Kiln Performance & Efficiency

S.
No.

Description

Degree of filling

Symbol

Formula

DF
%
P
Def
n
s

Thermal loading
or
Burning zone loading

Formula-1
TL
Gcal/hr/m2

F
NCV
A
Formula-2

P
H
A
3

Volumetric loading

VL
tpd/m3
P
A
L

Material residence time in kiln

RTK
min
L
Def
n
s

Clinker residence time in cooler

(Empirical relationship from
F.L. Smidth)

True CO2 in kiln exit gas

RTC
min
A
Ps
P
TCO2
vol%
CO2
CO2
O2

Excess air

EA

%
O2
CO2
8

Radiation heat losses

Convection heat losses

10 Forced convection heat losses

(when wind speed > 3.0 m/s)

11 %Ash absorption in clinker

RHL
kcal/hr/m2

CHL
kcal/hr/m2

FCHL
kcal/hr/m2

T
t

T
t

T
t
v
D

%AA
%
CC
Ash
P

12 Raw Mix:Clinker ratio

(dust to kiln)

RMCK
%AA
LOI

13 Raw Mix:Clinker ratio

(dust to silo)

RMCS
%AA
LOI
DL

14 Heat of reaction
or
Theoretical heat required to
produce 1 kg of clinker
or
Clinkerisation heat
(including Heat of combustibles)

HR
kcal/
kg-clinker

CaCO3
RMCK
MgCO3
LOI
Al2O3
CH2O
SiO2
Fe2O3
K2O

Na2O
C
S
15 False air w.r.t. mix
(based on O2 analysis)

FAMO
%
O2mix
O2gas

16 False air w.r.t. gas

(based on O2 analysis)

FAGO
%
O2mix
O2gas

17 False air w.r.t. mix

(based on CO2 analysis)

FAMC
%
CO2mix
CO2gas

18 False air w.r.t. gas

(based on CO2 analysis)

FAGC
%
CO2mix
CO2gas

Kiln Performance & Efficiency

Formula
3.2 * P
Deff 3 * n * s

Clinker production, tpd

Burning zone efective diameter, mts
Kiln speed, rpm
Kiln slope, %
F * NCV
A * 1000 * 1000

Fuel rate in kiln, kg/hr

Net calorific value of fuel, kcal/kg-fuel
Burning zone cross-sectional area, m2

P*H
A * 24 * 1000

Clinker production, tpd

Specific heat consumption in kiln, kcal/kg-clinker
Burning zone cross-sectional area, m2
P
A* L

Clinker production, tpd

Burning zone cross-sectional area, m2
Kiln length, mts
19 * L
Deff * n * s

Kiln length, mts

Burning zone efective diameter, mts
Kiln speed, rpm
Kiln slope, %
1.55 * A * Ps
P

Cooler grate cross-sectional area, m2

Static pressure at clinker droping area, mmWg
Clinker production, tpd
100 * ( CO2 + CO )
100 + ( 1.89 * CO ) - ( 4.78 * O2 )

Kiln exit gas CO2, vol%

Kiln exit gas CO, vol%
Kiln exit gas O2, vol%

Example

P
Def
n
S
DF
Target

F
NCV
A
TL
Target

P
H
A
TL
Target

P
A
L
VL
Target

L
Def
n
S
RTK
Target

A
Ps
P
RTC
Target

CO2
CO
O2
TCO2
Target

79 * O2

O2

0.21 * ( 100 - CO2 ) - O2

O2 content in gas, vol%

CO2 content in gas, vol%

CO2
EA
Target

4 * 10-8 * ( T4 - t4 )

Radiating body temperature, K

Ambient air temperature, K
80.33 * ( ( T + t ) / 2 )-0.724 * ( T - t )1.333

Radiating body temperature, K

Ambient air temperature, K
28.03 * ( ( T + t ) / 2 )-0.351 * v0.805 * D-0.195 * ( T - t )

Radiating body temperature, K

Ambient air temperature, K
Wind speed, m/s
Radiating body diameter, mts
CC * Ash
P

Coal consumption, tph

Ash content in fuel (as fired basis), %
Clinker production, tph
100 - %AA
100 - LOI

%Ash absorption, %
Loss on ignition of raw mix, %
( 100 - %AA ) * 100
( 100 - LOI ) * ( 100 - DL )

%Ash absorption, %
Loss on ignition of raw mix, %
Dust losses from preheater, %
( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO3 * RMCK )
+ ( 222 * Al2O3 / ( 100 - LOI ) ) + ( 11.6 * CH2O * RMCK )
- ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) )
- ( 1000 * ( K2O + Na2O ) / ( 100 - LOI ) )
- ( 79 * C * RMCK ) - ( 32 * S * RMCK )

CaCO3 content in kiln feed, %

Kiln feed:Clinker ratio, MgCO3 content in kiln feed, %
LOI content in kiln feed, %
Al2O3 content in clinker, %
Water of crystalisation in kiln feed, %
SiO2 content in clinker, %
Fe2O3 content in clinker, %
K2O content in clinker, %

T
t
RHL
Target

T
t
CHL
Target

T
t
v
D
FCHL
Target

CC
Ash
P
%AA
Target

%AA
LOI
RMCK
Target

%AA
LOI
DL
RMCS
Target

CaCO3
RMCK
MgCO3
LOI
Al2O3
CH2O
SiO2
Fe2O3
K2O
Na2O
C
S
HR
Target

Na2O content in clinker, %

Carbon content in kiln feed, %
Sulphur as pyrites in kiln feed, %
( O2mix - O2gas ) * 100
21 - O2gas

O2 content in mixture of gas, vol%

O2 content in unmixed gas, vol%
( O2mix - O2gas ) * 100
21 - O2mix

O2 content in mixture of gas, vol%

O2 content in unmixed gas, vol%
( CO2gas - CO2mix ) * 100
CO2gas

CO2 content in mixture of gas, vol%

CO2 content in unmixed gas, vol%
( CO2gas - CO2mix ) * 100
CO2mix

CO2 content in mixture of gas, vol%

CO2 content in unmixed gas, vol%

O2mix
O2gas
FAMO
Target

O2mix
O2gas
FAGO
Target

CO2mix
CO2gas
FAMC
Target

CO2mix
CO2gas
FAMC
Target

Example
5500
4.15
3.8
4
16.20
14-16
10000
6500
13.52
4.81
4.0-5.0

5500
280
13.52
4.75
4.0-5.0
5500
13.52
68
5.98
5.0-5.5
68
4.15
3.8
4
20.5
20-25
100
700
5500
19.7
20-25
36.5
0.002
4.2
45.7
2.8

26.5
17.5
10-15
517
305
2512
443
308
760
525
302
5
4.15
2088
26
15
208
1.88
1.74
35.58
1.525
1.74
35.5
8.1
1.658
75.1
1.53
1.6
34.5
4.17
1.05
13.47
2.41
0.38
0.27
0.2
0.04
389
-

3.6
2.8
4.4
5-7
3.6
2.8
4.6
5-7
32.1
34.5
7.0
5-7
32.1
34.5
7.5
5-7