Heat Calculation by SG.

Clinker Weighing test result 11 September 1997 Time (hour) Kiln Feed totalizer (T) Kiln Coal totalizer (T) ILC Calciner coal totalizer (T) SLC Calciner coal totalizer Clinker weighing total (T)

start

Stop 1 4 .1 3 81 30 41 11001.9 6 3 1 2 .8 2 1 20 78

L min GHV

Total 2 2 .1 3 81 71 86 11120.5 6 3 5 5 .3 2 12230.3

Ton/jam 8 41 45 118.6 42.5 152.3 2719.5

5 1 8 .1 1 4 .8 5 .3 1 9 .0 3 3 9 .9

8.542 kg air/kg Coal 5763 kcal/kg Coal

Fuel consumption Kiln (PW1) ILC Calciner (PW2) SLC Calciner (PW3) Total

Ton 118.6 42.5 152.3 313.4

Fuel Consumption

% 37.8% 13.6% 48.6% 100.0%

664 kc kcal/kg Clinker

Combustion air

ton/jam 14.8 5.3 19.0 39.2 (note:pfist

334632.9 kg kg air/jam 5577.2 5577.2 kg air/min air/min 0.984 0.984 kg air/kg air/kg clink clinker er

Clinker Faktor

1.52 (note:the dust return is not weighed)

Material Balance Pulvurized Coal Ash

X

kcal/kg terak

19. 19.67 % 0.1967 x kg 3.413E-05 x kg LOI LOI 35.1 35.18 8

Raw mix to clinker 

= (1 - 3.413* X*(10^-2))*100 100 100 - 35.1 35.18 8 = 1 .5 4 2 7 3 3 7 2 4 -

CO2 From raw mix

total carbonat = 0 .5 2 4 1 7 1 5 5 2

Free H2O in the raw mix

H2O

5 . 2 6 6E- 0 5 x

7 7 .2 2 % -

1 . 7 8 9E- 0 5 x 0 .5 %

Combined H2O in raw mix

=( 1.54 1.5427 2733 3372 724 4

-

5.26559E-05 x) *

= 0 .0 0 7 7 5 2 4 3 1

-

2.64602E-07 x

H2O =( 1.542733724 = 0 .0 1 7 2 7 8 6 1 8

1.12 % 5.26559E-05 x) * 5.89746E-07

C

Carbon from raw mix

=( 1.54 1.5427 2733 3372 724 4 = 0 .0 0 1 6 9 7 0 0 7

0.11 % -

5.26559E-05 x) * 5.79214E-08

Excess Air % Excess Excess Air =

79 * %O2 0.21 * (100 - % CO2) - %O2

Stage 1 ILC

average exit gas analiysis CO2 = 29 O2 = 3 .5 Excess air = 24.2

Stage 1 SLC

average exit gas analiysis CO2 = 32 O2 = 3 .5 Excess air = 25.6

Dust in Exit Gas

10.5%

Dust rate kiln Feed Total

56.28 tph 511.1 tph 567.38 tph

5 0 8 .5 4 4 5 5 6 4 .5 4 3 1

CLK = KF * (efficiency) (efficiency) * (1 - H2O) * (1-LOI) + (Coal 335 = 567.4 * (effic (efficiency) iency) * (1 - 0.05) * (1-0.35 (1-0.3518) 18) + 327.6227335 = 365.936837 * Efficiency Efficiency = 89.5% Dust =

Water from Coal

0.177 kg dust/kg dust/kg clinker clinker

Fine Coal H2O LHV Fine Coal Fine Coal Consumption

2.29 % 5763 kcal/kg Coal =

x 5763 =

Dry Coal consumption

0.000174 x

=

x

= Water from Coal

+ (15763

kg coal/kg terak

0.0229 )

0.000169547 x

=

x * 5763 =

kg coal Dry/kg terak 0.0229

3.97362E-06 x

kg air/kg terak

Combustion Air Rates: L min Air required

8.542 kg air/kg Coal x * 5763

=

=

0.001482214 x

=

8.3976694

8.542 kg Coal

kg air

kg air/kg Clk

Kiln Primary air 

Flow

150.7 kg air/min

(measurement pitot tube)

