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Alpha = Kiln inclination in % D N = Effective diameter of Kiln in meter = Rotation per minute rpm
Kiln Inlet
Kiln Outlet
B = t = 20 -28 Minutes
CLINKERISATION
12 CaO Lime stone 3Cao.SiO2 (C3S) Alite
100* CaO LSF = (2.8 SiO2 + 1.18 Al2O3 + 0.65 Fe2O3) 0.66 > LSF < 1.2 = = AR = > 0.64
SILICA RATIO
ALUMINA RATIO
LHV = LOW HEATING VALUE Kcal /Kg HHV = HIGH HEATING VALUE Kcal /Kg
M = % MOISTURE H = % HYDROGEN O = % OXYGEN
ultimate analysis
COAL USED IN CEMENT INDUSTRY LHV = 6500 7000 Kcal / Kg ASH = 12~15 % VOLATILE MATERIAL = 18~ 22 % MOISTURE = UP TO 12 %
D =Diameter in Meter
A = Alpha x
TxL
Alpha for steel (coefficient of linear expansion = 1.2x 10^ (-5) mm per Meter T= dT =( Average temp Ambient temp) Degre centigrade L1 A1= (T2a+T1)/2 - T A1= (T2b+T1)/2 - T Ambient temp = T X L1 X L2
T2a T1
L2
T2bb
A = A1 +A2
IMPOTANT PARAMETERS
KILN SPECIFIC VOLUME LOADING = TPD/ m3 or Specific Kiln capacity ~ 2.3 t / m3 at Kiln circumferential speed = 50 cm / sec KILN SPECIFIC THERMAL LOADING = Kcal / m2.hr Specific Kiln thermal loading Qp = 1.4 x 10 ^ 6 x D Kcal / m2. hr
Capacity of ID fan. Preheater cyclone design. Proclaimed Design & Volume. Kiln inclination & Volume. Kiln % filling, Specific volume loading &.Thermal loading. Kiln Drive capacity. System Design, Ducts, GCT, fan position & ESP.
For Gears: Pitch Diameter = Module x No. of Teeth Blank Diameter = Module x (No of Teeth+2)
For Airslide Cloth Fabric Polyester 100%. Min=140*C & Max = 260*C. Permeability = 400m3/hr-m2 or 6m3/min-m2. at 80mbar Tensile strength : WEFT = 1200 Kg/cm2 : WARP = 600 Kg/cm2 Air Required = 2.5-3.0(Closed type), (2 Cone silo Bins),(1.5Open Type)
II III IV
VI V
PYRO STRING
Mill charging:
Theta Theta
H = 0.16D
MILL CROSS SECTION
Dynamic Angle of Repose = 35 degree 20 minutes with Horizontal (Theta ) OR Dynamic Angle of Repose = 54 degree 40 minutes with Vertical (Theta )
G = gm.Sy.Pi. (R)^2.L
4
Constants:
Sy = specific gravity of ball 7.8-7.9 Ton / m3 gm = Bulk density of charge 4.5 Ton / m3 . Pi = 22/7 or 3.14
P= 12G
Seperator efficiency
A % fines of separator feed B % fines of Tailings/Reject C % fines of finished Product F TPH of separator feed D TPH of Tailings/Reject G TPH of finished Product
A %fines/F
s C%fine/G
1. n = C (A-B) A(C-B))
Ball Mill
3. F = L(1+D)
L/D=3 L / D = 4.5
Carman Lining
Classifying Liners
FLS Lining
Important Conversions
1 Barrel = 42 Gallons = 159 litres = 5.615 Cuft 1 Kcal = 4.187 J KCal / Kg x 1.8 = Btu / lb
OPC-43(IS8112)
OPC-43(IS12269)
PPC- (IS1489)Part-1
225 23 33 43
225 27 37 53
300 16 22 33
H 70 * L=H/2
Single Stream
TOP VIEW
SIDE VIEW
Kiln Data : 4.4 meter Diameter x 60 meter length Inclination = 3.5% Shell thicknesses = 25 mm , 28 mm , 35 mm , 65 mm Kiln speed = 3.5 to 5.25 RPM Preheater : Type : 6440 / PR 7044 VI Stage
Girth Gear :
Module = 39 No of Teeth = 148 Material of construction = CS 640 (Normalized Cast Steel) Dimensions = 550 mm (width)
Pinion :
Module = 39 No of Teeth = 28 Material of construction = 30 Cr Ni Mo V8 (Normalized CastSteel) Dimensions = 600 mm (width)
Material of construction = GS 24 Mn 5 (Normalized Cast Steel) Dimensions = 5620 OD x 4581 ID x 775 (width) Supporting Rollers Assemblies three nos : Main Drive
