Microsoft Excel 14.

0 Answer Report
Worksheet: [Coal Optimisation Calculator-Rev-01.xlsm]Coal Optimiser
Report Created: 03-Oct-19 2:48:41 PM
Result: Solver found a solution. All Constraints and optimality conditions are satisfied.
Solver Engine
Solver Options

Objective Cell (Max)

Cell Name Original Value Final Value
$F$30 TargetValue 3.6787 3.6787

Variable Cells
Cell Name Original Value Final Value Integer
$E$18:$E$29

Constraints
Cell Name Cell Value Formula Status Slack
$B$34:$B$37 >= $B$18:$B$21
$B$34 SA Total Used 50.00% $B$34>=$B$18 Binding 0.00%
$B$35 Afghan Total Used 0.00% $B$35>=$B$19 Binding 0.00%
$B$36 Darra Total Used 36.04% $B$36>=$B$20 Not Binding 17.04%
$B$37 Indonesian Total Used 31.00% $B$37>=$B$21 Binding 0.00%

$I$18 Ash % 14.72% $I$18<=$B$26 Not Binding 0.052797838

$I$19 Sulphur % 1.84% $I$19<=$B$27 Not Binding 0.001564105
$I$20 TM (ARB) % 15.00% $I$20<=$B$28 Binding 0
$I$21 IM (ADB) % 4.91% $I$21<=$B$29 Not Binding 0.000856568
$I$22 VM % 34.80% $I$22<=$B$30 Not Binding 0.051987838
$E$18:$E$29 >= 0
$E$18 South African 1 % Used 50.00% $E$18>=0 Not Binding 50.00%
$E$19 South African 2 % Used 0.00% $E$19>=0 Binding 0.00%
$E$20 Afghan 1 % Used 0.00% $E$20>=0 Binding 0.00%
$E$21 Afghan 2 % Used 0.00% $E$21>=0 Binding 0.00%
$E$22 Afghan 3 % Used 0.00% $E$22>=0 Binding 0.00%
$E$23 Afghan 4 % Used 0.00% $E$23>=0 Binding 0.00%
$E$24 Darra 1 % Used 0.00% $E$24>=0 Binding 0.00%
$E$25 Darra 2 % Used 36.04% $E$25>=0 Not Binding 36.04%
$E$26 Darra 3 % Used 0.00% $E$26>=0 Binding 0.00%
$E$27 Darra 4 % Used 0.00% $E$27>=0 Binding 0.00%
$E$28 Indonesian 1 % Used 31.00% $E$28>=0 Not Binding 31.00%
$E$29 Indonesian 2 % Used 0.00% $E$29>=0 Binding 0.00%
$E$19 South African 2 % Used 0.00% $E$19=0 Binding 0
$E$20 Afghan 1 % Used 0.00% $E$20=0 Binding 0
$E$29 Indonesian 2 % Used 0.00% $E$29=0 Binding 0
Type of Coal TM (ARB) IM (ADB) GCV (ADB) Ash (ARB) Sulphur VM (ARB)

South African 1 10.0% 3.30% 6,305 14.00% 0.73% 28.39%

South African 2 11.0% 3.50% 6,805 14.50% 0.73% 28.39%
Afghan 1 10.8% 3.00% 6,900 15.00% 0.83% 30.00%
Afghan 2 10.8% 3.00% 7,124 15.00% 0.83% 30.00%
Afghan 3 10.8% 3.00% 7,300 15.00% 0.83% 30.00%
Afghan 4 10.8% 3.00% 7,250 15.00% 0.83% 30.00%
Darra 1 11.0% 4.00% 5,000 18.00% 3.70% 20.00%
Darra 2 11.0% 4.00% 6,000 18.00% 3.50% 20.00%
Darra 3 11.0% 4.00% 5,059 18.00% 3.70% 20.00%
Darra 4 11.0% 4.00% 5,759 18.00% 3.70% 20.00%
IRANIAN 12.8% 0.00% 6,900 7.00% 1.41% 40.00%
Indonesian 2