0.027 kg air/kg Clk L min

= 2110.585833 kg air/min =

7.14% kebutuhan udara dari total combustion o

Kiln Coal Transport air 

Flow

81.8 kg air/min 0.015 kg air/kg Clk

L min

= 2110.585833 kg air/min =

3.9% kebutuhan udara dari total combustion o

ILC Calciner coal transport and primary air 

Flow

25.83 kg air/min 0.005 kg air/kg Clk

L min

= 756.3229167 kg air/min =

3.4% kebutuhan udara dari total combustion o

SLC Calciner coal transport and primary air 

Flow

91 kg air/min 0.016 kg air/kg Clk

L min

= 2710.305417 kg air/min =

3.4% kebutuhan udara dari total combustion o

Remaining air requirement ILC/kiln String =[( 0.001482214 x

*

(1 +

= 0.000946553 x

0.242 ))

*

(

*

(

-0.046

Remaining air requirement ILC/kiln String =[( 0.001482214 x

*

(1 +

= 0.000905049 x

Combustion products from coal

0.256 )) -0.016

9.349 kg gas/kg coal including w =

X

kcal/kg terak 5763 kcal/kg Coal

= 0.001622245 x kg gas/kg clk

9.349 kg gas/kg c

Extra air required to burn carbon in the kiln feed +

C

Air

Lb

1

11.53

lb/lb clk

0.0017

0.019566492

---------- > Including

24.2 % Excess air in ILC

0.024308

---------- > Including

25.6 % Excess air in SLC

0.024585

Extra Product of Combustion for ILC CO2 N2

0.006 kg CO2/kg clk 0.0187 Kg N2/kg Clk

Extra Product of Combustion for SLC CO2 N2

0.006 kg CO2/kg clk 0.0189 Kg N2/kg Clk

Excess Air ILC/kiln string

= [(

37.8%

= 0.000184636 x

SLC string

=[

+

48.6%

= 0.000184752 x

Sistem surface losses Radiation losses Kiln Radiation loss

+

*

0.0047 kg air/kg cl

*

+

13.6% ) 5763

8.542 5763

*

0.0050 kg air/kg cl

23

Cooler and firing hood radiation loss Preheater and tertiary air dust radiation loss

6 28

Cooler 124 C

Average clinker discharge temperature Heat of Cooler



= =

1 kg/kg clk #NAME?

Radiation Loss

*

124 *

kcal/kg clk

6 kcal/kg clk

Excess Air Flow

388554 kg/hr @

238 C 

1.158726595 kg air/kg clk CP

#NAME?

Heat Of excess Air

#NAME?

kcal/kg clk

Hot air for the raw mill Flow

122897 kg/hr @ 0.366497378 kg air/kg clk

CP

#NAME?

Heat Of excess Air

#NAME?

kcal/kg clk

Total Cooler loss

#NAME?

kcal/kg clk

407 C 

r feeder calibration not correct)

0.005025

0.0112

0.0011

sh) (39.17*0.1967)

f kiln fuel.

f kiln fuel.

v

f ILC Calciner.

f SLC Calciner.

37.8% +

13.6% )]

kg air/kg clk

48.6% )] kg air/kg clk

ter in Coal oal

-0.016

-0.027

-0.015

-0.005

CO2

+

N2

3.666667

8.85504

0.006222

0.015027

kg air/kg clk kg air/kg clk

8.542 *

0.256494 ] * x + (

kcal/kg clk

0.242331 ] * x + (

0.024585

-

0.024308

0.0196 )

-0.0196 )

kcal/kg clk kcal/kg clk

#NAME?

System Heat Input Fuel : Combustion Heat Free heat w/ coal Air : Primary Kiln Coal transport ILC Coal transport SLC Coal transport Remaining ILC Remaining SLC Extra for C - ILC Extra for C - SLC Cooler : Excess Air Hot air for RM Water from coal Raw Feed Returned dust Sum Of heat inputs

C

System Heat Input Combustion Product (Coal) Combustion Product (Carbon in mix) CO2 - ILC N2 - ILC CO2 - SLC N2 - SLC Excess Air In exit gas - ILC Excess Air In exit gas - ILC CO2 from Raw Feed Vapor from free H2O In feed Vapor from comb H2O In feed Dust Radiation : Kiln Preheater Cooler loss : Heat in Clinker Radiation Hot air for mill Excess Air Heat of reaction Sum Of heat inputs

