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L/S
Clay
M2
Loss
kg/day
kg/day
5%
0.05
Clay
M1
M3
Component
%
IN
M1
15
=
=
=
=
Loss
M2
15*0.05
0.75
14.25
M3
SiO2
70.69
+
+
+
OUT
M3
M3
kg/day
Al2O3
14.91
CaCO3
4.5
Fe2O3
6
MgCO3
1.5
M5
Loss
5%
0.05
Inert
2.4
Crusher
M4
M6
Component
%
IN
M4
85
=
=
=
=
Loss
M5
85*0.05
4.25
80.75
M6
SiO2
1.88
+
+
+
kg/day
Al2O3
1.2
CaCO3
94.45
Fe2O3
0.57
OUT
M6
M6
MgCO3
1.95
Inert
0
M8
Raw Mill
M3
M6
Loss
M3
14.25
IN
+
+
M6
80.75
M8
OUT
M8
M8
94.525
+
+
+
kg/day
Loss
M7
0.475
Composition of M7 & M8
SiO2
Al2O3
CaCO3
Fe2O3
MgCO3
11.591425 3.093675 76.909625 1.315275 1.788375
Component
kg/day
Component
%
=
=
=
=
M7
0.5%
0.005
MgCO3
1.88
Inert
0.342
Inert
0.36
Exhaust Gases
Kiln
M8
M9
IN
M8
94.525
=
=
kg/day
OUT
M9
+
+
Component
kg/day
SiO2
11.5
Analysis of M8
Al2O3
CaCO3
3.08
76.53
Component
Mwt
SiO2
60.06
Mwt of Component
Al2O3
CaCO3
101.94
100.09
Component
kmol/day
Exhaust Gases
Exhaust Gases
Fe2O3
1.31
MgCO3
1.78
Fe2O3
159.68
MgCO3
84.31
Moles of Component
SiO2
Al2O3
CaCO3
Fe2O3
MgCO3
0.192032 0.030196 0.764563 0.008196 0.021106
Inert
0.34
Component
%
C2S
20
Component
Mwt
C2S
172.22
Analysis of M9
C3S
C3A
60
12
C3S
228.30
C3A
270.18
C4AF
8
C4AF
485.95
Reaction In Kiln
CaCO3 -------------- CaO + CO2
MgCO3 ------------- MgO + CO2
CaO + Al2O3 ------------- CaO.Al2O3
4CaO + 2Al2O3 + CaO.Al2O3 ----------------- 5CaO.3Al2O3
5CaO + 3Al2O3 --------------- 5CaO.3Al2O3
2CaO + SiO2 -------------- 2CaO.SiO2
4CaO + 5CaO.3Al2O3 -------------- 3(3CaO.Al2O3)
CaO + 2CaO.SiO2 -------------- 3CaO.SiO2
4CaO + Al2O3 + Fe2O3 -------------- 4CaO.Al2O3.Fe2O3
1
2
3
4
5
6
7
8
9
3 + 4 ------------- 5
MgCO3
1
0.021106
X2
CO2
Weigh of CO2
----------------------
Y1
----------------------
Y2
=
=
Y1
CaO
1
X1
=
MgO
1
X2
=
CO2
1
Y1
0.764563 kmol/day
CO2
1
Y2
0.021106 kmol/day
+
Y2
kmol/day * Mwt
=
=
0.785668 kmol/day
34.577271 kg/day
2CaO
2
Y3
SiO2
1
0.192032
----------------------
Y3
X3
=
=
0.384065
0.192032
kmol/day
kmol/day
4CaO
4
Z4
Al2O3
1
Y4
Z4
Y4
X4
=
=
=
0.032783
0.008196
0.008196
kmol/day
kmol/day
kmol/day
5CaO
5
Z5
3Al2O3
3
Y5
Fe2O3
1
0.008196
----------------------
2Ca.SiO2
1
X3
----------
4CaO.Al2O3.Fe2O3
1
X4
5CaO.3Al2O3
1
X5
3(3CaO.3Al2O3)
3
X6
4CaO
4
Y6
Y6
X6
=
=
=
0.022001
0.007334
0.036668
kmol/day
kmol/day
kmol/day
5CaO.3Al2O3
----------1
X5 =
0.007334
=
=
0.029334
0.022001
kmol/day
kmol/day
CaO
1
Z7
2CaO.SiO2
1
Y7
-----------
3CaO.SiO2
1
X7
Weigh Ratio
Mwt
Mole Ratio
C3S
3CaO.SiO2
60%
3
228.3
0.013141
2.263
X7
X7
X7
2CaO.SiO2 Excess
2CaO.SiO2 Excess
Inerts in
MgO
CaO Excess
----------------------------
Amount of Inerts
=
=
=
=
=
=
=
Amount of Inerts
C2S
2CaO.SiO2
20%
1
172.22
0.005807
1
Inert in
=
=
=
Outlet
Reactant
CaCo3
Y3+Z4+Z5+Y6+Z7
0.148532 kmol/day
MgO
CaO Excess
Analysis of inlet
Moles of component * Mwt
CaO Excess * Mwt
0.340290
9.520970
+
kg/day
0.8509874
8.329693
Component
C2S
C3S
C3A
C4AF
Inert
Sum
kmol/day
0.058851
0.133181
0.022001
0.008196
-
Mwt
177.22
228.3
270.3
485.95
-
=
=
=
M9
60.285304
94.862575
kg/day
kmol/day * Mwt
10.429662
30.405208
5.946735
3.982729
9.520970
60.285304
%
17.3
50.4
10
6.6
15.8
100.0
Check
M8
94.525
94.525
+
+
Exhaust Gases
34.577271
M9
Cement Mill
M10
5%
0.05
M10
M11
M11
M.B of CaSO4:
0.0*M9 + M10 = 0.05M11
M.B of Clinker:
0.0 + M9 = 0.95M11 = 60.285304 kg/day
M11 = M9 / 0.95 = 60.285304 / 0.95
M11
63.458215
kg/day
M10
3.172911
kg/day
Real Quantities
Converted Balance
Annual Production
Working Days
1000000
ton/year
100
X
kg/day
kg/day
1000000
300
ton/year
day/year
3333333.3
kg/day
------------63.1
------------- 3333333.3
kg/day
kg/day
Basis
5282620.2
kg/day
M``
=
X*M / 100
M`` : Real quantities
X : the amount of clay and lime stone which produce 1000000 ton/day
M2
0.75
Clay
Loss
M1
15
M``
X*M / 100
M1``
M2``
M3``
=
=
=
792393
39619.65
752773.4
kg/day
kg/day
kg/day
M5
4.25
Loss
Crusher
M4
85
5%
0.05
14.25
M3
5%
0.05
80.75
M6