Clinker Weighing test result

11 September 1997 start Stop Total

Time (hour) 14.13 22.13 8
Kiln Feed totalizer (T) 813041 817186 4145
Kiln Coal totalizer (T) 11001.9 11120.5 118.6
ILC Calciner coal totalizer (T) 6312.82 6355.32 42.5
SLC Calciner coal totalizer 12078 12230.3 152.3
Clinker weighing total (T) 2719.5

L min 8.542 kg air/kg Coal

GHV 5763 kcal/kg Coal

Fuel consumption Ton % ton/jam

Kiln (PW1) 118.6 37.8% 14.8
ILC Calciner (PW2) 42.5 13.6% 5.3
SLC Calciner (PW3) 152.3 48.6% 19.0
Total 313.4 100.0% 39.2

Fuel Consumption 664 kcal/kg Clinker

Combustion air 334632.9 kg air/jam

5577.2 kg air/min
0.984 kg air/kg clinker

Clinker Faktor 1.52 (note:the dust return is not weighed)

Material Balance

Pulvurized X kcal/kg terak

Coal Ash 19.67 %

0.1967 x kg
3.413E-05 x kg

Raw mix to clinker LOI 35.18

= (1 - 3.413* X*(10^-2))*100
100 - 35.18
= 1.542733724 - 5.266E-05

CO2 From raw mix total carbonate 77.22 %

= 0.524171552 - 1.789E-05
Free H2O in the raw mix H2O 0.5 %

=( 1.542733724 - 5.26559E-005

= 0.007752431 - 2.64602E-007

Combined H2O in raw mix H2O 1.12 %

=( 1.542733724 - 5.26559E-005
= 0.017278618 - 5.89746E-007

Carbon from raw mix C 0.11 %

=( 1.542733724 - 5.26559E-005
= 0.001697007 - 5.79214E-008

Excess Air

% Excess Air = 79 * %O2

0.21 * (100 - % CO2) - %O2

Stage 1 ILC average exit gas analiysis

CO2 = 29
O2 = 3.5
Excess air = 24.2

Stage 1 SLC average exit gas analiysis

CO2 = 32
O2 = 3.5
Excess air = 25.6

Dust in Exit Gas 10.5%

Dust rate 56.28 tph

kiln Feed 511.1 tph 508.5445
Total 567.38 tph 564.5431

CLK = KF * (efficiency) * (1 - H2O) * (1-LOI) + (Co

335 = 567.4 * (efficiency) * (1 - 0.05) * (1-0.3518)
327.6227334711 = 365.9368374 * Efficiency
Efficiency = 89.5%

Dust = 0.177 kg dust/kg clinker

Water from Coal

Fine Coal H2O 2.29 %

LHV Fine Coal 5763 kcal/kg Coal

Fine Coal Consumption = x

5763

= 0.000174 x kg coal/kg terak

Dry Coal consumption = x + (1- 0.0229 )

5763

= 0.000169547 x kg coal Dry/kg terak

Water from Coal = x * 0.0229

5763

= 3.97362E-006 x kg air/kg terak

Combustion Air Rates:

L min 8.542 kg air/kg Coal

Air required = x * 8.542 kg air

5763 kg Coal

0.001482214 x kg air/kg Clk

8.3976694

Kiln Primary air

Flow 150.7 kg air/min (measurement pitot tube

0.027 kg air/kg Clk

L min 2110.585833 kg air/min

7.14% kebutuhan udara dari total combustion o

Kiln Coal Transport air

Flow 81.8 kg air/min

0.015 kg air/kg Clk

L min 2110.585833 kg air/min

3.9% kebutuhan udara dari total combustion o

ILC Calciner coal transport and primary air

Flow 25.83 kg air/min

0.005 kg air/kg Clk

L min 756.3229167 kg air/min

3.4% kebutuhan udara dari total combustion o

SLC Calciner coal transport and primary air

Flow 91 kg air/min

0.016 kg air/kg Clk

L min 2710.305417 kg air/min

3.4% kebutuhan udara dari total combustion o

Remaining air requirement ILC/kiln String

=[( 0.001482214 x * (1 + 0.242

= 0.000946553 x -0.046

Remaining air requirement ILC/kiln String

=[( 0.001482214 x * (1 + 0.256

= 0.000905049 x -0.016
Combustion products from coal 9.349 kg gas/kg coal including w

