Gas flow calculations Pyro-process section, GCT, ESP

Single string preheater Note : Values in blue colour to be entered 1 2 3 Clinker production Sp. heat consumption Raw meal feed ratio4500 765 0 0 4 Fuel firing ratioKiln PC Site atmospheric pressure LOI of kiln feed Clinker conversion factor Cooler vent fan Sp. vent air Temperature Pressure 35 65 10065 36 1.62 % % MmWG Tpd Kcal/kg clk % %

5 6 7 8

1.25

Nm3/kg clk

234375.0
250 18

Nm3/h
Deg C 'mmWG

461785.5659 128.2737683
9 Cooling air fans Sp. cooling air Preheater exit 2

m3/h m3/s
Nm3/kg clk

375000.00
10

Nm3/h Kg/kg clk Kg/kg clk Kg/kg clk

Kg/kg clk

Total gas from feed

0.583

Gases from combustion in kiln 0.378 Gases from combustion in calciner 0.706
1.084

Kg/kg clk Kg/kg clk

Kg/kg clk

Total gases at Kiln outlet

1.667
1.67 1.42

Kg/kg clk Kg/kg clk

kg/nm3

Density of PH gases (assumed) Oxygen at PH outlet

0.614
3.50

kg/m3
% Nm3/kg clk Nm3/kg clk Kg/kg clk

False air 20.11 Sp. gas quantity at kiln string O/L 1.410
Total 1.410 2.002

PH O/L Gas volume

Pressure Temperature(Before water spray) Temperature(After water spray)

264362.18
526 310 290

Nm3/h
mmwg Deg C Deg C

Gas volume

611545.547
169.87

m3/h
m3/s

Pressure Down comer temperature

610 310

MmWG Deg C

11

Total at PH O/L PH fan O2 at PH fan

169.873763 3.5

m3/s %

False air Sp. gas volume at PH fan Gas flow at PH fan

12 GCT

20.11 2.00 611545.55

0.00

% Kg/kg clk m3/h m3/h m3/hr kg/hr

Deg C

PH gas volume
Temperature

611545.55 375394.2915
310

Heat Water required

Final temp. (GCT O/L)

15015771.66
25622.43475 150

Kcal/hr kg/hr
Deg C

Sp. water requirement Gas density at GCT I/L Sp. gas volume at GCT O/L
13 ESP O2 at ESP inlet

0.136652985 0.170057048
1.42

kg/kg clk Nm3/kg clk

kg/nm3

0.646085092 2.138755873
4

kg/m3 kg/kg clk

%

False air Sp. gas volume at ESP I/L

23.66863905 2.202032674 412881.1264 469513.5363

1.42

% kg/kg clk kg/hr m3/hr

kg/nm3

Gas density at ESP

14 Precalciner evaluation Calciner effective volume

0.879380666
942.18

kg/m3
M3

Calciner gas residence time 7.562348656 Sp. gas in calciner 0.7

O2 2.5

Sec kg/kg clg

%

False air in PC Gas volume in PC

Calciner temp.

13.58695652 0.790735598 148262.9246

850 100 1.41

% kg/kg clg kg/h

Deg C MmWG kg/nm3

Density of gas Gas volume in PC

15 TAD

0.330561962 448517.8024 124.5882784 0.77123475 144606.5156 111837.9858

933 50

kg/m3 m3/h m3/s kg/kg clg kg/hr Nm3/h

Deg C MmWg

Gas flow in TAD

Gas temp. in TAD Pressure

Gas volume in TAD

TAD area

509740.8905 141.5946918
5.5126

m3/h m3/s
M2

TAD diameter Gas velocity in TAD

16 Burner- Kiln Fuel NCV

2.65 25.68564594
9950

M m/s
Kcal/kg

Sp. fuel consumptiom Fuel rate- kiln Margin 25 % Heat capacity of burner

0.076884422 5045.540201 6306.925251 62.75390625

Kg fuel/ kg clk Kg fuel/ hr Kg fuel/ hr Gcal/hr