Kiln system Mass and energy Balance

JOB AID

Kiln Heat Balance Calculation Calciner _ Preheater

Pyroprocessing

1/18

PR PYR T09-04 v1. - Jan 2009 The following colour code is used: Blue on yellow Cells to fill in Data input is carried out on 4 input sheets (Input Sheet 1 to 4).

This tool is used for kiln audits' balance calculations and reporting of them. This version is the official release 1 as division tool. Former versions distributed in CTEC area are replaced by this release - the changes and improvements compared to the April 2008 version are documented in the next page _ revision. A detailed training on the tool is provided in the process engineer training Pyroprocessing 2 (kiln audit training). To guide the user comments are available for most input cells and important calculation cells. This tool is using the updated Add IN Function thermodynamic.xla from January 2009 (1.5b). User should install the updated add-in prior to using the tool. The add in file as well as an installation guide is attached below. The new add in version allows the use of negative temperatures, an "Enthalpy_free" function without water evaporation is implemented. There are no makros used for calculation to keep the tool transparent. The only makro used is to ensure the proper function of the add ins - the makro is deleting any path to thermodynamic functions which might occure when copying from another PC. The add in function still have some logical checks which might cause error massages during data input (unlogical data as long as the input is not completed). Just aknowledge and continue with further data input. The cells are not protected to allow follow up with the formula auditing = take care not to modify. Input is done only on the input pages and to be customised example pages at the back. Summary layout of tool: 4 input sheets where data entry is processed into material balance, waste gas calculation and finally heat balance sheets. Balanced figures of performance results are summarized in a final sheet. The calculation and result sheets are created to be directly copied into the audit report. Preheater and/or precalciner kilns are supported by the tool (still separate line calciners with separated preheater strings need manipulation by user). For wet lines and long dry lines a separate version is in use within CTEC and available as division tool soon. Flow sheet example and example for cyclone speed calculations are added at the back, they are linked to the input sheets of the heat balance but are not used for heat balance results, they can be customised for the specific application.

Source: Authors:

CTEC Heat Balance Tool 2007 ; updated in 2008 Bernhard Koeck / Cenk Eskin Any error to report ? Suggestions for improvement ? Please contact your TC or the authors above.

All rights of reproduction, representation, adaptation and translation relating to this report belong to Lafarge SA. Lafarge SA reserves the right to exploit this report or not and to freely distribute it to all of its current and future subsidiaries worldwide in any form, whether paper, electronic or digital, including via internet and/or intranet. This report along with its content is of a confidential nature. In particular, it may not be reproduced, copied, transmitted, published, divulged and/or appropriated in whole or in part for personal use or for use by a third party without prior consent from the Production & Process Department, except for reproduction by or for affiliated Lafarge companies.

Kiln Heat Balance Tool _ Calciner Preheater

Revisions Version Division 1.0

Date Jan-09

Who DPC

CTEC 1_2_6

Nov-08

Bernhard Koeck

CTEC 1_1

Apr-08

CTEC test version

2007

Cenk Eskin Bernhard Koeck Cenk Eskin Bernhard Koeck

Comments CTEC Kiln Heat Balance Tool v. 1.2.6 becomes the division tool version 1 For publication on Cement Portal's Pyroprocessing domain Improvements / Correction since 1_1 All changes since the first CTEC release 1_1 are documented below. Official release within CTEC - spread out in CTEC area Used by CTEC process engineers since begin 2007 - first use in kiln audit training Sept 2007 - first sharing within the combustion COP

