Date 31-Jul-23

PH Fan Flow Calculations L-2

Time 9:40 hrs
PH Fan speed RPM 801
Dynamic pressure mmwc 5.39
Static Pressure mmwc -529
Temperature ⁰C 341
Density Kg/m3 0.55
Duct Dia m 4.500
Area m2 15.904
Velocity m/Sec 11.77
m3/Sec 187
PH fan Inlet Flow m3/hr 674,013
Nm3/hr 264,774
Sp. Air Nm3/Kg clk. 1.977
Kiln feed output TPH 221
Clinker KGPH 133939
PH BoilerI/L damper (Open) % 0
PH bypass damper (Open) % 100
Inlet pressure mmwg 0
Outlet pressure mmwg 0
Fan power KW 833.9
fan efficiency % 0.000
1 5
2 5
3 6
4 5
5 6
6 6
7 6
8 5
9 7
10 6
Dynamic pressure
11 3
12 3
13 3
14 2
15 7
16 6
17 5
18 6
19 5
20 7
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
25
25
36
25
36
36
36
25
49
36
9
9
9
4
49
36
25
36
25
49
 29
5.3851648071345
Gas Comp. (%)
O2 5.48
CO 0.0014
CO2 19.95
N2 74.5686

Final density
(kg /Nm3)
0.078
0.000
0.392
0.932
1.40
25-Oct-23 10-Jan-24
12:10 hrs 11:50
786 715
4.49 4.30
-530 -620
285 166
0.64 0.80
4.500 4.500
15.904 15.904
9.99 8.71
159 139
571,776 498,947
247,127 271,404
1.451 1.652
281 271
170303 164242
0 0
100 100
-530 -620
-68 -28
900 1054
86.883 82.955
4
3
4
3 5
4 4
5 3
4 3
5 4
5 4
5 3
4 5
4 4
5 4
5 4
6 5
5 5
5 6
4
5
4
4

16
9
16
9 25
16 16 Pb (mmwc)
25 9
16 9
25 16
25 16
25 9
16 25
16 16
25 16
25 16
36 25
25 25
25 36
16
25
16
16
20.1428571428571 18.5
4.48807944925857 4.30116263352131
Comp. (%) Comp. (%)
4.08 4.08
0.0056 0.0056
30.63 30.63
65.2844 65.2844

Final density Final density

(kg /Nm3) (kg /Nm3)
0.058 0.058
0.000 0.000
0.602 0.602
0.816 0.816
1.48 1.48
 Date 31-Jul-23
Esp Stack Flow Calculations L-2 Time 10:45 hrs
ESP Fan speed RPM 150
Dynamic pressure mmwc 1.24
Static Pressure mmwc 4
Temperature ⁰C 152.3
Density Kg/m3 0.78
Duct Dia m 4.00
Area m2 12.57
Velocity m/Sec 4.77
m3/Sec 60
Esp outlet Flow m3/hr 215,728
Nm3/hr 129,486
Corrective density at ESP Fan I/L Kg/m3 0.88
Flow at ESP Fan I/L Nm3/hr 123,012
Esp Fan I/L m3/hr 179,774
Sp. Air Nm3/Kg clk. 1.34
Kiln feed output TPH 221
Clinker KGPH 133939
AQC BoilerI/L damper (Open) % 0
AQC bypass damper (Open) % 100
Inlet pressure mmwg
Outlet pressure mmwg
Fan power KW
fan efficiency % #DIV/0!
1 0
2 1
3 1
4 1
5 1
6 1
7 1
8 1
9 1
10 1
Dynamic pressure
11 1
12 1
13 1
Dynamic pressure

14 1
15 2
16 2
17 2
18 2
19 1
20 1

0
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
1
1

Gas Comp. (%)

O2 21
CO 0.0145
CO2 15.69
N2 63.2955

Final density
(kg /Nm3)
0.300
0.000
0.308
0.791
1.29
25-Oct-23 10-Jan-24
11:25 hrs 11:30 hrs
429 377
7.84 6.16
-50 -82
240 111
0.64 0.85
3.00 3.00
7.07 7.07
13.18 10.12
93 72
335,354 257,552
165,945 169,693
0.88 0.88
157,648 161,208
230,393 235,596
1.35 1.43
281 271
170303 164242
0 100
100 0
-50 -82
5 18
135 135
27.8 51.7
7 5
9 6
8 7
10 7
7 8
8 7
8 6
9 6
7 5
8 6
9 6
9 6
10 5
 11 6
9 5
8 6
6 5
6
7
7

