Project No.: TD-07-01-ph-s Kiln no.

Date 1/25/2007
Plant Location Tabouk Cement, Saudi Arabia Country Code SAU

Plant Location
level above sea ambient temperature rel. humidity of air
[m] [ °C ] [%]
mean maximum mean maximum
0

Preheater Feed Preheater String - Calciner Type

pneumatic =
bucket elevator + belt weigher =
bucket elevator + rotary scale =
Preheater Type
No. of preheater stages
No. of preheater strings
1 A-string B-string 0 = none
2 1 = secondary burner
3 2 = AT-calciner
3 = AT-calciner w. tertiary air
4 = AS-calciner
5 = seperate line calciner

Clinker Cooler Type

walking beam cooler = 1
grate cooler = 2
satelite cooler = 3
other cooler = 4

Type
Preheater bag filter 1
Clinker Cooler reverse air filter 2
Bypass ESP 3
Raw Mill cyclones only 4

Pyro-Section History
Original Supply Modification
Year Supplier Capacity Year Supplier Comments
Preheater
Calciner
Kiln
Cooler
Bypass
ID-Fan

Aim of the Client

Project No.: TD-07-01-ph-s Kiln no. 0 Date 1/25/2007
Plant Location Tabouk Cement, Saudi Arabia 0 0 Country Code SAU

Actual Plant Capacity & Performance

preheater feed [t/h] practical fclinker [kgfeed / kgclinker]
clinker production [t/d]
return dust (in direct operation) [t/h] LOI of preheater feed [%]
bypass dust [t/h] net heat value Hu of fuel [kcal / kgfuel]
specific heat consumption [kcal / kgclinker] ash content of fuel [%]
seperation efficiency top stage [%]
bypass rate [%]

Actual Situation at Kiln Inlet

min. average max.
gas temperature at kiln inlet [°C]
pressure at kiln inlet [Pa]
Cl content of hot meal [%]
SO3 content of hot meal [%]
K2O ontent of hot meal [%]
Na2O content of hot meal [%]

Fuel Utilised
Quantity [t/h] Temperature [°C] Heat Value Hu [kcal / kgfuel]
fuels (as fired) kiln calciner kiln calciner kiln calciner
coal
pet coke
gas
oil

Gas Data
volume [Am³/h] temperature [°C] pressure [Pa]
main burner calciner main burner calciner main burner calciner
primary air
secondary air
tertiary air (before calciner)
bypass gas before cooling / / /
exhaust gas before preheater / / /

Pneumatic Conveying Air (if existing)

pneum. air raw meal feed [Nm³/h]
pneum. air alternat. Fuel [Nm³/h]
pneum. air other [Nm³/h]

Preheater Fan
pressure temperature volume speed power
[Pa] [°C] [Am³/h] [rpm] [kW]
design                              
actual

Data Conditioning Tower (if installed before preheater fan)

design actual
gas temp. before condit.tower [°C]
gas temp. after condit.tower [°C]
temperature of water sprayed [°C]
amount of water sprayed [kg/h]
Project No.: TD-07-01-ph-s Kiln no. 0 Date 1/25/2007
Plant Location Tabouk Cement, Saudi Arabia 0 0 Country Code SAU

Chemical Analysis Fuel Particle Size Distribution

A B C D E F retained kiln feed return dust clinker dust

type of fuel coal pet coke gas oil 0 0 d [µm]
Net calorific value [kJ/kg]                         1000
C [%]                         630
H [%]                         500
S [%]                         400
N [%]                         250
O [%]                         192
K [%]                         128
Na [%]                         96
Cl [%]                         64
ash content [%]                         48
moisture content [%]                         32
volatile content [%]                         24
density (20°C) [kg/m³]                         16
12
8
Chemical Analysis Feed Material 6
4
For preheater feed data is return dust ( filter dust) recycled as feed to raw
meal? (=direct operation; all connected, influencing aggregates like mills are YES NO 3
stopped) mark with "X"
hot meal
coal ash bypass dust 2
preheater feed return dust bypass gas (kiln feed)
[%] [%] [%] [%] [%] [%] 1.5
SiO2                         1
Al2O3                        
Fe2O3                        
CaO                         kiln feed return dust clinker dust
MgO                         [ t/m³ ] [ t/m³ ] [ t/m³ ]
K2O                         spec. weight
Na2O                         bulk density
SO3                        
Cl                        
l. o. ignition                        
CaOFREE / / /       / /
Project No.: TD-07-01-ph-s Kiln no. 0 Date 1/25/2007

