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Heat Balance Kiln & Cooler P 6: Instructions
Heat Balance Kiln & Cooler P 6: Instructions
Instructions:
1,Input all figures in red
2,Try figures in purple until fig
in "equal to" culumn is fullfilled
3,Make sure other leak.>0
Condition
Kiln Feed T/h 316 C for CO
SP Heat/ Total 0.5 0.5 CO=
PC decarbonation 0.9 0.1 CO=
C2 Out O2 % 1.5 C for CO=
RM % H2O 0.8 C for CO=
RM ig loss 0.36 check CO
SP O2 % 3.6
SP CO %: 0.12 Fuel
Kiln Inlet O2 1.5 HV Coal
Cooling Air 2.2 nm3/kg cl Oil/Fuel ratio
Vent Air 1.37 nm3/kg cl Heat
Other Air 0.365 nm3/kg cl kg/kg cl
Capacity t/h 176
Radiation Loss
Temp Surface Alpha Radiation Loss
c m2 w/m2 c kcal/h
SP 150 2400 17.97 4265299
Kiln 280 1248 26.06 6853175
Cooler 100 1342 15.58 1168429
Duct 140 892 17.46 1406610
Inlet Hood 200 0 20.73 0
Outlet Hood 150 250 17.97 579524
Mass calculation
kg/kg cl nm3/kg cl
CL ash 0.011
CL RM 0.989
RM/CL 1.545 1.545
CO2 RM 0.551 0.280
H2O RM 0.005 0.006
KF(dry) 1.785 1.785
moist kf 0.014 0.018
moist coal 0.003 0.004
Coal (dry) 0.120
SP dust 0.240
Amin= 1.198 0.931
Gmin= 1.308 0.965
CO 0.002 0.002
G'min 1.305 0.963
SPGmin 1.881 1.274
Aex 0.339 0.264
SPG 2.221 1.538
O2= 3.6
CO= 0.0012
MW SPG 32.344 /mole
Coal Combustion
O2 Req,d combustion gas
kg/kg coal Gas kg/kg coal nm3/kg coal kg/kg cl
0.332 H2O 0.373 0.465 0.046
1.773 CO2 2.438 1.241 0.302
-0.055 O2 0.000 0.000 0.000
0.147 NO2 0.212 0.103 0.026
0.046 SO2 0.092 0.032 0.011
F2O 0.000 0.000
0.000 moisture 0.000 0.000 0.000
0.011 CO 0.019 0.015 0.002
N2 7.418 5.935 0.919
2.254 10.552 7.791 1.308
Coal Balance
Moisture 0.003 0.003
Ash 0.011 0.011
Combustible 0.109
Amin 1.198
Gmin 1.308
1.322 1.322
HEAT BALANCE-COOLER
ReF. to
0.240
dust
0.014 moistureoisture
m
1.800 KF oisture
1.545
0.005 H2O
1.540
0.002 moisture
0.062 Coal e
1.049 0.006
ash
ash
81
Radiation Loss KF balance
kcal/kgcl KF,dry 1.785
24 KF,moisture 0.014 0.014
39 Dust 0.240
7 CL 0.989
8 CO2+H2O 0.556
0 1.800 1.800
3
Air
% vol wt frac
21 30 0.233
79 98.75 0.767
128.75 1
Mol wt 28.84
Leak Air area,m2 dp,mmH2O
Leak kiln inlet 0.15 15
kiln outlet 0.2 2
SP leakage
Cooler Leak
Total Leakage
Other Air
m3/h Nm3/h
Coal air-main 3000 2700
Coal Air-SP 2500 2250
Pri air 7641 6876.9
Feed Air 22000 19800
Leak air
35 deg c
/kgcl Cp Heat
0.018 576.05 8.3
0.004 0 0.0
0.963
0.002 3019 5.6
0.264
0.280
0.006
1.538 0.360 183.8
0.240 0.244 19.5
1.000 0.186 12.1
0.060 0.309 1.2
1.37 0.315 101.8
81.3
432
845.3
/kgcl Cp Heat
0.014 1 0.6
0.003 1 0.2
1.785 0.208 16.7
0.120 0.302 1.6
2.2 0.309 0.0
0.060 0.309 0.0
0.365 0.309 1.7
20.9
824
Sec.Air Calculation
Air
SP Out 0.264
C1 KF Air 0.113
KF Moist
KF H2O
C1 Inlet 0.151
C4 Out 0.096
SP Leak 0.055
C4-PC Coal Air 0.013
Amin -0.465
Gmin
Coal moist
CO2 RM
Kiln End 0.039
Kiln In Leak 0.043
SP Inlet 0.082
Ter Air 0.466
Kiln Coal Air 0.015
Prim Air 0.039
Kiln Out Leak 0.021
Amin -0.465
Coal Moist
CO2 RM
Gmin
Kiln Out Sec Air 0.429
Sec +Ter Air 0.896
