MC V0 B000 TOC v7 0 1 PDF

Table of contents (This file)
Chapter-2: Introduction
MC_V0_B000_Intro_01TXT The nature of mathematics of cement
MC_V0_B000_Intro_02TXT Mathematics of cement as against
non-mathematical approach
MC_V0_B000_Intro_03TXT Theoretical deductions versus empirical
deductions.
Chapter-3: Mathematical Models
MC_V0_B000_Models_01TXT An introduction to mathematical model
(MathCement model)
MC_V0_B000_Models_02TXT Constituents of a mathematical model
(MathCement model)
MC_V0_B000_Models_03TXT Why create a mathematical model (MathCement
model)?
MathCement
Preliminaries
MC_V0_B000_TOC
Topic: New table of contents including expanded tables of contents
Mathcad Version:MC2001
Approach to MathCement
Chapter-1: Preliminaries
MC_V0_B000_Foreword_01TXT Foreword by Dr. A.K.Chatterjee
MC_V0_B000_Preface_01TXT Preface - all editions
MC_V0_B000_Ebook_01TXT About using electronic books
MC_V0_B000_Readme_01TXT Read me
MC_V0_B000_TOC_01TXT
Volume-1 : Cement plant process calculations
MC_V1_TOC Expanded Table of Contents -Vol.1
Book 200 Process calculation of plant sections
Book 201 MC_V1_B201_Quarry_TOC Quarry Section
BIU MC_V1_B201_Quarry_1BIU Quarry Deposit Estimation
MC_V1_B201_Quarry_1 Quarry Deposit Estimation
BIU MC_V1_B201_Quarry_2BIU Quarry - Excavator
MC_V1_B201_Quarry_2 Quarry - Excavator
Chapter-4: Back to Basics
MC_V0_B101_Units_TOC Units
BIU MC_V0_B101_units_01BIU About Built-in Units
BIU MC_V0_B101_units_02BIU User Defined Units
MC_V0_B102_Review_TOC Process Review
MC_V0_B102_Review_1TXT NOx chemistry
BIU MC_V0_B102_Review_2BIU Density, specific weight, specific volume and
specific gravity
Mathematical techniques
MC_V1_B202_Crushing_3BIU Calculation of power for existing crusher at
different capacities -application of Rittinger's law
MC_V1_B202_Crushing_3 Calculation of power for existing crusher at
different capacities -application of Rittinger's law
BIU MC_V1_B202_Crushing_4BIU Calculation of power for existing crusher but to be
used for different / changed material - application
of Rittinger's law
MC_V1_B202_Crushing_4 Calculation of power for existing crusher but to be
used for different / changed material - application
of Rittinger's law
BIU MC_V1_B202_Crushing_5BIU Calculation of throughput for Roll Crusher
MC_V1_B202_Crushing_5 Calculation of throughput for Roll Crusher
BIU MC_V1_B202_Crushing_6BIU Double Rotor Hammer or Impact Crusher
Calculations
MC_V1_B202_Crushing_6 Double Rotor Hammer or Impact Crusher
Calculations
BIU MC_V1_B201_Quarry_3BIU_r3 Quarry - Dumper Calculations
MC_V1_B201_Quarry_3_r3 Quarry Dumper Calculations
Book 202 MC_V1_B202_Crushing_TOC Crushing Section
BIU MC_V1_B202_Crushing_1BIU_r5 Crusher and Auxiliaries Calculations
MC_V1_B202_Crushing_1_r5 Crusher and Auxiliaries Calculations
BIU MC_V1_B202_Crushing_2BIU Single Rotor Hammer or Impact Crusher
Calculations
MC_V1_B202_Crushing_2 Single Rotor Hammer or Impact crusher
calculations
BIU
MC_V1_B203_Preblending_4BIU Stockpile capacities-Kidney shaped windrows
-triangular section
MC_V1_B203_Preblending_4 Stockpile capacities-Kidney shaped windrows
-triangular section
Book 204 MC_V1_B204_Rawmill_TOC Raw Mill Section
MC_V1_B204_RawMill_1_r4 Bond Work Index of the various material based
on bond test mill result dry basis
Calculation of Power at Ball Mill Shaft for Raw
Material,based on Bond's Work Index
BIU MC_V1_B204_RawMill_2BIU
MC_V1_B204_RawMill_2 Calculation of power at Ball Mill shaft for Raw
material, based on Bond's work index
Raw Mill and Auxiliary Equipment Capacity
Calculations
Book 203 MC_V1_B203_Pre-blending_TOC Pre-blending Section
BIU MC_V1_B203_Preblending_1BIU Preblending and Stockpile Equipment -
Calculations
MC_V1_B203_Preblending_1 Preblending and Stockpile Equipment
Calculations
BIU MC_V1_B203_Preblending_2BIU Stockpile capacities-Longitudinal with trapizoidal
cross section
MC_V1_B203_Preblending_2 Stockpile capacities-Longitudinal with trapizoidal
cross section
BIU MC_V1_B203_Preblending_3BIU Stockpile capacities-Longitudinal with triangular
cross section
MC_V1_B203_Preblending_3 Stockpile capacities-Longitudinal with triangular
cross section
BIU
MC_V1_B204_RawMill_7BIU Calculation of Grinding Ball Size
MC_V1_B204_RawMill_7 Calculation of Grinding Ball Size
BIU MC_V1_B204_RawMill_8BIU Specific Heat of Raw Material as a Function of
Temperature
MC_V1_B204_RawMill_8 Specific Heat of Raw Material as a Function of
Temperature
Estimation of specific power consumption, at
mill shaft, based on the operating parameters
of close circuit ball mill
MC_V1_B204_RawMill_9 Estimation of specific power consumption, at
mill shaft, based on the operating
parameters of close circuit ball mill
Calculation of mill power demand for desired
output at specified feed and product sizes,
based on Bond Index.