49 25
81 36
64 49
100 49 PH fan inlet density 08
49 64 Pb (mmwc)
64 49
64 36
81 36
49 25
64 36
81 36
81 36
100 25
121 36
81 25
64 36
36 25
0 36
0 49
0 49

Comp. (%) Comp. (%)

21 21
0.0145 0.0145
15.69 15.69
63.2955 63.2955

Final density Final density

(kg /Nm3) (kg /Nm3)
0.300 0.300
0.000 0.000
0.308 0.308
0.791 0.791
1.29 1.29
inlet density 08.12.2019
 Raw Mill Fan L2

Static Pr. 10336

Br. Pr. 10266.4474318234

Effective Nozzle Ring Area NO Load

S.No Parameter Design Unit 6/29/2023

1 I/L Duct Dia 3.4 m 3.4

2 Area 9.1 m2 9.1

3 Avg. Diff Pr. mmwc 39.54

4 Fan I/L Temp 85 68

5 Fan inlet Static Pressure mmwc -1270 -560

6 Fan outlet Static Pressure mmwc -20 -40

7 Reference Density Kg/Nm3 1.35 1.34

8 Density Kg/m3 0.85-0.87 0.94

9 Air Flow m3/hr 650000 795762.49

10 Air Flow Nm3/hr 560955.41

11 Dust Load gm/m3 419.72

12 Raw mill feed TPH

13 Fan Speed RPM 980 750

14 Motor Kw 3200 1434

15 Fan Efficiency % 75.2 82.72

Nozzle Area m2 3.06

Nozzle Velocity gm/m3 m/s 50.92
45
40
39
41
35
29
42
41

43
39
42
38
40
41
41
37
46
48
42
31
42
31
36
41
37
43
44
38
42
43
35
41
32
29
38
46
47
51
55
38
47
 45
42
39
31
27
28
31
2025
1600
1521
1681
1225
841
1764
1681
1849
1521
1764
1444
1600
1681
1681
1369
2116
2304
1764
961
1764
961
1296
1681
1369
1849
1936
1444
1764
1849
1225
1681
1024
841
 1444
2116
2209
2601
3025
1444
2209
2025
1764
1521
961
729
784
961
1601.4375
40.0179647159
Gas
O2
CO
CO2
N2
8/2/2023 10/31/2023 1/23/2024

3.4 3.4 3.4

9.1 9.1 9.1

25.92 22.15 17.62

79.9 67.2 62

-763.5 -860 -840

-40 -25 -52

1.373 1.411 1.425

0.91 0.96 0.99

655023.26 589582.53 518509.52

436197.54 402858.44 360611.77

549.60 644.52 732.87

360.00 380.00 380.00

750 761 730

1307 1350 1240

103.94 104.54 94.46

2.80 2.80 2.80

64.98 58.49 51.44
29 25 20
25 24 18
24 24 15
25 21 16
23 23 18
24 22 16
26 22 16
25 21 18