Min Qty of coal to be used Optimal Mix

Coal % Used Type of Coal % Used Rs / NCV Tonnage Required
SA 0% South African 1 0.00% - -
Afghan 25% South African 2 0.00% - -
Darra 50% Afghan 1 0.00% - -
Indonesian 25% Afghan 2 45.00% 1.3953 387.72
Total 100.00% Afghan 3 0.00% - -
Afghan 4 0.00% - -
Max limilts of Coal Components Darra 1 0.00% - -
Component % Darra 2 45.00% 1.0977 387.72
Ash 20.00% Darra 3 0.00% - -
Sulphur 2.00% Darra 4 0.00% - -
TM (ARB) 15.00% IRANIAN 10.00% 0.3153 86.16
IM(ADB) 5.00% Indonesian 2 0.00% - -
VM 40.00% Total 100.00% 2.8082 861.61

Type of Coal Total Used

SA 0.00%
Afghan 45.00%
Darra 45.00%
Indonesian 0.00%
 H2 (Calc) GCV (ARB) NCV (Calc) Cost Rs / NCV Use in Mix

3.73% 5,868.15 5,611.42 20,000 3.56 Y

4.06% 6,276.11 5,996.44 - N
4.22% 6,345.15 6,058.20 - N
4.37% 6,551.14 6,256.78 19,400 3.10 Y
4.48% 6,712.99 6,412.80 - Y
4.45% 6,667.01 6,368.48 - Y
2.44% 4,635.42 4,435.74 - N
3.10% 5,562.50 5,329.46 13,000 2.44 Y
2.48% 4,690.11 4,488.47 - Y
2.94% 5,339.07 5,114.07 - Y
4.49% 6,016.80 5,709.38 18,000 3.15 Y
- 0.029 - 147.77 - N

Final Coal Mixture

Component %
Ash 15.55%
Sulphur 2.09% 2.14
TM (ARB) 11.09%
IM (ADB) 3.15%
VM 26.50%
GCV (ARB) 6,052.82
H2 3.81%
NCV 5,784.74
Coal Characteristics Value Unit Type of Cell
Total Moisture (ARB) 15.20 % Input
Inherent Moisture (ADB) 4.80 % Input
Gross Calorific Value (ADB) 6,900 kCal /kg Input
Ash Content (ARB) 7.80 % Input
Volatiles (ARB) 32.40 % Input
Hydrogen (Calculated) 4.18 %
Gross Calorific Value (ARB) 6,146 kCal /kg
Net Calorific Value (Calculated) 5,840 kCal /kg

ADB = Air dried basis

ARB = As received basis

Converstion tables
1 kCal = 0.556 BTU
1 KCal = 4.187 kJ
 Data Entry Cells
Clinker to be Produced (tons per day) 7,100
Targetted Fuel Consumption (kcal/kg) 702
NCV Calculated for Coal MixCoal 5,785
Coal required for Clinker to be Produced (tons) 862 14,113,189 16,380
Handling Losses 2.50%
Moisture Losses 4.00%
Gross Coal Requirement (tons) 918 15,030,546 16,380 2166

PC Main 2144
Ratio of Usage 70% 30% 2100
Qty Used per day (ton) 603 258
Coal Feed Rate (tph) expected 25 11
Coal Feeder Limit (tph) at NCV of 6000 kcal/kg 30 30

SA Indonesia Afghan Darra

Mix Ratios 0.00% 10.00% 45.00% 45.00%
Coal required for Clinker to be Produced (tons per day)) 0 86 388 388
Value of Coal for Clinker (Rs) 0 1,550,900 7,521,864 5,040,425
Gross Coal Requirement (tons per Day) 0 92 413 413 cost Rs/ton
Value of Gross Coal Required (Rs) 0 1,651,708 8,010,785 5,368,052 2,113
Coal Average Rate per ton (Rs) 0 18,000 19,400 13,000
Available Stocks (Tons) 24,687 15,846 19,501 1,385
Numbers of Days 173 47 3
Coal Mix Derived Can be Used for Days --> 3
 % GCV GCV
PRICE PER Coal Mix % %
T.Moist (DB) (ARB)
TON Ratio IM ADB Sulfur
ARB Kcal/Kg Kcal/Kg

