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    Holcim Guide For Process Engineers

    Uploaded by

    Satish Kumar
    The document provides reference guides for calculations related to cement kiln systems, material technology, and mechanical process technology. It includes equations and parameters for determining kiln gas volume, excess air, secondary air requirements, material residence time in the kiln, required kiln drive power, clinker cooler exit temperature, thermal power from fuels, fan power requirements, and more. It also covers topics like lime saturation, silica ratio, classifications of raw mix components, and uniformity indicators for clinker and cement. Process parameters and typical ranges are given for crushers, ball mills, filters, ductwork, and conveying equipment. Bulk densities of process materials are also included in a table.

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    © All Rights Reserved
    Download as RTF, PDF, TXT or read online from Scribd

    Holcim Guide For Process Engineers

    Uploaded by

    Satish Kumar
    709 views95 pages
    The document provides reference guides for calculations related to cement kiln systems, material technology, and mechanical process technology. It includes equations and parameters for determining kiln gas volume, excess air, secondary air requirements, material residence time in the kiln, required kiln drive power, clinker cooler exit temperature, thermal power from fuels, fan power requirements, and more. It also covers topics like lime saturation, silica ratio, classifications of raw mix components, and uniformity indicators for clinker and cement. Process parameters and typical ranges are given for crushers, ball mills, filters, ductwork, and conveying equipment. Bulk densities of process materials are also included in a table.

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    Holcim guide for Process Engineers

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    The document provides reference guides for calculations related to cement kiln systems, material technology, and mechanical process technology. It includes equations and parameters for determining kiln gas volume, excess air, secondary air requirements, material residence time in the kiln, required kiln drive power, clinker cooler exit temperature, thermal power from fuels, fan power requirements, and more. It also covers topics like lime saturation, silica ratio, classifications of raw mix components, and uniformity indicators for clinker and cement. Process parameters and typical ranges are given for crushers, ball mills, filters, ductwork, and conveying equipment. Bulk densities of process materials are also included in a table.

    Copyright:

    © All Rights Reserved
    Download as RTF, PDF, TXT or read online from Scribd
    Download as rtf, pdf, or txt
    709 views95 pages

    Holcim Guide For Process Engineers

    Uploaded by

    Satish Kumar
    The document provides reference guides for calculations related to cement kiln systems, material technology, and mechanical process technology. It includes equations and parameters for determining kiln gas volume, excess air, secondary air requirements, material residence time in the kiln, required kiln drive power, clinker cooler exit temperature, thermal power from fuels, fan power requirements, and more. It also covers topics like lime saturation, silica ratio, classifications of raw mix components, and uniformity indicators for clinker and cement. Process parameters and typical ranges are given for crushers, ball mills, filters, ductwork, and conveying equipment. Bulk densities of process materials are also included in a table.

    Copyright:

    © All Rights Reserved
    Download as RTF, PDF, TXT or read online from Scribd
    Download as rtf, pdf, or txt
    of 95

    Reference Guide for

    “Kiln Systems”
    When doing calculations on cement kilns it is usual to work withspecific quantities referred to 1 kg of clinker. Therefore the fuel consumption is expressed as q in
    MJ/kg cliand the kiln gas volume as VKilngasin Nm3/kg cli.

    Excess air

    Therefore the kiln exhaust gas volume VKilngas, wetwith excess air at the actual measured O2concentration is for kilns with drykiln feed:

    Secondary Air and Air to Kiln


    Ideal Gas Conversion

    Barometric Pressure

    with:

    Material Residence Time in Kiln

    with:

    with:
    Required Kiln Drive Power to be Installed

    with:

    Clinker Cooler Exit Temperature

    with:

    Transport Efficiency of Grate Cooler

    with:
    with:

    Thermal Power (from Fuels)

    with:

    Specific Axial Impulsion of Burner

    with:

    with:
    Electrical Power Requirement for Fan

    with:

    Total Pressure Increase (Rough Estimation)

    with:

