Page-1/5

PLANT : BINANI CEMENT - 09.06.2004

208.50 km3/hr
Clinker
Hopper

Gypsu
m Ho...

False Air

5 mass%, w

47.31 km3/hr

172.64 tph
Sepax Fan

37.51 tph

106.0 deg.C

108.4 deg.C

ESP
E.S.P.
355/38 kW/amps

Sepax
Cyclones

16.71 tph
Elevator

146.32

tph, dry

10.14

0.00

% H2O

5.00

1168 rpm
Separator

19.12 %

31.5 amps

Stack

Belt Conveyor
ESP Fan
50 amps
6.74 km3/hr

Airslide

108.0 deg.C

62 amps

JPF
5.76 tph
Coarse Return

45.25

km3/hr

35.64

tph

115.0

deg.C

156.47 tph
17.68 %

185.00 tph
83.78 %
157 tph, wet

110.0 deg.C

Folaphone 69 %

100.00 %
Cement

Ball Mill
UMS 46x16.5

28.77 km3/hr

341.47 tph

31.05 tph

46.91 %

34.5 deg.C

115.0 deg.C

Silos

Cement Mill - 1
110.0 deg.C

324.76 tph
48.67

2.18 m3/hr
Water Pump, I/L

10/04/2015 03:37:22 288630647.xls Pic

1.87 m3/hr
Water Pump, O/L

Cement Silos

LU001016-CMP#Ver.2.3D***

Page-2/5

Cement Mill Basic Calculations : UMS 46 x 16.5 BM

Site Conditions
Plant Elevation

Equipment Specifications
mts +MSL

402

Mill Diameter

mts

4.60

mts

16.50

Barometric Pressure

mmWG

9827

Mill Length

Barometric Pressure

mmHG

723

Mill System

deg.C

34.5

Mill Speed

Ambient Air Temperature

Radiation Surface

m2

271.18

Separator Type

Pitot Constt. S-Type, L=1m

S1

0.883

ESP Fields

Pitot Constt. S-Type, L=2m

S2

0.847

Cement Grade

1.000

Pitot Constant - L Type

open/closed
rpm

closed
15.20

Sepax 400M-222
nos.
OPC grade

Feed - Product - Water

4
43

Mill Operation - CCR

Mill Feed Rate, wet

tph

157.00

Mill Main Drive - I

kW

2320

Mill Feed Rate, dry

tph

156.47

Mill Main Drive - II

kW

2207

Clinker Feed Rate

tph

146.32

Total Main Drive Power

kW

4527

Gypsum Feed Rate, wet

tph

10.68

Total Installed Power

kW

2600x2

rpm

1168

Percent Gypsum

6.80

Separator Speed ( Max. 1500 )

Percent Water, Gypsum

5.00

Separator Load

Gypsum Feed Rate, dry

tph

10.14

Folaphone

Clinker Temperature

deg.C

124.3

Sepax Elevator Load

amps

32

Gypsum Temperature

deg.C

31.0

Silo Elevator Load

amps

62

Mill Output, dry

tph

156.47

Sepax Fan Load

Coarse Return, Calc.

tph

124.04

ESP Fan Load

Coarse Return, CCR

tph

185.00

Mill Sp. Power Consumption

Coarse Return Temp.

deg.C

110.0

Water Injection, Inlet

m /hr

2.182

Water Injection, Outlet

m /hr

1.874

Water Injection, Total

tph

4.06

amps

144

69.0

kW/amps
amps
kWh/ton-Cem

Cement Fineness (Blaine)

355/38
50
33.38

m2/kg

311

Sepax Fan Damper

100

Sepax Fan Speed

98.50

Dampers / Speed

Diaphragm Temperature

deg.C

110.0

Mill Inlet

100

Cement Temperature

deg.C

115.0

ESP Fan

84

Water Temperature

deg.C

35.0

Dedusting Fan

1345

Water Vapor (ESP I/L)

Mat. Concn. at Sep. Outlet

Sepax Dust Load

gm/m3-wg
kg-cem/kg-wg

108
0.1650

1.62

Heat & Dust Parameters

Evaporation Heat

deg.

