Alkali-sulfur (ASR)Quality Comparison

 Kiln feed SO3 & Alkali ratio in kiln feed, Hot meal & fuel mix

 As per standard Alkali Sulfur ratio (ASR) should be in the range of 1.0 to 1.1

 It has been seen that during run in Feb-March, it was maintained to near about 0.95 to 1.1

- SO3 in kiln feed was varying from 0.53 to 0.55 and Alkali (Na2O & K2O) was 0.81
- SO3 in the kiln feed maintained 0.4 to 0.45 and Alkali was 0.71
- Pet-coke ratio was 21-24 % and ash % was 25

 At present run of kiln the Sulfur and Alkali percentage

- SO3 in kiln feed is 0.53 to 0.58 and Alkali is 0.69 to 0.71 so as higher ASR is 1.3 to 1.5
- Pet-coke ratio is 17-20 % and Ash % is 34
 Kiln Feed Quality Analysis
Kiln Feed Quality
FEED
Date R212 Alkali
QUANTITY LOI (%) SiO2 (%) Al2O3 (%) Fe2O3 (%) CaO (%) MgO (%) SO3 (%) Na2O (%) K2O (%) LSF SM AM R90 (%) TC LSF SD
(MT) (%)

 
18-Jun 310 36.18 11.84 3.08 2.35 40.85 3.68 0.56 0.08 0.61 106.58 2.18 1.31 15.82 1.85 80.66 0.58 0.69
19-Jun 337 36.10 11.80 3.13 2.37 40.80 3.64 0.55 0.11 0.59 106.60 2.15 1.32 15.84 1.94 80.50 0.52 0.70
20-Jun 333 36.18 11.83 3.12 2.39 40.85 3.67 0.55 0.07 0.60 106.55 2.15 1.30 15.96 1.86 80.66 0.34 0.66
21-Jun 333 36.21 11.81 3.12 2.39 40.77 3.76 0.55 0.06 0.59 106.45 2.14 1.30 16.60 2.00 80.69 0.33 0.66
22-Jun 348 36.16 11.78 3.10 2.43 40.74 3.73 0.55 0.06 0.59 106.60 2.13 1.27 15.89 1.89 80.58 0.29 0.66
23-Jun 378 36.14 11.82 3.12 2.43 40.71 3.73 0.56 0.06 0.60 106.16 2.13 1.28 14.95 1.80 80.53 0.43 0.66
24-Jun 377 35.96 11.88 3.19 2.49 40.95 3.41 0.54 0.08 0.63 105.98 2.09 1.28 16.17 1.93 80.28 0.83 0.71
25-Jun 380 35.48 11.90 3.20 2.52 41.12 2.86 0.49 0.09 0.64 106.14 2.08 1.27 15.68 1.88 79.43 0.31 0.72
26-Jun 332 35.82 11.94 3.18 2.46 41.12 3.16 0.53 0.06 0.63 106.02 2.12 1.29 15.85 1.92 80.08 0.87 0.69
 
26-Feb 360 35.52 12.29 3.23 2.39 40.97 3.00 0.58 0.11 0.72 103.04 2.19 1.35 16.43 1.85 79.46 0.53 0.83
27-Feb 362 35.51 12.36 3.20 2.34 40.90 3.04 0.60 0.10 0.73 102.48 2.23 1.37 16.07 1.80 79.41 0.82 0.82
28-Feb 405 35.65 12.16 3.16 2.30 40.98 3.10 0.57 0.10 0.71 104.35 2.23 1.37 16.28 1.79 79.70 0.39 0.82
01-Mar 404 35.56 12.08 3.16 2.23 41.02 3.00 0.55 0.10 0.71 105.15 2.24 1.42 16.08 1.78 79.55 0.45 0.81
02-Mar 392 35.62 12.20 3.24 2.25 41.13 2.97 0.54 0.10 0.72 104.28 2.22 1.44 16.16 1.84 79.70 0.90 0.82
 