LIST OF MODIFICATIONS (VERSION 1.1 TO VERSION 1.2.6) 1) waste gas calculation: LHV as fired is corrected with 594kcal/KJ water instead of 596 before. 2) waste gas calculation and calciner waste gas calculation: correction of O88 - ambient air moisture was not considered in mass section 3) Change of clinker heat of formation. Dehydration of clay is considering the cristal water. C3S is without SO3 substraction. 4) False air tertiary air related to tertiary air input at the calciner 5) Correction of moisture - material balance N9 and O9 6) Material balance C42: Chlorine added to total 7) Material balance G68: corrected D45 (bypass dust) instead of D44 8) Input3: for a preheater kiln cells B36,B37,G31,G10,J10 "Not applicable for preheater kiln" sentance added 9) Input 3 C35: preheater false air in a preheater kiln is calculated using a separate equation and not linked to Waste Gas Calc. M115 "Tertiary air into calciner" 10) Input 3 I31: no value in case of preheater kiln 11) Heat value of CO in the exit gas considered as heat loss 12) Material balance: S, Cl and Fuel Ash is taken from as fired (was taken from input 2 before without considering wet/dry) 13) Material balance C37 and 38 --- correction of S2-/TOC and moisture calculation (dry --> dry+TOC/S-->wet+TOC/S). Correction of all dependend calculations which had been C36 before to C 37 (calculated clinker analyse, CO2 raw mix,...) 14) A new input field (input 1 - kiln feed balanced dry) is created to avoid circular reference in the material balance - used to calculate the SO2 emissions and the S2- fuel ash part. 15) Material balance: Kiln feed S2- trapped is added to fuel ash. 16) Correction of material balance based on kiln feed 17) TOC and S flow in exit gas calculations (P54 and Q 54) are based on C37 material balance 18) heat capacity for gases from temperature 0°C to -50°C is added 19) enthalpy for H2Ov without heat of vaporization is replaced: enthalpy_free(" "; ) 20) enthalpy for kiln feed, filter dust and bypass dust are based on their chemical composition 21) enthalpy for coal (dry) is based on volatile content 22) enthalpy for oil is based on the density 23) material balance H68 corrected 24) Input 1 E25 deleted (bypass dust now by default not included in clinker weighing) 25) Calculation of secondary air is corrected by using blendtemperature_free. In version 1 vol % moisture had been used in I22 instead of mass %. 26) Corrction of bypass impact in waste gas calculation - N76 / N87 / N90. 27) Calculation of CO2 and CO2 fossil added, input fields for % fossil per fuel added. 28) Waste gas calc and calciner exit gas: Correction of cell D77 and O77 - use of calculated Oxygen in C117 instead of 20,95. 29) Sulfide considered in LOI check - input 1 30) Waste gas calculations Q31 - Sulfide oxydation into SO3 instead of SO2 is considered depending on the trapping coefficient, Fe2O3 oxidation from FeS2 is considered. 31) Waste gas calcualtion neutral combustion air - Oxidation into SO3 instead of SO2 is considered. 32) Heat Calculation Cooler - F23 and L10 - changed back from blendtemperature_free to blendtemperature considering recalculated energies in I21 and I22 (the blendtemperature_free function used before showed in some iteration cases an error). 33) Material balance - SO2 emissions not considered as output for the back calculation of kiln feed or clinker. 34) Waste gas calculation and calciner exit gas calculation (D100,...) - ambient moisture considered in the excess air of kiln and excess air of line. CO considered in the excess air as well. 35) blendtemperature_free replaced by blendtemperature with recalcualted enthalpy. (primary air and false air in heat calculation kiln) 36) Waste gas calculation g74 - ambient moisture considered in the bypass excess air. 37) Material balance D67 - decarbonatisation energy of bypass dust - taking CaO free in bypass dust as input figure 38) Waste gas calculation and calciner exit gas calculation - C63 is taking directly the decarbonatisation CO2 from the material balance - considering the bypass dust CO2 as well. 39) Change to the updated thermodynamic.xla (1.5b - Jan 2009). Improoved help and description of the add ins. Correction of blendtemperature_free, new Enthalpy_rawmix. 40) Material Balance T26 / X26 and AC26: Use of new Enthalpy_rawmix function. Chemical analyse is totalised to 100% to avoid missing Enthalpy out of analytics below 100%.

