Mathcement-PYRO, a Mathematical Model to establish Heat, Gas

and Mass balance in the Pyro Processing Section of modern

cement plants.
By Saumitra Pal, Pune, India
Summary
Live-Math technique, based on mathematical software Mathcad has been used to develop a
mathematical model to represent combined functioning of preheater, precalciner, kiln and grate-cooler.
The basic process parameters are inputted in the model. Initial calculations are based on certain
assumptions of fuel efficiency, temperature of the tertiary air, circulating dust at kiln inlet, calcinations
function etc. Mass balances at various preheater stages are carried out starting from the lowermost
stage. It then calculates gas flow rate at each stage followed by stage wise heat balance calculation.
Heat balance provides the temperature profile across the preheater. The model makes validation
checks. The user can control the looping calculation by changing the assumed fuel efficiency to
converge on the conditionality satisfaction.
The model shifts to grate cooler and establishes cooler function to evaluate the temperature of tertiary air
which then is re-entered in the calculation of preheater. Calculations are repeated till conditions are
satisfied.
The advantage of using this model is seen in its power to present all calculation steps in real
mathematical notation and in live format. It presents investigative possibility in plant operation and
design by allowing the users to manipulate data and operating conditions.
Part A (Approach to the model)
1. Introduction
Even though the topics of heat, gas and mass balance of pyro-processing section of a cement plant are
nothing new, the method of establishing these have never been easy. Due to many complexities of
iterative calculation involving many parameters, it has not been practical to do such calculations
manually.
The outcome of a computer program is like a black box. A major problem faced by the young engineers
joining the industry is their failure to appreciate a computer output in the absence of detailed explanation
of the calculation procedure. This often leads to a situation where they develop a lack of confidence
when they face scrutiny. Mathcement_PYRO, a mathematical model for combined heat, gas and mass
balance addresses these issues very effectively.
2. Basic advantages of the model
Uses standard mathematical notations
Mathcement_PYRO uses Mathcad software in the background to provide the users a live
mathematical worksheet where standard mathematical notations are used. Unlike a spreadsheet,
real life mathematical notations make life so much easier for the engineers and scientists in their
understanding of the calculations and the results.
It is not a spreadsheet
It is not a spreadsheet. In a spreadsheet we are restricted to use a rigid tabular format where the
formulae in the cells are hidden. So it becomes difficult to check or track back a calculation or getting
the whole picture. In Mathcement_PYRO calculation formulae and explanatory text inter mingle
like you would do on paper using a paper.
It is a powerful program with normal English language interface
It is powerful mathematical model calculation program that uses normal English on the foreground.
So every step and every statement and every formula is directly seen and can be interacted with by
the user. It gives the user great possibility to play with it as he likes and do experiments to his hearts
content. At the end of the session the program restores everything to original states.
3. Mathematical model an appreciation
Modeling from theory as opposed to formulating data driven model
In many problems, formulation of mathematical model can be a very challenging task. In case of
empirical models, it is fairly easy to formulate models from given data or where we can collect data
from appropriate experiments. But such models have severe limitations in the validity of our
interpretations from the graph.
A more accurate and dependable problem solving process is based more on theory and less on
data. This is called theoretical modeling.
Theoretical Modeling involves:1) Very thorough understanding of the problem 2) Identification of
important features 3) Make assumptions and simplifications 4) Defining variables 5) Use of sub
models 6) Establishing relations between variables 7) Solving equations 8) Interpretation and
validation of the model( i.e. question the results of the model) 9) Making improvements to the model
10) Explaining the outcome
The process of solving real life problems by using the above steps is called mathematical modeling
This essentially has three phases:
1) First phase
In the first phase we formulate the mathematical model by describing real life problem in terms
of mathematical structures, (graphs, equations, inequalities listing carefully all assumptions that
we make)
2) Second phase
In the second phase we solve any equations that may occur.
3) Third phase
In the third phase we use appropriate data to test the model. This is when we interpret the
