Material out = Material in + Generation - Consumption - Accumulation

Accumulation = 0 (Steady State)

Generation & Consumption = 0 (No Chemical Reaction)
Material out = Material in
Dry Basis 100 kg/day
85%
85
15%
15

L/S
Clay

M2

Loss

kg/day
kg/day
5%

0.05

Clay
M1
M3

Component
%

IN
M1
15

=
=
=
=

Loss
M2
15*0.05
0.75
14.25

M3
SiO2
70.69

+
+
+

OUT
M3
M3

kg/day

Al2O3
14.91

CaCO3
4.5

Fe2O3
6

MgCO3
1.5

M5

Loss

5%

0.05

Inert
2.4

Crusher
M4
M6

Component
%

IN
M4
85

=
=
=
=

Loss
M5
85*0.05
4.25
80.75

M6
SiO2
1.88

+
+
+
kg/day

Al2O3
1.2

CaCO3
94.45

Fe2O3
0.57

OUT
M6
M6

MgCO3
1.95

Inert
0

M8
Raw Mill
M3
M6
Loss

M3
14.25

IN
+
+

M6
80.75
M8

OUT
M8
M8
94.525

+
+
+
kg/day

Loss
M7
0.475

Composition of M7 & M8
SiO2
Al2O3
CaCO3
Fe2O3
MgCO3
11.591425 3.093675 76.909625 1.315275 1.788375

Component
kg/day

Component
%

=
=
=
=

Concentration of Composition in Mixture

SiO2
Al2O3
CaCO3
Fe2O3
12.20
3.2565
80.96
1.38

M7
0.5%
0.005

MgCO3
1.88

Inert
0.342

Inert
0.36

Exhaust Gases
Kiln
M8
M9
IN
M8
94.525

=
=
kg/day

OUT
M9

+
+

Component
kg/day

SiO2
11.5

Analysis of M8
Al2O3
CaCO3
3.08
76.53

Component
Mwt

SiO2
60.06

Mwt of Component
Al2O3
CaCO3
101.94
100.09

Component
kmol/day

Exhaust Gases
Exhaust Gases

Fe2O3
1.31

MgCO3
1.78

Fe2O3
159.68

MgCO3
84.31

Moles of Component
SiO2
Al2O3
CaCO3
Fe2O3
MgCO3
0.192032 0.030196 0.764563 0.008196 0.021106

Inert
0.34

Component
%

C2S
20

Component
Mwt

C2S
172.22

Analysis of M9
C3S
C3A
60
12

C3S
228.30

C3A
270.18

C4AF
8

C4AF
485.95

Reaction In Kiln
CaCO3 -------------- CaO + CO2
MgCO3 ------------- MgO + CO2
CaO + Al2O3 ------------- CaO.Al2O3
4CaO + 2Al2O3 + CaO.Al2O3 ----------------- 5CaO.3Al2O3
5CaO + 3Al2O3 --------------- 5CaO.3Al2O3
2CaO + SiO2 -------------- 2CaO.SiO2
4CaO + 5CaO.3Al2O3 -------------- 3(3CaO.Al2O3)
CaO + 2CaO.SiO2 -------------- 3CaO.SiO2
4CaO + Al2O3 + Fe2O3 -------------- 4CaO.Al2O3.Fe2O3