BIU MC_V1_B204_RawMill_10BIU_r3
MC_V1_B204_RawMill_3 Raw Mill and Auxiliary Equipment Capacity
Calculations
Raw Material Drying - Estimation of total
moisture to be evaporated from feed
MC_V1_B204_RawMill_4_r3 Raw Material Drying - Estimation of total
Moisture to be Evaporated from Feed
Raw Mill Heat Balance - Evaluation of Hot Gas
Requirement for Drying
MC_V1_B204_RawMill_5 Raw Mill Heat Balance - Evaluation of Hot
Gas Requirement for Drying
Calculation of Ball Mill Percentage Filling as
per Measurement
MC_V1_B204_Rawmill_6 Calculation of Ball Mill Percentage Filling as
per Measurement
BIU
MC_V1_B204_RawMill_13 Ball Mill Critical Speed and Ball Charge Calculations
BIU MC_V1_B204_RawMill_14BIU_r4 Vertical Roller Mill -- Calculation of Power
MC_V1_B204_RawMill_14_r4 Vertical Roller Mill -- Calculation of Power
BIU MC_V1_B204_RawMill_15BIU_r3 Radiation Loss in Raw Mill Heat Balance
MC_V1_B204_RawMill_15_r3 Radiation Loss in Raw Mill Heat Balance
Calculation of false air coming into grinding mill
system
MC_V1_B204_RawMill_16 Calculation of false air coming into grinding mill
system
Calculation of water pressure at nozzle over
material bed of Vertical Roller Mill with supply
from overhead tank
MC_V1_B204_RawMill_10_r4 Calculation of mill power demand for desired
output at specified feed and product sizes,
based on Bond Index.
BIU MC_V1_B204_RawMill_10_1BIU Calculation of mill output for different feed and
product sizes
MC_V1_B204_RawMill_10_1 Calculation of mill output for different feed and
product sizes
BIU MC_V1_B204_RawMill_11BIU Calculation of Efficiency of Dynamic Air Separator
MC_V1_B204_RawMill_11 Calculation of Efficiency of Dynamic Air
Separator
BIU MC_V1_B204_RawMill_12BIU Average Piece Weight of Grinding Media
MC_V1_B204_RawMill_12 Average Piece Weight of Grinding Media
BIU MC_V1_B204_RawMill_13BIU Ball Mill Critical Speed and Ball Charge
Calculations
Calculation of auxiliary drive rating of Ball Mill for
raw grinding
MC_V1_B204_RawMill_21_r1 Calculation of auxiliary drive rating of Ball Mill for
raw grinding
BIU MC_V1_B204_RawMill_22BIU_r2 Calculation of makeup charge or ball mills
MC_V1_B204_RawMill_22_r2 Calculation of makeup charge or ball mills
BIU MC_V1_B204_RawMill_23BIU_r1 Calculation of wear rate of grinding balls in ball
mills
MC_V1_B204_RawMill_23_r1 Calculation of wear rate of grinding balls in ball
mills
BIU MC_V1_B204_RawMill_24BIU Calculation of Recirculation Air in Raw Grinding
Vertical Roller Mill
MC_V1_B204_RawMill_24 Calculation of Recirculation Air in Raw Grinding
Vertical Roller Mill
MC_V1_B204_RawMill_17 Calculation of water pressure at nozzle over
material bed of Vertical Roller Mill with supply
from overhead tank
BIU MC_V1_B204_RawMill_18BIU Calculation of retention time of material in a two
compartment ball mill
MC_V1_B204_RawMill_18 Calculation of retention time of material in a two
compartment ball mill
BIU MC_V1_B204_RawMill_19BIU_r1 Rosin-Rammler equation -calculation of predicted
residue on sieve and variaton calculations
MC_V1_B204_RawMill_19_r1 Rosin-Rammler equation -calculation of predicted
residue on sieve and variaton calculations
BIU MC_V1_B204_RawMill_20BIU Calculation of mean diameter of fine ground
particles
MC_V1_B204_RawMill_20 Calculation of mean diameter of fine ground
particles
MC_V1_B205_Blending_4_r2 Calculation of blending factor by methods of
standard deviation
Book 206 MC_V1_B206_Kilnfeed_TOC Kiln-feed Section
Locating feeding point of material into Preheater
Gas ducts
BIU MC_V1_B206_Kilnfeed_1BIU_r3
MC_V1_B206_Kilnfeed_1_r3 Locating feeding point of material into
Preheater Gas ducts
Book 207 MC_V1_B207_Clinker_TOC Clinkerisation (kiln,pre-heater)
Section
BIU MC_V1_B207_Clinker_1BIU_r3 Calculation of Kiln and Auxiliary Equipment
Capacities.