results of mathematical analysis and criticize the model hopefully suggesting improvements to
the model.
4. Mathcement PYRO an analysis of the mathematical model
a. Our real life problem
As we produce clinker from the pyro processing section of the plant, we would like to reduce
fuel consumption to the minimum to save on energy and costs. To this end, we need to
theoretically forecast the fuel consumption and establish various operating parameters
relating to gas flow, material flow, and respective temperatures and heat losses and take
corrective action.
b. Important considerations and features
i. Raw meal, in practically dry and finely ground state, enters the top stage of the
preheater. The material is dispersed in the stream of hot kiln exhaust gases coming up
from the previous or lower stage cyclone. In the gas duct, heat transfer takes place
between the gases and the material. The material is heated and fully dried and the
gases lose heat. The temperature differential between the gases and the material at the
end of the gas duct , i.e. before entry to the top stage cyclone is expected to be about
20 deg. C
ii. Preheater cyclones are dust separation units, which separate the heated raw meal from
the gases. The gases leave the cyclones through the top opening connected to the gas
duct and the material spiral down and exit through the meal chutes. The degree of
separation of dust from the gases is dependent on the cyclone collection efficiency. As
the efficiency is dependent on specific design these values are inputted for each model
analysis.
iii. Heat losses due to radiation from the preheater stages depend on the surface area,
temperature and type of lining. Detailed mathematical analysis, here, is not considered
important as values may not show significant difference.
iv. Circulating dust at kiln inlet cannot be measured accurately on a day to day basis,
where as situation at the kiln inlet can vary widely, depending on many factors which do
not merit any mathematical analysis that could influence any significant change in
operating techniques.
v. Calcination function of raw meal is conducted in the laboratory and forms the basis of
calculating heat requirement for calcinations
vi. Basic fuel analysis provides heat values as well as establishing theoretical air for
combustion.
vii. Provision is made to consider different fuel grades for kiln and precalciner
viii. Kiln radiation losses are derived from shell temperature measurements.
ix. Recuperation efficiency of clinker cooler is a function of mechanical design adopted in
various commercial models. Hence efficiency value is considered as an input for the
model
c. Important assumptions
i. Temperature differential between gas and material at the end of heat transfer at each
preheater stage is assumed to be 20 deg. C unless actual measured values are
available.
ii. Leakages of false air into the system are assumed to be a function of overall exhaust
gas quantity from the preheater. A parallel calculation is provided to establish actual
leakage air quantities by actual measurement of oxygen in the gases at various stages
of preheater.
The mathematical model covers the complete pyro processing section which include preheater,
precalciner, kiln and clinker cooler. The model establishes the following process status:
Temperature profile of gas flow along preheater and precalciner
Temperature profile of material flow down the preheater
Radiation losses across preheater, precalciner, kiln and cooler
Material flow rate across pyro section
Gas flow rate across pyro section
Heat balance for preheater and kiln
Heat balance for clinker cooler
5. Use MathCADs built-in units
This model uses MathCADs built in units. So you will not find conventional unit conversion
factors in the equations used.
In the mathematical model, a preheater stage includes cyclone separator, gas duct from the
outlet of previous cyclone up to the inlet of the cyclone of the current stage.
6. Development issues
While developing the mathematical model, following issues have been considered.
Understanding of the technological issues
Analyzing the mechanics of various influencing parameters
Formulation of mathematical model
Developing simulation software
Testing
Implementation
Maintenance and up-gradation
7. Convention used for describing a preheater stage in the model
Figure 1 Convention used for describing a preheater stage in the model
Part B ( Mathcement_PYRO , the mathematical model - abbreviated)
Input Data
Base temperature for heat balance calculation t
base; Loss
on ignition of raw meal GV;
Moisture in raw meal F; Reaction enthalpy (heat) of clinker R
W from
laboratory investgation-390 -420;
Starting temperature of decarbonation T
A;
End temperature for decarbonation T
E ;
Temperature of gas at kiln inlet T
OE;
Circulating dust load at kiln inlet S
OE
default value 0.3 or consider as a function of gas velocity at kiln
inlet; Percent fuel firing in precalciner -V
C; Temperature
of raw meal feed to preheater -T
R
Cyclone efficiency -stage wise
Cyclone efficiency -stage 1-