1
2
3
4
5
6
7
8
9

3 + 4 ------------- 5

Moles of Components By the Reaction

CaCO3
1
0.764563
X1

MgCO3
1
0.021106
X2

CO2
Weigh of CO2

----------------------

Y1

----------------------

Y2

=
=

Y1

CaO
1
X1
=

MgO
1
X2
=

CO2
1
Y1

0.764563 kmol/day

CO2
1
Y2

0.021106 kmol/day

+
Y2
kmol/day * Mwt

=
=

0.785668 kmol/day
34.577271 kg/day

2CaO
2
Y3

SiO2
1
0.192032

----------------------

Y3
X3

=
=

0.384065
0.192032

kmol/day
kmol/day

4CaO
4
Z4

Al2O3
1
Y4

Z4
Y4
X4

=
=
=

0.032783
0.008196
0.008196

kmol/day
kmol/day
kmol/day

5CaO
5
Z5

3Al2O3
3
Y5

Fe2O3
1
0.008196

----------------------

2Ca.SiO2
1
X3

----------

4CaO.Al2O3.Fe2O3
1
X4

5CaO.3Al2O3
1
X5

3(3CaO.3Al2O3)
3
X6

Y5 = Total moles of Al2O3 - Y4

Y5
X5
Z5

4CaO
4
Y6
Y6
X6

=
=
=

0.022001
0.007334
0.036668

kmol/day
kmol/day
kmol/day

5CaO.3Al2O3
----------1
X5 =
0.007334
=
=

0.029334
0.022001

kmol/day
kmol/day

CaO
1
Z7

2CaO.SiO2
1
Y7

-----------

3CaO.SiO2
1
X7

From outlet % Analysis

Weigh Ratio
Mwt
Mole Ratio

C3S
3CaO.SiO2
60%
3
228.3
0.013141
2.263
X7
X7
X7

2CaO.SiO2 Excess
2CaO.SiO2 Excess

Inerts in
MgO
CaO Excess

----------------------------

Amount of Inerts

=
=

weigh ratio / mwt

Divided by 0.005806

=
=
=

SiO2 kmol/day *2.263 / (2.263+1)

0.133181 kmol/day
Y7
=
Z7
=
0.133181

=
=

SiO2 kmol/day* (1/2.263+1)

0.058851 kmol/day

The amount of CaO excess

The amount of CaO excess
The amount of CaO excess

Amount of Inerts

C2S
2CaO.SiO2
20%
1
172.22
0.005807
1

Inert in

=
=
=

Outlet
Reactant
CaCo3
Y3+Z4+Z5+Y6+Z7
0.148532 kmol/day

MgO

CaO Excess

Analysis of inlet
Moles of component * Mwt
CaO Excess * Mwt

0.340290
9.520970

+
kg/day

0.8509874

8.329693

% Analysis of the clinker

Component
C2S
C3S
C3A
C4AF
Inert
Sum

kmol/day
0.058851
0.133181
0.022001
0.008196
-

Mwt
177.22
228.3
270.3
485.95
-

=
=
=

M9
60.285304
94.862575

kg/day
kmol/day * Mwt
10.429662
30.405208
5.946735
3.982729
9.520970
60.285304

%
17.3
50.4
10
6.6
15.8
100.0

Check
M8
94.525
94.525

+
+

Exhaust Gases
34.577271

M9
Cement Mill
M10
5%

0.05

M10

M11

From the Mill:

Balance:
M9

M11

M.B of CaSO4:
0.0*M9 + M10 = 0.05M11
M.B of Clinker:
0.0 + M9 = 0.95M11 = 60.285304 kg/day
M11 = M9 / 0.95 = 60.285304 / 0.95
M11

63.458215

kg/day

M10

3.172911

kg/day

Real Quantities
Converted Balance
Annual Production
Working Days
1000000

ton/year

100
X

kg/day
kg/day

1000000
300

ton/year
day/year

3333333.3

kg/day

------------63.1
------------- 3333333.3

kg/day
kg/day

Basis

5282620.2

kg/day

M``
=
X*M / 100
M`` : Real quantities
X : the amount of clay and lime stone which produce 1000000 ton/day

M2
0.75

Clay

Loss

M1

15

M``

X*M / 100

M1``
M2``
M3``

=
=
=

792393
39619.65
752773.4

kg/day
kg/day
kg/day

M5
4.25

Loss

Crusher
M4

85

5%

0.05
14.25
M3

5%

0.05
80.75
M6