C= 100-
Formula a e x y b
x/100-y

Standard Coal 100% 10.0 2.80 1.00 6500 5850

SCANERIO
DARA 10200 40% 8.9 2.28 2.56 5200 4737

SA 18600 25% 10.2 3.20 0.87 6500 5837

AFGHAN 18000 25% 9.3 2.71 0.72 6500 5896

INDO 20150 10% 10.0 2.60 2.00 6500 5850

100%
 FUEL OPTIMIZATION
Cherat Cement Company

Heat Heat Price

Avg Coal
NCV ARB coal meal Coal Consumption t/h Consumpti GCV (ARB)
meal CV
on Rs/1000Kcal

O=(M*98/90)-
N M Calciner t/h Kiln t/h Total t/h kcal/kg kk d=a/c
50

Standard
5600 6098 6048 23 11 34 691

SCANERIO
4487 4886 2.2
5587 6084 3.2
5572 26 11 37 699.1
5646 6147 3.1
5600 6098 3.4
 International coal
Mix Heat Price Saving
heat Price
Coal Mix Saving per day @33% Dara
Ratio Heat Con 695 Kcal/kg kk
Rs/1000Kcal Rs/1000Kcal Rs/1000Kcal

e f g=e*0.5+f*0.5 h=g-f S=696*h*7100/1000000

RS MILLION

40%
25%
25%
2.77 3.12 0.35 2.76
10%
Trade TM (ARB) IM (ADB) GCV (ADB) Ash (ARB) Sulphur VM (ARB)
S.A
Afghan
Local

Afg
ash DB Sul
7230 0.9
6992 0.81
7190 0.78
7087 0.85
Afg SA
tm vm gcv sul tm im vm ash
10 6305 0.73 10 3.3 28.39 14
11
10.98
11.33
11.02
9.96

Local
5615 2.98 11.96
6129 3.65 11.93
5491 4.17 10.35
5064 3.82 10.88
5001 3.98 9.97
5953 3.63
5059
5792
 GCV
PRICE PER Coal Mix % % %
(ADB)
TON Ratio T.Moist ARB IM ADB Sulphur
Kcal/Kg

Formula a e x y

Standa
Standard Coal 100% 10% 2.80% 1% 6750

DARA 11000 50% 9% 2.28% 3.7 5300

SA 18084 25% 11% 3.20% 0.78 6300

AFGHAN 18084 25% 11% 2.71% 0.83 7100

 FUEL OPTIMIZATION
Cherat Cement Company

GCV (ARB) Avg Coal

NCV ARB coal meal Coal Consumption t/h
Kcal/Kg meal CV

N M O=(M*98/90)-50 Calciner t/h Kiln t/h Total t/h

Standard
6250 6000 6006 5956 23 11 34

SCANERIO 1
4919.259108 4669 4674

5805.371901 5555 5560 5189 28.3 11 39

6495.014904 6245 6250

7026.50602
 International coal
Heat Heat Price Mix Heat Price Saving
Coal Mix heat Price
Consumpti GCV (ARB)
Ratio
on Rs/1000Kcal
Rs/1000Kcal Rs/1000Kcal Rs/1000Kcal

kcal/kg kk d=a/c e f g=e*0.5+f*0.5 h=g-f

689

2.4 50%

696 3.3 25% 2.72 3.08 0.36

2.9 25%
 Saving per day Dara
Heat Con 695 Kcal/kg kk

S=699*h*7100/1000000

2.77
 SA Iranian Afghan Darra
Present mix 25% 0% 25% 50%
0% 20% 40% 40%
0% 10% 45% 45%
0% 10% 40% 50%
20% 20% 40% 40%
0% 0% 40% 60%
0% 0% 45% 55%
Coal Cost R/tkk kiln feed Sulfur
2166 2.1
2139 2.01
2113 2.16
2088 2.2
2204 2
2037 2.43
2037 2.3