8/10/2019 Grate cooler thermal Analysis.ppt

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By

Abdul Manan

13103046

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Mass Balance Analysis

Global Mass Balance kiln system

Grate Cooler Mass Balance

Balance Energy of Grate Cooler

Eficiency Thermal

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Suspension Preheater

Kiln Feed 273 ton/h

Coal 8124.3 kg/h

Primary Air coal 28 m3/min

Natural Gas 3630.75 kg/h

Rice Husk (RH) 11.8 ton/h

Primary Air RH 68 m3/min

Grate Cooler Measurement

Clinker Ratio 1.76

Air Cooler Rate 5900 m3/min

Exhaust Air rate 7.44 m/s

Tin Grate Gooler 1450C

Tout grate cooler 103C

Texhaust air 241CTsecondary air 950C

T3rd air 950C

Tambient 32C

Kiln

Coal 8124.3 kg/h

Primary Air 40 m3/min

Raw Material

Composition % w.t

CaO 44.04

SiO2 12.91

Al2O3 3.23

Fe2O3 2.11

MgO 1.19

SO3 0.27

H2O 0.8

Lost of Ignition 35.45

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Coal (Proximate Analysis)

Composition % w.t

Whole

Water

3.6

Ash 19.3

Volatile

Matter

41.4

Fixed

Carbon

35.7

Coal (Ultimate Analysis)

Composition % w.t

C 71.2

H 4.5

O 21.9

N 0.9

S 0.7

Rice Husk

Composition % w.t

C 38.3

H 4.36

O 35.45

N 0.83

Ash 20.6

H20 8.3

Natural Gas

Composition % w.t

CH4 58.37

C2H6 4.78

C3H8 3.49

C4H10 1.6

C5H12 0.59

C6H14 0.49

N2 2.77

CO2 27.91

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Flow Input (Kg/h) Output (Kg/h)

Kiln Feed

Coal (SP)

Coal (Kiln)

Rise husk

Natural Gas

Cooler Air

Primary Air SP

Primary Air Kiln

Primary Air Rise Husk

Clinker Out

Gas out

CO2 Calcination

Steam

Return Dust

Exhaust Air

273,000

4,890

6,990

11,800

3,285

410,640

1,766

2,523

4,289

155,114

234,514

85,273

2,184

35,202

206,249

Total 719,003 718,536

Loss mass 647

Global Mass Balance

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Flow Input (Kg/kg clinker) Output (Kg/ kg clinker)

Kiln Feed

Coal (SP)

Coal (Kiln)

Rise husk

Natural Gas

Cooler Air

Primary Air SP

Primary Air Kiln

Primary Air Rise Husk

Clinker Out

Gas out

CO2 Calcination

Steam

Return Dust

Exhaust Air

1,7600

0,0315

0,0451

0,0761

0,0212

2,6474

0,0135

0,0163

0,0277

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1,0000

1,5119

0,5497

0,0141

0,2269

1,3297

Total 4,6365 4,6323

Loss mass 0,0042

Global Mass Balance

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Flow Input (Kg/kg Clinker) Output (Kg/kg Clinker)

Air Cooler

Leak Air

Clinker+ kiln cooler ash

Clinker Out

Exhaust Air

3rdAir

2ndAir

Kiln Cooler Ash

2,6474

0,0080

1,1000

-

-

-

-

-

-

-

-

1

1,3297

0,9150

0,4107

0,1000

Total 3,7553 3,7553

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Flow Input (kcal/kg Clinker) Output (Kg/kg Clinker)

Air Cooler

Leak Air

Clinker+ kiln cooler ash

Clinker Out

Exhaust Air

3rdAir

2ndAir

Kiln Cooler Ash

Heat Loss

20,08

0,06

422,67-

-

-

-

--

-

-

-19,26

77,87

218,18

97,93

22,427,16

Total 442,81 442,81

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t =

=

76.4 %=

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firebrick

grate cooler wall

grate plate

Leak Air

Causes of Heat loss:

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Conclusion

Termal Efficiency of Grate Cooler is 76.4%

Grate Cooler is working properly based on

(Duda,W.H.Cement Data Book.1986)

Suggestion

Evaluate the Thermal Efficiency periodically

Raplace grate plate periodically

Raplace fire brick periodically

Repair the leakage