Cooler Cooling Air 2.2
Exhaust Air 1.37
Leak Air 0.066
35 Deg C
Crusher Cooling Air
Cp Kcal/Kgcl kg/kg cl
0.257 337.3 1.000
0.257 18.1 0.054
0.309 0.0 2.833
0.309 0.0 0.077
0.309 0.0 0.085
355 4.048
moistureoisture
m KF air 0.113 0.151
oisture
Top Cy
H2O
1.250 0.151
SP leak 0.055 0.096
1.250 0.096
Gmin
0.483
0.513 0.039
0.039
CO2 0.483
Gmin
moisture
Amin 0.465
Cooler
Cooling air
2.2
6
64
9
9
2.7
1.7
Air Balance
Cooling air 2.833
other air 0.469
Amin= 1.198
Aex 0.339
Vent air 1.764
3.302 3.302
nm3/kg cl
0.043
0.021
0.055
0.05
0.169
0.349
Nm3/kg cl
0.015
0.013
0.039
0.113
0.169
Gas Total O2 %
1.274 1.538 3.6
0.018
0.006
1.250 1.401 2.3
1.250 1.346 1.5
0.483
0.002
0.252
0.513 0.552 1.5
0.002
0.028
0.483
0.000
3.6
2.3
1.5
2.9
1.5
HEAT BALAN
Instructions:
1,Input all figures in red
2,Try figures in purple until fig
in "equal to" culumn is fullfilled
3,Make sure other leak.>0
Condition
Kiln Feed T/h 558 C for CO (by SPG trial)
SP Heat/ Total 0.55 0.45 CO= 0.0008 nm3/kg cl
PC decarbonation 0.9 0.1 CO= 0.001 kg/kg cl
C2 Out O2 % 1.5 C for CO= 0.000 kg/kg cl
RM % H2O 0.5 C for CO= 0.004 kg/kg coal
RM ig loss 0.36 check CO 0.001 kg/kg cl
SP O2 % 3.2
SP CO %: 0.06 Fuel Oil Coal
Kiln Inlet O2 2 HV Coal 10000 6650
Cooling Air 2 Oil/Fuel ratio 0 1.000
Vent Air 1.246 Heat 0 734
Other Air 0.286 kg/kg cl 0.000 0.110
Capacity t/h 332
Radiation Loss 49
Temp Surface Alpha Radiation Loss
c m2 w/m2 c kcal/h kcal/kgcl
SP 100 5000 15.58 4353311 13
Kiln 280 1530 26.06 8401729 25
Cooler 80 2500 14.71 1423139 4
Duct 100 2500 15.58 2176656 7
Inlet Hood 200 0 20.73 0 0
Outlet Hood 150 0 17.97 0 0
Mass calculation
kg/kg cl nm3/kg cl
CL ash 0.010
CLRM 0.990
RM / CL 1.547 1.547
CO2 RM 0.550 0.280
H2O RM 0.006 0.008
KF(dry) 1.671 1.671
moist kf 0.008 0.010
moist coal 0.003 0.004
Coal (dry) 0.107
SP dust 0.124
Amin= 1.070 0.831
Gmin= 1.167 0.861
CO 0.001 0.001
G'min 1.166 0.861
SPGmin 1.735 1.164
Aex 0.269 0.209
SPG 2.005 1.373
O2 %= 3.2
CO %= 0.0006
MW SPG 32.707 /mole
Coal Combustion
O2 Req,d combustion gas
kg/kg coal Gas kg/kg coal nm3/kg coal kg/kg cl
0.332 H2O 0.373 0.465 0.041
1.784 CO2 2.452 1.248 0.271
-0.055 O2 0.000 0.000 0.000
0.147 NO2 0.212 0.103 0.023
0.046 SO2 0.092 0.032 0.010
F2O 0.000 0.000
0.000 moist 0.000 0.000 0.000
0.005 CO 0.009 0.007 0.001
N2 7.436 5.949 0.821
2.259 10.575 7.805 1.167
Coal Balance
Moisture 0.003 0.003
Ash 0.010 0.010
Combustible 0.097
Amin 1.070
Gmin 1.167
1.180 1.180
HEAT BALANCE-COOLER
ReF. to 35 Deg C
Crusher Cooling Air
Input /Kgcl Deg c Ref Cp Kcal/Kgcl
Clinker 1.000 kg 1350 35 0.257 337.3
dust 0.048 kg 1350 35 0.257 16.3
Cooling Air 2.000 nm3 35 35 0.309 0.0
Crusher air 0.060 nm3 35 35 0.309 0.0
Cooler Leak 0.051 nm3 35 35 0.309 0.0
Total Input 3.766 354
Output
Sec Air 0.805 nm3 880 35 0.333 226.4
dust 0.048 kg 880 35 0.224 9.1
Ter Air 0.000 nm3 35 0.306 0.0
dust ter 0.000 kg 35 0.216 0.0
Clinker 0.975 kg 100 35 0.186 11.8
Air Vent 1.246 nm3 288 35 0.315 99.4
