certain amount of false air is inevitableinevitable • #as a substantial influence on t!e !eat consumption, po'er consumption, production and coatin/ build< ups in pre!eater to'er• Closer to t!e kiln outlet, t!e effect 'ill be substantial-substantial • If 7-6 k/ of false air8k/ of clinker enters at

















Common areas to be !atched for false air  reheater doors  Kiln inlet seal  reheater fan damper seal.  *iln hood inspection door and cleanin0 holes















• "ue to the leaka0e air the operatin0 point of I" fan is shifted from its ma)imum efficiency point causin0 more po!er consumption • 'he in0ression of false air may lo!er the ma)imum kiln production due to the increase in















Air leak t!rou/! an aperture of area A9m @: 'it! a differential pressure of D9mmO%: can be calculated from $olume 9m? 8!r: J M77 1 A 1 s0 Rt 9 D:

Results from reference model> model>















C$ER $(( #eat loss in Cooler e1it air Clinker















• A bed !ei/!t of >77 < K77mm to be maintained by means of adFustin/ t!e /rate speed and under/rate pressure- A !i/!er bed t!ickness improves t!e !eat recuperation and reduces t!e !eat losses for cooler• Avoidin/ blo'in/ pot !oles by maintainin/ t!e

















Results from reference model> model>















CC$&E E##ICIE&C















• A6oidin0 build,ups in the preheater usin0















Indicators of oor Cyclone Efficiency















C&C$:(I&















Mod 7

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