Professional Documents
Culture Documents
Phy
1.77 (Phy)^1/2 L
________________
Alpha* D*N
Kiln
Kiln
Inlet
Outlet
7.5m/sec
Mat velo Max
B
=
t = 20 -28
Minutes
4.5m/sec
Mat Velo Min
CLINKERISATION
12 CaO
Lime stone
3Cao.SiO2 (C3S)
Alite
2 SiO2
Silica oxide
1450*C
2 Al2O3
Aluminium oxide
Fe2O3
Iron oxide
3 CaOAl2O3 (C3A)
Tricalcium Aluminate
4CaO.Al2O3.Fe2O3 (C4AF)
Tetra Calcium Alumino Ferrite
100* CaO
LSF =
(2.8 SiO2 + 1.18 Al2O3 + 0.65 Fe2O3)
0.66 > LSF < 1.2
=
=
AR = > 0.64
SILICA RATIO
SiO2
SR =
(Al2O3 + Fe2O3)
2.2 >
=
SR < 2.6
=
ALUMINA RATIO
Al2O3
AR =
Fe2O3
1.5 >
=
AR < 2.5
=
H = % HYDROGEN
O = % OXYGEN
ultimate
analysis
D =Diameter in
Meter
L = Length in meter
WEIGHT OF CYLINDRICAL( kiln) SHELL = W
A = Alpha x
TxL
Skin Temperature
Diagram
X L1
X L2
T2bb
T1
T2a
A = A1 +A2
L2
IMPOTANT PARAMETERS
KILN SPECIFIC VOLUME LOADING = TPD/ m3
or Specific Kiln capacity ~ 2.3 t / m3 at Kiln circumferential
speed = 50 cm / sec
KILN SPECIFIC THERMAL LOADING = Kcal / m2.hr
Specific Kiln thermal loading Qp = 1.4 x 10 ^ 6 x D Kcal / m2. hr
Capacity of ID fan.
Preheater cyclone design.
Proclaimed Design & Volume.
Kiln inclination & Volume.
Kiln % filling, Specific volume loading &.Thermal
loading.
Kiln Drive capacity.
System Design, Ducts, GCT, fan position & ESP.
For Gears:
Pitch Diameter = Module x No. of Teeth
Blank Diameter = Module x (No of Teeth+2)
IB
II
III
IV
Riser
Duct
KILN STRING
V
VI
V
950*C
T.A.Duct
SLC
PYRO STRING
KILN
I Girth gear
II
III
Mill charging:
Theta
Theta
H
H = 0.16D
MILL CROSS SECTION
G = gm.Sy.Pi. (R)^2.L
4
G = 4620(R)^2.L
TAGGARTS FORMULA
Constants:
Sy = specific gravity of
ball 7.8-7.9 Ton / m3
gm = Bulk density of charge
4.5 Ton / m3
.
Pi = 22/7 or 3.14
2.
B-A
P= 12G
SEPARATOR
B%fines/D
A %fines/F
Seperator efficiency
s
C%fine/G
Ball Mill
1.
n = C (A-B)
A(C-B))
3.