Miscellaneous Parameters

kcal/kg

594.6

Gas Velocity a/c Ch.I

m/s

0.46

kcal/kW

860

Gas Velocity a/c Ch.II

m/s

0.53

Mill Surf. Radiation Heat

kcal/m2/hr

393

False Air a/c ESP w.r.t. Mix, vol.%

dry%

5.00

Mill Surf. Convection Heat

kcal/m2/hr

293

False Air a/c ESP Fan (Norms)

0.50

Cyclone Dust (FLS Norms)

gm/m3-wg

30.0

Avg. Surface Temp. of Mill

deg.C

97.0

ESP Dust

gm/m -wg

369.2

Wind Speed

Mcal/hr

21.81

Junction Draft

Grinding Heat

ESP+Aux. Heat Emissions

m/s

3.0

mmWG

101

PLANT : BINANI CEMENT - 09.06.2004

Cem. Mill No.

<< ERRORS >>

Error1

0.0000

Error2

0.0000

Page-3/5

Cement Mill Power & Separator Calculations : UMS 46 x 16.5 BM

BALL MILL POWER CALCULATION
Description
Effective Length, L

Lining Thickness, t

mm

Effective Diameter, D
Charge Density

Comp. I

Comp. II

Combined

4.330

11.410

15.740

95.0

40.0

4.410

4.520

7.854

7.854

t/m

Charge Amount

Comp.I

Comp.II

Hichrome Balls

90 mm

25 mm

15.770

41.920

Hichrome Balls

80 mm

20 mm

22.480

83.850

Hichrome Balls

70 mm

15 mm

14.710

83.850

Hichrome Balls

60 mm

15.960

68.920

209.620

278.54

68.229

213.263

281.49

10.33

41.76

Total Charge (booked), F

Total Charge (calc.), F
Specific Surface

m /t
2

Mean Piece Weight

Total Surface

gms/ball

1554.59

22.68

712

8754

t/kWhnet

5.30

14.30

12.06

0.73

0.73

0.73

4.30

4.50

4.45

Relative Efficiency
Torque Factor (B4), u

Media Bulk Weight, g

t/m

Arm of Gravity, a

0.665

0.644

Segment Width, W

4.010

4.170

Free Height, H

3.123

3.132

Centre Distance, h

0.918

0.872

m3

66.14

183.08

249.22

Filling Degree, q

23.99

25.89

25.38

Critical Speed, nc

20.14

19.90

20.02

rpm

15.20

15.20

15.20

Calculated Power, Nnet

kWnet

1155

3485

4640

Calculated Power, Ngr

kWgr

1224

3694

4919

Compartment Volume, V

Mill Speed, n

SEPARATOR PERFORMANCE & EFFICIENCY

Parameters

% Residue

Used for

Blaine

212m

90m

45m

Calculation

m2/kg

Feed, Ro

100.00

100.00

100.00

100.00

Coarse, Rg

83.78

83.78

95

Mill Discharge, Rd

48.67

48.67

219

Separator Feed, Rm

46.91

46.91

236

ESP Dust, Re

19.12

19.12

265

Fines, Rf

17.68

17.68

311

Circ. Factor, Calc.

1.79

1.79

Circ. Factor, CCR

2.18

2.18

Sep. Efficiency, Vs

80.72

80.72

Fines Efficiency, Vf

86.49

86.49

Coarse Effciency, Vc

78.98

78.98

0.2

yes/no

yes

yes

Dust from ESP

tph

16.71

16.71

265

Rg > 44 * Rf

HMB Simulation

Volume, m3/ball

0.0003817
0.0002681
0.0001796
0.0001131

Balls, nos.
5260
10677
10429
17968
44333

Arm of Gravi

a
h/D
a

Volume, m3/ball

Weight, gms/ball

Surface, m2/ball

0.0000082

2997.90

64.26

0.02545

0.00196

0.0000042

2105.52

32.90

0.02011

0.00126

0.0000018

1410.53

13.88

0.01539

0.00071

888.27

Balls, nos.

