WHR Calculation For Cement Kiln

Ambient temp deg C
1 Raw materials
Moi in feed Raw materials %
To be dried to %
Water to be evaporated product kg/kg rawmeal
Water injection kg/kg rawmeal
Heat required to evaporate water kcal/kg water
Temp after raw mill deg C
Heat required to heating product to outlet
temp kcal/kg rawmeal
Heat required/kg rawmeal kcal/kg rawmeal
2 Coal
Moi in coal
To be dried to
Water to be evaporated kg/kg
Water injection kg/kg coal
Temp after coal mill deg C
Heat required/kg coal kcal/kg coal
3 Cement
Moisture in feed
To be dried to
Water to be evaporated kg/kg
Water injection kg/kg cement
Temp after cement mill deg C
Heat required/kg cement kcal/kg cement
To convert heat required in kcal/kg

4 clinker
Ratio raw material/clinker
Calorific kcal/kg coal
Ratio coal/clinker kg coal/kg clinker
Heat consumption kcal/kg clinker
Coal using kg/kg clinker
Factor for running hours

Kiln output t/d
Rawmill capacity t/h
Coalmill capacity t/h
Rawmeal t/h
Finecoal t/h
Kiln hours
Rawmill hours h/day
Coal mill hours h/day
Factor for rawmill running
Factor for coalmill running
Raw mill
kg rawmeal/kg clinker
Heat for rawmeal kgcal/kg rawmeal
Heat required for raw materials kcal/kg clinker
Coal
Ratio coal/clinker kg/kg clinker
Factor for coalmill running
Heat for drying coal kcal/kg coal
Heat required for drying coal kcal/kg clinker
Cement
Required ratio of cement product/clinker kgcement/kg clinker
Heat required for dryring cement kcal/kg clinker
Kilngas
Temp degC
cp kJ/(Nm3K)
Vol Nm3/kg cli
Cooler exhaust gas

Temp degC
cp kJ/(Nm3K)
Vol Nm3/kg cli
Heat in waste gases from preheater (from

kilngas temp deg C to temp after mill) kcal/kg clinker
Heat in cooler vent (from cooler vent air
temp degC to temp after cement mill) kcal/kg clinker
Total kcal/kg clinker
Less heat required for drying with above

mentioned moisture of raw materials and
coal. Heat required for drying would be:
for drying rawmaterials kcal/kg clinker
for drying coal kcal/kg clinker
Total kcal/kg clinker
Net heat available for cogeneration from
preheater kcal/kg clinker
MW
for drying cement, 2 lines kcal/kg clinker
Net heat available for cogeneration from

cooler kcal/kg clinker
MW
Net heat available for cogeneration kcal/kg clinker
MW
Changing ratio of power %
Power generator MW
Total
Actual generator MW
Fan 1 m3/h
Fan 2 m3/h
Fan 3 m3/h
Fan 4 m3/h
Fan 5 m3/h
Fan 6 m3/h
Fan 7 m3/h
Fan 8 m3/h
Fan 9 m3/h
Fan 10 m3/h
Fan 11 m3/h
Actual Q m3/h
Std Q Nm3/h
Cooling air ratio Nm3/kg cli
Secondary air Nm3/kg cli
Ter air Nm3/kg cli
% gas to WHR
Gas to WHR Nm3/kg cli
Kiln 1 Kiln 2 Sunny Rainy
30.00 30.00 30.00 30.00
2.19% 2.19% 2.19% 7.00%

0.20% 0.20% 0.20% 0.20%
0.0199 0.0199 0.0199 0.0681
- 0.0040 0.0111 0.0111
665.28 665.28 665.28 665.28
80.00 80.00 80.00 80.00
10.23 10.23 10.23 10.23
23.50 26.16 30.89 62.95
11.00% 11.00% 7.16% 7.16%

1.75% 1.75% 1.00% 1.00%
0.0941 0.0941 0.0623 0.0623
- - 0.0444 0.0444
911.75 911.75 911.75 911.75
55.00 75.00 80.00 80.00
5.02 15.29 16.37 16.37
90.86 101.13 113.67 113.67
0.20% 0.20% 0.20% 0.20%

0.10% 0.10% 0.10% 0.10%
0.0010 0.0010 0.0010 0.0010
- - 0.0250 0.0250
665.28 665.28 665.28 665.28
88.00 88.00 80.00 80.00
- - - -
0.67 0.67 17.30 17.30
1.58 1.58 1.58 1.58

6,750 6,750 6,750 6,750
0.1156 0.1156 0.1156 0.1156
780.00 780.00 780.00 780.00
0.1156 0.1156 0.1156 0.1156
2,750 12,500 6,100 6,100

