Importance..

Around 25% of the total production cost is

spent for Heat
Economy of the plant depends of its specific
Heat consumption
Reduction in specific heat consumption
leads to smoother and easier kiln operation

Reduction in cooler Loss

Secondary Air & TAD
Temp raise
Improved flame in kiln
& better combustion in
Calciner
Less circulation of
volatile matter
Less formation of Build
ups in Riser Pipe
Smoother and easier
kiln Operation

Reduction in
Specific Heat
Consumption
Reduction in
Specific Vent Gas
Flow

Increased Rawmeal
Feed to Kiln

More Clinker
Production

Controllable Parameters

Rawmeal
Combustibles
Air Distribution
False Air Intake
Cooler Loss
Cyclone Efficiency

CONTENTS
Introduction
Rawmeal Quality and Properties

Heat of reaction
Content of combustible materials
Content of free & combined moisture
Temperature of kiln feed

Combustibles, Quality & Properties

Types of fuel
C.V.of fuels
Moisture in Coal

Contents
Air Distribution
Primary air
Excess air in Kiln
False air intake

Cooler Loss
Preheater Cyclone Efficiency
Conclusion

HEAT BALANCE
Heat In put

Kcal /Kg
Clinker

Heat through Coal

Combustion

689.04

94.39

Sensible heat in Raw meal

25.06

3.43

Sensible heat in Fuel

0.98

0.13

Sensible Heat in Air

14.87

2.03

Total Heat In put 729.95

100 %

Heat Out put

Kcal /Kg
Clinker

Heat in PH exit Gases

140.85

19.29

Heat in PH exit Dust

3.97

0.54

Heat of reaction

402.5

55.14

Cooler exhaust air

94.57

12.95

Heat in Clinker discharge

23.1

3.16

Heat in H2O evaporation

1.69

0.23

Radiation Loss

61.9

8.48

Rawmeal Quality and

Properties
Influence on
* Heat of reaction
* Content of combustible material
* Content of free and combined moisture
* Temperature of kiln feed

Heat of Reaction...
The theoritical amount of energy required to
convert the rawmeal into the corresponding
mixture of clinker minerals
Energy chemically absorbed by the
formation of clinker

Heat of Reaction

Heat required to
decompose the
carbonates,
silicates and
chemically
combined water

Heat liberated by
the formation of
calcium silicates,
alkali sulphates
and combustion
of organic
compounds

 Heat of reaction (HOR) will be normally in the range

of 385 - 420 Kcals / Kg of clinker

It is an inherent characteristic of a rawmix

and it is not in the power of the operational
staff to influence
It can be reduced by using the materials like blast
furnace slag which is having around 55% CaO and
very low heat of reaction
Increase in HOR by 1Kcal / Kg of clinker increases
* 1.1 kcals / kg of clinker in specific heat consumption
* 0.3 degC in exit gas temperature
* 0.3% in specific power consumption

COMBUSTIBLE MATERIAL
Organic matter present in the rawmeal
partly substitute the fired fuel and thus
reduces the fuel expense
Typical combustibles in raw mix comprise
Soil, Organic matter, Pyrite , Coal Shale
etc..
But they burn in the preheater lower
cyclones and thus less efficiently burnt and
increases the exit gas temperature.
Leads to frequent CO formation in the
exit gas

Effect of Combustible materials on Heat

consumption

10Kcals/ Kg of
clinker as
Combustibles in
Rawmeal

Less
than10Kcals/
kg of clinker
Reduction in
specific Heat
Consumption

Heat Loss
in
Preheater
Exit Gas

Operating considerations
CO problems
Increase in Exit gas temperature

CO can not be reduced only by more excess air

Exit gas volume also increases with Excess air
Can Manage by PH gas down comer cooling if PH fan is a
bottleneck or having the GCT before the ID fan

Content of Free and Combined

Water
Free water in rawmeal evaporates at top stage
cyclones and reduce the preheater exit gas
temperature to some extent
Combined moisture (chemically bound
water) evaporates at second stage cyclone.
Combined moisture will be around 0.5 -1.5%
in rawmill which is not affected by the drying
process in rawmill.

