Kiln Performance & Efficiency (Assembled and e

Description Symbol Formula

(3.2∗𝑃)/
( 〖 𝐷𝑒𝑓𝑓〗 ^3∗𝑛∗𝑠)
Degree of filling DF (%)
P Clinker production, tpd
Deff Burning zone effective diameter, mts
n Kiln speed, rpm
s Kiln slope, %

(𝐹∗𝑁𝐶𝑉)/
(𝐴∗ 〖 10 〗 ^6 )
F Fuel rate in kiln, kg/hr
NCV Net calorific value of fuel, kcal/kg-fuel
Thermal loading or A Burning zone cross-sectional area, m2
TL (Gcal/hr/m2 )
Burning zone loading
M

(𝑃∗𝐻)/(𝐴∗2.4∗ 〖 1
^4 )
P Clinker production, tpd
H Specific heat consumption in kiln, kcal/kg-clinker
A Burning zone cross-sectional area, m2

𝑃/(𝐴∗𝐿)

Volumetric loading VL (tpd/m3)

P Clinker production, tpd

A Burning zone cross-sectional area, m2
L Kiln length, mts

(19∗𝐿)/(𝐷𝑒𝑓𝑓∗𝑛∗𝑠)

Material residence time

RTK (min)
in kiln
L Kiln length, mts
Deff Burning zone effective diameter, mts
n Kiln speed, rpm
s Kiln slope, %

(1.55∗𝐴∗𝑃𝑠)/𝑃
Clinker residence time
in cooler (Empirical RTC (min)
relationship)

Clinker residence time
in cooler (Empirical
relationship)
(1.55∗𝐴∗𝑃𝑠)/𝑃
RTC (min)
A Cooler grate cross-sectional area, m2
Ps Static pressure at clinker droping area, mmWg
P Clinker production, tpd

(100∗(𝐶𝑂2+𝐶𝑂))/
(100+(1.89∗𝐶𝑂)−(4.78
True CO2 in kiln exit gas TCO2 (vol%)

CO2 Kiln exit gas CO2, vol%

CO Kiln exit gas CO, vol%
O2 Kiln exit gas O2, vol%

(79∗𝑂2)/
(0.21∗(100−𝐶𝑂2)−
Excess air EA (%)

O2 O2 content in gas, vol%

CO2 CO2 content in gas, vol%

Radiation heat losses RHL (kcal/hr/m2)

4∗ 〖 10 〗 ^(−8)∗(𝑇^

T Radiating body temperature ,C

t Ambient air temperature, C

80.33∗( 〖 (𝑇+𝑡)/2) 〗 ^(−0.724)∗

Convection heat losses CHL (kcal/hr/m2)

T Radiating body temperature ,C

t Ambient air temperature, C

"28.03 * ( ( T + t ) / 2 )-0.351 * v 0.805 * D

Forced convection heat
losses (when wind FCHL (kcal/hr/m2)
speed > 3.0 m/s) T Radiating body temperature,C
t Ambient air temperature,C
v Wind speed, m/s
D Radiating body diameter, mts

(𝐶𝐶∗𝐴𝑠ℎ)/𝑃
%Ash absorption in
%AA (%)
clinker
 (𝐶𝐶∗𝐴𝑠ℎ)/𝑃
%Ash absorption in
%AA (%)
clinker
CC Coal consumption, tph
Ash Ash content in fuel (as fired basis), %
P Clinker production, tph

(100−%𝐴𝐴)/
Raw Mix:Clinker ratio (100−𝐿𝑂𝐼)
RMCK (-)
(dust to kiln)

%AA %Ash absorption, %

LOI Loss on ignition of raw mix, %

"( 100 – %AA ) * 100" /"(

* ( 100 – DL )"
Raw Mix:Clinker ratio
RMCS (-)
(dust to silo)
%AA %Ash absorption, %
LOI Loss on ignition of raw mix, %
DL Dust losses from preheater, %

"( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMC

"+ ( 11.6 * CH2O * RMCK )– ( 511.6 * SiO2 / ( 100 – LO
 – ( 1000 * ( K2O + Na2O )  / ( 100 – LOI ) )– ( 79 *
CaCO3 CaCO3 content in kiln feed, %
RMCK Kiln feed:Clinker ratio, –
Heat of reaction or MgCO3 MgCO3 content in kiln feed, %
Theoretical heat
required to produce 1 HR (kcal/kg-clinker) LOI LOI content in kiln feed, %
kg of clinker or Al2O3 Al2O3 content in clinker, %
Clinkerisation heat CH2O Water of crystalisation in kiln feed, %
SiO2 SiO2 content in clinker, %
Fe2O3 Fe2O3 content in clinker, %
K2O K2O content in clinker, %
Na2O Na2O content in clinker, %
C Carbon content in kiln feed, %
S Sulphur as pyrites in kiln feed, %

"( O2mix – O2gas )

False air w.r.t. mix 100" /"21 – O2gas"
FAMO (%)
(based on O2 analysis)

O2mix O2 content in mixture of gas, vol%

O2gas O2 content in unmixed gas, vol%

False air w.r.t. gas

FAGO (%)
(based on O2 analysis)
 "( O2mix – O2gas )
False air w.r.t. gas 100" /"21 – O2mix"
FAGO (%)
(based on O2 analysis)