MC_V1_B207_Clinker_1_r3 Calculation of Kiln and Auxiliary Equipment Capacities
Book 205 MC_V1_B205_Blending_TOC Blending and Storage Section
BIU MC_V1_B205_Blending_1BIU Calculation of Blending & Storage Silos and
Auxiliary Equipment Capacity for Raw-meal
preparation
MC_V1_B205_Blending_1 Calculation of Blending & Storage Silos and
Auxiliary EquipmentCapacity for Raw-meal Preparation
BIU MC_V1_B205_Blending_2BIU_r3 Calculation of Kiln Feed Raw-meal Systems
MC_V1_B205_Blending_2_r3 Calculation of Kiln Feed Raw-meal Systems
BIU MC_V1_B205_Blending_3BIU Calculation of Kiln Feed Raw-meal Quantity
MC_V1_B205_Blending_3 Calculation of Kiln Feed Raw-meal Quantity
BIU MC_V1_B205_Blending_4BIU_r2 Calculation of blending factor by methods of
standard deviation
BIU MC_V1_B207_Clinker_7BIU Kiln Tyre / Shell Ovality
MC_V1_B207_Clinker_7 Kiln Tyre / Shell Ovality
BIU MC_V1_B207_Clinker_8BIU_r4 Kiln Capacity check
MC_V1_B207_Clinker_8_r4 Kiln Capacity check
BIU MC_V1_B207_Clinker_9BIU Degree of Decarbonation of Raw Meal
-Definition and calculation
MC_V1_B207_Clinker_9 Degree of Decarbonation of Raw Meal
-Definition calculation
BIU MC_V1_B207_Clinker_10BIU Degree of Decarbonation of Raw Meal
Calculation on Operating Data
MC_V1_B207_Clinker_10 Degree of Decarbonation of Raw Meal
Calculation on Operating Data
BIU MC_V1_B207_Clinker_11BIU Reaction Enthalpy -Decarbonation and
Clinkerisation
MC_V1_B207_Clinker_11 Reaction Enthalpy -Decarbonation and
Clinkerisation
BIU MC_V1_B207_Clinker_2BIU_r3 Leakages through Kiln Air Seals
MC_V1_B207_Clinker_2_r3 Leakages Through Kiln Air Seal
BIU MC_V1_B207_Clinker_3BIU Calculation of Specific Heats of Clinker as a
Function of Clinker Temperature
MC_V1_B207_Clinker_3 Calculation of Specific Heats of Clinker as a
Function of Clinker Temperature
BIU MC_V1_B207_Clinker_4BIU Kiln Retention Time and Related Parameters
MC_V1_B207_Clinker_4 Kiln Retention Time and Related Parameters
BIU MC_V1_B207_Clinker_5BIU_r3 Kiln sinter zone cooling fans
MC_V1_B207_Clinker_5_r3 Kiln Sinter Zone Cooling Fans
BIU MC_V1_B207_Clinker_6BIU_r3 Calculation of nose ring cooling air for kiln inlet
MC_V1_B207_Clinker_6_r3 Calculation of nose ring cooling air for kiln
inlet
Kiln Hydraulic Thruster - A Note
BIU MC_V1_B207_Clinker_17BIU Kiln Drive Specification
MC_V1_B207_Clinker_17 Kiln Drive Specification
BIU MC_V1_B207_Clinker_18BIU Calculation of expansion of Kiln in hot condition
MC_V1_B207_Clinker_18 Calculation of expansion of Kiln in hot
condition
BIU MC_V1_B207_Clinker_19BIU Calculation of Temerature Profile of Kiln Shell in
hot condition
MC_V1_B207_Clinker_19 Calculation of Temperature Profile of Kiln
Shell in hot condition
BIU MC_V1_B207_Clinker_20BIU Calcination Function
MC_V1_B207_Clinker_20 Calcination Function
BIU MC_V1_B207_Clinker_12BIU Theoretical Heat of Clinker Formation -
Calculation
MC_V1_B207_Clinker_12 Theoretical Heat of Clinker Formation -
Calculation
Calculation of kiln mass under operating
conditions
BIU MC_V1_B207_Clinker_13BIU
MC_V1_B207_Clinker_13 Calculation of Kiln mass under Operating
Conditions
BIU MC_V1_B207_Clinker_14BIU Calculation of Kiln Torque under Operating
Conditions
MC_V1_B207_Clinker_14 Calculation of Kiln Torque under Operating Conditions
BIU MC_V1_B207_Clinker_15BIU_r3 Calculation for Kiln Hydraulic Thruster
MC_V1_B207_Clinker_15_r3 Calculation for Kiln Hydraulic Thruster
Text MC_V1_B207_Clinker_16TXT
no files here MC_V1_B208_ClCooling_1BIU BIU
Clinker Cooling Section MC_V1_B208_ClCooling_TOC Book 208
Calculation of fresh cooling air and water to
reduce the temperature of kiln (alkali) bypass
gases before release to atmosphere
MC_V1_B207_Clinker_25
Calculation of fresh cooling air and water to
reduce the temperature of kiln (alkali) bypass
gases before release to atmosphere
MC_V1_B207_Clinker_25BIU BIU
Alkali bypass systems
Correlation Between Central Chord Angle or
Charge Angle and Degree of Filling of Kiln
MC_V1_B207_Clinker_24
Correlation Between Central Chord Angle or
Charge Angle and Degree of Filling of Kiln
BIU MC_V1_B207_Clinker_21BIU Calculation of false air infiltration into kiln
preheater system
MC_V1_B207_Clinker_21 Calculation of false air infiltration into kiln
preheater system
BIU MC_V1_B207_Clinker_22BIU Calculation of Alkali Bypass System
MC_V1_B207_Clinker_22 Calculation of Alkali Bypass System
BIU MC_V1_B207_Clinker_23BIU Calculation of Range of Bypass Quantity of
Gases from Kiln to Limit Alkali concentration in
Clinker
MC_V1_B207_Clinker_23 Calculation of Range of Bypass Quantity of
Gases from Kiln to Limit Alkali concentration in
Clinker
BIU MC_V1_B207_Clinker_24BIU
MC_V1_B209_Clstore_TOC Clinker Storage Section
BIU MC_V1_B209_Clstore_1BIU Calculation of Clinker Transport Equipment
Capacity and Clinker Stockpile
MC_V1_B209_Clstore_1 Calculation of Clinker Transport Equipment
Capacity and Clinker Stockpile
Book 210 MC_V1_B210_Cement_TOC Cement Grinding Section
BIU MC_V1_B210_Cement_1BIU Calculation of Cement Mill and Auxiliary