220 860 450 450
28.00 100.00 45.00 45.00
215.61 842.85 441.03 419.34
25.36 90.59 42.20 42.20
24.00 24.00 24.00 24.00
20.15 23.43 21.85 22.98
12.53 15.95 16.70 16.70
0.84 0.98 0.91 0.96
0.52 0.66 0.70 0.70
1.33 1.54 1.44 1.51

23.50 26.16 30.89 62.95
31.17 40.35 44.44 95.26
0.1156 0.1156 0.1156 0.1156

0.060 0.077 0.080 0.080
90.86 101.13 113.67 113.67
5.48 7.76 9.14 9.14
0.71 0.71 0.71 0.71

- - 12.29 12.29
345 345 345 345

1.5101 1.5101 1.5101 1.5101
1.40 1.40 1.40 1.40
400.00 400.00 400.00 400.00

1.3311 1.3311 1.3311 1.3311
0.47 0.47 0.47 0.47
134.03 134.03 134.03 134.03
47.14 47.14 48.35 48.35

181.17 181.17 182.38 182.38
31.17 40.35 44.44 95.26

5.48 7.76 9.14 9.14
36.66 48.12 53.58 104.40
97.38 85.91 80.45 29.63
12.96 51.96 23.74 8.75
- - 24.58 24.58
47.14 47.14 23.76 23.76
6.27 28.51 7.01 7.01
144.51 133.05 104.21 53.40
19.2 80.5 30.8 15.8

21.00 21.00 21.00 21.00
4.04 16.90 6.46 3.31
20.93
22.00 6.79 3.48
9,000 9,000
40,000 40,000
29,000 29,000
29,000 29,000
50,000 50,000
60,000 60,000
54,000 54,000
52,000 52,000
70,000 70,000
60,000 60,000
80,000 80,000
323,000 323,000
291,020 291,020
1.14 1.14
0.33 0.33
0.40 0.40
90% 90%
0.37 0.37 V
94,930
9,480.00
21.07
Kiln gas analysis t^0 t^1 t^2
CO2 31.00 c p,CO2 0.2852 1.63 0.000963 -4.61E-07
N2 66.00 c p,N2 0.6072 1.30 3.05E-05 9.65E-08
O2 3.00 c p,O2 0.0276 1.30 0.000192 -9.4E-09
H2O 8.00 c p,H2O 0.0800 1.49 9.52E-05 2.02E-07
cp kilngas 1.41 0.00 (0.00)
V kilngas 160,417
Enthalpy kilngas 21533
1.410809 0.000306 -5.69E-08
Kiln gas analysis t^0 t^1 t^2

CO2 31.00 c p,CO2 0.2852 1.63 0.000963 -4.61E-07
N2 66.00 c p,N2 0.6072 1.30 3.05E-05 9.65E-08

O2 3.00 c p,O2 0.0276 1.30 0.000192 -9.4E-09
H2O 8.00 c p,H2O 0.0800 1.49 9.52E-05 2.02E-07
cp kilngas 1.41 0.00 (0.00)
V kilngas 729,167
Enthalpy kilngas 97878
1.410809 0.000306 -5.69E-08
temp MW Effective Power gen

500 11.8662902228 25% 2.97
t^3
8.9E-11
-3.22E-11
-1.01E-11
7.35E-11
0.00 1.51
1.51
1.14E-11
t^3
8.9E-11
-3.22E-11
-1.01E-11
7.35E-11
0.00 1.51
1.51
1.14E-11

WHR Calculation For Cement Kiln

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What factors affect the heat requirements for drying raw materials and coal?

What factors affect the heat requirements for drying raw materials and coal?

How is the net heat available for cogeneration calculated?

How is the net heat available for cogeneration calculated?

Ambient temp deg C

To convert heat required in kcal/kg

Factor for running hours

Cooler exhaust gas

Heat in waste gases from preheater (from

Less heat required for drying with above

for drying cement, 2 lines kcal/kg clinker

Net heat available for cogeneration from

Net heat available for cogeneration kcal/kg clinker

2.19% 2.19% 2.19% 7.00%

11.00% 11.00% 7.16% 7.16%

0.20% 0.20% 0.20% 0.20%

1.58 1.58 1.58 1.58

2,750 12,500 6,100 6,100

1.33 1.54 1.44 1.51

0.1156 0.1156 0.1156 0.1156

0.71 0.71 0.71 0.71

345 345 345 345

400.00 400.00 400.00 400.00

134.03 134.03 134.03 134.03

47.14 47.14 48.35 48.35

31.17 40.35 44.44 95.26

12.96 51.96 23.74 8.75

47.14 47.14 23.76 23.76

6.27 28.51 7.01 7.01

144.51 133.05 104.21 53.40

19.2 80.5 30.8 15.8

22.00 6.79 3.48

1.410809 0.000306 -5.69E-08

Kiln gas analysis t^0 t^1 t^2

N2 66.00 c p,N2 0.6072 1.30 3.05E-05 9.65E-08

temp MW Effective Power gen

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