st1
Cyclone efficiency -stage 2-

st2
And so on
For calculation of false air to be based on default percentages at each stage as given below input Cfal=0
OR
For calculation of false air to be based on oxygen measurement/indication at each stage as inputted
below.Cfal=1
False air leakage into the system -stage wise as percent of exhaust air - Default values
False air -stage 1-
Fa1
;
False air -stage 2 and so on
False air in terms of oxygen measurement by Orsat apparatus: Important: If the measured values are
not available, please enter the values as "0".Calculation will then proceed with default values as % of
exhaust gas.
Oxygen at inlet chamber (after mixing with precalciner gases) O2
inch
Oxygen at outlet of cyclone stage1 (start of gas duct) O2
st1

Oxygen at outlet of cyclone stage2 (start of gas duct) O2
st2

Oxygen at outlet of cyclone stage3 (start of gas duct) O2
st3
and so on
Temperature difference between gas and material in each stage -
Tg_m

(i.e. the difference in temperature of gas leaving the cyclone and the temperature of material the cyclone
through the meal chute)
Following data to be considered if actual measurement is done. If the measured values are not available,
please enter the values as "0".Calculation will then proceed with default value of 20 deg.K
Temperature difference between gas and material
in 1st. stage -
Tg_m1

Temperature difference between gas and material
in 2nd.stage -
Tg_m2

and so on
Radiation and convection losses in kiln and T.A duct and various stages of preheater
Radiation and convection losses in stage 1 R
L1
Radiation and convection losses in stage 2 R
L2
And so on:
Radiation and convection losses in kiln and cooler R
kiln
Radiation and convection losses in T.A duct R
LTA
Excess air ratio at precalciner F
air.pc
Theoretical air for combustion (NTP) at precalciner L
th.pc
Theoretical products of combustion (NTP) at precalciner C
th.pc
Primary (transport air) air to precalciner L
pa.pc
Excess air ratio at kiln
air.kiln
Theoretical air for combustion at kiln L
th.kiln
Theoretical products combustion at kiln C
th.kiln
Primary air to kiln L
pa.kiln
Heat value of fuel to kiln (as fired) H
uk
Heat value of fuel to precalciner (as fired) H
upc
Ash in fuel to kiln (as fired basis) F
ashk
Ash in fuel to precalciner (as fired basis) F
ashpc
Temperature of fuel to kiln (as fired) t
fuelk
Temperature of fuel to precalciner (as fired) t
fuelpc
Temperature of clinker from kiln to cooler t
cl
Formulation of the model (Step wise Calculation formulae and procedure)
Theoretical heat of formation of clinker is calculated from
H
f
R
W
30
kcal
kgcl
:
Let's assume fuel efficiency, i.e. heat release by fuel per kg. clinker -

f
767
kcal
kgcl
:

Total Fuel requirement F
req
Fuel fired to precalciner F
pc
F
pc
V
C

f

H
upc
:

Fuel fired to kiln F
kiln
F
kiln
F
req
F
pc
:
Ash going into precalciner with fuel ASH
pc

ASH
pc
F
ashpc
F
pc
:
Ash going into kiln with fuel ASH
kiln
ASH
kiln
F
ashk
F
kiln
:
Total ash absorbed in clinker ASH
tot
ASH
tot
ASH
kiln
ASH
pc
+ :
Loss on ignition, corrected for ash GV
c
GV
c
1
1
1
1 GV
1
1 ASH
tot

1 +

,
:
Raw meal requirement for producing unit mass of clinker -RM
F
RM
F
1 ASH
tot

1 GV
c

:
Assume total loss on ignition is entirely due to release of CO
2
from raw meal
CO
2
in kiln feed raw meal - RM
CO2
RM
CO2
GV
c
RM
F
:
Raw meal quantity fully calcined (loss free basis) in kiln -RM
cal.kiln
RM
cal.kiln
1 ASH
kiln
:
Assume temperature at kiln inlet for calcined raw meal - t
kf.rm
t
kf.rm
1143 K :
Loss on ignition as linear relation to temperature difference between start and end temperature of
decarbonation-
Loss on ignition of raw meal at kiln inlet LOI
ki
LOI
ki
T
E
t
kf.rm

T
E
T
A

GV
c
:
Quantity of raw meal at kiln inlet Rm
ki
RM
ki
RM
cal.kiln
1 LOI
ki

:
Quantity of circulating dust at kiln inlet -S
OE
Material at discharge chute of cyclone -1 / preheater stage 1- M
1
M
1
RM
ki
S
OE
+ :
Quantity of material entering cyclone 1 - MI
1
MI
1
M
1

st1
:
Dust at exhaust from cyclone stage 1- S
1
S
1
MI
1
1
st1

( )
:
Ash coming into raw meal from precalciner -MI
1ash
MI
1ash
ASH
pc
:
The quantity of raw meal that has lost CO2 in precalciner- MI
1CO2
MI
1CO2
RM
ki
MI
1ash
:
CO2 released in precalciner -
This is calculated by calculating the presence of CO2 in raw meal entering the kiln and then subtracting it
from total amount of CO2 present in raw meal feed.
CO2 in raw meal entering kiln -RM
ki.co2
RM
ki.co2
RM
ki
RM
cal.kiln
:
CO2 released in precalciner -CO2
pc
CO2
pc
RM
CO2
RM
ki.co2
:
Quantity of material discharged through meal chute from cyclone stage 2 - M
2
M
2
MI
1
CO2
pc
+
( )
MI
1ash
S
OE
+
( )
:
Quantity of material entering cyclone 2 - MI
2
MI
2
M
2