PR PYR T09-04 v1

KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 1 Rawang, Malaysia Plant Name RK3# Name of the Kiln Kiln Type Precalciner March 13, 2012 Date of measurement Date of report Ambient temperature, °C Altitude above sea level, m. Atmospheric pressure, hPa Ambiente relative humidity, %

SO2 trapping % of S-2

50%

TOC burnt in calciner Ratio hot meal/kk Kiln inlet dust g/kgck

1.19

Kiln Feed Flowrate wet, kg/h H2O, % Temperatures,°C Crystall Water, %

41720

0.21

0

69

445

1

0.4

Kiln Feed

40 1008

Err:511

50%

150

199540

Kiln feed dry - back calculated, kg/h:

Clinker t/d

4789

0

No

0.00%

Preheater dust Bypass Dust

0 0 308680

305338

Clinker

SiO2 ,% Al2O3 ,% Fe2O3 ,%

6.81

12.11

22.48

0.99

3.94

5.34

0.41

1.84

4.74

CaO, % MgO, % LOI ,% CO2 ,% K2O ,% Na2O ,% SO3 ,%

50.38

44.93

65.69

0.48

0.48

0.64

40.3

34.9

TOC ,% Cl- , % S-2 ,% LOI check Total

Hot meal

39.3 0.18

0.91

0.52

1.3

0.03

0.04

0.07

0.27

0.28

0.6

0.06

TiO ,% P2O5 ,% Non Carbonated CaO in Kiln Feed / Total CaO, % Non Carbonated MgO in Kiln Feed / Total MgO, %

Clinker

30

0%

Is there a by-pass in the kiln? Volume ratio of gas extraction at the by-pass, %

Preheater dust Bypass Dust

280000

0.116 0.033 0.6 free lime: 0.00

34.50

99.64

64.65

0.00

1.71 99.91

2.17

KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 2 KILN FUELS on Burner Choose Fuel Typeð Coal

AF-sol.

Name of Fuel Flowrate, kg/h fired

Servo Coal

Analyse (dry / wet) Carbon, %

dry

Gas

Coal

PRECALCINER FUELS

Coal

Coal

Coal

Coal

AF-sol.

Servo Coal Bottom feed

8625

8075 dry

71250 dry

OTHERS

AF-sol.

Rice husk 1040 dry

Wood

TOC

6917 dry

56.80

56.80

12.90

41.20

45.90

5.90

5.90

1.05

5.90

8.30

0.50

0.50

0.14

0.06

0.10

Oxygen, % Nitrogen, %

15.50

15.50

5.13

34.51

42.30

0.50

0.50

0.26

0.91

0.30

Ash, %

19.50

19.50

79.29

16.47

2.50

98.70

0.00

0.00

0.00

0.00

0.00

98.70

98.77

99.05

5279

16089

16747.2

99.40 100.00 33830

13.81

13.81

2.05

18.36

48.30

0.00

Temperatures,°C

60

60

70

30

30

volatiles,% fossil carbon, %

40

40

11

68

79

100%

100%

100%

100%

100%

Ash 1

Ash 2

Ash 3

Ash 4

Ash 5

Ash 6

Ash 7

Ash 8

Ash 9

Ash 10

SiO2, %

51.78

51.78

36.13

94.44

Al2O3, %

16.45

16.45

13.35

0.15

6.96

Fe2O3, %

7.98

7.98

12.42

0.11

21.53

32.48

CaO, %

7

7

6.1

0.52

24.18

MgO, % K2O, %

4.47

4.47

0.55

0.67

0.96

2.66

2.66

1.47

2.13

2.05

Na2O, %

2.84

2.84

0.24

0.49

0.76

TiO, % P2O5, %

0.73

0.73

0.379

0.01

0.28

0.36

0.36

0.162

0.97

0.906

Total, %

94.27

94.27

70.801

99.49

90.106

0

0

0

0

0

0.00 dry

100

24144

oil density, kg/dm³

0 wet

100

24144

LHV [kJ/kg] H2O, %

S-2

0 dry

Hydrogen, % Sulphur, %

Cl-, % Total, %

SNCR

100%

0.00

100.00 13120

100

0

KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 3 Preheater Exit Gas

Nm3/h

°C

Err:511

462

Preheater Water Injection

Err:511

0

Preheater Exit Static Pressure, hPa

0

Kiln Physical Properties

kJ/kgck

Kiln

97.3

Err:511

115

Kiln Diameter, m.