Equipment
MC_V1_B210_Cement_1 Calculation of Cement Mill and Auxiliary
Equipment
BIU MC_V1_B210_Cement_2BIU Calculation of Cement Grindability based on
Ziesel Value
MC_V1_B210_Cement_2 Calculation of Cement Grindability based on
Ziesel Value
BIU MC_V1_B208_ClCooling_2BIU Calculation of Grate Cooler Drive Power
MC_V1_B208_ClCooling_2 Calculation of GrateCooler Drive Power
BIU MC_V1_B208_ClCooling_3BIU Calculation of Grate Cooler Recuperation
Efficiency -T.A. Duct Tapping from Cooler
MC_V1_B208_ClCooling_3 Calculation of Grate Cooler Recuperation
Efficiency - T.A.Duct Tapping from Cooler
BIU MC_V1_B208_ClCooling_4BIU Calculation of Grate Cooler Recuperation
Efficiency -T.A. Duct Tapping from Kiln Hood
MC_V1_B208_ClCooling_4 Calculation of Grate Cooler Recuperation
Efficiency - T.A.Duct Tapping from Kiln Hood
BIU MC_V1_B208_ClCooling_5BIU Calculation of Grate Cooler Offset from Kiln axis
MC_V1_B208_ClCooling_5 Calculation of Grate Cooler Offset from Kiln
axis
Book 209
MC_V1_B210_Cement_7 Sizing of Close Circuit Cement Mill
BIU MC_V1_B210_Cement_8BIU Cement Mill Output at Different Finenesses
MC_V1_B210_Cement_8 Cement Mill Output at Different Finenesses
BIU MC_V1_B210_Cement_9BIU Cement Mill Cooling Air
MC_V1_B210_Cement_9 Cement Mill Cooling Air
BIU MC_V1_B210_Cement_10BIU Mill Radiation Loss
MC_V1_B210_Cement_10 Mill Radiation Loss
BIU MC_V1_B210_Cement_11BIU Cement Mill Grinding Performance as a Function
of Surface Generated
MC_V1_B210_Cement_11 Cement Mill Grinding Performance as a
Function of Surface Generated
BIU MC_V1_B210_Cement_3BIU Cement Mill Heat Balance and Calculation of Hot
Gas for Drying
MC_V1_B210_Cement_3 Cement Mill Heat Balance and Calculation of
Hot Gas for Drying
BIU MC_V1_B210_Cement_4BIU Calculation of Cement Mill Output as a function
of Grinding Media Load
MC_V1_B210_Cement_4 Calculation of Cement Mill Output as a
function of Grinding Media Load
BIU MC_V1_B210_Cement_5BIU Estimation of grindability of Clinker based on the
operating parameters
MC_V1_B210_Cement_5 Estimation of grindability of Clinker based on
the operating parameters
BIU MC_V1_B210_Cement_6BIU Calculation of Water Spray in the Mill for Cooling
MC_V1_B210_Cement_6 Calculation of Water Spray in the Mill for
Cooling
BIU MC_V1_B210_Cement_7BIU Sizing of Close Circuit Cement Mill
The Barometric pressure at site based on the
altitude above mean sea level
MC_V1_B301_Site_1BIU BIU
Plant Site MC_V1_B301_Site_TOC Book 301
Process design calculations - support systems Book 300
Evaluation of effect of weighing accuracy of packing m/c MC_V1_B211_Cmtstore_2
Evaluation of effect of weighing accuracy of
packing m/c
MC_V1_B211_Cmtstore_2BIU BIU
Calculation of Cement Transport and Silo and Auxiliary
Equipment
MC_V1_B211_Cmtstore_1
BIU MC_V1_B210_Cement_12BIU Expected Power Draw of Cement Mill as a
Function of Speed
MC_V1_B210_Cement_12 Expected Power Draw of Cement Mill as a
Function of Speed
BIU MC_V1_B210_Cement_13BIU_r2 Clinker grinding mill - calculation of capacity and
power
MC_V1_B210_Cement_13_r2 Clinker grinding mill - calculation of capacity and
power
Book 211 MC_V1_B211_Cmtstore_TOC Cement Storage and Dispatch Section
BIU MC_V1_B211_Cmtstore_1BIU Calculation of Cement Transport and Silo and
Auxiliary Equipment
MC_V1_B302_Dedust_25 Sketches for K - factors -set5
BIU MC_V1_B302_Dedust_3BIU Calculation of Pressure Losses in Ducting
conveying powdery material
MC_V1_B302_Dedust_3 Calculation of Pressure Losses in Ducting
conveying powdery material
BIU MC_V1_B302_Dedust_31BIU Calculation of Friction Losses in Ductings from
Tables /Graphs
MC_V1_B302_Dedust_31 Calculation of Friction Losses in Ductings from
Tables /Graphs
BIU MC_V1_B302_Dedust_4BIU Design Parameters for Design of Duct Systems
MC_V1_B302_Dedust_4 Design Parameters for Design of Duct
Systems
Text MC_V1_B302_Dedust_5TXT Duct balancing
MC_V1_B301_Site_1 The Barometric pressure at site based on the altitude
above mean sea level
Book 302 MC_V1_B302_Dedust_TOC Dedusting Systems
Text MC_V1_B302_Dedust_1 Estimation of Vent Air Volume
Text MC_V1_B302_Dedust_2TXT K - Factors
MC_V1_B302_Dedust_10 Electrostatic Precipitator- Specific Collection
Area
BIU MC_V1_B302_Dedust_11BIU Electrostatic Precipitator- Performance Evaluation
MC_V1_B302_Dedust_11 Electrostatic Precipitator- Performance
Evaluation
BIU MC_V1_B302_Dedust_12BIU Electrostatic Precipitator- To calculate Migration
Velocity
MC_V1_B302_Dedust_12 Electrostatic Precipitator- To calculate
Migration Velocity
BIU MC_V1_B302_Dedust_13BIU_r3 Chimney design
MC_V1_B302_Dedust_13_r3 Chimney Design
BIU MC_V1_B302_Dedust_14BIU Calculation of flow through duct based on
Pitot tube measurement
MC_V1_B302_Dedust_14 Calculation of flow through duct based on Pitot
tube measurement
BIU MC_V1_B302_Dedust_6BIU Glass Bag House -Calculation of Gas Volume as
Function of temperature.
MC_V1_B302_Dedust_6 Glass Bag House -Calculation of Gas Volume
as Function of temperature.