Free moisture
1 Determined by Raw mill
2

outlet temp
Free water evaporate at temp
below 100 Deg C;

3 Usually less than 1 % by

weight (range :0.5 to 0.8%)

Combined moisture
It is characteristic of minerals
in the raw materials
Combined water evaporate at
temp above 100 Deg C;
Usually 0.5 1.5 % by
weight

4 Every 0.2 % moisture adds to Every 0.2 % moisture adds to

0.4 Kcal/kg clinker heat consn 1.1 Kcal/kg clinker heat consn

Influence of Free moisture in Raw meal

Free moisture in rawmeal

Raise in Sp heat
consn

Redn in
Exit gas
temp

Reduction in
Sp Power

More
moisture
gives flow
problem

Raw mill
output can
improve
with more
moisture
in raw
meal

Influence of Free and Combined Moisture

Free moisture ( for
Every 1 % by wt)
+ 1.8 Kcal / kg clinker

Specific
Heat consn
Exit gas temp -16 Deg C

Combined moisture ( for

Every 1 % by wt)
+ 5.6 Kcal / kg clinker
- 35 Deg C

-1.3 %
- 6.9 %
Specific
Power consn
Net effect 1.0 kcal/kg clinker more 0.5 Kcal/kg clinker heat
after adjusting the
power benefit

consn more after

adjusting the power
benefit

( for 1 million TPA @ Rs 430/Mkcal & Rs 4/ Kwh)

 Influence of free and combined moisture on

heat consumption is only moderate
But. the effect on preheater exit gas
temperature may be beneficial to the ID fan
capacity and power consumption

Temperature of Kiln Feed

1. Determined by the temp in the raw mill outlet
2. Has some influence on heat economy

Parameter affected

Exit gas temp

Per 10 Deg C
increase in Kiln
feed temp
-0.5 Kcal / Kg
clinker
+ 5.4 Deg C

Sp Power

+ 1.1 %

Specific Heat consn

FUELS QUALITY
AND PREPARATION

Based on the fuel used

Combustion gas volume varies
Amount of ash content also varies
Heat consumption also varies
Temperature profile of kiln system varies

Firing with coal will increase the specific

heat consumption as compared with oil
firing because of the introduction of coal
ash into the kiln
Specific Heat
As the Ash in
coal increases

consumption, exit
gas temp, smoke gas
volume increases

For gas fired kiln..

Smoke gas volume will be more as the
natural gas contains more of Hydrogen
the preheater exit temperature is high and
specific power consumption of the ID Fan
will also be high
Oil to Coal
Sp Heat

+ 12 Kcal /Kg cl
Due to coal ash

Exit gas temp +5 Deg C

Sp Power

+ 2%

Oil to gas
+ 12 Kcal /Kg cl
Due to more hydrogen
in Gas
+ 13 Deg C
+ 14% due to more
flue gas volume

Calorific value of fuels

NCV:
The Net CV is the amount of useful heat
released from combustion
Lower the NCV, higher will be the Heat consumption

Lower the NCV, harder will be the kiln operation

Hydrogen / Carbon ratio affects the NCV
Increase of Sulphur reduces the NCV
Coal displays higher difference in NCV due to variations in
ash and type
Oil displays fairly less change in NCV for different grades
Low C.V coals are cheaper than high C.V coals

Calorific value of fuels

Results from reference
model: The Influence of the Net C.V of fuel

Exit gas temp

- 1.1 Deg C

Coal per 100

Kcal /Kg coal
increase in NCV
- 0.2 Kcal / Kg
clinker excl. ash
content effect
- 0.5 Deg C

Sp Power
consumption

- 1.0 %

- 0.1 %

Sp heat
consumption

Fuel oil per 100

Kcal /Kg oil
increase in NCV
No influence

MOISTURE in COAL
A minimum residual moisture is required in
the fine coal to avoid self ignition
A higher moisture content will reduce the
flowability and cause dangerous build-ups
H ig h M o is t u r e c o n t e n t o f c o a l
B u lid U p s in F in e C o a l B in

I n c r e a s e d S m o k e g a s V o lu m e

R e d u c e d c a lo r ific V a lu e

R e d u c e d F lo w a b ilit y

In c r e a s e d H e a t lo s s in E x it G a s

I n c r e a s e d S p e c ific H e a t C o n s u m p tio n

L e s s k iln p r o d u c tio n

I n c r e a s e d I D F a n P o w e r c o n s u m p tio n

M o r e a s h d ilu tio n o f c lin k e r

Issues:

Residual moisture is determined by

the self
ignition characteristic of coal

Lignite and high volatile coals has

more
self ignition property and
requires high
residual moisture

Too much residual moisture will

affect
flow ability and cause
dangerous build ups

Moisture in coal adds up to inactive

gas
volume thro kiln system

Results from reference model:

The influence of Moisture in fine coal

Sp heat consumption

Per 1 % increase in
moisture of coal
+ 0.45 Kcal / kg clinker

Exit gas temp

Sp power consumption

+1.0 Deg C
+ 0.7 %

Operating considerations:
For Direct firing systems the heat consumption increases
with more coal moisture
For indirect firing systems the effect is minimal

AIR DISTRIBUTION
Influence of .
Primary air
Excess air
False air

False air
Excess air
Primary air

PRIMARY AIR
Injected through the burner pipe into the kiln for
flame formation and control
Using hot primary air will improve the heat
economy but needs bigger fan and ducting
Minimizing the primary air will improve the heat
economy by using more secondary air
Preheater kilns are more sensitive to primary air
Amount of primary air determined by
* Flame formation
* Burner design
* Design of firing installation

AIR DISTRIBUTION PRIMARY AIR

Results from reference model:
Influence of Primary air quantity and temperature
For PH kilns

For Calciner kilns

P.Air Per 1
% increase

Primary Air
Per 10 Deg C
temp increase

P.Air Per 1
% increase

Primary Air
Per 10 Deg C
temp increase

Sp heat
consn

+ 1.7 Kcal /
kg clinker

- 0.4 Kcal /
kg clinker

+ 0.7 Kcal /
kg clinker

- 0.2 Kcal /
kg clinker

Exit gas
temp

+ 0. 4 Deg C

- 0. 15 Deg C

+ 0. 3 Deg C

-0.06 Deg C

Sp Power
consn

+ 0.5 %

- 0.5 %

+ 0.2 %

- 0.06 %

Excess Air in the KILN

A certain excess air is maintained in the kiln
inlet to avoid CO formation and reducing
conditions in kiln
Increase in kiln draft increases the heat
consumption but neutralised by the increased
heat recuperation from the cooler
The amount of excess air during operation is
determined by the Oxygen content in the kiln
inlet and preheater exit, which continuously
monitored by the on-line gas analysers.

Increased
Excess Air
More heat
Loss in
preheater
Heat loss

Increased ID
Fan Load
Excess O2 in
Smoke Gas
Movement of
Heat towards
inlet
Cooling of
Burning Zone

The influence of Excess air on the heat consn and other

parameters for PH and ILC Kiln

For PH kiln Per %

Increase in excess air
in kiln

For Calciner kiln Per

% Increase in excess
air in kiln

Sp heat consn

Independent of excess +0.1 Kcal / kg clinker

air
up

Exit gas temp

+1.7 Deg C

Sp power consn + 1.7 %

+0.9 Deg C
+0.9 %

For a specific heat consumption of

750 KCals/Kg of clinker ,
Theo. Combustion air = 1.06 Kg of air/Kg of clinker
= 0.8198 Nm3 / Kg of Clinker
@10% Excess air
Combustion air = 1.166 Kg of air /Kg of clinker
= 0.9018 Nm3 / Kg of Clinker
The waste gas quantity from preheater is
= 1.5 NM3 / Kg of clinker

False air intake.

As it is a induced draft system, intake of certain
amount of false air is inevitable.
Has a substantial influence on the heat
consumption, power consumption, production and
coating build- ups in preheater tower.
Closer to the kiln outlet, the effect will be
substantial.
If 0.1 kg of false air/kg of clinker enters at
preheater top cyclones,
it increases the specific heat consumption by 1
kcal/kg of clinker, whereas the increase in specific
heat cinsumption is 1.8 kcals for kiln inlet seal
leakage.