30 22 19

29 20 20

23 19 16

26 21 18

28 24 19

27 20 22

29 23 20

20 22 19

19 26 18

25 27 19

27 26 17

33 27 18

35 26 19

36 28 21

32 27 20

27 21 24

29 22 20

26 24 18

29 23 18

31 22 20

30 25 21

27 21 22

28 25 21

29 26 18

27 24 20

26 24 21

28 27 23

27 26 22

25 24

22 20

21 23

24 24

22 23
 24 19

24 19

26 15

23 14

25 16

24 19

25 18

841 625 400

625 576 324

576 576 225

625 441 256

529 529 324

576 484 256

676 484 256

625 441 324

900 484 361

841 400 400

529 361 256

676 441 324

784 576 361

729 400 484

841 529 400

400 484 361

361 676 324

625 729 361

729 676 289

1089 729 324

1225 676 361

1296 784 441

1024 729 400

729 441 576
841 484 400
676 576 324
841 529 324
961 484 400
900 625 441
729 441 484
784 625 441
841 676 324
729 576 400
676 576 441
 784 729 529
729 676 484
0 625 576
0 484 400
0 441 529
0 576 576
0 484 529
0 576 361
0 576 361
0 676 225
0 529 196
0 625 256
0 576 361
0 625 324
569.625 563.770833333 376.541666667
23.8668179697 23.7438588552 19.4046815657
Comp. (%) Comp. (%) Comp. (%)
11.61 9.25 7.72
0.0023 0.0033 0.0044
14.26 20.24 22.61
74.1277 70.5067 69.6656
Final density Final density Final density
(kg /Nm3) (kg /Nm3) (kg /Nm3)
0.1659069 0.1321825 0.1103188
0.00002875 0.00004125 0.000055
0.2800664 0.3975136 0.4440604
0.92659625 0.88133375 0.87082
1.3725983 1.4110711 1.4252542
Static Pr. Coal Mill
10336Fan Performance
Coal Mill Fan No Load
Mean Sea Level 538
Barometric Pressure 9661
Parameter Unit 6/28/2023 8/2/2023 11/6/2023
I/L Duct Dia m 1.7 1.7 1.7
Area m2 2.27 2.27 2.27
Feed TPH 0.00 29.00 31.50
MD Load A 0.00 529.00 563.00
Sep RPM RPM 700.00 941.00 901.00
Avg. Diff Pr. mmwg 25.9 19.1 17.8
Fan I/L Temp ˚C 62.8 62.8 66.5
Static Pressure mmwg -592 -640 -655
mmwg 10 40 18
Fan outlet Static Pressure mmwg
Kg/NM3 1.34 1.38 1.42
Density Kg/M3 0.96 0.98 1.00
Air Flow M3/Hr 159,824 135,658 130,044
Air Flow Nm3/hr 114,009 96,258 91,117
Fan Speed RPM 800 751 741
Motor KW 384.75 355 358.2
Fan Efficiency % 74.02 76.92 72.32
Dust Load gm/m3 0.00 213.77 242.23
Area Of One Nozzle m2 0.0177 0.0177 0.0177
Nozzle Area m2 0.85 0.64 0.64
Nozzle Velocity m/s 52.23 59.11 56.66
23 28 16
25 20 21
19 21 25
20 22 22
20 21 23
21 20 21
26 17 22
30 16 19
31 14 15
34 15 13
32 16 14
36 21 10
24 22 11
33 20 12
32 22 16
28 25 19
29 26 21
27 24 18
26 23 19
31 14 16
32 16 13
29 17 11
28 18 20
27 19 17
25 20 18
24 17 19
21 19 18
30 20 16
31 18 23
529 784 256
625 400 441
361 441 625
400 484 484
400 441 529
441 400 441
676 289 484
900 256 361
961 196 225
1156 225 169
1024 256 196
1296 441 100
576 484 121
1089 400 144
1024 484 256
784 625 361
841 676 441
729 576 324
676 529 361
961 196 256
1024 256 169
841 289 121
784 324 400
729 361 289
625 400 324
576 289 361
441 361 324
900 400 256
 669.714285714 365.357142857 318.214285714
25.8788385697 19.114317745 17.8385617614
c Comp. (%) Comp. (%) Comp. (%)
O2 16 10.31 8.36
CO 0.041 0.0027 0.0039
CO2 9 16.19 22.2
N2 74.959 73.4973 69.4361

Final density Final density Final density

(kg /Nm3) (kg /Nm3) (kg /Nm3)
0.229 0.147 0.119
0.001 0.000 0.000
0.177 0.318 0.436
0.937 0.919 0.868
1.34 1.38 1.42
1/1/2024
1.7
2.27
27.50
503.00
941.00
20.0
64.54
-627
32

1.42
1.01
137,106
96,923
741
376.6
71.02
200.58
0.0177
0.55
69.69
20
22
16
22
20
18
17
20
22
21
20
21
20
17
24
23
20
21
20
18
25
26
25

400
484
256
484
400
324
289
400
484
441
400
441
400
289
576
529
400
441
400
324
625
676
625
400.230769231
20.0057683989
Comp. (%)
8.36
0.0039
22.2
69.4361

Final density
(kg /Nm3)
0.119
0.000
0.436
0.868
1.42
Altitude 538 m
Barometric pressure Pb 9661 mmwc
KILN FEED 281 TPH
CLINKER PROD. 187.3 TPH
CLINKER PROD. 4496 TPD

Flow measurment with PITOT

Blower(482BL-1) Axial Air
Motor speed (Max 1490) 1295 rpm
Motor Load 144 amp
Pressure 5491 mmwc
Temperature 91.5 °C
Air Density 1.42 kg/m3
Filter Area 0.20 m²
Air speed 2.30 m/s
Air flow 0.46 m3/s
Air flow 1651 m3/hr
Air flow 0.65 kg/s
Air flow calculated 1504 Nm3/h