0.01131

Mean Piece Wt., gms/ball

Sp. Surface, m2/t

652397

15770000

41920000

133.86

1280.98

2548728

22480000

83850000

214.67

3202.83

6041430

14710000

83850000

160.54

4270.44

15960000
9242555

203.21

68920000

209620000

712.27

8754.24

1554.59

22.68

10.33

41.76

Arm of Gravity
Comp-I

Comp-I

4.010

4.170

15.275

16.046

1.466

1.455

0.665

0.644

0.208

0.193

0.657

0.639

24.29

26.06

Page-4/5

Cement Mill Heat & Mass Balance Calculations : UMS 46 x 16.5 BM

S.

Constraints

No.

Amount
tph

Temp.

kNm3/hr

deg.C

Cp

Heat

kcal/kg/deg.C kcal/hr x 103

kcal/kg-Cem

INPUT
1

Clinker, dry

146.32

124.3

0.190

3453

22.07

Gypsum, dry

10.14

31.0

0.211

66

0.42

Water, gyp

0.53

31.0

1.000

17

0.11

Water Spray, Inlet

2.18

35.0

1.000

76

0.49

Water Spray, Outlet

1.87

35.0

1.000

66

0.42

Inlet Air, dry

30.59

24.22

34.5

0.242

256

1.63

Water, air

0.46

34.5

1.000

16

0.10

Coarse Return

124.04

110.0

0.188

2569

16.42

Grinding Heat

3699

23.64

10217

65.30

TOTAL INPUT
OUTPUT
1

Cement

263.80

115.0

0.189

5729

36.61

Total Air, dry

30.59

23.65

115.0

0.270

950

6.07

ESP Dust

16.71

115.0

0.189

363

2.32

Water Vapour

5.05

115.0

0.449

260

1.66

Evaporation

4.59

2729

17.44

Surface Heat Losses

97.0

186

1.19

Balance / Losses

0.00

10217

65.30

TOTAL OUTPUT

PLANT : BINANI CEMENT - 09.06.2004

10/04/2015 03:37:22 288630647.xls HMB

LU000111-CMP#Ver.1.4***

Heat Cap - Coefficients

Gas/Mat

*T^0

*T^1

*T^2

*T^3

*T^4

0.2485

-3.340E-06 4.440E-08 -2.797E-11 5.597E-15 Not used in calc.

0.1244

0.000E+00 0.000E+00 0.000E+00 0.000E+00 Not used in calc.

O2

0.2130

7.796E-05 -7.563E-08 4.074E-11 -8.183E-15

CO2

0.1906

1.771E-04 -1.733E-07 9.315E-11 -1.894E-14

N2+Ar

0.2465

-3.284E-06 4.366E-08 -2.750E-11 5.504E-15

H2O,steam

0.4445

2.910E-05 6.887E-08 -3.726E-11 6.472E-15

H2O, liq.

1.0000

Rawmeal

0.2060

1.014E-04 -3.673E-08

Clinker

0.1742

1.414E-04 -1.283E-07 5.074E-11

Cement

0.1742

1.414E-04 -1.283E-07 5.074E-11

Gypsum

0.2070

1.414E-04 -1.283E-07 5.074E-11

10/04/2015 03:37:22 288630647.xls HMB

LU000111-CMP#Ver.1.4***

Page-5/5

Cement Mill Air Flow Calculations : UMS 46 x 16.5 BM

Flow Analysis

Mill

Mill

ESP

False Air

Sepax Fan

Sepax

Inlet

Outlet

Outlet

ESP

Inlet

Vent

Dry Bulb Temp.

deg.C

34.5

115.0

108.4

34.5

106.0

108.0

Wet Bulb Temp.

deg.C

22.0

65.0

22.0

39.0

39.0

Dew Point (F4)

deg.C

19.5

62.7

19.5

25.0

35.0

Dew Point, calc.

