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Kiln Filling Degree Calculations

1. The document provides calculations for various parameters related to kiln design and operation, including volumetric loading, thermal loading, effective volume, effective cross section, percentage filling, and feed retention time. 2. Formulas are given for evaluating parameters of other cement plant equipment, such as cooler performance, mill dimensions and capacity, critical mill speed, and tyre expansion. 3. Numerical examples are shown for some calculations.

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Abhishek
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562 views9 pages

Kiln Filling Degree Calculations

1. The document provides calculations for various parameters related to kiln design and operation, including volumetric loading, thermal loading, effective volume, effective cross section, percentage filling, and feed retention time. 2. Formulas are given for evaluating parameters of other cement plant equipment, such as cooler performance, mill dimensions and capacity, critical mill speed, and tyre expansion. 3. Numerical examples are shown for some calculations.

Uploaded by

Abhishek
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
  • Thermal Loading of Kiln: Covers how to calculate thermal loading for kiln operation considering heat loss and production capacity.
  • Kiln Effective Volume: Defines the effective volume calculation of the kiln using geometric dimensions.
  • Volumetric Loading of Kiln: Details the volumetric loading calculation of the kiln including parameters like diameter, length, and thickness.
  • Kiln % Filling: Describes the percentage filling capacity of the kiln and lists methods to calculate it with operational constants.
  • Cooler Performance: Analyzes performance metrics of the cooler, focusing on its thermal efficiency and associated variables.
  • Kiln Feed Retention Time: Provides formula and data required to calculate feed retention time within the kiln.
  • Kiln Effective Cross Section: Explains how to determine the effective cross section area of the kiln.
  • Critical Speed of Ball Mill: Explains the critical speed calculation for a ball mill, providing equations and examples.
  • Internal Volume of Mill: Outlines the calculation for determining the internal volume of a cement mill.
  • Evaluate Expansion: Details evaluation techniques for expansion in different components of the kiln, measured under specified conditions.

1.

Volumetric loading of Kiln


D : Diameter of the Kiln (m)
Volumetric Loading (TPD/m³) tk : Lining Thickness of the Kiln (m)
Clinker Production (TPD) L : Length of the Kiln (m)
π * ((D – 2tk) ²/4) * L
TPD π D tk L
2
1200 3.14 3 0.2 4 45
1200 3.14 1.69 45
1200 238.797
5.03 TPD/m³

2. Thermal loading of Kiln

Thermal Loading
Clinker (TPD) * Heat consumption * %firing in kiln * 10³
π* ((D – 2tk) ²/4) * 24*L
Thermal Loading : (kcal/hr/m²)
Heat consumption : (kcal/kg)
D : Diameter of the Kiln (m)
tk : Lining Thickness of the Kiln (m)

TPD [Link]. Firing% π D tk


1000 780 30 10000 3.14 3 0.2 24

234000000000.00 5731.128
40829658.6640536 10000000
4.08 kcal/hr/m²

3. Kiln Effective Volume

Effective volume (m³) π * D² * L


4
D : Kiln effective diameter (m) (ID of brick)
L : Kiln length (m)

3.14 2.6 45 4
3.14 6.76 45 4
238.797 m³
4. Kiln effective cross section
π * D²
Effective Cross Section area (m2) =
4

D : Kiln effective diameter (m) (ID of brick)


L : Kiln length (m)
π D
3.14 3 4
28.26 7.07 m2

5. Kiln % filling

3.2 * kiln capacity (TPD)


% filling =
D³ * Kiln speed (RPM) * Kiln slope (%)

D : Kiln effective diameter (m)


Typical values : 13 – 17%
TPD D RPM slope
3.2 1200 2.6 3.5 3.5
3840 17.576 215.306
17.84 % filling

6. Kiln feed Retention Time


11.2 * L
T= (min)
r*D*s

L : Kiln Length (m)


r : Kiln Speed (rpm)
D : Effective Diameter (m)
S : Slope (Degrees)
L r D s
T 11.2 45 3.2 2.6 2.5
504 20.8
24.23 (min)

7. Cooler performance
a. Thermal Efficiency of cooler
Qc – Q1 * 100
E
Qc
E : Thermal efficiency of cooler (%)
Qc : Heat content of clinker, cooler in (kcal/kg)
Q1 : Total heat losses in cooler (kcal/kg)

Qc Q1 Qc
E
650 250 650
40000 650
61.54 %

8. Internal volume of mill Cement Mill Raw Mill

Vm = π * D² * L 3.14
4 3.14

Vm : Internal volume of the mill (m³)


D : internal diameter of the mill, liner to liner (m)
L : internal length of mill (m)

3.14 3.4 3.4 12.5 4


3.14 11.56 12.5 4
453.73 4
Ans 113.43 m³

9. Critical Speed of Ball mill


Cement Mill Raw Mill

Nc = 42.3 Nc = 42.3
(RPM)
√D √D
42.3 3.4 42.3
42.3 1.84 42.3
Ans 22.94 (RPM) Ans 22.29

10. Evaluate Expansion


Expansion at 250˚C
1st Tyre Expansion (mm) 1.2* (T˚C final - T˚C initial) * Length (m)
100
1.2 253 108 3.16
100
1.2 1.45 3.16

Expansion (mm) 5.50 Ans.

Expansion at 250˚C
2nd Tyre Expansion (mm) 1.2* (T˚C final - T˚C initial) * Length (m)
100
1.2 265.5 141 3.16
100
1.2 1.245 3.16

Expansion (mm) 4.72 Ans.

Expansion at 250˚C
3rt Tyre Expansion (mm) 1.2* (T˚C final - T˚C initial) * Length (m)
100
1.2 277.5 150 3.16
100
1.2 1.275 3.16

Expansion (mm) 4.83 Ans.


clinker tpd*sp. Heat cons.
crossection area*24*1000

45
Raw Mill Caol Mill

3.6 3.6 7.5 4 3.14 2.4 2.4 6 4


12.96 7.5 4 3.14 5.76 6 4
305.208 4 108.5184 4
Ans 76.30 m³ Ans 27.13 m³

Raw Mill Caol Mill

Nc = 42.3
(RPM) (RPM)
√D
3.6 42.3 2.4
1.90 42.3 1.55
22.29 (RPM) Ans 27.30 (RPM)
253

265.5

277.5
V ∏
H(R²+r²+Rr)
3

3.14

875
1 1 0.2
0.2 2.6
0.52
464
498 215 215
928 464
1750 5530 5500
430
1320 660

928
430
498 249

3.27 1.56
1.71 2.3 0.43
1.69119

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