Parameters Unit Design

Swirl position % 0-100
Primary air pressure at Burner inlet mbar 461
Primary single air flow rate Nm3/hr 6758
Central air pressure at Burner inlet mbar 80
Central air flow Nm3/hr
Coal conveying air pressure at Burner inlet mbar 23
Coal conveying air flow Nm3/hr 2500
Coal conveying tip exit velocity m/s 29
LHV of Fuel(100% Australian) KCal/kg 8000
Pet-coke/Australian coal %/% 100 / 0
Kiln inlet oxygen % >3
Fine coal in Kiln firing TPH 8.46
Burner Power MW 79
Total combustion air required Nm3/hr 84500
Primary air % 8.0
Central air % 0.0
Axial air % 70.00
Radial air % 30.00
Coal conveying air % 3.0
Total primary air inclusive conveying air % 10.96
Site atmospheric pressure Pa 966116
Single air pressure at burner inlet Pa 46100
Specific Momentum N/MW 3.1

Parameters Flow (m3/Sec) Area (m2)

Axial+Central 3173.318 0.002769
Radial 0.000 0.002688
Transport air 0.245 0.04164573761415
Total Burner momentum (%m/sec) 2945026
 Dat

Blower(482BL-3) Radial Air Coal transport air Blower (482BL-06) Ki

Motor speed (Max 1490) 1244 rpm Motor speed
Motor Load 73 amp Motor Load
Pressure 995 mmwc P
Temperature 47.7 °C T
Air Density 1.13 kg/m3 ΔP
Filter Area 0.11 m² Factor
Air speed 6.80 m/s Filter Dimension
Air flow 0.77 m3/s Filter Area
Air flow 2785 m3/hr Air density
Air flow 0.88 kg/s Air speed
Air flow calculated 3173 Nm3/h Air flow
Air flow
Measured Air flow
0 Air flow calculated
5491
1504
36 7 8

40 171.767284428671
1072
6
6245
00/100
2.5
7.50
54
58498
2.6
0.0
70.00
30.00
1.8
4.40
966116
549100
3.8

Air % Nozzle velocity Momentum

2.57 1145817.21 2945014.92
0.00 0.00 0.00
1.83 5.89 10.80
 Dated: 22.05.2022

Coal transport air Blower (482BL-06) Kiln Coal transport air Blower (482BL-05) Precalciner
1400 rpm Motor speed 1220
28 Amp Motor Load 115
1844 mmwc P 5000
50 °C T 80
mbar ΔP
1.21 Factor 1.42
mm Filter Dimension 0.52*0.52
0.07 m² Filter Area 1.08
1.21 kg/m3 Air density 1.42
3.30 m/s Air speed 1.60
0.245 m3/s Air flow 1.731
884 m3/hr Air flow 6230
0.30 kg/s Air flow 2.45
1072 Nm3/h Air flow calculated 6738

0.2454375
9 12 13 14 13

4
3.735
(482BL-05) Precalciner
rpm
kw
mmwc
°C 1.7
mbar 1.7
1.8
mm 2.1
m²
kg/m3
m/s
m3/s
m3/hr
kg/s
Nm3/h

12 11 9 10 11 12 13 11
Coal Mill
Date 11/6/2023
Inlet 5.14
Outlet 7.8
Fan Inlet 8.42
Fan Outlet 8.37
% False air 20.31
Across circuit 25.78

Raw Mill 11/6/2023 1/23/2024

PH fan outlet 3.54
Inlet 7.31 5.63
Mill outlet 7.60
Fan Inlet 9.25 7.72
Fan Outlet 9.4 7.75
% False air 16.70 15.86
Across circuit 18.22 16.12
Altitude 538 m
Barometric pressure Pb 9661 mmwc
KILN FEED 120 TPH
CLINKER PROD. 80.0 TPH
CLINKER PROD. 1920 TPD

Flow measurment with PITOT

Blower(482BL-1) Axial Air
Motor speed (Max 1490) 1160 rpm
Motor Load 49 kw
Pressure 4020 mmwc
Temperature 91.5 °C
Air Density 1.28 kg/m3
Filter Area 0.20 m²
Air speed 2.00 m/s
Air flow 0.40 m3/s
Air flow 1436 m3/hr
Air flow 0.51 kg/s
Air flow calculated 1448 Nm3/h