st2
:
Dust at exhaust from cyclone stage 2- S
2
S
2
MI
2
1
st2

( )
:
Fig 2. Gas and material flow at kiln inlet
In the similar manner we establish the mass balance in all the cyclone stages
Fixing Temperature at various stages
We have already fixed the temperature of material at the exit of cyclone stage 1 based on operating
experience
Temperature of material at the exit of cyclone stage 1- TM
ex.1
TM
ex.1
t
kf. rm
:
Loss of CO2 in precalciner - already calculated
Assume temperature of material from precalciner to be same as temperature of material at exit of
cyclone 1
Temperature at precalciner - t
pc
t
pc
TM
ex.1
:
Default temperature difference between gas and material
in each stage -
Tg_m

(i.e. the difference in temperature of gas leaving the cyclone and the temperature of material the cyclone
through the meal chute) Default value is taken as 20 deg. K in absence of stage wise measured values.
Tg_m 2 0K :
Tg_m 20K
Temperature of gas at the exit of cyclone stage 1- TG
ex.1
Tg_m1 ifTg_m1 0 Tg_m1 ,Tg_m ,
( )
:
Tg_m1 20K
TG
ex.1
TM
ex.1
Tg_m1 + :
Assume temperature of tertiary air to precalciner - t
ta

t
ta
1063 K :
Based on the above data we shall now fix the temperature at various stages of cyclone as well as gas
flow rates.
But before we proceed we first establish the overall mass balance.
Theoretical air for combustion - A
th
in

Nm
3
/kg.cl
Theoretical air for combustion -at kiln - L
th.kiln
A
th
L
th.ki ln

f
:
Theoretical products of combustion -G
com
Theoretical products combustion -at kiln - C
th.kiln

G
com
C
th.kiln

f
:
Theoretical air to kiln -A
th.kiln

Percent fuel firing in precalciner -V
C
Percent fuel firing in kiln -V
kiln
V
kiln
1V
C
:
A
th.kiln
V
k iln
A
th
:
Total combustion air to kiln including excess air A
tot.kiln
Excess air ratio at kiln- F
air.kiln
A
tot.kiln
F
air.kiln
A
th.kiln
:
Products of combustion of fuel in kiln - G
com.kiln
G
com.kiln
V
kiln
G
c om
:
Quantity of excess air in kiln - A
ex.kiln
A
ex.kiln
A
tot.kiln
A
th.kiln
:
CO2 released in kiln - VM
ki.co2

Molecular weight of CO2 - MW
co2
V
mola l
22.4 m
3
:
VM
ki.co2
RM
ki.co2
MW
co2
V
molal
:
Gas quantity at kiln inlet (going out of kiln) - G
out.kiln
G
out.kiln
G
com.kiln
A
ex.kiln
+VM
ki.co2
+ :
Primary air quantity to kiln -PA
kiln
Primary air to kiln -L
pa.kiln
as percentage of total air -input data
PA
kiln
L
pa .ki ln
A
tot.kiln
:
Secondary air quantity to kiln - SA
kiln
SA
kiln
A
tot.kiln
PA
kiln
:
Theoretical air to precalciner -A
th.pc

A
th.pc
A
th
A
th.kiln
:
Total combustion air to precalciner including excess air A
tot.pc
Excess air ratio at precalciner- F
air.pc
A
tot.pc
F
air.pc
A
th.pc
:
Products of combustion of fuel in precalciner - G
com.pc
G
com.pc
V
C
G
com
:
Quantity of excess air in precalciner - A
ex.pc
A
ex.pc
A
tot.pc
A
th.pc
:
CO2 released in precalciner - VM
pc.co2

Molecular weight of CO2 - MW
co2
Loss of CO2 in precalciner - already calculated
VM
pc.co2
CO2
pc
MW
co2
V
molal
:
Total gas quantity from precalciner - G
out.pc
G
out.pc
G
com.pc
A
ex.pc
+VM
pc.co2
+ :
Primary air / transport air quantity to precalciner -PA
pc
Primary air / transport air to precalciner -L
pa.pc
as percentage of total air -input data
Primary (transport air) air to precalciner -L
pa.pc
PA
pc
L
pa.pc
A
tot.pc
:
Tertiary / Secondary air quantity to precalciner - TA
pc
TA
pc
A
tot.pc
PA
pc
:
Total air from clinker cooler for combustion = secondary air to kiln + tertiary air to precalciner -
TSA
cooler
TSA
cooler
SA
kiln
TA
pc
+ :
Nm
3
/kg.cl
Gases entering cyclones
Total gas quantity entering cyclone stage (excluding false air) 1 -V
in.1
V
in.1
G
out.pc
G
out.kiln
+ :
Quantity of moisture in raw meal being evaporated -RM
H2O