F = L(1+D)
L/D=3
L / D = 4.5
Carman Lining
Classifying
Liners
Slegton
Magotteaux
Lining
Lining
FLS Lining
Important Conversions
Characteristic
Blaine
3 Days(MPa)
7 Days
28 Days
OPC-43(IS8112)
225
23
33
43
OPC-43(IS12269)
225
27
37
53
PPC- (IS1489)Part-1
300
16
22
33
H
70 *
L=H/2
Single Stream
TOP VIEW
SIDE VIEW
Kiln Data :
4.4 meter Diameter x 60 meter length
Inclination = 3.5%
Shell thicknesses = 25 mm , 28 mm , 35 mm , 65 mm
Kiln speed = 3.5 to 5.25 RPM
Preheater :
Desc
Kiln string
Pyro string
I Cyclone Twin
(Diameter)
4000 m
6400 m
4400 m
7000 m
Dip tube
(Diameter)
2000 m
3200 m
2200 m
3500 m
Girth Gear :
Module = 39
No of Teeth = 148
Material of construction = CS 640 (Normalized Cast Steel)
Dimensions = 550 mm (width)
Pinion :
Module = 39
No of Teeth = 28
Material of construction = 30 Cr Ni Mo V8 (Normalized CastSteel)
Dimensions = 600 mm (width)
Main Drive
Pinion
Kiln
Shell
RWN-500
Motor KW = 710
Aux G.B SDA 250 54.35: 1
Motor
RWB-178
G.B
G.B
Motor
Pinion
Kiln Axis
Concord Alingnomatic
Geared Coupling
G.G
MID KILN
FEEDING
% of Filling or
Kilns Degree
=
Area of cross section of Kiln (A)
% of Kiln
filling
110
15.65
105
13.75
100
12.1
95
10.7
90
9.09
85
7.75
80
6.52
75
5.42
70
4.5
Theta
Segment
r = radius inside lining
A1 =
r^2
O Sin O
A = II r^2
4.5
4.0
3.5
3.0
2.0
10
11
12
13
Note : In practical Kiln operation the kiln load should not exceed
13%,since higher Kiln loads impair the heat tranfer
Kiln diameter
(m)
up to 2.8 m
3 m to 3.4 m
> 3.4 m
H.P =
W x bd x td x N x F x 0.0000092
rd
Note :
This is Frictional
Horse Power
H.P = (D x Sin O) ^3 x N x L x K
Total power =
Arun Shourie
Relation Manager - Insurance
Dir: +91 (22) 4086 3835 / +91 99200 29366
40*
L
v
H
Dab
K%
Z Cos O
H = Z Sine O
2
Kiln Diameter = D
Kiln lining thickness = a
Kiln Coating thickness = b
Angle of Repose of kiln load = O = 40* say
Kiln Load = K % Value from table below
Depth of bed in Kiln = Y % To be measured
Kiln load = K %
10
11
12
13
14
15
Depth of
material bed in
Kiln = Y %
9.75
11
12.2
13.4
14.5
15.6
16.7
17.7
1.8.8
19.8
21
B
7000
SCF
10.478 SCF
Kg of Coal
a = % Moisture in coal ( as fired )
B = Heat value of coal ( Kcal / kg as fired )
% Loading of Kiln :
Cxfxt
dxV
Theoretical Flame
Temperature fuel oil :
T =
Q
Vg x Cp
Q = heating value of
oil , K cal / kg
C = Capacity of Kiln Ton / hr
f = Ton (Kg) dry feed / Ton ( kg) of Clinker
t = residence time
d = Bulk density of dry feed ton (Kg) / m^3
V = Internal volume of kiln in m^3
Vg = Volume of
combustion gases ,
Nm^3 / Kg
Cp = Specific heat of
combustion gases
=0.40 at 2000*C for
fuel class S
Martins Formula :
v
2.826
C =
X D^3
Vg
C = Kiln Capacity Ton / Hr
V = Gas Velocity in gas discharge end , m / sec
Vg = specific gas volume , m^3 / kg clinker
D = Kiln Diameter on Bricks, m
V^2
ID ^ 5
Constant
V = Gas volume
ID = Inside Diameter of ducts /
cyclones respectively
D = 0.536
(V) ^ 2 x Vt
4
Vt = V0 273 + t + K
273
C
P
K = dust concentration in
Gas , grams / m^ 3
D = cyclone Diameter , m
V = Gas volume passimg cyclone , m ^ 3 / Sec
Vt = sp. gr. of gas at aver. Temp , Kg / m ^ 3
C = Coefficient for pressure drop = 110
P = Pressure drop in cyclone in mm WG
H
70 *
L=H/2
Single Stream
Multiplication
Factor Y
Al2O3
5.92
MgO
1.05 6.48*MgO6.48
63.91
7.646
CaO
2.22
+ 13.1
+ 6.8
+ 488.7
+ 18.8
H2O
3.2
5.86
SiO2
22.68
5.11
Fe2O3
2.31
0.59
_ 117
_ 1.4
Net %
99.27
Net Kcal / Kg
= 409.0
+
527.4
_
118.4
Q = 2.22 Al203 + 6.48 MgO + 7.646 CaO + 5.86 H2O + 5.11 SiO2 + 0.59 Fe2O3
A-B
X 100
A
A = Heat loss of clinker leaving the kiln
B = Heat loss of the clinker cooler
3250 (347 K )
(X.n)
Y=
H t2 H t3
t1 = Temperature of Kiln exit gases
t2 = Temperature of gas to be achieved or maitained
t3 = temperature of water (15*C)
H t2 = Heat content of water at t2
H t3 = Heat content of water at t3