Plant Location Tabouk Cement, Saudi Arabia 0 Country Code SAU

String 1
Measuring temp pressure O2 CO NOx SO2
Point [ °C ] [ Pa ] [%] [%] [%] [%]
outlet 1
downcomer duct
inlet 2
outlet 3
cyclone 1
inlet 4
outlet 5
cyclone 2
inlet 6
outlet 7
cyclone 3
inlet 8
outlet 9
cyclone 4
inlet 10
outlet 11
cyclone 5
inlet 12
outlet 13
cyclone 6
inlet 14
calciner loop duct, kiln outlet 15
riser inlet 16
outlet 17
combustion chamber
inlet 18
outlet 21
tertiary air duct
inlet 22
orifice 23
kiln inlet chamber
kiln 24
outlet 48
inlet 49
outlet 50
inlet 51
52
53
Project No.: TD-07-01-ph-s Kiln no. 0 Date 1/25/2007

Plant Location Tabouk Cement, Saudi Arabia 0 Country Code SAU

String 2
Measuring temp pressure O2 CO NOx SO2
Point [ °C ] [ Pa ] [%] [%] [%] [%]
outlet 25
downcomer duct
inlet 26
outlet 27
cyclone 1
inlet 28
outlet 29
cyclone 2
inlet 30
outlet 31
cyclone 3
inlet 32
outlet 33
cyclone 4
inlet 34
outlet 35
cyclone 5
inlet 36
outlet 37
cyclone 6
inlet 38
calciner loop duct, outlet 39
kiln riser inlet 40
outlet 41
combustion chamber
inlet 42
outlet 45
tertiary air duct
inlet 46
orifice 47
kiln inlet chamber
kiln 24
outlet 54
inlet 55
outlet 56
inlet 57
58
59
Project No.: APO-08-02-ph-s Kiln no. 3 Date 2/2/2008
Plant Location Orizaba-Apasco-Holcim 0 0 Country Code MEX

Input of actual dimensions for cyclone and raiser duct

for square cyclone inlet give data for "a" and "b" only
raiser duct to bottom cyclone = kiln raiser or loop duct

stage Unit 1 2 3 4 5 6
number of cyclones nocyc /
total cyclone height ht mm
cylindrical height of cyclone hc mm
diam. of cyclone dc mm
diam. of meal pipe dm mm
excentricity of cyclone inlet c mm
height of cyclone inlet a mm
vertical section of cycl. inlet a1 mm
width of cyclone inlet b mm
horizontal section of cycl. inlet b1 mm
dip tube diameter do mm
dip tube height hd mm
inlet spiral angle αE deg.
steel thickness dip tube sd mm
material of dip tube dmat /
steel thickness cyclone ssteel mm
lining thickness cyclone s1lining mm
lining thickness cyclone roof shlining mm
Project No.: APO-08-02-ph-s Kiln no. 3 Date 2/2/2008
Plant Location Orizaba-Apasco-Holcim 0 0 Country Code MEX

calciner, kiln
down comer 2 => 1 3 => 2 4 => 3 5 => 4 6 => 5 riser
type /
number of raiser ducts norais /
cyclone inlet height a mm
cyclone inlet width b mm
riser duct diam. at dip tube d1 mm = orifice
riser duct diam. at middle section d2 mm
steel thickness riser duct ssteel mm
lining thickness riser duct s1lining mm
insulation outside steel s2insul mm
h mm = total length
h1 mm
k mm
k1 mm
m mm
h3 mm
e mm
f mm
n mm
bR deg.
h2 mm
Project No.: TD-07-01-ph-s Kiln no. 0 Date 1/25/2007
Plant Location Tabouk Cement, Saudi Arabia 0 0 Country Code SAU

all diameter data refer to dimension between lining

Average Dimensions and Data Sinter Zone Dimensions and Data

Length [m]
Diameter [m] Diameter [m]
Lining [m] Lining [m]
Inclination [%]

Material Kiln Inlet Section Dimensions and Data

filling degree [° DEG]
Angle of Repose [° DEG] smallest Diameter [m]
Bulk Density [t/m³] Lining [m]

Drive
Max. Speed [Rpm]
installed power [ kW]
operat at [ kW]
Project No.: TD-07-01-ph-s Kiln no. 0 Date 1/25/2007
Plant Location Tabouk Cement, Saudi Arabia 0 0 Country Code SAU

Clinker production rate t/d

Clinker hot temperature °C
Clinker cold temperature °C =exit temperature
Wall loss kcal/kg ck

Flow T° P
[m³/h] [ °C ] [ Pa ]
Secondary air
Tertiary air
Coal mill take-off
Raw mill take-off
Vent air