BIU MC_V1_B302_Dedust_7BIU GCT and ESP - Calculation of Gas Volume
MC_V1_B302_Dedust_7 GCT and ESP - Calculation of Gas Volume
BIU MC_V1_B302_Dedust_8BIU Sizing of Gas Conditioning Tower
MC_V1_B302_Dedust_8 Sizing of Gas Conditioning Tower
BIU MC_V1_B302_Dedust_9BIU Electrostatic Precipitator- Deutsch Efficiency
Formula
MC_V1_B302_Dedust_9 Electrostatic Precipitator- Deutsch Efficiency
Formula
BIU MC_V1_B302_Dedust_10BIU Electrostatic Precipitator- Specific Collection Area
BIU MC_V1_B302_Dedust_20BIU Calculation relating to conversion of industrial
gases from standard volume to operating volume
and vice-versa
Book 303 MC_V1_B303_Lab_TOC Laboratory Investigations and
Raw Mix Designs
BIU MC_V1_B303_Lab_1BIU Loss on Ignition of Kiln Feed Raw Meal
MC_V1_B303_Lab_1 Loss on Ignition of Kiln Feed Raw Meal
BIU MC_V1_B303_Lab_2BIU Silica Ratio and Requirement of Components
MC_V1_B303_Lab_2 Silica Ratio and Requirement of Components
BIU MC_V1_B303_Lab_3BIU Alumina Ratio and Requirement of Components
MC_V1_B303_Lab_3 Alumina Ratio and Requirement of
Components
BIU MC_V1_B302_Dedust_15BIU Calculation of pressure loss in duct due to friction
and bends
MC_V1_B302_Dedust_15 Calculation of pressure loss in duct due to friction
and bends
BIU MC_V1_B302_Dedust_16BIU Velocity selection for ducting design
MC_V1_B302_Dedust_16 Velocity selection for ducting design
BIU MC_V1_B302_Dedust_17BIU Calculation for air curtain
MC_V1_B302_Dedust_17 Calculation for air curtain
BIU MC_V1_B302_Dedust_18BIU Calculation of migration velocity of operating ESP
MC_V1_B302_Dedust_18 Calculation of migration velocity of operating ESP
BIU MC_V1_B302_Dedust_19BIU Calculation of dedusting efficiency of a dust
separator in terms of degrees of dust separation
BIU MC_V1_B303_Lab_8BIU Percentage Liquid and Burnability Index Cement
Clinker - Calculation
MC_V1_B303_Lab_8 Percentage Liquid and Burnability Index
Cement Clinker - Calculation
BIU MC_V1_B303_Lab_9BIU Total Carbonate Content in Kiln Feed Raw Meal-
Calculation
MC_V1_B303_Lab_9 Total Carbonate Content in Kiln Feed Raw
Meal- Calculation
BIU MC_V1_B303_Lab_10BIU To Calculate Quantity of CaO Required to Attain
Specific Value of Total Carbonate Content in Kiln
Feed Raw Meal
MC_V1_B303_Lab_10 To Calculate Quantity of CaO Required to
Attain Specific Value of Total Carbonate
Content in Kiln Feed Raw Meal
BIU MC_V1_B303_Lab_11BIU Kiln Dust Loss in Terms of Kiln Feed Raw
Meal-and Apparant Degree of Calcination
MC_V1_B303_Lab_11 Kiln Dust Loss in Terms of Kiln Feed Raw
Meal-and Apparent Degree of Calcination
BIU MC_V1_B303_Lab_4BIU Lime Saturation Factor - Calculation
MC_V1_B303_Lab_4 Lime Saturation Factor Calculation
BIU MC_V1_B303_Lab_5BIU Hydraulic Ratio of Kiln Feed Raw Meal -
Calculation
MC_V1_B303_Lab_5 Hydraulic Ratio of Kiln Feed Raw Meal -
Calculation
BIU MC_V1_B303_Lab_6BIU Burnability Factor of Kiln Feed Raw Meal -
Calculation
MC_V1_B303_Lab_6 Burnability Factor of Kiln Feed Raw Meal - Calculation
BIU MC_V1_B303_Lab_7BIU Complex Compounds of Cement Clinker -
Calculation by Bogue's Formulae
MC_V1_B303_Lab_7 Complex Compounds of Cement Clinker - Calculation by
Bogue's Formulae
Text MC_V1_B303_Lab_21TXT Separation of ESP and Filter Dust
BIU MC_V1_B303_Lab_22BIU Volatility of alkalies
MC_V1_B303_Lab_22 Volatility of alkalies
Raw-mix Design
BIU MC_V1_B303_Lab_23BIU Raw-mix Design for Two Components
MC_V1_B303_Lab_23 Raw-mix Design for Two Components
BIU MC_V1_B303_Lab_24BIU Raw-mix Design based on Hydraulic Module
MC_V1_B303_Lab_24 Raw-mix Design based on Hydraulic Module
BIU MC_V1_B303_Lab_25BIU Raw-mix Design based on Lime Saturation Factor
MC_V1_B303_Lab_25 Raw-mix Design based on Lime Saturation
Factor
BIU MC_V1_B303_Lab_26BIU Three Component Raw-mix Design based on
Lime Saturation Factor and Silica Ratio
Text MC_V1_B303_Lab_12TXT Quantity of Raw Material Samples for Lab.
Investigation
Text MC_V1_B303_Lab_13TXT Coal Samples -A Point of View
Text MC_V1_B303_Lab_14TXT Purposes of Tests
Text MC_V1_B303_Lab_15TXT Tests Conducted at Physical Laboratory
Text MC_V1_B303_Lab_16TXT Chemical Tests at Chemical Lab.