29-Mar 530 35.93 11.91 3.14 2.38 41.16 3.23 0.44 0.10 0.65 106.67 2.16 1.32 14.97 1.70 80.29 0.46 0.75
30-Mar 507 36.01 11.91 3.05 2.43 41.12 3.33 0.51 0.09 0.61 106.74 2.17 1.26 14.68 1.67 80.43 0.85 0.70
31-Mar 499 35.89 12.01 3.16 2.49 40.74 3.49 0.50 0.06 0.67 104.50 2.12 1.27 14.87 1.72 80.08 0.39 0.73
                                     
07-Mar 397 35.4 12.0 3.3 2.3 41.0 2.9 0.87 0.1 0.8 105.2 2.1 1.4 16.2 1.8 79.3 0.9 0.93
08-Mar 406 35.59 11.98 3.15 2.35 40.84 3.16 0.65 0.18 0.73 105.27 2.18 1.34 15.90 1.85 79.55 0.38 0.91
11-Mar 333 35.42 11.95 3.18 2.35 40.77 3.05 0.58 0.19 0.72 105.25 2.16 1.36 15.72 1.79 79.22 0.42 0.91
12-Mar 321 35.74 11.92 3.14 2.33 40.71 3.38 0.43 0.12 0.67 105.49 2.18 1.35 15.98 1.89 79.80 0.47 0.79
13-Mar 325 35.91 11.88 3.10 2.38 40.81 3.46 0.41 0.09 0.65 106.08 2.17 1.30 15.96 1.82 80.14 0.16 0.74
14-Mar 321 35.78 11.87 3.15 2.36 40.93 3.26 0.41 0.10 0.63 106.36 2.15 1.34 15.86 1.83 79.94 0.56 0.73
 Hot Meal -Quality Analysis
Hot Meal Analysis
Date Kiln Feed Na2O (%) K2O (%) SO3 (%) KF - LOI HM - LOI Calcinatio KF - LOI HM - LOI Calcinatio
Cl - (%) Na2O (%) K2O (%) SO3 (%) Cl - (%) Alkali SO3 ASR
(%) (%) n (%) (%) (%) n (%)

18-Jun 310 0.11 2.22 2.43 0.41 36.35 1.28 97.72 0.11 2.15 2.54 0.39 36.35 1.69 96.98 2.75 2.43 1.07
19-Jun 337 0.11 2.17 3.74 0.40 36.32 1.31 97.68 0.11 2.20 3.70 0.40 36.32 1.46 97.39 2.68 3.74 1.68
20-Jun 333 0.11 2.25 3.48 0.41 36.28 8.72 78.91 0.11 2.30 3.64 0.43 36.28 8.85 78.37 2.77 3.48 1.51
21-Jun 333 0.11 2.13 3.01 0.42 36.25 14.54 64.04 0.11 2.11 3.04 0.41 36.25 14.44 63.96 2.66 3.01 1.38
22-Jun 348 0.11 2.10 3.00 0.41 36.25 11.89 70.99 0.11 2.07 2.95 0.41 36.24 12.03 70.76 2.62 3.00 1.39
23-Jun 378 0.11 2.55 2.92 0.47 36.33 8.75 78.98 0.11 2.58 3.01 0.47 36.33 8.82 78.85 3.13 2.92 1.12
24-Jun 377 0.11 3.07 3.32 0.52 36.29 2.05 96.32 0.11 3.10 3.30 0.52 36.29 2.18 96.08 3.70 3.32 1.06
25-Jun 380 0.11 2.80 2.72 0.47 36.25 1.63 97.09 0.11 2.89 2.92 0.48 36.25 1.85 96.68 3.38 2.72 0.95
26-Jun 332 0.11 2.20 1.89 0.39 36.31 1.77 96.84 0.11 2.20 1.93 0.40 36.31 1.84 96.72 2.70 1.89 0.84