RM
H2O
M
feed
1 F
M
feed
:
M
feed
Volume of moisture in raw meal being evaporated -VM
H2O

Molecular weight of water -MW
H2O
MW
H2O
18.02 kg :
VM
H2O
RM
H2O
MW
H2O
V
molal
:
RM
H2O
False air leakage into the system -stage wise as
Percent of exhaust air (input data)
False air -stage 1-
Fa1

False air -stage 2-
Fa2
False air -stage 3-
Fa3

False air -stage 4-
Fa4

False air -stage 5-
F a5
False air % in stage 1as percentage of gas entering the system including PC, by oxygen measurement
F
a1m
%
F
a1m
O2
st1
O2
inch

21 % O2
st1

:

F
a2m
O2
st2
O2
st1

21 % O2
st2

:
Similar calculations are done for all stages
Let total exhaust air from preheater - E Nm
3
/kg.cl
EV
in.1
EF
a1
F
a2
+F
a3
+F
a4
+F
a5
+
( )
+ VM
H2O
+
E
V
in.1
VM
H2O
+
1 F
a1
F
a2
+ F
a3
+ F
a4
+ F
a5
+
( )

:
VM
H2O
Gas volumes after stage 1 - V
out.1
V
out.1
V
in.1
F
a1
E + : E

V
out.m1
V
in.1
F
a1m
V
in.1
+ :
Gas volumes after stage 2 - V
out.2
V
out.2
V
out.1
F
a2
E + : E

V
out.m2
V
out.m1
F
a2m
V
out.m1
+ :
Similar calculations are carried out at all stages
Further calculations will proceed based on gas volumes including leakage/false air.As these are basis for
calculation, choice is made based on value of Cfal in input data block
Conditions:
V
out.1
if Cfal 0V
out.1
, V
out.m1
,
( )
:V
out.1
Similar conditional statements are written for other stages
Percentage of calcination achieved in the precalciner - PC
cal
PC
cal
CO2
pc
RM
CO2
:
Heat of reaction in precalciner - Rw.pc
R
w.pc
R
W
PC
cal
:
At this point we take up heat balance of preheater stages
HEAT BALANCE
Heat balance for preheater stage 1
The purpose is to find the temperature of raw meal coming into the gas duct from the meal chute in the
upper stage cyclone no. 2
Heat input with fuel to precalciner -
Combustion heat of fuel -H
com.pc
H
com.pc
F
pc
H
upc
:
Specific heat of coal at ambient temp. S
coal
Sensible heat of fuel -H
s.pc
H
s.pc
F
pc
t
fuelpc
t
base

( )
S
coal
:
Fig.3 Diagrammatic Model for heat balance at cyclone stage1
Balance heat output and heat input to find the unknown value of temperature of material coming in from
stage 2
Let the temperature of material from stage 2 be- TM
ex.2
TM
ex.2

degK
Sp. heat of material at TM
ex.2
be given by - C
p.mat2

C
p.mat2

kcal/kg degK diff.
Sp. heat of material at TM
ex.1
be given by - C
p.mat1

Converting to dimensionless
t
m
TM
ex.1
K
273 :
SP
heat1
1.975 10
01
1.77 10
04
t
m
+ 1.455 10
07
t
m
2

_
,
kcal
kg K
:
C
p.mat1
SP
heat1
:
Sp. heat of dust at TG
ex.1
be given by - C
p.s1

t
m
TG
ex.1
K
273 :
SP
heat1
1.975 ( ) 10
01
1.77 10
04
t
m
+ 1.455 10
07
t
m
2

1
]
kcal
kg K
:
C
p.s
SP
heat1
:
Sp. heat of gas at TG
ex.1
be given by - C
pg

t
g
TG
ex.1
K
273 :
CP
heat2
0.3336 0.64 10
4
t
g
+

_
,
kcal
m
3
K
:
C
pg
CP
heat2
:
Let Sp. heat of air at temp. t
ta
be given by - C
p.air

t
g
t
ta
K
273 :
CP
heat1
0.309 0.268 10
4
t
g
+

_
,
kcal
m
3
K
:
C
p.air
CP
heat1
:
Sp. heat of kiln exhaust gas at T
OE
be given by - C
pg.toe

t
g
T
OE
K
273 :
CP
heat2
0.3336 0.64 10
4
t
g
+

_
,
kcal
m
3
K
:
C
pg.toe
CP
heat2
:
Output heat -Stage1
Heat with material going into kiln -oh
1
oh
1
RM
ki
TM
ex.1
t
base