Text MC_V1_B303_Lab_17TXT Mineralogical Investigations
Text MC_V1_B303_Lab_18TXT Fuel Investgation
Text MC_V1_B303_Lab_19TXT Raw Mix Investgation
Text MC_V1_B303_Lab_20TXT Burnability Investigation
BIU MC_V1_B303_Lab_31BIU Calculation of Effect of Coal Ash Absorption on
Clinker Analysis
MC_V1_B303_Lab_31 Calculation of Effect of Coal Ash Absorption on
Clinker Analysis
BIU MC_V1_B303_Lab_32BIU Calculation of Two Component Raw Mix Design
Considering Effect of Coal Ash Absorption
MC_V1_B303_Lab_32 Calculation of Two Component Raw Mix
Design Considering Effect of Coal Ash
Absorption
BIU MC_V1_B303_Lab_33BIU Raw-mix design calculation with three
components to match desired potential clinker
compounds
MC_V1_B303_Lab_33 Raw-mix design calculation with three
compounds
BIU MC_V1_B303_Lab_34BIU Evaluation of influence of coal ash on clinker
composition
MC_V1_B303_Lab_26 Three Component Raw-mix Design based on
Lime Saturation Factor and Silica Ratio
BIU MC_V1_B303_Lab_27BIU Calculation of Coal Ash Absorption
MC_V1_B303_Lab_27 Calculation of Coal Ash Absorption
BIU MC_V1_B303_Lab_28BIU No files here
Raw-mix design calculation with two
compounds
BIU MC_V1_B303_Lab_29BIU
MC_V1_B303_Lab_29 Raw-mix design calculation with two
components to match desired potential
clinker compounds
BIU MC_V1_B303_Lab_30BIU Calculation of Potential Clinker Composition
MC_V1_B303_Lab_30 Calculation of Potential Clinker Composition
Calculation of Coal Analysis and Heat Values
Coal
MC_V1_B304_Fuel_2 Calculation of Coal Analysis and Heat Values
of Coal
BIU MC_V1_B304_Fuel_3BIU_r3 Calculation of combustion air for burning of coal
MC_V1_B304_Fuel_3_r3 Calculation of combustion air for burning of coal
BIU MC_V1_B304_Fuel_4BIU Calculation of theoretical air for combustion of
coal and products of combustion
MC_V1_B304_Fuel_4 Calculation of theoretical air for combustion of
coal and products of combustion
BIU MC_V1_B304_Fuel_5BIU Calculation of Flame Temperature
MC_V1_B304_Fuel_5 Calculation of Flame Temperature
Text MC_V1_B304_Fuel_6TXT Reactivity of Coal as a Function of Fineness
MC_V1_B303_Lab_34 Evaluation of influence of coal ash on clinker
composition
Material Properties
BIU MC_V1_B303_Lab_35BIU Properties of Bulk Solids - Bulk Density
Determination
MC_V1_B303_Lab_35 Properties of Bulk Solids - Bulk Density
Determination
Properties of Bulk Solids - Characteristics
Influencing Behaviour Pattern
Text MC_V1_B303_Lab_36TXT
BIU MC_V1_B303_Lab_37BIU Properties of Bulk Materials - Methods of particle size
analysis
Book 304 MC_V1_B304_Fuel_TOC Fuels and Combustion
BIU MC_V1_B304_Fuel_1BIU_r3 Calculation of Capacities in Coal Preparation
Section
MC_V1_B304_Fuel_1_r3 Calculation of Capacities in Coal
Preparation Section
BIU MC_V1_B304_Fuel_2BIU
MC_V1_B304_Fuel_12 Vertical Roller Mill for grinding coal- calculation
of capacity and power
Hot air for drying moisture in Vertical Roller Mill
for grinding coal
MC_V1_B304_Fuel_13 Hot air for drying moisture in Vertical Roller Mill
for grinding coal
BIU MC_V1_B304_Fuel_14BIU Calculation of combustion air for burning of fuel
oil
MC_V1_B304_Fuel_14 Calculation of combustion air for burning of fuel oil
BIU MC_V1_B304_Fuel_15BIU Calculation of combustion air for burning of
gaseous fuels
MC_V1_B304_Fuel_15 Calculation of combustion air for burning of
gaseous fuels
BIU MC_V1_B304_Fuel_16BIU Gaseous fuels - calculation of products of
combustion
Gaseous fuels - calculation of products of
combustion
MC_V1_B304_Fuel_16
BIU MC_V1_B304_Fuel_7BIU Specific heats of gases as function of temp. T
MC_V1_B304_Fuel_7 Specific heats of gases as function of temp. T
Text MC_V1_B304_Fuel_8TXT Coal Grinding-Process considerations
Text MC_V1_B304_Fuel_9TXT Coal Dosing and Firing-Process considerations
Text MC_V1_B304_Fuel_10TXT Coal Burner -Process considerations
BIU MC_V1_B304_Fuel_11BIU Calculation of density of a mixture of dry and
wet flue gases
MC_V1_B304_Fuel_11 Calculation of density of a mixture of dry and
wet flue gases
Vertical Roller Mill for grinding coal- calculation
BIU MC_V1_B304_Fuel_21BIU Calculation of total heat loss due to moisture in
coal fired to kiln / furnace
MC_V1_B304_Fuel_21 Calculation of total heat loss due to moisture in
coal fired to kiln / furnace
BIU MC_V1_B304_Fuel_22BIU Calculations to Fix Locating Co-ordinates of Kiln
Burner
MC_V1_B304_Fuel_22 Calculations to Fix Locating Co-ordinates of Kiln
Burner
BIU MC_V1_B304_Fuel_23BIU_r1 Determination of Fuel Oil Stock in a Cylindrical
Horizontally Mounted Tank.
MC_V1_B304_Fuel_23_r1 Determination of Fuel Oil Stock in a Cylindrical
Horizontally Mounted Tank.
MC_V1_B304_Fuel_24TXT Basic constituents of Coal
MC_V1_B304_Fuel_25TXT Heat values of fuels
BIU MC_V1_B304_Fuel_17BIU Combustion of fuel - calculation of chemical
reactions
Combustion of fuel - calculation of chemical
reactions
MC_V1_B304_Fuel_17
BIU MC_V1_B304_Fuel_18BIU Orsat analysis and calculation of air / fuel ratio
as function of carbon burnout
MC_V1_B304_Fuel_18 Orsat analysis and calculation of air / fuel ratio
as function of carbon burnout
BIU MC_V1_B304_Fuel_19BIU Combustion calculations for burning of fuel oil