    Influence of Fan Speed on Volume flow, Static Pressure and Power Consumption

    with:

    with:

    with:
    Water Dew Point

    with:

    with:

    Cooling Water Injection for Gas Cooling

    with:

    Air Inleakagein Process Filters from Temperature Reading

    with:
    Air Inleakagein Process Filters from Oxygen Measurement

    with:
    Reference Guide for

    “Material Technology”
    Lime Saturation (LS)

    Silica Ratio (SR)

    Alumina Ratio (AR)

    Total Alkali (total %)

    Molar alkali/sulfurratio

    Molar alkali/CI ratio

    Degree of precalcination
    Typical Moduli of Industrial Clinker

    LS and SR Moduli in Holcim Clinker

    AR and SR Moduli in Holcim Clinker


    Physcio-chemical Burnability Model

    Example for Physcio-chemical Burnability Model


    Classification of Raw Mix Components:

    Mineral Composition of Raw Mixes:

    Liquid Phase (LP)

    Correlation of Quantity of Liquid Phase with Silica Ratio


    Correlation between the main clinker Minerals and the main moduli
    Correlation with Alumina Ratio
    Uniformity Indicator Clinker

    Uniformity Indicators Cement

    Impacts of Cement uniformity

    Uniform Kiln Feed Quality: A Key to Excellent Kiln Performance


    Electromagnetic spectrum

    Radiation
    General Conversion

    Conversion of US and UK units into SI units


    Frequency table

    Measure of location
    Mean

    Measure of variability
    Significance of standard deviation

    Range

    Criteria for normal distribution


    Kurtosis

    Skewness

    Standardised normal distribution (Z)


    Reference Guide for

    “Mechanical Process Technology”


    [t/h]

    [kN]

    [kW]

    [kN/m2]

    [N/mm2]

    [kWh/t]

    [kWh/t]
    β Clinker2.3 –2.85 [°]
    β RawMaterial 2.85–4.0 [°]
    β Slag1.7 –2.3 [°]
    β= attack angle

    K ≤ 6000 kN/m2

    α Clinker6.9 –9.2 [°]


    α RawMaterial 9.2–12.6 [°]
    α Slag5.7 –7.5 [°]
    α= nip angle

    E Cliinker2.5 –3 [kWh/t]
    E RawMaterial2.0 –2.5 [kWh/t]
    E Slag~ 3 [kWh/t]

    Ec= Closed circuit (with separator or/and slab recirculation)


    or
    Fig. 8: duct-slope for limestone, slag, cement dedusting
    Filter bag dimension

    Filter bag dimension


    DedustingAir Quantities
    Venting Hood Design
    Duct Elbow, Joint and Branch Design
    Fig. 19: Example vertical curve

    Belt width shall not be less than 800 mm, for special applications 650 mm belts may be used.
    Packing plants 500 mm flat belts may be applicable.
    The minimum belt width for reversible conveyors shall not be less than 800 mm.
    mwet= mass wet [kg]mdry= mass dry[kg]mH2O= mass water
    Table 1 –Material Bulk Densities

    C
    li
    n
    k
    e
    r
    C
    e
    m
    e
    n
    t
    Lumpy

    Fine, dry

    Wet
    C
    la
    y
    G
    y
    p
    s
    u
    m
    (r
    a
    w
    <
    2
    5
    m
    m
    )
    Ir
    o
    n
    O
    r
    e
    K
    il
    n
    D
    u
    st
    Li
    m
    e
    st
    o
    n
    e
    (c
    r
    u
    s
    h
    e
    d
    )
    Coarse, wet
    P Ground, dry
    u
    z
    z
    ol
    a
    n
    Aerated
    R Not aerated
    a
    w
    M
    e
    al
    S
    a
    n
    d
    (
    D
    r
    y)
    S
    h
    al
    e
    (c
    r
    u
    s
    h
    e
    d
    )
    Fl
    y
    a
    s
    h
    Crushed

    Granular,
    wet
    Ground
    S Granulated
    la blast
    g furnace
    (GGBFS)

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