( )
C
p.mat1
:
Heat going out with dust with gases from cyclone -oh
2
oh
2
S
1
TG
ex.1
t
base

( )
C
p.s
:
Heat going out with gases from cyclone -oh
3
oh
3
V
out.1
TG
ex.1
t
base

( )
C
pg
:V
out.1
Heat going out as radiation -oh
4

oh
4
R
L1
:
Heat going out with calcined material as heat of reaction -oh
5
oh
5
R
w.pc
:

OH
1
1
5
i
oh
i

:
Input heat -Stage1
Combustion heat of fuel -hi
1
heat
1
H
com. pc
:
Sensible heat of fuel -hi
2
heat
2
H
s.pc
:
Heat from tertiary air -hi
3
heat
3
TA
pc
t
ta
t
base

( )
C
p.air
:
Heat from kiln gas -hi
4
heat
4
G
out.kiln
T
OE
t
base

( )
C
pg.toe
:
Heat with material from stage 2 - hi
5
heat
5
M
2
TM
ex2
t
base

( )
C
p.mat2
: C
p.mat2
heat
5
heat
5
a
1
heat
1
:

a
3
heat
3
:

a
2
heat
2
:

a
4
heat
4
:

x
5
heat
5
:heat
5
IH
1
1
4
i
a
i

x
5
+ : x

IH
1a
1
4
i
a
i

:
by balancing
x
5
OH
1
IH
1a
:
C
p.mat2
0.1975 0.177 10
3
TM
ex2

_
,
+ 0.1455 10
6
TM
ex2
2
: TM
ex2
M
2
TM
ex2
t
base

( )
C
p.mat2
x
5
To find TM.
ex2
We first make a guess fot the value of TM.
ex2
between 500 and 1000
TM
ex2
600 :
Formula applicable for temp. in degC. So first we treat temp. in degC and the reconvert it to Kelvin
Given
"Given" This is key word
M
2
TM
ex2
t
base
K
273

1
1
]
0.1975 0.177 10
3
TM
ex2
+ 0.1455 10
6
TM
ex2
( )
2

1
]

x
5
kcal
kg
0
TM
ex2
Find TM
ex2
( )
273 +
( )
K : TM
ex2
Find TM
ex2
( )
273 +
( )
K :
Similarly we proceed with the heat balance of stage 2 and till the top stage.
Heat balance for preheater stage 5
The purpose is to find the temperature of exit gases and separated material in the upper stage cyclone
no. 5 - and check if all correlations are correct. If not, recalculate for convergence between calculated
value and assumed values of fuel efficiency.
Temperature of gas at the exit of preheater stage 5 cyclone - TG
ex.5
Fig.4 Diagrammatic model for heat balance at cyclone stage 5
TG
ex.5
TG
ex.5

TM
ex5
TM
ex5
Diff
TG
ex.5
K
TM
ex5
K
:
TM
ex5
Diff1 Diff 20 :Diff
Note:
We have to make a number of trial and error to achieve convergence. To understand how it is
done please follow the observation below:
1) Go to beginning of the calculation where we have assumed the value for fuel efficiency -

f
2) Change the value of

f
and come down to the bottom at this page. Enable Mathcad to
recalculate.
3) Record the value of Diff and Diff1. Our aim is to converge the value of Diff1 closest to 0
(zero) by selecting different values of

f

4) If the value of Diff is > 20, then the value of Diff1 is >0 . Go to beginning of calculation and
select a new value. You have to see whether you converge on to 0 (zero) for Diff1 by reducing
the assumed value of

f
or by increasing it. All will depend on your choice of initial value. Once
you are within the range of (+) (-) 0.2 for Diff1, you can stop further calculation as you have
achieved convergence for all practical purposes.
Having achieved convergence, we have achieved mass, gas and heat balance of kiln
preheater system but it still doesnt include clinker cooler .So we have to now proceed with the
cooler calculations.
Heat balance of clinker cooler
Temperature of hot clinker from kiln to cooler t
clh
Specific loading of clinker cooler -SL
clr
obtained by dividing nominal output of kiln in tonnes / day by
effective grate area of cooler in m
2