MC_V1_B304_Fuel_19 Combustion calculations for burning of fuel oil
BIU MC_V1_B304_Fuel_20BIU Gaseous fuels - combustion calculations
MC_V1_B304_Fuel_20 Gaseous fuels - combustion calculations
Belt Conveyor -Length of Conveyor Belt in a Roll
BIU MC_V1_B305_Convey_5BIU Belt Conveyor --Length of Belt and Speed
MC_V1_B305_Convey_5 Belt Conveyor --Length of Belt and Speed
BIU MC_V1_B305_Convey_6BIU_r3 Rubber belt conveyor -calculation of belt width
and capacity
MC_V1_B305_Convey_6_r3 Rubber belt conveyor -calculation of belt width
and capacity
BIU MC_V1_B305_Convey_7BIU Design of Fluidised Gravity Conveyor for raw meal
or cement
MC_V1_B305_Convey_7 Design of Fluidised Gravity Conveyor for raw meal
or cement
Design of Fluidised Gravity Conveyor for raw mill
return grits with fines
BIU MC_V1_B305_Convey_8BIU
return grits with fines
MC_V1_B305_Convey_8
Book 305 MC_V1_B305_Convey_TOC Conveying Systems
BIU MC_V1_B305_Convey_1BIU_r4 Vertical bucket elevator (chain type) calculation
MC_V1_B305_Convey_1_r4 Vertical bucket elevator (chain type)
calculation of capacity and power
BIU MC_V1_B305_Convey_2BIU Deep Bucket or Deep Pan type Conveyors
-Power and Filling
MC_V1_B305_Convey_2 Deep Bucket or Deep Pan type Conveyors
-Power and Filling
BIU MC_V1_B305_Convey_3BIU Screw Conveyor
MC_V1_B305_Convey_3 Screw Conveyor
BIU MC_V1_B305_Convey_4BIU Belt Conveyor -Length of Conveyor Belt in a Roll
MC_V1_B305_Convey_4
BIU MC_V1_B305_Convey_13BIU Various selection charts for power and tension
calculations of rubber belt conveyor -
MC_V1_B305_Convey_13 Various selection charts for power and tension
calculations of rubber belt conveyor -
Book 306 MC_V1_B306_Fans_TOC Air and Gas Handling (Fans,
Blowers & Compressors
BIU MC_V1_B306_Fans_1BIU Calculation of Fan Motor Power
MC_V1_B306_Fans_1 Calculation of Fan Motor Power
BIU MC_V1_B306_Fans_2BIU Calculation of Fan Operating Volume
MC_V1_B306_Fans_2 Calculation of Fan Operating Volume
Design of Fluidised Gravity Conveyor for cement
mill return grits with fines
Design of Fluidised Gravity Conveyor for cement
mill return grits with fines
MC_V1_B305_Convey_9
return grits without fines
return grits without fines
MC_V1_B305_Convey_10
BIU MC_V1_B305_Convey_11BIU Design of Fluidised Gravity Conveyor for cement
mill grits without fines
MC_V1_B305_Convey_11 Design of Fluidised Gravity Conveyor for cement
mill grits without fines
BIU MC_V1_B305_Convey_12BIU Power and tension calculations of rubber belt
conveyor -
MC_V1_B305_Convey_12 Power and tension calculations of rubber belt
conveyor -
MC_V1_B306_Fans_7BIU Calculation of velocity pressure and pressure
head development due to flow of air in a duct
MC_V1_B306_Fans_7 Calculation of velocity pressure and pressure
head development due to flow of air in a duct
BIU MC_V1_B306_Fans_8BIU Calculation of system resistance in a ducting
system and selecting an appropriate fan based
on their characteristic curves
MC_V1_B306_Fans_8 Calculation of system resistance in a ducting
system and selecting an appropriate fan based
on their characteristic curves
BIU MC_V1_B306_Fans_9BIU Calculation and plotting of system resistance
curves by introduction of change in system
design in a ducting system
MC_V1_B306_Fans_9 Calculation and plotting of system resistance
curves by introduction of change in system
design in a ducting system
BIU MC_V1_B306_Fans_10BIU Calculation of fan pressure development as a
function of gas temperature.
MC_V1_B306_Fans_10 Calculation of fan pressure development as a
Text MC_V1_B306_Fans_3TXT Design of Large Fans -Requirement of Motor Data
BIU MC_V1_B306_Fans_4BIU Calculation of linear expansion of shafts -during
hot running conditions
MC_V1_B306_Fans_4 Calculation of Expansion of Fan shaft -
During Hot Condition
BIU MC_V1_B306_Fans_5BIU Calculation of Fan Pressure and Power Rating
MC_V1_B306_Fans_5 Calculation of Fan Pressure and Power Rating
BIU MC_V1_B306_Fans_6BIU Calculation of pressure development by fans and
blowers
MC_V1_B306_Fans_6 Calculation of pressure development by fans and
blowers
BIU
BIU MC_V1_B307_Matrls_1BIU Ventilation of Ball mills and cooling air calculation
MC_V1_B307_Matrls_1 Ventilation of Ball mills and cooling air calculation
BIU MC_V1_B307_Matrls_2BIU Solving with LMTD -heat transfer in cooler or
dryer.
MC_V1_B307_Matrls_2 Solving with LMTD -heat transfer in cooler or
dryer.
BIU MC_V1_B307_Matrls_3BIU Soil Properties Calculations
MC_V1_B307_Matrls_3 Soil Properties Calculations
BIU MC_V1_B307_Matrls_4BIU Evaluation of hot gas utilisation factor in a drying
system
MC_V1_B307_Matrls_4 Evaluation of hot gas utilisation factor in a drying
system
MC_V1_B306_Fans_10 Calculation of fan pressure development as a
function of gas temperature.
BIU MC_V1_B306_Fans_11BIU Calculation of fan pressure development at a new
location - considering change in barometric
pressure
MC_V1_B306_Fans_11 Calculation of fan pressure development at a new
location - considering change in barometric
pressure
BIU MC_V1_B306_Fans_12BIU Calculation of fan output data under test
conditions.
MC_V1_B306_Fans_12 Calculation of fan output data under test
conditions.