Material of construction = CS 640 (Normalized Cast Steel) Dimensions = 5620 OD x 4581 ID x 775 (width) Tyre Supporting Roller Girth Gear Kiln Shell
Pinion
Kiln Main Drive : RWN-500 Aux G.B SDA 250 54.35: 1 Motor 30 KW ; 1500 RPM
Gear box = SDN 800 Ratio = 54.35:1 Motor KW = 710 Input RPM = 100 - 1000
Motor RWB-178
=
Area of cross section of Kiln (A)
Theta
% of Kiln filling 15.65 13.75 12.1 10.7 9.09 7.75 6.52 5.42 4.5
Segment
r = radius inside lining
A1 =
r^2 2
O Sin O
A = II r^2
4.5 9
4.0 10
3.5 11
3.0 12
2.0 13
Note : In practical Kiln operation the kiln load should not exceed 13%,since higher Kiln loads impair the heat tranfer
H.P =
W x bd x td x N x F x 0.0000092 rd
W = Total vertical load on all roller shaft bearing,lb bd = roller shaft bearing diameter , inches rd = roller diameter , inches td = tire or riding rind diameter , inches N = rpm of Kiln shell P = Coefficient or friction of roller bearings , 0.018 for oil lub bearings & 0.06 for grease lub bearings Note : This is Frictional Horse Power 1
H.P = (D x Sin O) ^3 x N x L x K
D = Kiln dia .inside lining , ft
Sin O = read from diagram depending on %Load N = rpm of Kiln shell L = length of kiln in ft K = 0.00076
Total power =
Arun Shourie Relation Manager - Insurance Dir: +91 (22) 4086 3835 / +91 99200 29366
40* L v H
Dab 2
V
X K%
H = Z Sine O
Kiln Diameter = D Kiln lining thickness = a Kiln Coating thickness = b Angle of Repose of kiln load = O = 40* say Kiln Load = K % Value from table below Depth of bed in Kiln = Y % To be measured
Kiln load = K % Depth of material bed in Kiln = Y % 5 6 7 8 9 10 11 12 13 14 15
9.75
11
12.2
13.4
14.5
15.6
16.7
17.7
1.8.8
19.8
Z Cos O
21
B 7000
SCF
10.478 SCF
% Loading of Kiln :
Cxfxt dxV
C = Capacity of Kiln Ton / hr f = Ton (Kg) dry feed / Ton ( kg) of Clinker t = residence time d = Bulk density of dry feed ton (Kg) / m^3 V = Internal volume of kiln in m^3
Vg = Volume of combustion gases , Nm^3 / Kg Cp = Specific heat of combustion gases =0.40 at 2000*C for fuel class S
Martins Formula : 2.826 v C = X D^3 Vg C = Kiln Capacity Ton / Hr V = Gas Velocity in gas discharge end , m / sec Vg = specific gas volume , m^3 / kg clinker D = Kiln Diameter on Bricks, m
V^2 ID ^ 5
Constant
D = 0.536
(V) ^ 2 x Vt
4
C P
Vt = V0 273 + t + K
273
D = cyclone Diameter , m V = Gas volume passimg cyclone , m ^ 3 / Sec Vt = sp. gr. of gas at aver. Temp , Kg / m ^ 3 C = Coefficient for pressure drop = 110 P = Pressure drop in cyclone in mm WG
H 70 * L=H/2
Length of Dip Tube = Gas inlet height Pressure drop across cyclone = 55 60 mbar
Single Stream
1.05 6.48*MgO6.48 63.91 7.646 3.2 22.68 2.31 99.27 5.86 5.11 0.59 Net Kcal / Kg
+
527.4
_ 118.4
Q = 2.22 Al203 + 6.48 MgO + 7.646 CaO + 5.86 H2O + 5.11 SiO2 + 0.59 Fe2O3
X = Specific Heat consumption of the kiln , Kcal / Kg clinker n = Excess Air number = 1.1 Cooler fans designed for Specific Volume of 3 3.15 st.m^3/Kg clinker
Y=
H t2 H t3
t1 = Temperature of Kiln exit gases t2 = Temperature of gas to be achieved or maitained t3 = temperature of water (15*C) H t2 = Heat content of water at t2 H t3 = Heat content of water at t3