Parameters Unit Design

Swirl position % 0-100
Primary air pressure at Burner inlet mbar 461
Primary single air flow rate Nm3/hr 6758
Central air pressure at Burner inlet mbar 80
Radial air flow Nm3/hr
Coal conveying air pressure at Burner inlet mbar 23
Coal conveying air flow Nm3/hr 2500
Coal conveying tip exit velocity m/s 29
LHV of Fuel(100% Australian) KCal/kg 8000
Pet-coke/Australian coal %/% 100 / 0
Kiln inlet oxygen % >3
Fine coal in Kiln firing TPH 8.46
Burner Power MW 79
Total combustion air required Nm3/hr 84500
Primary air % 8.0
Radial Air % 0.0
Axial air % 70.00
Radial air % 30.00
Coal conveying air % 3.0
Total primary air inclusive conveying air % 10.96
Site atmospheric pressure Pa 966116
Single air pressure at burner inlet Pa 46100
Specific Momentum N/MW 3.1

Parameters Flow (m3/Sec) Area (m2)

Axial 0.399 0.002769
Radial 3.783 0.002688
Transport air 2.291 0.04164573761415
Total Burner momentum (%m/sec) 51382
 Dat

Blower(482BL-4) Radial Air Coal transport air Blower (482BL-06) Ki

Motor speed (Max 1490) 1480 rpm Motor speed
Motor Load amp Motor Load
Pressure 2200 mmwc P
Temperature 47.7 °C T
Air Density 1.26 kg/m3 ΔP
Filter Area 0.48 m² Factor
Air speed 7.90 m/s Filter Dimension
Air flow 3.78 m3/s Filter Area
Air flow 13617 m3/hr Air density
Air flow 4.77 kg/s Air speed
Air flow calculated 13939 Nm3/h Air flow
Air flow
Measured Air flow
0 Air flow calculated
4020
1448
36 7 8
13939
40 144.055544842953
9204
55
6600
00/100
1.5
4.00
31
39567
3.7
35.2
70.00
30.00
23.3
62.15
966116
402000
4.4

Air % Nozzle velocity Momentum

3.66 143.98 526.91
35.23 1407.19 49575.16
23.26 55.01 1279.73
 Dated: 22.05.2022

Coal transport air Blower (482BL-06) Kiln Coal transport air Blower (482BL-05) Precalciner
1400 rpm Motor speed 1220
26 KW Motor Load 115
1297 mmwc P 5000
50 °C T 80
mbar ΔP
1.16 Factor 1.42
mm Filter Dimension 0.52*0.52
0.31 m² Filter Area 1.08
1.16 kg/m3 Air density 1.42
7.40 m/s Air speed 1.60
2.291 m3/s Air flow 1.731
8248 m3/hr Air flow 6230
2.65 kg/s Air flow 2.45
9204 Nm3/h Air flow calculated 6738

2.29104
9 12 13 14 13

4
3.735
(482BL-05) Precalciner
rpm
kw
mmwc
°C 1.7
mbar 1.7
1.8
mm 2.1
m²
kg/m3
m/s
m3/s
m3/hr
kg/s
Nm3/h

12 11 9 10 11 12 13 11
Static Pr. 10336

Br. Pr. 9509.04020872928

Effective Nozzle Ring Area

S.No Parameter Design Unit 1/23/2024

1 I/L Duct Dia m 5

2 Area m2 19.6

3 Avg. Diff Pr. mmwc 2.12

4 Fan I/L Temp 70

2 Stack Static Pressure mmwc -86

3 Fan outlet Static Pressure mmwc 5

5 Reference Density Kg/Nm3 1.43

6 Density Kg/m3 1.03

8 Kg/Nm3

9 Air Flow m3/hr 380916.08

11 Air Flow Nm3/hr 276398.94

12 Dust Load gm/m3 876.83

13 Nozzle Velocity m/sec 5.39

14 Fan Speed RPM 300

15 Motor Kw 101

16 Fan Efficiency % 101.59

2
3
2
2
3
2
2
2
2

2
3
2
1
2
2
1
2
2

4
9
4
4
9
4
4
4
4
4
9
4
1
4
4
1
4
 4

4.5
2.1213203435596
c Comp. (%)
O2 8.16
CO 0.039
CO2 22.55
N2 69.251

Final density
(kg /Nm3)
0.117
0.000
0.443
0.866
1.43