= X kcal/kg terak 9.349

5763 kcal/kg Coal

= 0.001622245 x kg gas/kg clk

Extra air required to burn carbon in the kiln feed

C + Air

Lb 1 11.53

lb/lb clk 0.0017 0.0195664918

---------- > Including 24.2 % Excess air in ILC

---------- > Including 25.6 % Excess air in SLC

Extra Product of Combustion for ILC

CO2 0.006 kg CO2/kg clk

N2 0.0187 Kg N2/kg Clk

Extra Product of Combustion for SLC

CO2 0.006 kg CO2/kg clk

N2 0.0189 Kg N2/kg Clk

Excess Air

ILC/kiln string = [( 37.8% + 13.6%

5763

= 0.000184636 x + 0.0047
 SLC string =[ 48.6% * 8.542
5763

= 0.000184752 x + 0.0050

Sistem surface losses

Radiation losses
Kiln Radiation loss
Cooler and firing hood radiation loss
Preheater and tertiary air dust radiation loss

Cooler

Average clinker discharge temperature 124 C

Heat of Cooler 1 kg/kg clk * 124

= 23.54 kcal/kg clk

Radiation Loss 6 kcal/kg clk

Excess Air

Flow 388554 kg/hr @ 238

1.158726595 kg air/kg clk

CP 0.248327168

Heat Of excess Air 68.48290386 kcal/kg clk

Hot air for the raw mill

Flow 122897 kg/hr @ 407

0.366497378 kg air/kg clk

CP 0.25229205

Heat Of excess Air 37.6 kcal/kg clk

Total Cooler loss 135.66 kcal/kg clk
 Ton/jam

518.1
14.8
5.3
19.0
339.9

(note:pfister feeder calibration not correct)

n is not weighed)

x
 x) * 0.0050251

x) * 0.0112

x) * 0.0011

2O) * (1-LOI) + (Coal Ash)

0.05) * (1-0.3518) + (39.17*0.1967)
al/kg terak

al Dry/kg terak

surement pitot tube)

ri total combustion of kiln fuel.

ri total combustion of kiln fuel.

ri total combustion of ILC Calciner.

ri total combustion of SLC Calciner.

)) * ( 37.8% + 13.6% )] -0.027 -0.015 -0.005

kg air/kg clk

)) * ( 48.6% )] -0.016

kg air/kg clk
s/kg coal including water in Coal

kg gas/kg coal

CO2 + N2

3.6666667 8.85504

0.0062224 0.0150271

0.0243081 kg air/kg clk

0.0245852 kg air/kg clk

) * 8.542 * 0.2423313 ] * x + ( 0.0243081 -0.0196 )

kg air/kg clk
 * 0.2564935 ] * x + ( 0.0245852 - 0.0196 )

kg air/kg clk

23 kcal/kg clk
6 kcal/kg clk
28 kcal/kg clk

* 0.1898576

C
 System Heat Input C kg/kg
Fuel : Combustion Heat
Free heat w/ coal 80 0.000174 x
Air : Primary 32
Kiln Coal transport 32
ILC Coal transport 32
SLC Coal transport 32
Remaining ILC 32 0.00094655 x
Remaining SLC 32 0.00090505 x
Extra for C - ILC 32
Extra for C - SLC 32
Cooler : Excess Air 32
Hot air for RM 32
Water from coal 80 3.974E-006 x
Raw Feed 90 -5.266E-05 x
Returned dust 90
Sum Of heat inputs

