Chapter 10

HEAT BALANCE
(ENGLISH SYSTEM OF UNITS)

In Chapter 12 there are graphs that show the mean specific heat for
gases and solids at stated temperatures. In all the formulas given, " ß " de-
notes the heat content (Btu/ton clinker) and " c " denotes the mean spe-
w

cific heat of the gas or solid at the stated temperature.

HEAT INPUT

10.01 Heat Input from Combustion of Fuel

Q = WA A q = .....Btu/ton

10.02 Heat Input from Sensible Heat in Fuel

=
Q = W ^ m ( 7
F - 3 2
) Btu/ton

10.03 Heat Input from Organic Substance in Kiln Feed

It is assumed that the organic matter in the kiln feed has a constant
heat value of 9050 Btu/lb.
Ill
112 CEMENT MANUFACTURER'S HANDBOOK

Ô - g 9050 = Btu/ton

(find g in 8.01).

10.04 Heat Input from Sensible Heat in Kiln Feed

Qi = WdF Cm Vc -32)

Q 2 = (H 0inslurry)(r -32)
2 c

Ô, Total = Btu/ton

10.05 Heat Input from Cooler Air Sensible Heat

Btu/ton

(find w in 8.10).
f

10.06 Heat Input from Primary Air (Sensible Heat)

Make sure to include in this calculation only that amount of primary air
that originates from ambient source. Do not include the fraction of pri-
mary air that has its origin from the cooler air.

(r-32) = Btu/ton

(find w in 8 . 1 0 ) .
4
 HEAT BALANCE (ENGLISH SYSTEM OF UNITS) 113

10.07 Heat Input from Infiltrated Air (Sensible Heat)

When the temperature in the area of the firing hood is significantly dif-
ferent from " 7 * \ use the appropriate temperature in the ensuing calcula-
tion.

w c
Q =
il7T\ m 1
(T -32) = Btu/ton

(find w in 8.09).
s

Note: The fuel efficiency, i.e., the specific heat consumption of the
kiln under investigation, is given by the result obtained in 10.01.
One must keep in mind that this value is expressed in terms of gross
Btu per ton of clinker. A footnote should be used to state whether
the fuel efficiency is expressed in net or gross Btu per ton clinker to
avoid confusion when this fuel efficiency is compared with European
kilns that state this efficiency exclusively as net Btu per ton.

HEAT OUTPUT

10.08 Heat Required for Clinker Formation

Obtain this directly from 8.04.

Q = .Btu/ton

10.09 Heat Loss with Exit Gas

The heat loss in the exit gas is calculated from the heat content of each
individual gas component. The weight of each component can be obtained
from 8.13.
114 CEMENT MANUFACTURER'S HANDBOOK

W c T i2
Qco 2 = C0 m( BE- ) 2

= W
HOm c T
( BE - 32) =
QH O
2 2

= c T 2
Qso2
*>S0 m( BE-3 ) 2

QN 2 " W
N m( BE- ) 2
c T 32

öexcess air
=
^excess air w ( B E " ^ ) c 7 3 =

fötal: ß = Btu/ton

10.10 Heat Loss Due to Moisture in Feed or Slurry

In 8.13, the total amount of water, including the chemically combined

water, has been calculated. This weight is used in the following calculation.
Keep in mind that the result obtained represents only the amount of heat
that has to be expanded to turn the given weight of water into steam at
32 F. The heat losses associated with raising this steam to the kiln exit gas
temperature have already been included in 10.09.

1 0 7 5 8 B t u
Q 5 8
("total h o) 2 - = /ton

10.11 Heat Losses Due to Dust in Exit Gases

Q = k c x m (T BE - 32) * Btu/ton

(find Ar in 8.02).
1

10.12 Heat Loss with Clinker at Cooler Discharge

Q = 2000c m (T cl -.32) = Btu/ton

 HEAT BALANCE (ENGLISH SYSTEM OF UNITS) 115

10.13 Heat Loss at Cooler Stack

60
= w c 7
Ö * m ( ^r-32) = Btu/ton

( f i n d W i n 8.10).
2

10.14 Radiation and Convection Losses on Kiln Shell

The shell temperature is measured over the entire length of the kiln in
five-foot intervals by means of a radiation pyrometer. The total kiln length
is then divided into three equal areas and the average shell temperature,
T , is calculated for each zone. In Chapter 13, a graph is given that shows
z

the heat transfer coefficient,^ , to be used in the following calculations.

Let

s s = kiln shell surface area,

03 - '.(T(Tz 3

Total: Q = Btu/ton
116 CEMENT MANUFACTURER'S HANDBOOK

It is advisable to plot the temperatures found on graph paper to have a

record available that shows potential weak areas in the lining or any sig-
nificant changes in temperatures when the kiln is tested again at a later
time.

10.15 Heat Loss Due to Calcination of Wasted Dust

This heat loss refers only to that fraction of dust which is wasted and
not returned to the kiln.
Calculate first the percent calcination of the kiln dust:

§ - C /
g - u
i g _

Second, calculate the total carbonates contained in the wasted dust:

a +b
rc
dust = — W k dF 2 = Ib

The heat loss due to calcination of the wasted dust is determined by

B
ß < rC dust (685.1) = Btu/ton

(find a, b, i in 8.01 and k in 9.02).

2
 Heat Balance

Heat input Btu/ton Percent Heat output Btu/ton Percent

HEAT BALANCE (ENGLISH SYSTEM OF UNITS)

10.01 : Combustion of fuel 10.08: Theoretical heat required
10.02: Sensible heat in fuel 10.09: Exit gas losses
10.03: Organic matter in feed 10.10: Evaporation of moisture
10.04: Sensible heat in feed 10.11: Dust in exit gas
10.05: Sensible heat in cooler air 10.12: Clinker discharge
10.06: Sensible heat in primary air 10.13: Cooler stack losses
10.07: Sensible heat in infiltrated air 10.14: Kiln shell losses
10.1 S: Losses due t o calcination
of wasted dust
Unaccounted losses

Total 100 Total 100

•— . — i

N o t e : Unaccounted losses are calculated by difference t o make the two sidss equal

117