4.7

11.4

Kiln Speed, rpm

3.0

Nm³/h

Transport air 1

914

°C

2846

30

Transport air 2 Precalciner Exit Static Pressure,hPa

Transport air 3

-8.8

Transport air 4 Gas measurements Kiln inlet,% (dry) Preheater outlet, % (dry) Calciner Outlet, % (dry) Main burner Primary air 1

O2 [%]

CO [%]

5.2

0.0274

3.65

0.08

1.3

0.15

Nm³/h

°C

7283

Precalciner burners

30

Primary air 2

Nm³/h

°C

Transport air 1

2835

30

1240

30

Err:511

Transport air 2 Transport air 3

3455

30

Err:511

Transport air 4

3455

30

%

Precalciner burners By-Pass

Primary air 1 Primary air 2 Primary air 3

False air

## Extracted kiln inlet gas

Nm³/h

°C

Err:511

30

Kiln inlet sealing Airlift

Err:511

30

4.0

6813

65

Err:511

Preheater false air

Err:511

30

Err:511

Tertiary air false air

24997

30

Err:511

False air calciner

6700

Nm³/h Err:511

Preheater false air assessment for preca kiln

%

Kiln hood sealing

4.0

74

Tertiary Air Duct

Main burner

°C

Kiln Length, m.

Preheater

-84.93 Nm3/h

Precalciner Exit Gas

Wall Losses

l/h

Gas Flowrate

°C

Err:511

Kiln Slope, %

4.0

Refractory thickness, mm.

230

Clinker Density, t/m3

1.4

KILN AUDIT HEAT BALANCE TOOL - DATA ENTRY SHEET 4 - COOLER Cooler fans

Fan # 1 Fan # 2 Fan # 3 Fan # 4 Fan # 5 Fan # 6 Fan # 7 Fan # 8 Fan # 9 Fan # 10 Fan # 11 Fan # 12 Fan # 13 Fan # 14 Total Air leakage leaving cooler False air entering cooler

Flowrate, Temperature, Grate Area, Nm3/s/m 2 Nm3/h °C m2

Cum. Area, m2

34342

30

7.1

1.35

7.09

58918

30

9.3

1.76

16.38

95217

30

15.6

1.70

31.93

28311

30

7.2

1.10

39.11

40356

30

12.1

0.93

51.16

39295

30

13.6

0.80

64.78

28235

30

15.1

0.52

79.87

28489

30

21.2

0.37

101.03

Flowrate, Nm3/h

Secondary air Tertiary air Mill take off #1 Mill take off #2 Exhaust air measured Exhaust air calculated Hot clinker temperature, °C Cold clinker temperature, °C

Exhaust air water injection

353164

101.03

Err:511 Err:511

Cooling air:

1.77Nm³/kgcl

901

360 Err:511 1450 227

litres/h or kg/h

0.97

Wall losses of cooler

Temperature °C

kJ/kgck 24.00

Temperature °C

KILN AUDIT HEAT BALANCE TOOL - MATERIAL BALANCE CALCULATIONS

Flowrate, [t/h] H2O, [%]

Kiln Feed Servo Coal 280 8.625

0 0

Kiln Fuels 0 0

0 0

0 0

0.00 0.00 0.00

0.00 0.00 0.00

Precalciner Fuels 0 Servo Coal Bottom feed Rice husk Wood Preheater dBypass Dust 0 8.075 71.25 1.04 6.917 41.72 0

0.21

Sulphur, [%] Ash, [%] Cl, [%]