26-Feb 360 0.11 2.73 3.22 0.41 36.11 2.00 96.39 0.11 2.74 3.35 0.41 36.11 2.20 96.03 3.24 3.22 1.16
27-Feb 362 0.12 2.31 2.26 0.35 36.06 1.54 97.22 0.11 2.37 2.43 0.36 36.06 1.74 96.86 2.78 2.26 0.95
28-Feb 405 0.11 2.24 2.41 0.35 35.98 1.43 97.42 0.11 2.35 2.76 0.36 35.98 2.07 96.23 2.70 2.41 1.05
01-Mar 404 0.11 2.54 2.64 0.39 36.11 1.84 96.68 0.11 2.52 2.69 0.40 36.11 1.96 96.46 3.04 2.64 1.02
02-Mar 392 0.11 2.49 2.41 0.38 36.07 1.66 97.01 0.11 2.55 2.45 0.39 36.07 1.59 97.13 2.98 2.41 0.95

07-Mar 397 0.20 2.63 2.73 0.39 35.95 1.29 97.67 0.12 2.65 2.81 0.40 35.95 1.31 97.64 3.22 2.73 1.00
08-Mar 406 0.12 2.93 3.75 0.46 36.15 1.52 97.27 0.12 2.80 3.41 0.44 36.15 1.70 96.95 3.51 3.75 1.25
11-Mar 332 0.12 2.40 2.60 0.38 36.10 1.46 97.38 0.12 2.27 2.65 0.36 36.10 1.46 97.38 2.90 2.60 1.06
12-Mar 321 0.11 2.22 2.35 0.37 36.40 1.42 97.48 0.11 2.29 2.42 0.37 36.40 1.57 97.22 2.70 2.35 1.03
13-Mar 324 0.11 2.08 2.19 0.34 36.01 1.57 97.17 0.11 2.10 2.25 0.34 36.01 1.73 96.87 2.54 2.19 1.02
14-Mar 321 0.11 1.85 2.21 0.32 36.10 1.10 98.04 0.11 1.85 2.26 0.32 36.10 1.26 97.74 2.28 2.21 1.16
                                     
29-Mar 530 0.11 3.22 2.37 0.50 36.20 1.50 97.32 0.11 3.20 2.33 0.50 36.20 1.54 97.23 3.83 2.37 0.72
30-Mar 507 0.11 3.20 2.04 0.51 36.33 1.37 97.57 0.11 3.11 1.98 0.50 36.33 1.41 97.50 3.82 2.04 0.63
31-Mar 499 0.11 2.80 1.91 0.44 36.19 1.02 98.19 0.11 2.79 2.05 0.44 36.19 1.00 98.21 3.34 1.91 0.67
 Fuel Mix- Analysis
Fuel Mix
R#90µ
Date IND IMP PET TOTAL R#212µ (%) ASH (%)
(%)

               
18-Jun 84   16 100 4 0 35.0
19-Jun 83   17 100 5 0 35.5
20-Jun 80   20 100 4 0 31.4
21-Jun 79   21 100 4 0 30.9
22-Jun 79   21 100.00 4.90 0.06 30.2
23-Jun 79   21 100.00 3.80 0.00 31.5
24-Jun 81   19 100.00 4.35 0.02 30.7
25-Jun 85   16 100.00 4.38 0.00 31.0
26-Jun 83   17 100 4.16 0.00 32.9
               
26-Feb 75   25 100.00 7.47 0.20 26.0
27-Feb 75   25 100.00 7.25 0.23 27.5
28-Feb 75   25 100.00 8.48 0.20 26.4
01-Mar 78   22 100.00 8.52 0.24 27.5
02-Mar 79   21 100.00 7.65 0.33 27.9
               
07-Mar 79   21 100.0 7.9 0.2 26.9
08-Mar 83   17 100.0 8.4 0.2 28.1
11-Mar 80   21 100.0 8.1 0.2 27.9
12-Mar 75   25 100.0 8.3 0.2 25.9
13-Mar 77   24 100.0 8.5 0.3 25.6
14-Mar 81   20 100.00 6.89 0.13 27.9
 Heat Balance at 5500 TPD
             