Cooler function is dependent on specific design of a cooler . Here we consider cooler function for normal
reciprocating grate cooler. The recuperation efficiency and temperature of cooled clinker are functions of
specific cooler loading at nominal kiln output.
t
clc
30.435 2.174
SL
clr
tonne
m
2
day

,
+ 273 +

1
1
1
1
]
K :
Total air from clinker cooler for combustion at NTP = secondary air to kiln + tertiary air to
precalciner TSA
cooler
TSA
cooler
SA
kiln
TA
pc
+ :TA
pc
Cooler function for recuperation efficiency of cooler - t
rec
%

rec1
81.071 0.329
SL
clr
tonne
m
2
day

,
% :

rec2
77.7 0.24
SL
clr
tonne
m
2
day

,
% :

rec
if
SL
clr
tonne
m
2
day
40
rec1
,
rec2
,

,
:
Assume temperature of tertiary air to precalciner - t
ta

The specific heat of Air based on its temperature -CP
heat

t
g
t
ta
K
273 :
t
ta
CP
heat1
0.309 0.268 10
4
t
g

_
,
+

1
]
kcal
m
3
K
: t
g
The specific heat of Clinker based on its temperature(For the temperature range of 0-1500 deg.c )
t
m
t
clh
K
273 :
SP
heat3
1.742 10
01
1.415 10
04
t
m
+1.283 10
07
t
m
2
5.077 10
11
t
m
3
+

_
,
kcal
kg K
:
Heat input to cooler by hot clinker -H
cl
H
cl
1t
clh
t
base

( )
SP
heat3
:t
base
Recuperation efficiency of cooler -
rec
Heat recuperated by Secondary air and Tertiary air from heat received from clinker -H
rec
H
rec
H
cl

rec
:H
cl
Assume temperature of secondary air to kiln t
sec
H
rec
TSA
cooler
t
sec
t
base

( )
CP
heat1

or by substituting and re-arranging

H
rec
TSA
cooler
t
sec
t
base

( )
0.309 0.268 10
4
t
sec
+

_
,

So
H
rec
TSA
cooler
t
sec
t
base

( )
0.309 0.268 10
4
t
sec
+

_
,

Substituting for value of

H
rec
TSA
cooler
t
sec
t
base

( )
0.309 0.268 10
4
t
sec
+

_
,
H
rec
0
Guess value
t
sec
790 :
TSA
cooler
m
3
kg

,
t
sec
t
base
K
273

1
1
]
0.309 0.268 10
4
t
sec
+

_
,

H
rec
kcal
kgcl
0
t
sec
Find t
sec
()
273 +
( )
K : t
sec
Find t
sec
()
273 +
( )
K :
but t
ta
and t
sec
are same as they are tapped from kiln hood together.
diff t
sec
t
ta
: t
ta
If diff >0.5 degK change the assumed value t
ta
to same as t
sec
and recalculate. Check for convergence
of fuel efficiency
diff diff
t
ta
t
sec
:t
sec
t
ta
t
ta
Temperature of hot clinker from kiln to cooler t
clh
Specific loading of clinker cooler -SL
clr
obtained by dividing nominal output of kiln in tonnes / day by
effective grate area of cooler in m
2

Requirement of cooling air at nominal kiln output. C
air.n1
in Nm
3
/kg cl
Temp. of cooling air - t
amb
Altitude factor -E
f
Relative humidity -RH %
Moisture in ambient air H2O
amb
Water vapour in cooling air from atmosphere - H2O
cair
Conversion factor - A1 to convert 1 kg. of dry air to equivalent wet air volume at NTP
Moisture in ambient air H2O
amb
Density of dry air at NTP
density of dry air at NTP =1.292 kg /Nm
3
dry
A1
H2O
amb
18.02 kg
22.4 m
3 1

air.dry
+ :
H2O
amb
Molecular wt. of water -=18.02
Molal volume of all gases at NTP =22.4Nm
3
Therefore : Requirement of cooling air at nominal kiln output in terms of kg. of dry air C
air.n2
in kg dry
air /kg cl
C
air.n2
C
air.n1
A1
:
A1
Therefore water vapour in cooling air from atmosphere - H2O
cair
H2O
ca ir
H2O
amb
C
air.n2
:C
air.n2
Input heat with dry cooling air H
cair
The specific heat of Air based on its temperature -CP
heat

converting to dimensionless
t
g
CP
heat1
0.309 0.268 10
4
t
g
+

air.dry
kg
m
3

,
kcal
kg K
:
t
g
H
cair
C
air.n2
t
amb
t
base

( )
CP
heat1
: CP
heat1
Input heat with water vapour in cooling air H
w
The specific heat of water vapour based on its temperature -CP
heat2

tg
t
amb
K
273 :
t
amb
CP
heat2
0.42 0.000185 t
g
+
( )
kcal
kg K
: t
g
H
w
H2O
cair
t
amb
t
base