0.43 16.81 0.00

0 Kiln Feed

Ash 1

0.00 0.00 0.00 Ash 2

0.00 0.00 0.00 Ash 3

Ash 4

Ash 5

0.00 0.00 0.00 Ash 6

0.43 16.81 0.00 Ash 7

0.14 77.66 0.00 Ash 8

0.05 13.45 0.00 Ash 9

0.05 1.29 0.00 Ash 10

0 Dust 1

0 Bypass Dust

SiO2

6.81

51.78

0

0

0

0

0

51.78

36.13

94.44

32.48

12.11

0

Al2O3

0.99

16.45

0

0

0

0

0

16.45

13.35

0.15

6.96

3.94

0

Fe2O3

0.41

7.98

0

0

0

0

0

7.98

12.42

0.11

21.53

1.84

0

CaO

50.38

7

0

0

0

0

0

7

6.1

0.52

24.18

44.93

0

MgO

0.48

4.47

0

0

0

0

0

4.47

0.55

0.67

0.96

0.48

0

LOI CO2

40.30

0.4

0

39.30

0

0

K2O

0.18

2.66

0

0

0

0

0

2.66

1.47

2.13

2.05

0.91

0

Na2O

0.03

2.84

0

0

0

0

0

2.84

0.24

0.49

0.76

0.04

0

SO3

0.06

0

0

TiO P2O5

0

0.73

0

0

0

0

0

0.73

0.379

0.01

0.28

0

0

0

0.36

0

0

0

0

0

0.36

0.162

0.97

0.906

0

0

Cl

0

0

0

KILN AUDIT HEAT BALANCE TOOL - MATERIAL BALANCE RESULTS Material Balance Based on Clinker Weighing

t/h Kiln Feed (dry)

kg/kgck

305.34

1.53

Material Balance Based on Kiln Feed

t/h

kg/kgck

279.41

Elemental Balance Based on Clinker Weighing

1.52

Clinker SiO2

Measured

Calculated

22.48

18.72

5.34

4.63

Kiln Feed (dry + TOC + S )

305.34

1.53

279.41

1.52

Al2O3

Kiln Feed (wet+TOC+S-2)

305.98

1.53

280.00

1.52

Fe2O3

4.74

3.81

58.37

0.29

58.37

0.32

CaO

65.69

69.50

0.43

0.00

0.43

0.00

MgO

0.64

0.85

0.00

0.00

0.00

0.00

0.00

0.00

364.14

1.82

338.22

1.84

LOI CO2

0.00

0.00

-2

Total Fuel Ash Total Fuel SO3 Total Fuel Cl  Clinker Preheater Dust Bypass Dust SO2 in preheater exit Dehydration+Decarbonation 

199.54

1.00

184.06

1.00

K2O

0.52

0.53

41.72

0.21

41.72

0.23

Na2O

0.07

0.14

0.00

0.00

0.00

0.00

SO3

0.28

0.31

0.00

0.12

0.12

0.03

0.05

0.00 99.91

0.00 98.66

0.00

0.00

0.00

122.88

0.62

112.44

0.61

TiO P2O5

364.14

1.82

338.22

1.84

Cl

Kiln feed wet / clinker

1.53

1.52

Raw mix dry / clinker

1.32

1.29

Factor kiln feed / clinker for production:

1.40



KILN AUDIT HEAT BALANCE TOOL - THEORETICAL HEAT OF CLINKER FORMATION CALCULATION Ash Corr. Clinker Compounds

SiO2

Clinker gr/kgck

Bypass

116.51

Al+F

0.022 Metakaolin

0.047

Kaolin

0.054 SiO2

0.091

Al2O3

14.03

Fe2O3

11.74

CaCO3 Cal.

CaO

638.89

MgO

4.24

46.9

58.30

C2S, [%]

29.1

17.50

0.00

MgCO3 Cal.

0.002

C3A, [%]

6.1

6.50

0.00

CO2=>

0.258

C4AF, [%]

14.4

13.30

Delta

all Nm³/kgck 0.3063