deg.C

19.6

62.1

62.7

19.6

25.1

35.2

kg/kg-dg

0.015

0.165

0.170

0.015

0.021

0.038

Avg. Ps

mmWG

-25.00

-110

-190

-110

-524

-93

RMS Pd

mmWG

3.33

20.00

5.08

mts

0.80

1.00

1.20

2.00

0.50

O2, dry

vol %

21.00

21.00

21.00

21.00

21.00

21.00

CO2, dry

Water Vapor

Duct Diameter

vol %

0.00

0.00

0.00

0.00

0.00

0.00

N2, dry

vol %

79.00

79.00

79.00

79.00

79.00

79.00

Density, dry - O2

kg/m3

1.203

0.945

0.954

1.193

0.927

0.964

Density, dry - CO2

kg/m3

1.665

1.308

1.319

1.650

1.282

1.334

Density, dry - N2

kg/m3

1.058

0.832

0.839

1.049

0.815

0.848

Density - H2O

kg/m3

0.677

0.532

0.537

0.671

0.521

0.543

Mass - O2, dry

kg

25.27

19.85

20.03

25.05

19.46

20.25

Mass - CO2, dry

kg

0.00

0.00

0.00

0.00

0.00

0.00

Mass - N2, dry

kg

83.61

65.69

66.28

82.89

64.38

67.01

Mass - H2O

kg

1.63

14.12

14.67

1.62

1.76

3.32

O2, wet

mass %

22.86

19.92

19.83

22.86

22.73

22.36

CO2, wet

mass %

0.00

0.00

0.00

0.00

0.00

0.00

N2, wet

mass %

75.66

65.92

65.64

75.66

75.21

73.98

H2O

mass %

1.48

14.17

14.53

1.48

2.06

3.66

Gas Density, dry

kg/Nm

1.293

1.293

1.293

1.293

1.293

1.293

Gas Density, wet

kg/Nm

1.282

1.191

1.188

1.282

1.277

1.265

Gas Density, dry

kg/m

1.089

0.855

0.863

1.079

0.838

0.873

Gas Density, wet

kg/m

1.079

0.788

0.793

1.070

0.828

0.854

S1

S2

S1

m/s

15.90

16.00

11.62

18.44

9.54

m2

0.503

0.785

1.131

3.142

0.196

Gas Flow Rate, wet

tph

31.05

35.64

37.51

1.88

172.64

5.76

Gas Flow Rate, wet

kNm3/hr

24.22

29.93

31.57

1.46

135.18

4.55

Gas Flow Rate, wet

km3/hr

28.77

45.25

47.31

1.75

208.50

6.74

Gas Flow Rate, wet

m3/min

480

754

788

29

3475

112

tph

0.46

5.05

5.45

0.03

3.55

0.21

Gas Flow Rate, dry

Pitot Tube

S1/S2/L

Gas Velocity
Duct C.S. Area

Moisture, by diff.

tph

30.59

30.59

32.06

1.85

169.09

5.55

Gas Flow Rate, dry

kNm /hr

23.65

23.65

24.79

1.43

130.76

4.29

Gas Flow Rate, dry

km /hr

28.09

35.76

37.15

1.71

201.68

6.35

Gas Flow Rate, dry

m /min

468

596

619

29

3361

106

kcal/kg/C

0.242

0.270

0.271

0.242

0.245

0.248

259.54

1107.10

1100.98

15.68

4479.80

154.28

tph

16.71

0.00

6.25

0.20

Sp. Heat, gas

Heat Content, gas
Dust, gas
Sp. Heat, Dust

Mcal/hr

kcal/kg/C

0.189

0.188

0.188

0.188

Heat Content, Dust

Mcal/hr

362.83

0.00

124.52

4.11

Heat Content, total

Mcal/hr

259.54

1469.93

1100.98

15.68

4604.32

158.38

MILL VELOCITY
Mill I/L

Diaph.

Diaph.

Heat Cap - Coefficients

Gas/Mat

*T^0

*T^1

*T^2

Mill O/L

0.2485

-3.340E-06

4.440E-08

-2.797E-11 5.597E-15

*T^3

*T^4

72.3

112.5

0.1244

0.000E+00

0.000E+00

0.000E+00 0.000E+00

O2

0.2130

7.796E-05

-7.563E-08

4.074E-11 -8.183E-15

CO2

0.1906

1.771E-04

-1.733E-07

9.315E-11 -1.894E-14

N2+Ar

0.2465

-3.284E-06

4.366E-08

-2.750E-11 5.504E-15

2.910E-05

6.887E-08

-3.726E-11 6.472E-15

0.053

0.128

H2O,steam

0.4445

-25

-110

H2O, liq.