Vent Dust 0.025 kg 288 35 0.204 1.3
Radiation 4.3
Crusher air 0.060 nm3 100 35 0.311 1.2
3.766 354
Sec+ Ter Air 0.805 nm3/kg cl= 1.04 kg/kg cl
Heat Balance 118 Sec Air Dust 60 g/NM3
Polysius 101 Ter Air Dust 20 g/NM3
FLS 103 Vent air dust 40 g/NM3
0.124 1.164
dust gas
0.008 moistureo
isture
1.679 KF m
oisture
1.547 Top Cy
0.006 H2O
1.540 1.145
1.145
CO2 Gmin
1.045 0.495
0.002 moisture
0.061 Coal e Amin
1.050 0.006
ash PC-C2
ash
0.417
0.417
0.417
Clinker
1.000
HEAT BALANCE KILN & COOLER P 11
Air
% vol wt frac
21 30 0.233
79 98.75 0.767
128.75 1
Mol wt 28.84
Heat
5
0
147
9
12
1
99
49
428
753
Heat
0
0
16
1
0
0
0
1
19
734
Sec.Air Calculation
Air Gas Total O2 %
SP Out 0.209 1.164 1.373 3.2
C1 KF Air 0.000
KF Moist 0.010
KF H2O 0.008
C1 Inlet 0.209 1.145 1.355 3.2
C4 Out 0.088 1.145 1.234 1.5
SP Leak 0.121
C4-PC Coal Air 0.019
Amin -0.457
Gmin 0.474
Coal moist 0.002
CO2 RM 0.252
Kiln End 0.044 0.417 0.461 2
Kiln In Leak 0.023
SP Inlet 0.067 0.417 0.484 2.9
Ter Air 0.459
Kiln Coal Air 0.015
Prim Air 0.046
Kiln Out Leak 0.011
Amin -0.374
Coal Moist 0.002
CO2 RM 0.028
Gmin 0.388
Kiln Out Sec Air 0.346 0.000
Sec +Ter Air 0.805
Cooler Cooling Air 2
Exhaust Air 1.246
Leak Air 0.051
0.209 0.209 3.2
air
0.209 3.2
SP leak 0.121 0.088
0.088 1.5
0.474
0.457 0.545
Amin coal air 0.019 0.526
0.067 2.9
0.044 2.0
0.044
0.388
Amin 0.374
Cooling air
2
Amin Gmin
0.041 Coal Amin Gmin
0.669 kg /kg coal 9.695 10.575
0.055 nm3/kg coal 7.530 7.805
0.065 kg/kcal 0.0015 0.0016
0.046 nm3/kcal 0.0011 0.0012
0.000 Oil
0.028 kg/kcal 0.0015 0.0016
0.092 nm3/kcal 0.0012 0.0013
0.004 Oiland Coal
1.000 kg/kcal 0.0015 0.0016
nm3/kcal 0.0011 0.0012
1.070
0.269
1.604
2.944
Perhitungan Batu Bara (data fine coal ind. IV rata-rata bulan april)
Komponen %w Komposisi gas buang (mol)
C 55.73 CO2 204.35 4.6444 14.29%
H 5.30 4.16 H2O 47.718 2.651 8.15%
S 0.79 SO2 1.58 0.0247 0.08%
A 18.68 18.68 0.00%
O 18.44 9.32 O2 32.918 1.0287 3.16%
N 1.06 N2 676.5 24.161 74.32%
H2O 10.26 Total 9.8174 32.509
Total 100.00
HHV (kcal/kgcoal) 5601
Udara (Nm3/kg coal) 5.78
Udara (kg air/kg coal) 7.54
C/H 10.51
(C+H)/O 3.31
Faktor Konversi
btu/lb = 252.00 0.56 kcal/kg
1 btu = 0.45 cal
1 lb = 0.0624 kg
3
1 ft /lb = 0.0283 m3/kg
1 ft3 = 1.29 m3
ρ udara (kg/m3) 28.84
mr Udara
Fraksi berat udara
O2 0.233
N2 0.767
kiln feed 330 t/h
String A String B
% Umpan 46 54
Raw mix (t/h) 151.8 178.2
O2 2.02 2.47
CO 0.125 0.06
Fine Coal (t/h) 10.49 23.08
False air (%)
SA TA EA
Temp. 820 607 245
K10 K11 K12 K13 K14 K15 K16 K17
Flow fan (m3/hr) 34.336 12.207 54.907 21.26 45.375 10.728 30.727 62.894
K18 K19 K20 K21
14.042 4.484 3.384 32.91
Simulasi proporsi Raw Material dengan kandungan kimia Lime Stone, Clay dan target rawmix ya
Material 1 2 Material 1
Clay C C Clay C
Harga per ton Raw Mix dalam Rp Harga per ton Raw Mix dalam Rp
Rawmix Rawmix
inasi Material
LS2
SS
IS
si Raw Material
81.00
13.49
3.77
1.75
100.01
14.57
3.90
2.64
43.07
76.92
4.43
102.46
91.41
2.23
1.48
99.00
2.30
1.40