Cement production has been one of the most energy intensive industries in the world. In order to produce
clinker, rotary kilns are widely used in cement plants. This paper deals with the energy audit analysis of a dry
type rotary kiln system working in a cement plant in FCCL. The kiln has a capacity of 3000 ton-clinker per day.
It was found that about 40% of the total input energy was being lost through hot flue gas (19.15%), cooler
stack (5.61%) and kiln shell (15.11% convection plus radiation). Some possible ways to recover the heat losses
are also introduced and discussed.
THE IMPORTANCE OF HEAT BALANCES
The heat balance calculation is basically a calculation where heat inputs and outputs are measured, calculated
and compared.
The heat balance calculation provides a snap shot of the specific heat consumption of the kiln system with the
kiln in stable operating conditions. The purpose of the heat balance calculation is to:
Establish the specific heat consumption of the stable operating kiln
Yield information about where the heat losses occur in the system
Gather information on the size of heat losses where they occur.
With this information, the plant personnel can decide if any action is required and identify the points where
attention might be needed.
The specific heat consumption of a kiln is calculated based on the calorific consumption and the clinker
production. The calorific consumption can be calculated when the fuel consumption and the net heat value of
the fuel are known. The kiln clinker production can be calculated either from weighing the clinker, from
calculations based on the consumption of raw meal or from the amount of cement that is produced. The figure
for specific heat consumption is often available on the factory calculated on a weekly or monthly basis.
However the value for the long-term specific heat consumption will always be higher than the corresponding
figure for the periods of stable kiln operation, as it includes the period where the kiln production is low.
The approach taken here in performing a heat balance emphasizes the practical aspects and uses simplifications
to permit a rapid set-up and calculation. The simplifications will limit the accuracy of the heat balance to
approximately + 2% relative. This must be considered satisfactory as many of the measured values in the plant,
such as air flows and surface heat losses, will have a greater margin of relative error.
For the practical use of the results where also the historic changes are evaluated, the absolute figures might not
be so important. The important thing is to ensure that the values are reproducible. If, for instance, the surface
heat loss from the pre heater is continuously underestimated in the balance, the trend in the specific heat
consumption and other heat losses over a time period will still be clear.
HEAT BALANCE PROCEDURAL STEPS
When a heat balance is performed, the procedure is as follows:
Calculate the energy flows. This is often calculated in kcal/kg clinker but can equally be joule/min or
other units.
Air Balance in System
Calciner
Kiln
Excess air
Radiations
Tertiary Air
Secondary Air
Crusher
False Air
False Air
Cooling Air
Set point of K10 Fan
Density of Air
=
=
135 x 1.293
20.83.3
Air from
K10
K11
K12
K13
K14
K15
K16
K17
K18
K19
K20
135 x 1.293
3000 ton/D x 1000/ 24x60
135 x 1.293
20.83.3
135 x 1.293
20.83.3
320 x 1.293
20.83.3
320 x 1.293
20.83.3
520 x 1.293
20.83.3
520 x 1.293
20.83.3
615 x 1.293
20.83.3
460 x 1.293
20.83.3
460 x 1.293
20.83.3
510 x 1.293
20.83.3
Total
710x47/100
Calciner 53 %
Primary Air
.084 kg air / kg ck
Kiln 9% of Lmin
where L min
Combustion air
Excess Air
Note for calculation
Kiln 18%
( ( 1.18=
% of O2 in Lab by
Calciner 10%
( 1.10=
orsat apparatus
L min
=
=
Combustion air =
Primary Air
=
=
Total combustion air = L
Secondary Air
Secondary Air
=
=
Tertiary Air
L min
1.41 x 376.3
1000
3.6% of L min
L (Calciner)
x L min
Tertiary Air
Air Balance
Syste
m
AIR IN
AIR OUT
383
15.30
6.00
7.65
OUTPUT
Secondary Air Heat Content
Tertiary Air Heat content
Clinker dust
Radiation
151.80
127.10
20.66
6.00
280 C0
875 C0
25 C0
?
1450 C0
105 C0
Specific Heat
A + (B x T x 10-6)
Table 1
Sr. #
1
2
3
4
5
6
7
8
9
Element
A
0.196
0.443
0.244
0.218
0.237
0.206
0.186
0.262
0.420
CO2
H2O Vapor
N2
O2
Air
Raw Meal
Clinker
Coal (30% Vol.)
Oil
INPUT
Sr. #
1
1.00
Temp
Co
1450
2
3
Clinker Dust 2 %
Cooling Air + False
Air
POWER
.02
2.575
1450
25
kg / kg ckr
B
118
39
22
30
23
101
54
390
0
CP T
0.264
0.238
0.264
C
-43
28
0
0
0
-37
0
0
0
Heat content k cal /
kg ckr
1450 x 0.264 x 1
383
1450x0.264x.02
7.63
15.30
6.00
409.3
Total Input
OUTPUT
Sr. #
1
Secondary
Tertiary
Excess
4
5
Clinker dust
Radiation
Amount
Temp kg
0.484
0.484
0.565
T Co
1200
1184
875
0.265
0.265
0.257
1.526
1.526
1
25
280
25
105
0.187
0.343
0.243
0.1929
CP
K cal / kg ckr.