1.0000

3.33

Rawmeal

0.2060

1.014E-04

-3.673E-08

0.80

1.00

Clinker

0.1742

1.414E-04

-1.283E-07

5.074E-11

21.00

21.00

Cement

0.1742

1.414E-04

-1.283E-07

5.074E-11

0.00

0.00

Gypsum

0.1742

1.414E-04

-1.283E-07

5.074E-11

79.00

79.00

1.072

0.951

1.483

1.316

0.943

0.837

23.5771

Sp. Gravity, dry - O2

kg/Nm3

0.603

0.535

-4042.90

Sp. Gravity, dry - CO2

kg/Nm3

22.50

19.98

-37.58

Sp. Gravity, dry - N2

kg/Nm3

0.804

Sp. Gravity - H2O

kg/Nm3

0.00

0.00

74.47

66.12

5.09

10.98

22.05

20.58

0.00

0.00

72.96

68.11

4.99

11.31

1.293

1.293

1.255

1.210

0.970

0.861

0.941

0.806

10.63

7.95

0.503

0.785

18.1

18.1

14.4

15.0

19.2

22.5

321

375

0.90

2.05

17.2

16.1

13.3

12.4

17.7

18.7

296

311

0.250

0.264

327.39

538.14

#REF!

0.000

#REF!

327.39

#REF!

Rho H2O-Steam, kg/Nm

23

Heat Cap - Coefficients

Not used in calc.
Not used in calc.

1.429
1.977
1.257
0.804

sheet 1 of 2

Process, Efficiency & Performance Monitoring

Section : CEMENT MILL - UMS 4.6x16.5 BM
MILL No. 1 / 2

Time :

Date :

Site Conditions & Constants :

Plant Elevation

mts +MSL

Ambient Air Temperature

deg.C

Pitot Constant (S-Type : L=01m)

0.883

(P.S. No. 601)

Pitot Constant (S-Type : L=02m)

0.847

(P.S. No. V422)

Pitot Constant (L-Type : L=01/02m)

1.000

Process Parameter Requirement :

Mill Feed Rate-Wet, tph

Coarse Temp., deg.C

Gypsum, %

Cement Temp., deg.C

Free H2O in Gypsum, %

Water Inj. I/L, m3/m

Clinker Temp., deg.C

Water Inj. O/L, m /m

Gypsum Temp., deg.C

Water Temp., deg.C

Wind Speed, m/s

Mill Surf. Temp. deg.C

Residue (+45/+90/+212 m) / Blaine analysis :

Sepax Inlet, S

ESP Dust, D

Fines, F

ESP Drop-test, tph

Coarse, G

Mill Inside Dimensions :

Chmb.I/II Dia., mts

GM Type, Bal/Cpb/Dpb

Chmb.I/II Length, mts

GM Const. Mat.

Chmb.I/II Lin. Thick., mm

Chmb.I Ball Dia., mm

Chmb.I/II Loading, %

Chmb.II Ball Dia., mm

Chmb.I/II Seg. Width, mts

Chmb.I/II Free Ht., mts

Folaphone, %

Main Drive Load, kW

Coarse Return (CCR), tph

Spx. Sep. Load, amps

Diaphragm Temp., deg.C

Spx. Sep. Speed, rpm

Spx. Elev. Load, amps

ESP Fan Load, amps

Silo Elev. Load, amps

ESP Fan Damper, %

Spx. Fan Load, kW/amps

Mill Sp. Power, kWh/t

Spx. Fan Spd./Dmp., %/%

Ded. Fan Damper, %

Other Parameters in CCR :

10/04/2015 03:37:22 288630647.xls Mon-Form

sheet 2 of 2
Flow Measurement & Gas Analysis :
Flow/Gas Analysis
Mill
Inlet
Dry Bulb Temperature

deg.C

Wet Bulb Temperature

deg.C

Static Pressure

"WG

Dynamic Pressure

"WG

Time Period

Mill
Outlet

Tapping Location
ESP
Spx. JPF
Outlet
Inlet

Sepax
Duct

hh.mm - hh.mm

Signature
Process Engineer (Monitoring)

