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Heat Balance Cement Industry Excel Sheet-Er - Raza Hussaini
Heat Balance Cement Industry Excel Sheet-Er - Raza Hussaini
This excel sheet calculates heat Balance of pyroprocessing in cement industry.Nevertheless it should very much stresseed here
"This sheet does not does miracles,instead it's based on the methology of Gospel In Gospel Out,Garbage in Garbage Out
This sheet is locked and password proctected to ensure NO dilution of calculations.please don’t ask me password
For time being this calculation are done for (MKS System only).
It is assumed that you supply very precise data based on which accuracy of entire heat balance calculations lies.
Calculation procedure:
1) Enter the required data on input page just replace the existing values
2) Go to detailed calculation sheet there you get explanation of entire calculations
3) Heat balance report can be printed on Output page
Notes:
1) Be cautious while entering specific heat values as it directly influences your calculations be sure of souce and uncertainity
2) This calculation are based on heat balance procedure given in Cement Manufacturer's Handbook By Kurt E.Peray
If one has any doubts they can refer to Chapter 11 , 12 & 13 of the book
It's good to talk , I'll be happy to modify/upgrade the calculations based on suggestions/criticism you can contact me here
mohammedhussaini@live.com
I expect genuine suggestions/doubts plase do little home work refer Peray before contacting me.
Diclaimer:
1) This sheet is not copyright property hence it can used freely any how it is password protected
2) "I" don't take any kind for the responsibility of calculation results, it's interpetation lies to it's user
3) This sheet has been througly checked before uplaoding as asured maximum accuracy however there could some discripancies
tresseed here
arbage Out"
me password
uncertainity
me discripancies
Fuel Analysis
Units
AA Percent ash %
AH Percent hydrogen %
AC Percent carbon %
AN Percent Nitrogen %
AO Percent oxygen %
AS Percent Sulpher %
AM Percent Moisture %
AQ Heat value Kcal/kg
Weights of materials
Kiln Dimensions
L1 Kiln length m
L2 Kiln Diameter m
L3 Effective bruner tip orifice area m2
L4 Length of chain section m
L5 Total chain surface area m2
L6 Effective kiln feedend throat area m2
L7 Refractory thickness m
L8 Sum total of (all) chain length m
L9 kiln shell thickness m
L10 kiln slope degree
Lx lining and coating thickness mm
Ly length of burning zone m
SS Kiln Shell Surface area m2
Operating parameters
Temperatures
TF Fuel as fired C
o
T Kiln room C
o
Dimensions
Specific Heats
21.3
6.5
2.8
66.8
1.2
0.3
0.45
0.1
35.6
0.4
0
2.69
28.1
1.2
70.7
26.98
5
22
753
110220
1.55
0.11
0.02
7.3
1
65.5
4.33
1
0.23
0.4
20
297
1.27
21.7
6.7
2.9
66.3
1
0.8
0.85
0.25
41
82
252
268
85
24
293
265
79
29
4.75
54.55
79.6
54.55
41.1
2.74
0.15
0.27
5028
0.23
0.21
0.23
0.24
0.23
0.23
0.25
0.26
0.19
0.23
0.47
0.17
0.26
0.19
20.5
18
10.2
1 Amount of Feed Required to produce one kilogram of clinker MKS
Subtotal 1.562
2 Dust loss
C3S = 4.07 Hca - (7.6 HSi+ 6.72 HAl + 1.43 HFe + 2.85 HS) 53.470
C2S = 2.87 HSi - 0.75 C3S 22.177
C3A = 2.65 HAl - 1.69 HFe 12.854
C4AF = 3.04 HFe 8.816
LSF = 100 HCa/(2.8 HSi + 1.65 HAl + 0.35 HFe) 91.034
S/R = HSI/(HAl + HFe) 2.260
A/R = HAI/ HFe 2.310
percent liquid = 1.13 C3A + 1.35 C4AF + HMg + HAlk 28.277
I = 4.11 HAl + 6.48 HMg + 7.646 HCa - 5.116 HSI -0.59 HFe 428.219
x = (EO2/100).(100+x)+(3.78 EO2/100).(100+x)-478.(DO2/100)
n = 100.x/(100+x)
Check = W1 = 1 1.000
W3+W4+W5
11 Products of Combustion
N2 from fuel = WA*((AN/100) + 3.3478 (0.0267 AC + 0.01 AS + 0.08 AH - 0.01 AO)) 0.872
a) ( At 0 oC , 760 mm Hg)
dO1 = (1.977 CO2 + 2.927 SO2 + 0.806 H2O + 1.251 N2 + 1.2928 excess air) 1.557 kg/Nm3
Wgm
Vs = ((VBe)*(Wcl))/3600 71.822
Specific area loading = (24 WCl / (1000 (m2 surface))) 123.716 daily t/m2
inside kiln surface volume = kiln inside surface area x lengt of kiln 864.767
Specific volume loading = 24 WCl / ( 1000 ( m3 volume)) 3.059 daily t/m3
(Contd…..)
HEAT BALANCE
Heat inputs
18 Heat inputs from the Combustion of Fuel
Q = WA . Aq 827.514 kg/kg.cli
Heat inputs from the Combustion of Fuel 827.51 96.13 Heat required for clinker cooling
Heat inputs from Sensible heat in fuel 0.73 0.08 Heat loss with kiln exit gas
organic substance in kiln feed* 0.00 0.00 Heat loss Due to Moisture in Feed or Slurry
Heat input from sensible heat inkiln feed 14.48 1.68 Heat losses Due to Dust in the Kiln Exit Gases
Heat input from cooler Air sensible Heat 17.01 1.98 Heat Loss with Clinker at Cooler Discharge
Heat input from primary air sensible heat 1.04 0.12 Heat Loss at Cooler Stack
Heat inprt from infiltrated Air sensible heat 0.09 0.01 Heat Losses By radiation on Kiln Shell
Unaccounted losses
428.22 49.74
121.23 14.08
56.13 6.52
0.31 0.04
15.73 1.83
151.25 17.57
27.40 3.18
1.41 0.16
59.18 6.87
860.85 100