IN A CEMENT PLANT WHERE DOES THE HEAT GO ??!!! + EXCEL SHEET FOR HEAT BALANCE

HELLO DEAR , IF YOU NEED TO DOWNLOAD THE MANUALS AND FORMULAS AND EBOOKS FOR 27 EXPERIENCED EX-HOLCIM ENGINEER PLEASE CLICK HERE NOW, THIS IS THE ULTIMATE ESSENTIAL PACKAGE CONTAIN BOOKS , PROCESS MANUALS AND EXCEL SHEETS FOR CALCULATIONS.

BY  pradeep kumar

For perpetual pyro process in a kiln the heatrequired is only heat of clinker mineral formation,
ie., 380 – 400 Kcal/kg clinker. 280 – 350 Kcal/kg clinker is wasted which is about 40 – 45 % .
The dream of design engineer is to make heat losses to minimum and how to optimize the heat consumption.

The preheater heat losses

Pre heater gas temperature Design of cyclones
No of stages
Dust loss
Inlet / out let velocity ratio Location of meal distribution boxes

Preheater( Surface) heat losses through radiation

Calciner gas retention time Combustion effciency

Coal residue & raw meal residue Location of firing nozzles

Burner Operation

Burning zone, Flame-profile

Low momentum burner

High momentum burner

Lafarge Multi Channel burner

PillardRotoFlame

Cement kiln flame types

Straight flame – essentially external recirculation

Type-1 flame
Weak internal recirculation & external recirculation

Type-2 flame
Strong internal recirculation & external recirculation

Objectives

“It is desirable to operate the kiln at the lowest fuel consumption. This must be consistent with the highest practical output at an acceptable market quality.”

WHY TO DO IT

• To get a detailed view of the kiln line performance
• Evaluate exact data for heat consumption, production,…
• Basis for comparison impact of investment or modifications carried out & comparison to other plants
• Detect weak points – Action Plan
• Detect optimization potential
• Check of sensors, weigh feeder,…

Boundary selection

• Any boundary shape can be chosen.
• Every stream that crosses the envelope must be taken into account.
• The boundary line is chosen so that the boundary points are:useful for the balance goals &easily accessible for reliable measurements

TO DOWNLOAD THE MANUALS AND FORMULAS AND EBOOKS FOR 27 EXPERIENCED EX-HOLCIM ENGINEER PLEASE CLICK HERE NOW, THIS IS THE ULTIMATE ESSENTIAL PACKAGE CONTAIN BOOKS , PROCESS MANUALS AND EXCEL SHEETS FOR CALCULATIONS.