O2mix O2 content in mixture of gas, vol%

O2gas O2 content in unmixed gas, vol%

"( CO2gas – CO2mix

False air w.r.t. mix 100" /"CO2gas"
FAMC (%)
(based on CO2 analysis)

CO2mix CO2 content in mixture of gas, vol%

CO2gas CO2 content in unmixed gas, vol%

"( CO2gas – CO2mix

False air w.r.t. gas 100" /"CO2mix"
(based on CO2 analysis) FAGC (%)

CO2mix CO2 content in mixture of gas, vol%

CO2gas CO2 content in unmixed gas, vol%
& Efficiency (Assembled and edited By Alain G. RAAD Lebanon)
Formula Calculation
Variables
(3.2∗𝑃)/ P 5500
Deff 4.15
( 〖 𝐷𝑒𝑓𝑓〗 ^3∗𝑛∗𝑠) n 3.8
s 4

meter, mts
Results
DF 16.2003646

Method 1
Variables
(𝐹∗𝑁𝐶𝑉)/ F 10000
(𝐴∗ 〖 10 〗 ^6 ) NCV 6500
A 13.52

kcal/kg-fuel Results
al area, m2 TL 4.80769231
Method 2
Variables
(𝑃∗𝐻)/(𝐴∗2.4∗ 〖 10 〗 P 5500
^4 ) H 280
A 13.52

n kiln, kcal/kg-clinker Results

al area, m2 NPB 4.74605523
Variables
𝑃/(𝐴∗𝐿) P 5500
A 13.52
L 68

al area, m2 Results
VL 5.98242255
Variables
(19∗𝐿)/(𝐷𝑒𝑓𝑓∗𝑛∗𝑠) L 68
Deff 4.15
n 3.8
s 4

meter, mts
Results
RTK 20.4819277
Variables
(1.55∗𝐴∗𝑃𝑠)/𝑃 A 100
 (1.55∗𝐴∗𝑃𝑠)/𝑃
Ps 700
P 5500

l area, m2
oping area, mmWg Results
RTC 19.7272727
Variables
0∗(𝐶𝑂2+𝐶𝑂))/ CO2 36.5
CO 0.002
0+(1.89∗𝐶𝑂)−(4.78∗𝑂2))
O2 4.2

Results
TCO2 45.6687274
Variables
(79∗𝑂2)/ O2 2.8
(0.21∗(100−𝐶𝑂2)−𝑂2) CO2 26.5

Results
EA 17.5069252
Variables
T 244
t 25
〖 10 〗 ^(−8)∗(𝑇^4− 𝑡^4)

e ,C Results
RHL 2544.97272
Variables
T 170
t 25
𝑡)/2) 〗 ^(−0.724)∗ 〖 (𝑇−𝑡) 〗 ^1.333

e ,C Results
CHL 843.434526
Variables
T 170
)/2) -0.351
*v 0.805
*D -0.195
* ( T – t )" t 25
v 4.15
D 4
e,C

Results
mts FCHL 1222.9586
Variables
∗𝐴𝑠ℎ)/𝑃 CC 26
∗𝐴𝑠ℎ)/𝑃
Ash 15
P 208

basis), % Results
%AA 1.875
Variables
(100−%𝐴𝐴)/ %AA 1.74
(100−𝐿𝑂𝐼) LOI 35.58

Results
% RMCK 1.5253027
Variables
00 – %AA ) * 100" /"( 100 – LOI ) %AA 1.74
00 – DL )" LOI 35.5
DL 8.1

% Results
,% RMCS 1.65768319
Variables
085 * MgCO3 * RMCK )+ ( 222 * Al2O3 / ( 100 – LOI ) )" CaCO3 75.1
.6 * SiO2 / ( 100 – LOI ) ) – ( 59 * Fe2O3 / ( 100 – LOI ) )" RMCK 1.53
( 100 – LOI ) )– ( 79 * C * RMCK ) – ( 32 * S * RMCK ) MgCO3 1.6
LOI 34.5
% Al2O3 4.17
CH2O 1.05
,% SiO2 13.47
Fe2O3 2.41
K2O 0.38
ln feed, % Na2O 0.27
C 0.2
S 0.04

,% Results
ed, % HR 388.898703

Variables
"( O2mix – O2gas ) * O2mix 3.6
100" /"21 – O2gas" O2gas 2.8

s, vol% Results
vol% FAMO 4.3956044
Variables
 "( O2mix – O2gas ) * O2mix 3.6
100" /"21 – O2mix" O2gas 2.8

s, vol% Results
vol% FAGO 4.59770115
Variables
"( CO2gas – CO2mix ) * CO2mix 32.1
100" /"CO2gas" CO2gas 34.5

gas, vol% Results

s, vol% FAMC 6.95652174
Variables
"( CO2gas – CO2mix ) * CO2mix 32.1
100" /"CO2mix" CO2gas 34.5

gas, vol% Results

s, vol% FAGC 7.47663551
 Target

14 - 16

4.0 - 5.0

5.0 - 5.5

20 - 25

20 - 25
 20 - 25

10.0 - 15.0

-
 -

5.0 - 7.0

5.0 - 7.0
5.0 - 7.0

5.0 - 7.0

5.0 - 7.0