Flow T° Flow
[liter/h] [ °C ] [ kg/h ]
Vent air water spray

Cooling fans Flow T° Ps Grate area

[m³/h] [ °C ] [ Pa ] [ m² ]
#1 Fan 1
#2 Fan 2
#3 Fan 3
#4 Fan 4
#5 Fan 5
#6 Fan 6
#7 Fan 7
#8 Fan 8
#9 Fan 9
#10
#11
#12
Cooler ID fan
Total

Clinker Cooler Off-gas Heat Exchanger

type air/air design actual
gas temp. before heat [°C]
exchanger
gas temp. after heat [°C]
exchanger
temperature of water/air [°C]
for cooling
quantity of water/air [kg/h] [m³/h]
Project No.: TD-07-01-ph-s Kiln no. 0 Date 1/25/2007
Plant Location Tabouk Cement, Saudi Arabia 0 0 Country Code SAU

required received
general arrangement preheater incl. all levels
structural arrangement incl. beam sizes
kiln
clinker cooler
arrangement down comer duct
tertiary air duct
preheater meal feed
ID-fan
existing bypass system
detail drawings incl. lining stage 1 cyclone
riser duct 2-1
stage 2-cyclone
riser duct 3-2
stage 3 cyclone
riser duct 4-3
stage 4 cyclone
riser duct 5-4
stage 5 cyclone
kiln riser / calciner
combustion chamber
kiln inlet chamber
kiln orifice
fan curves ID-fan
raw mill filter fan
cooling fan bypass
filter fan bypass
clinker cooler filter fan
other technical information plant flow sheet
CCR print out of all plant sections
°C Pa °C Pa

°C

°C Pa

°C Pa
°C Pa

°C
 °C Pa °C Pa °C Pa

Pa °C Pa

°C Pa °C Pa

°C
°C Pa °C Pa

°C

Pa °C Pa
°C Pa String 1

Press. Diff. Sep. Eff.

Press [mbar]
[mbar] [%]
stage 5 -51.62 11.42 94.21
stage 4 -40.20 9.67 92.24
stage 3 -30.53 6.37 91.21
stage 2 -24.16 5.79 91.21
stage 1 -18.37 5.37 91.11
calciner -13.00 8.00
kiln inlet -5.00 5.00

Safety Pressure Drop [%] 0%

Safety Sep. Eff. [%] 0%

Sep. Eff.
Press [mbar] Press. Diff.
[%]
stage 5 -54.00 12.00
°C Pa stage 4 -42.00 8.00
stage 3 -34.00 7.00
stage 2 -27.00 7.00
stage 1 -20.00 7.00
calciner -13.00 8.00
kiln inlet -5.00 5.00

Safety Pressure Drop [%] 0%

Safety Sep. Eff. [%] 0%

Pa
Pa
 String 1

spec. Gas No. of No. of meal pipe

T [°C ] O2 [%]
Nm3 / kg cli Cyclons Risers diam.
315 3.60 1.50 2 2 400
485 3.10 1.40 1 1 600
635 2.60 1.35 1 1 600
760 2.30 1.30 1 1 600
870 2.00 1.25 1 1 800
890 2.00 1.20 1 1
1100 2.50 0,6

String 2

spec. Gas No. of No. of meal pipe

T [°C ] O2 [%]
Nm3 / kg cli Cyclons Risers diam.
315 3.60 1.50 2 2 400
485 3.10 1.40 1 1 600
635 2.60 1.35 1 1 600
760 2.30 1.30 1 1 600
870 2.00 1.25 1 1 800
890 2.00 1.20 1 1
1100 2.50 0,6
Project No.: TD-07-01-ph-s Kiln no. 0 Date
Plant Location Tabouk Cement, Saudi Arabia 0 0 Country Code

Future Plant Performance

clinker production [t/d]
specific heat consumption [kcal / kgclinker]
bypass rate [%]

Future Chemical Analysis Fuel

A B C D
type of fuel coal pet coke gas oil
Net calorific value [kJ/kg]                        
C [%]                        
H [%]                        
S [%]                        
N [%]                        
O [%]                        
K [%]                        
Na [%]                        
Cl [%]                        
ash content [%]                        
moisture content [%]                        
volatile content [%]                        
density (20°C) [kg/m³]                        

Future Fuel Utilised

Quantity [t/h] Temperature [°C] Heat Value Hu [kcal / kgfuel
fuels (as fired) kiln calciner kiln calciner kiln
coal
pet coke
gas
oil
 1/25/2007
SAU

E F
0 0

eat Value Hu [kcal / kgfuel]

calciner