Common areas to be watched for false air

Preheater doors

Kiln inlet seal

Preheater fan damper seal.
Kiln hood inspection door and cleaning holes
Expansion, welded and flanged joints in preheater
kiln outlet seal
A 100cm x 10cm hole at kiln riser duct with a
draught of 70mmwG will allow a false air of 4 kg of
air / sec .
For a production of 4000 TPD , it is 0.08 kg/kg of
clinker and the specific heat consumption will
increase by
(0.08/0.1)x 18 = 14.4 Kcals/ Kg of clinker

 Due to the leakage air, the operating point of ID

fan is shifted from its maximum efficiency point
causing more power consumption
The ingression of false air may lower the
maximum kiln production due to the increase in
specific smoke gas quantity.
Amount of false air entry and the profile of false
air can be found out by measuring the oxygen
content in various places.
(O2 outlet - O2 inlet)
% False Air = -------------------- X 100
at inlet
( 21 - O2 outlet)

Air leak through an aperture of area A(m2) with a

differential pressure of DP(mmWG) can be
calculated from
Volume (m3 /hr) = 8900 x A x sq Rt ( DP)

Results from reference model:

The influence of False air on the heat consn and other
parameters for PH and ILC Kiln

Sp heat consn
Sp power
consn

Per 0.1 kg air /kg

clinker Increase in
false air in top
cyclone
1 kcal /kg clinker

Per 0.1 kg air /kg

clinker Increase in
false air in kiln inlet

+ 1.7 %

+0.9 %

18 kcal /kg clinker

COOLER LOSS
Heat loss in
Cooler exit air
Clinker
Radiation
With normal wear in daily operation, the cooler
loss can often increased by 10-20 Kcals/Kg of
clinker and ID fan power consumption by 3-6%
For grate coolers, optimum recuperation is
achieved when clinker is well distributed over
the cooler width, which can be optimised by
adjusting air distribution

 A bed height of 400 - 600mm to be maintained by

means of adjusting the grate speed and undergrate
pressure. A higher bed thickness improves the
heat recuperation and reduces the heat losses for
cooler.
Avoiding blowing pot holes by maintaining the
gaps between the grate plates minimum.
Reducing the false air entry in cooler
Reducing the heat loss by proper refractory
maintenance
Optimizing the cooler specific air consumption.
Secondary air and tertiary air temperatures are the
important indicators of the cooler efficiency and
heat recuperation.

Results from reference model:

Influence of cooler loss on heat consn & other parameters
For PH kiln Per 1 kcal For Calciner kiln Per
/kg cl Increase in
1 kcal /kg cl Increase
cooler loss
in cooler loss

Sp heat consn

+ 1.0 Kcal / Kg cl + 1.1 Kcal / Kg cl

Exit gas temp

+0.3 Deg C

+0.4 Deg C

Sp Power consn

+0.28%

+0.4%

CYCLONE EFFICIENCY
Higher efficiency of cyclones will reduce the
specific heat consumption especially for the
bottom stage cyclones.
Though cyclone efficiency is based on the design
aspect, we can reduce the heat consumption by
means of the following important points as they
have high impact on specific heat consumption.
# Periodic maintenance of Dip tubes
# Material flap gates and spreader boxes are most
important for better heat transfer in preheater.

 Avoiding build-ups in the preheater using

air blaster, regular cleaning and keeping
the surface smoother.
Maintaining the cyclone interior portion
properly.
Temperature difference between the inlet
and outlet of the cyclones is the indication
of the cyclone efficiency.
Temperature and pressure profile should be
measured in preheater for analysing the
cyclones performance.

Indicators of Poor Cyclone Efficiency

Small Difference in gas inlet / outlet
temperature
Change in temperature profile
Increase in PH Exit gas temp
Increased dust loss
Increase in ID fan power
Change in Kiln feed factor

CONCLUSION
Important Optg Parameters
A Change
in

By

Results in a change in

Unit

Heat
Kcal /kg

Temp
0
C

ID Fan
%

0.1
0.1
0.1

Kg /kg cl

Kg /kg cl

18
17
18

21
5.0
21

23
5.1
25

Cy 3

0.1

Kg /kg cl

5.9

-0.6

11

Cy 1 (top)

0.1

Kg /kg cl

0.9

-9.4

5.0

False air intake

Inlet seal
Kiln hood
Cy 5

Kg /kg cl

(bottom)

Important Optg Parameters

A Change
in

By

Unit

Air distribution
%
Primary
1.0
Air
Cooler Loss
Std Cooler 1.0 Kcal /kg cl
loss
Efficiency of Cclone

Results in a change in
Heat
Kcal /kg

Temp
0
C

ID Fan
%

1.7

0.5

0.5

1.0

0.3

0.3

Cy 5

1.0

-0.6

-1.1

-0.6

Cy 1 (top)

1.0

-0.2

1.8

-0.7