10/04/2015 03:37:22 288630647.xls Mon-Form

Cement Mill Tromp Curve - Sepax Separator 400M-222

Sieve

% Residue

Cir. Factor

Vs

Sieve

Tromp

2.40

10.72

95.10

2.27

12.02

1.5

39.86

91.50

2.31

11.44

3.0

41.61

80.90

88.10

2.31

24.44

6.0

32.59

63.20

76.40

86.60

2.29

37.46

10.0

20.93

53.70

71.40

85.30

2.27

49.27

14.0

16.70

24.0

38.30

65.80

85.25

2.41

67.76

20.0

0.47

32.0

23.60

55.60

76.90

2.50

65.50

28.0

45.42

48.0

8.50

36.00

52.60

2.66

50.75

40.0

70.21

64.0

5.70

25.90

38.20

2.64

33.91

56.0

88.28

mm

Rf

Rm

Rg

1.0

93.40

95.50

97.00

2.0

89.20

92.50

4.0

81.80

87.30

8.0

71.50

12.0
16.0

96.0

2.40

14.00

21.00

2.66

12.28

80.0

88.42

128.0

1.20

8.80

12.90

2.85

-4.12

112.0

90.82

12

2.46

Tromp Curve
100.00
90.00

Wt.% in Coars e , %

80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
1.0

10.0

100.0

1000.0

Particle , m m
CUT SIZE

30.22

KAPPA

0.55

DELTA

0.47

Separator Efficiencies
100.00
90.00
80.00

Efficiency, %

70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
1.0

10.0

Vs

PLANT : BINANI CEMENT - 09.06.2004

Cement Mill :

Particle Size , m m

Vf

Vc

100.0

Vf*Vc

1000.0

Tromp
39.86
41.61
32.59
20.93
16.70
0.47
45.42
70.21
88.28
88.42
90.82

0
0
0
0
0
20
0
0
0
0
0
20

0.00
0.00
0.00
0.00
0.00
0.47
45.42
70.21
88.28
88.42
90.82
-

45.42
70.21

28.00
40.00

50

CUT SIZE

30.22

KAPPA

0.55

DELTA

0.47

Sieve

Ro
0.00
0.00
0.00
0.00
0.00
0.47
45.42
70.21
88.28
88.42
90.82

0.00
0.00
0.00
0.00
0.00
20.00
28.00
40.00
56.00
80.00
112.00

0.47
45.42

20.00
28.00

25

X25

24.37

70.21

40.00

88.28

56.00

X75

44.24

1.50
3.00
6.00
10.00
14.00
20.00
28.00
40.00
56.00
80.00
112.00

75

Corr. Rm
95.54
92.71
87.56
81.37
77.11
72.48
66.20
55.28
34.71
25.01
13.45
8.15

100.00

Tromp Rg

Corr. Vs

1.90
3.60
3.40
1.50
1.30
0.05
8.35
24.30
14.40
17.20
8.10

11.37
11.73
17.94
30.95
43.36
58.52
66.63
58.13
42.33
23.09
4.08

Vf

Tromp Rm
2.83
5.14
6.20
4.26
4.63
6.28
10.93
20.57
9.69
11.56
5.30

1.5
3.0
6.0
10.0
14.0
20.0
28.0
40.0
56.0
80.0
112.0

61.11
63.46
62.05
64.72
67.97
71.21
74.74
68.76
53.82
48.16
42.71
37.96

Corr. Vf

Vc

Corr. Vc

Vf*Vc

62.28
62.75
63.39
66.35
69.59
72.97
71.75
61.29
50.99
45.44
40.34

59.25
57.50
59.43
61.67
63.94
66.92
75.89
83.04
91.11
91.67
93.55
95.22

58.38
58.47
60.55
62.80
65.43
71.40
79.46
87.07
91.39
92.61
94.38

36.21
36.49
36.88
39.91
43.46
47.65
56.72
57.10
49.03
44.15
39.96
36.15

Corr.
Vf*Vc
36.35
36.68
38.39
41.69
45.56
52.18
56.91
53.07
46.59
42.05
38.05