( )
CP
heat2
: CP
heat2
Heat input to cooler by hot clinker - - H
cl
Total heat input to cooler -H
t.in
H
t.in
H
cl
H
w
+H
cair
+ : H
cair
Heat going out with cooled clinker -H
clo
The specific heat of Clinker based on its temperature ( For the temperature range of 0-1500 deg.c )
t
g
t
amb
K
273 :
t
amb
t
m
t
clc
K
273 :
SP
heat4
1.742 10
01
1.415 10
04
t
m
+1.283 10
07
t
m
2
5.077 10
11
t
m
3

_
,
+

1
]
kcal
kg K
:
SP
heat4
0.188
kcal
kg K

H
clo
1t
clc
t
base

( )
SP
heat4
:t
base
Heat going out from clinker cooler as radiation -H
rad
H
rad
0. 015 H
t.in
: H
t.in
Heat leaving cooler as recuperated by secondary and tertiary air -H
rec
H
rec
kcal
kgcl
H
rec
Heat with cooler exhaust gases -H
c.exh
Volume of exhaust gases from cooler -V
c.exh
in terms of
V
c.exh
C
air.n1
TSA
cooler
:TSA
cooler
at NTP
Quantity of exhaust gases from cooler -G
c.exh
in terms of
G
c.exh
V
c.exh
A1
:
A1
Heat going out with cooler exhaust gases - H
c.exh
is found by difference
H
c.exh
H
t.in
H
clo
H
rad
+H
rec
+
( )
: H
rec
Temperature of cooler exhaust gases -t
c.exh
t
c.exh
t
base
()

1
]
G
c.exh
0.24
( )
H2O
amb
G
c.exh

( )
0.43 +

1
]
H
c.exh
t
c.exh
150 :
Guess value
Given
t
c.exh
t
base
K
273

1
1
]
G
c.exh
0.24 ( ) H2O
amb
G
c.exh
( )0.43 +

1
]

H
c.exh
kcal
kgcl
0
t
c.exh
Find t
c.exh
( )
273 +
( )
K : t
c.exh
Find t
c.exh
( )
273 +
( )
K :
Fig.5 Diagrammatic model for cooler heat balance
Overall heat balance of preheater, kiln and cooler
sp. heat of coal -S
f
Heat input:
Combustion heat of fuel to kiln -CH
kiln
Ch
kiln
F
kiln
H
uk
:H
uk
Combustion heat of fuel to precalciner -CH
pc
CH
pc
F
pc
H
upc
:H
upc
Sensible heat of fuel to kiln- SH
kiln
SH
kiln
F
kiln
S
f
t
fuelk
t
base

( )
: t
base
Sensible heat of fuel to precalciner -SH
pc
SH
pc
F
pc
S
f
t
fuelpc
t
base

( )
: t
base
Sensible heat with feed material to preheater
Total input heat -H
ti
H
ti
Ch
kiln
CH
pc
+SH
kiln
+SH
pc
+heat
3
+ : heat
3
Heat output:
Theoretical heat of clinker formation TH
cl
TH
cl
R
W
30
kcal
kgcl
:
kgcl
Evaporation of moisture in raw meal
Cooler losses including heat with cooler exhaust ,outgoing clinker -L
cl
L
cl
H
c.exh
H
clo
+ : H
clo
Losses due to radiation from kiln,T.A.Duct, preheater, cooler- R
L
R
L
R
L1
R
L2
+R
L3
+R
L4
+R
L5
+R
kiln
+H
rad
+R
LTA
+ : R
LTA
Heat with preheater exhaust gases incl. dust-x
4

Bypass losses- L
by
Total output heat - H
to
H
to
TH
cl
L
H2O
+L
cl
+R
L
+x
4
+L
by
+ : L
by
Heat unaccounted for: = H
un
H
un
H
ti
H
to
: H
to
Conclusion:
As stated earlier, the live calculation using this model is carried out by Mathcement_PYRO. The entire
process of calculation with its internal loops cant be handled manually. In addition, evaluation of effects
of various changes in the input data singly or jointly needs to be studied to get the maximum benefit out
of this model.