C

kg/kg 80 0.000174 x 32 32 32 32 32 0.0009466 x 32 0.000905 x 32 32 32 32 80 3.974E-06 x 90 -5.266E-05 x 90

0.027 0.015 0.005 0.016 -0.04622 -0.01628 0.02431 0.02459 1.15873 0.3665 1.54273 0.177

kg/kg 348 0.0016222 x 348 348 348 348 348 0.0001846 x 348 0.0001848 x 348 -1.789E-05 x 348 348 348

k 1 0.2932 0.004070102 0.2377 0.2377 0.2377 0.2377 0.2377 0.007200951 0.2377 0.006885208 0.2377 0.2377 0.2377 0.2377 1.0000 0.00031789 #NAME? #NAME? #NAME? #NAME?

kcal/kg C

k kcal/kg C 0.2579 0.145595223 0.006 0.0187 0.006 0.019 0.0047 0.00502 0.52417 0.00775 0.01728 0.177

0.2319 0.2517 0.2319 0.2517 0.2450 0.015742344 0.2450 0.01575218 0.2319 -0.00144354 788 0.4600 0.2367

124

1

0.1927

407 238

0.3665 1.15873

0.2464 0.2425 0.17564621

#NAME? x 0.17565 x

+

#NAME? 665.394721

#NAME? x = x =

#NAME? #NAME?

Summary al/kg x x

C

#NAME? #NAME? #NAME?

System Heat Input Fuel : Combustion Heat Free heat w/ coal Air : Primary Kiln Coal transport ILC Coal transport SLC Coal transport Remaining ILC Remaining SLC Extra for C - ILC Extra for C - SLC Cooler : Excess Air Hot air for RM Water from coal Raw Feed Returned dust Sum Of heat inputs

C

0.5020577 1.6349262 0.5020577 1.6535638 0.4042731 0.4278995 42.293343 6.1089155 2.7657381 14.590608 23 28 23.894304 6 36.748299 66.868735 410 665.39472

System Heat Input Combustion Product (Coal) Combustion Product (Carbon in mix) CO2 - ILC N2 - ILC CO2 - SLC N2 - SLC Excess Air In exit gas - ILC Excess Air In exit gas - ILC CO2 from Raw Feed Vapor from free H2O In feed Vapor from comb H2O In feed Dust Radiation : Kiln Preheater Cooler loss : Heat in Clinker Radiation Hot air for mill Excess Air Heat of reaction Sum Of heat inputs

0.2051346 0.1113471 0.0351601 0.1238703 -0.3516419 -0.1238703 0.1849249 0.187033 8.8150728 2.7881479

x x

x x

+

x

+

al/kg x

x x x

x =

80 32 32 32 32 32 32 32 32 32 32 80 90 90

348 348 348 348 348 348 348 348 348 348 348

124 407 238

Kcal/kg

kg/kg

kcal/kg C

kcal/kg #NAME? #NAME? 0.205135 0.111347 0.03516 0.12387 #NAME? #NAME? 0.184925 0.187033 8.815073 2.788148 #NAME? #NAME? #NAME? #NAME?

#NAME? 0.027 0.015 0.005 0.016 #NAME? #NAME? 0.024308 0.024585 1.158727 0.366497 #NAME? #NAME? 0.177

0.2932 0.237736 0.237736 0.237736 0.237736 0.237736 0.237736 0.237736 0.237736 0.237736 0.237736 1 #NAME? #NAME?

kg/kg #NAME?

kcal/kg C kcal/kg 0.2579 #NAME?

0.006 0.019 0.006 0.019 #NAME? #NAME? #NAME? 0.007752 0.017279 0.177156

0.231857 0.251656 0.231857 0.251656 0.245004 0.245004 0.231857 788 0.459963 0.236667

0.502058 1.634926 0.502058 1.653564 #NAME? #NAME? #NAME? 6.108915 2.765738 14.59061 23 28 1 0.192696 23.8943 6 0.366497 0.246361 36.7483 1.158727 0.242474 66.86874 410 #NAME?