System Heat Input C kg/kg

Combustion Product (Coal) 348 0.00162225 x
Combustion Product (Carbon in mix)
CO2 - ILC 348
N2 - ILC 348
CO2 - SLC 348
N2 - SLC 348
Excess Air In exit gas - ILC 348 0.00018464 x
Excess Air In exit gas - ILC 348 0.00018475 x
CO2 from Raw Feed 348 -1.789E-05 x
Vapor from free H2O In feed 348
Vapor from comb H2O In feed 348
Dust 348
Radiation : Kiln
Preheater
Cooler loss : Heat in Clinker 124
Radiation
Hot air for mill 407
Excess Air 238
Heat of reaction
Sum Of heat inputs
kg/kg kcal/kg C kcal/kg
1x
0.2932 0.0040701024 x
0.027 0.2377 0.20513465
0.015 0.2377 0.11134714
0.005 0.2377 0.03516011
0.016 0.2377 0.12387029
-0.04622 0.2377 0.0072009509 x -0.3516419
-0.01628 0.2377 0.0068852076 x -0.12387029
0.024308 0.2377 0.18492487
0.024585 0.2377 0.18703296
1.158727 0.2377 8.81507283
0.366497 0.2377 2.78814786
1.0000 0.00031789 x
1.542734 0.2148312 -0.001018091 x + 29.8284585
0.177 0.2148312 3.42527933
1.0174560599 x + 45.2289164

kg/kg kcal/kg C kcal/kg

0.2579 0.1455952231 x

0.006 0.2319 0.50205773

0.0187 0.2517 1.63492616
0.006 0.2319 0.50205773
0.019 0.2517 1.65356384
0.0047 0.2450 0.0157423443 x 0.40427313
0.005019 0.2450 0.0157521795 x 0.42789948
0.524172 0.2319 -0.001443536 x 42.2933435
0.007752 788 6.10891545
0.017279 0.4600 2.76573811
0.177 0.2367 14.5906078
23
28
1 0.1927 23.894304
6
0.366497 0.2464 36.7482989
1.158727 0.2425 66.8687352
410
0.1756462104 x 665.394721

1.017456 x + 45.228916395 =
0.175646 x 665.39472105

0.84181 x = 620.16580465
x = 736.705332 Kcal/kg
Summary

System Heat Input C kg/kg kcal/kg C

Fuel : Combustion Heat
Free heat w/ coal 80 0.127834 0.2932
Air : Primary 32 0.027 0.237736
Kiln Coal transport 32 0.015 0.237736
ILC Coal transport 32 0.005 0.237736
SLC Coal transport 32 0.016 0.237736
Remaining ILC 32 0.651108 0.237736
Remaining SLC 32 0.650472 0.237736
Extra for C - ILC 32 0.0243081 0.237736
Extra for C - SLC 32 0.0245852 0.237736
Cooler : Excess Air 32 1.1587266 0.237736
Hot air for RM 32 0.3664974 0.237736
Water from coal 80 0.002927 1
Raw Feed 90 1.503942 0.2148312
Returned dust 90 0.177 0.2148312
Sum Of heat inputs

System Heat Input C kg/kg kcal/kg C

Combustion Product (Coal) 348 1.195117 0.2579
Combustion Product (Carbon in mix)
CO2 - ILC 348 0.006 0.2318565
N2 - ILC 348 0.019 0.251656
CO2 - SLC 348 0.006 0.2318565
N2 - SLC 348 0.019 0.251656
Excess Air In exit gas - ILC 348 0.140764 0.245004
Excess Air In exit gas - ILC 348 0.141126 0.245004
CO2 from Raw Feed 348 0.510991 0.2318565
Vapor from free H2O In feed 348 0.0077524 788
Vapor from comb H2O In feed 348 0.0172786 0.4599629
Dust 348 0.1771561 0.2366672
Radiation : Kiln
Preheater
Cooler loss : Heat in Clinker 124 1 0.192696
Radiation
Hot air for mill 407 0.3664974 0.246361
Excess Air 238 1.1587266 0.242474
Heat of reaction
Sum Of heat inputs
 kcal/kg
736.70533
2.9984661
0.2051346
0.1113471
0.0351601
0.1238703
4.953337
4.9484988
0.1849249
0.187033
8.8150728
2.7881479
0.2341912
29.078426
3.4252793
794.79422

kcal/kg
107.26078

0.5020577
1.6349262
0.5020577
1.6535638
12.001742
12.032614
41.229882
6.1089155
2.7657381
14.590608
23
28
23.894304
6
36.748299
66.868735
410
794.79422