        Date 24.06.2023  
  Cooler - Indicative Mass and Heat Balance
  Pyroprocessing - Indicative Mass and Heat Balance  
    RCCPL,MP BIRLA CEMENT            
  Kiln Feed 360 TPH Amb. Temp. 31  
  HEAT INPUT Relative to 0 Deg C  
  Factor 1.56        
  Production 5538 TPD            
             
  Mass flow Temperature Specific heat Heat (ref 0˚C)  
             
  Heat Input relative to 0 deg C       kg/kg cl deg C kcal/kg oC kcal/kg clinker  

    Mass flow Sp.heat capacity Temperature Heat     Clinker 1.0 1400 0.276 387  
    kg/kg clinker Kcal/kg degC deg C kcal/kg Clinker     Dust 0.05 1400 0.276 19.3  
  Sensible heat of Kiln Feed 1.56 0.236 65 23.89  
  Cooling air 12 nos 2.10 34 0.242 17.0  
  Sensible heat of Cooling air 2.71 0.242 31 20.33  
  Sensible Heat of PH Leak Air 0.13 0.247 31 1.00     Fan energy       4.44  
  Sensible heat of Fuel 0.15 0.286 65 2.70  
   
  Total Heat Input 3.15 428  
  Sensible heat of primary 0.04 0.242 104 0.90  
  Sensible heat of Coal Conveying air 0.10 0.243 73 1.68        
  Sensible Heat from Kiln feed moisture 0.002 0.447 65 0.07     HEAT OUTPUT Relative to 0 Deg C  
  Sensible Heat from coal moisture 0.002 0.447 65 0.07  
     
  Total Input 4.68     51  
                Mass flow Temperature Specific heat Heat  
  Heat Output relative to 0 deg C       kg/kg cl deg C kcal/kg oC kcal/kg clinker  
    Mass flow Sp.heat capacity Temperature Heat  
  Secondary air 0.49 980 0.334 161.9  
    kg/kg clinker Kcal/kg degC deg C Kcal/kg clinker  
  Tertiary air 0.47 936 0.334 147.6  
  Heat of PH Exit Gases 2.10 0.244 345 176.4  
  Heat of PH Exit Dust 0.06 0.251 345 5.4     WHR AQC air   0.46 364 0.316 52.7  
  Heat of reaction       427.62  
  ESP tap1 air 0.34 185 0.316 19.9  
  Heat Through AQC whrs 0.59 0.247 364 53.30  
  Heat Through Cooler Vent 1 0.44 0.244 185 19.9     ESP tap2 air 0.36 164 0.316 18.6  
  Heat Through Cooler Vent 2 0.46 0.244 164 18.6  
  Clinker 1.00 109 0.207 22.6  
  Heat Through Clinker 1.00 0.209 109 22.9  
  Heat from Cooler exit dust 0.02 0.209 185 0.7     Heat of Cooler Exit Dust 0.02 220 0.209 1.1  
  Radiation Loss from Preheater       29.5     Radiation       4.0  
  Radiation Loss from TAD       2.5  
   
  Total Heat output 3.15 428  
  Radiation Loss from Kiln       18.50  
               
  Radiation Loss from Cooler       2.5  
               
  Total Output 4.68     778  
             

  Specific Fuel Consumption 727  

 Heat Balance at 5500 TPD
 Maintaining higher oxygen level to mitigate the SO3 recirculation

(Total cooling air 2.10 Nm3/kg cl)

 False air – 6.25 % (Near to our target), With false air sealing job being taken by applying the sealing
material

 PH exit temp is higher (i.e. 345 Deg C against standard 270 Deg C) resulting higher loss of heat.

 Specific fuel consumption is – 727 Kcal/kg Cl