153.70 value is not correct
151.80 correct
127.10
104.01
9.04
20.66
6.00
Total Output 409.3 Kcal/ kg ckr
HEAT IN
Fuel Oil
Raw Meal
Cooling Air
Primary Air
Combustion Heat
Electric Power
3.51
21.04
15.30
0.51
700
6.00
1
2
3
4
5
6
7
8
HEAT OUT
Exit Gases
Dust loss
Evaporation of H2O
Radiation Pre-Heater
Radiation Kiln
Radiation Cooler
Clinker Temp
Excess Air
143.37
10.06
5.37
33
35.04
6.00
20.66
104
Heat of Reaction
747.3
392
749.50
Heat Out
Exit Gases (Dry basis)
4.5% O2
30% CO2
1
1- 79
21
= 1.346
4.5
100-30-4.5
Table 2
Stoichiometric Combustion Air and Combustion Smoke Gas
per 1000 kcal fired
Oil
Coal
Stoichiometric
Combustion Air
Kg air / 1000 kcal
1.41
1.39-1.43
Nm3 air / 1000 kcal
1.09
1.07-1.10
Combustion gasses at
Stoichiometric combust
Nm3 smoke gas / 1000 kcal
Gas density kg / Nm3
1.16
1.30
1.12-1.18
1.35
Combustion Gas =
1.16 x 710/1000
Excess Air (1.346-1) x 1.09x710/1000
Total
Convert into kg / kg ckr.
Again from table gas density
= 1.3x1.092
Again from table 2 Co2 from Raw mix
Total
Amount of Gases
Gas consist of O2, Co2 & NO2
O2%
1.97x.045
CO2%
1.97x0.30
NO2%
1.97x(1-0.49-0.3)
Gas
1.43
1.10
1.22
1.24
=
=
=
=
=
=
=
=
=
0.088 kg / kg ckr.
0.591 kg / kg ckr.
1.291 kg / kg ckr.
=
=
=
0.218+(30x300x10-6)+(0x3002x10-9)
0.196+(118x300x10-6)+(-43x3002x10-9)
0.244+(22x300x10-6)+(0x3002x10-9)
Cp for O2%
Cp for CO2%
Cp for NO2%
Hence,
Cp O2%
Cp CO2%
Cp NO2%
=
=
=
0.227
0.2275
0.2506
=
=
=
.008x300x0.227
=
-0.591x300x0.2275 =
.008x300x0.227
=
Total Heat in Exit Gases
5.99
40.34
97.04
143.37 Kcal / kg
=
=
=
0.206 + (101x300x10-6)+(-37x3002x10-9)
0.2362
0.2362x300x0.142 = 10.06 K cal/ kg ckr.
60Co ~ 100 Co
1 Kcal
Heat .008x1(100c-60c)
=
=
1 Kg H2O at 1Co
0.32 Kcal/ kg ckr.
Evaporation of H2O
By definition we know 539 Kcal/ kg water
Heat of evaporation, 0.008 x 537
Heating of Water Vapors
100C0----- into 300Co
Heating capacity Cp 100Co
Cp 300Co
=
=
So
Cp 100Co
Cp 300Co
Heat content
=
=
0.447
0.457
=
=
.008 (300x0.457-100x.447)
0.739
Now total Heat less due to evaporation of H2O will be by combining above three values.
=
0.32+4.312+0.739 =
5.371 Kcal/kg ckr.
Heat Content In Radiation
A. In Calciner
Surface temperature of Calciner
=
250Co
Ambient temperature
=
30Co
From Pose 15 we can calculates Radiation =
4019 Kcal/m3 L
From Pose 1 we know surface area of each part of the Calciner
I.e.
B. for Roof
4019 x 44.2 x 24
3000 x 1000
4019 x 145.7 x 24
3000 x 1000
4019 x 55.7 x 24
3000 x 1000
=
4019 x 78.9 x 24
3000 x 1000
Total
= 17.69+15.3 approx
=
=
=
7.26+1.42+1.79+2.54
17.69 Kcal / kg ckr.
33.00
G. From Kiln
From page 15
Kiln
Surface Temperature
Ambient Temperature
We noted radiation
Volume of Kiln By Formula
=
=
=
=
5689 x 692 x 24
=
3000 x 1000
H. from Smoke chamber=
5689x78x24
=
3000 x 1000
Total Radiation
300Co
30Co
5145 Kcal/m3 L (brick lining)
(4.15-0.44)2 x 64 = 692m3
4
31.49 Kcal/kg ckr.
3.55 Kcal/ kg ckr.
=
)
= 35.04 Kcal/Kg ckr.
Total Heat from Cooler (
)
= 6.00 Kcal/Kg ckr.
Heat Capacity in Clinker Outlet
Cp
=
0.186+(54x80x10-6)
+ (0x80x10-9)
=
0.186 + (.00432)
Cp
=
0.192
Heat Content
=
3000x(105-30)x.192
=
20.66 Approx. Kcal/ Kg ckr.
1000x60x24
Excess Air
For further calculation we know that first calculates secondary air def: secondary air:- combustion air coming
from the cooler to the kiln is called secondary Air.
From Table 2
Main
Furnace Oil
=
.00141 kg of air / Kcal.
=
10,000 Kcal / kg ckr.
=
.00141x10,000 =
14.1 kg of air / kg or oil
700 Kcal / kg of clinker ( FCCL Design figure)
Air needed per kg of clinker.
M kg of air
kg of clinker
.00141 =
0.987
=
=
HEAT IN
Fuel oil
Temperature of oil
Oil requirement Approx
=
=
Heat Content
=
=
Cp Oil
Heat content
=
=
120C0
4.7 Tons / h in Calciner, 4.0 tons / h Kiln
(4.00+4.7) x 24 x 1000
0.0796 kg of oil / kg ckr.
3000 x 1000
0.42
0.42x120x0.0696 = 3.51 Kcal/kg ckr.
1.68
Cp material
=
=
=
=
0.212x60C0x1.68
21.4 Kcal/ kg ckr.
=
=
=
0.042 kg / kg ckr.
0.019 kg / kg ckr.
35 Co
0.061
=
0.237
.061 x 0.237 x 35
Heat Of Combustion
Oil used
8.9 tons of Furnace oil