BIU MC_V1_B306_Fans_13BIU Calculation of fan output as a function of change
in speed
MC_V1_B306_Fans_13 Calculation of fan output as a function of change
in speed
Book 307 MC_V1_B307_Matrls_TOC Materials and Processing -General
Folder
MC_V1_B308_Hydraulics_3BIU
MC_V1_B308_Hydraulics_3 Calculation of static pressure in a pipeline based
on measurement by U-Tube Manometer
BIU MC_V1_B308_Hydraulics_4BIU Water jet calculation in cement grinding mill
MC_V1_B308_Hydraulics_4 Water jet calculation in cement grinding mill
BIU MC_V1_B308_Hydraulics_5BIU External water jet calculation in cement grinding
mill
MC_V1_B308_Hydraulics_5 External water jet calculation in cement grinding
mill
BIU MC_V1_B308_Hydraulics_6BIU Efficiency calculation of a centrifugal pump in
operation
MC_V1_B308_Hydraulics_6 Efficiency calculation of a centrifugal pump in
operation
Pressure and power calculation of a centrifugal
pump to pump water
BIU MC_V1_B308_Hydraulics_7BIU
BIU MC_V1_B307_Matrls_5BIU Estimation of cement requirement for building
brick wall
MC_V1_B307_Matrls_5 Estimation of cement requirement for building
brick wall
Book 308 MC_V1_B308_Hydraulics_TOC Plant Hydraulics
BIU MC_V1_B308_Hydraulics_1BIU Quality of Plant Cooling Water
MC_V1_B308_Hydraulics_1 Quality of Plant Cooling Water
BIU MC_V1_B308_Hydraulics_2BIU Hydraulic jack -calculation of power requirement
MC_V1_B308_Hydraulics_2 Hydraulic jack -calculation of power requirement
Calculation of static pressure in a pipeline based
on measurement by U-Tube Manometer
BIU
Fluid flow - calculation of flow through pipeline
with ventury meter
MC_V1_B308_Hydraulics_11 Fluid flow - calculation of flow through pipeline
with ventury meter
BIU MC_V1_B308_Hydraulics_12BIU Selection of pipeline in pumping system design
MC_V1_B308_Hydraulics_12 Selection of pipeline in pumping system design
BIU MC_V1_B308_Hydraulics_13BIU Energy in liquids -an approach to Barnaulli's
equation
MC_V1_B308_Hydraulics_13 Energy in liquids -an approach to Barnaulli's
equation
BIU MC_V1_B308_Hydraulics_14BIU Calculation of pressure, downstream in a pipeline
MC_V1_B308_Hydraulics_14 Calculation of pressure, downstream in a pipeline
Pressure and power calculation of a centrifugal
pump to pump water
MC_V1_B308_Hydraulics_7
BIU MC_V1_B308_Hydraulics_8BIU Fluid flow - calculation of Raynold's number and
friction factor
MC_V1_B308_Hydraulics_8 Fluid flow - calculation of Raynold's number and
friction factor
BIU MC_V1_B308_Hydraulics_9BIU Fluid flow - calculation of flow between three
interconnected tanks in star formation
MC_V1_B308_Hydraulics_9 Fluid flow - calculation of flow between three
interconnected tanks in star formation
Fluid flow - calculation of work done by a pump to
empty a sump and lift the water to over head tank
Fluid flow - calculation of work done by a pump to
empty a sump and lift the water to over head tank
MC_V1_B308_Hydraulics_10
Pump systems
Net Positive Suction Head NPSH
BIU MC_V1_B308_Hydraulics_20BIU Calculation of Net Positive Suction Head (NPSH)
for pumplocated above reservoir level.
MC_V1_B308_Hydraulics_20 Calculation of Net Positive Suction Head (NPSH)
for pumplocated above reservoir level.
BIU MC_V1_B308_Hydraulics_20BIUa Calculation of Net Positive Suction
Head (NPSH) for pumplocated above
reservoir level.
Using global
variable
BIU MC_V1_B308_Hydraulics_21BIU Calculation of Net Positive Suction Head (NPSH)
for pump located below reservoir level.
MC_V1_B308_Hydraulics_21 Calculation of Net Positive Suction Head (NPSH)
for pump located below reservoir level.
BIU MC_V1_B308_Hydraulics_15BIU Pressure loss in a pipeline due to fluid flow
MC_V1_B308_Hydraulics_15 Pressure loss in a pipeline due to fluid flow
BIU MC_V1_B308_Hydraulics_16BIU Calculation of power required for a pump to
deliver water through a pipeline system
MC_V1_B308_Hydraulics_16 Calculation of power required for a pump to
deliver water through a pipeline system
Text MC_V1_B308_Hydraulics_17TXT Pumping terminologies
BIU MC_V1_B308_Hydraulics_18BIU Pumping laws
MC_V1_B308_Hydraulics_18 Pumping laws
MC_V4_B201_KilnPH_1BIU Preheater exhaust gases- calculation
MC_V4_B201_KilnPH_1a Preheater Exhaust Gases -with oil firing
BIU MC_V4_B201_KilnPH_1aBIU Preheater Exhaust Gases -with oil firing
MC_V4_B201_KilnPH_2 Pressure loss in kiln and preheater
BIU MC_V4_B201_KilnPH_2BIU Pressure loss in kiln and preheater
MC_V4_B201_KilnPH_3 Preheater fan rating
BIU MC_V4_B201_KilnPH_3BIU Preheater fan rating
MC_V4_B201_KilnPH_4 Tertiary air and ducting to precalciner
BIU MC_V4_B201_KilnPH_4BIU Tertiary air and ducting to precalciner
Book 309 MC_V1_B309_Insulation_TOC Insulation
BIU MC_V1_B309_Insulation_1BIU General Specifications for Insulation in Cement
Plant
MC_V1_B309_Insulation_1 General Specifications for Insulation in
Cement Plant
Volume-4 : Simulation model for pyro-processing
MC_V4_TOC Expanded Table of Contents - Vol.4
Book 200 Process calculation of plant sections
Book 201 MC_V4_B201_KilnPH_TOC Kiln Preheater Section
MC_V4_B201_KilnPH_1 Preheater exhaust gases- calculation
BIU
MC_V4_B201_KilnPH_9 Input data calculation for file B201_KilnPH_10
BIU MC_V4_B201_KilnPH_9BIU Input data calculation for file B201_KilnPH_10BIU
BIU MC_V4_B201_KilnPH_10BIU Heat gas and mass balance in 5 stage
preheater with precalciner
MC_V4_B201_KilnPH_11 Radiation losses from kiln
BIU MC_V4_B201_KilnPH_11BIU Radiation losses from kiln
BIU MC_V4_B201_KilnPH_12BIU Calculation of false air into the system
BIU MC_V4_B201_KilnPH_13aBIU Kiln heat balance
MC_V4_B201_KilnPH_5 Primary air fan for coal firing in kiln
BIU MC_V4_B201_KilnPH_5BIU Primary air fan for coal firing in kiln
MC_V4_B201_KilnPH_6 Mass balance in a single cyclone preheater
stage
BIU MC_V4_B201_KilnPH_6BIU Mass balance in a single cyclone preheater
stage
MC_V4_B201_KilnPH_7 Mass balance in multiple preheater stages
BIU MC_V4_B201_KilnPH_7BIU Mass balance in multiple preheater stages
MC_V4_B201_KilnPH_8 Gas balance in preheater
BIU MC_V4_B201_KilnPH_8BIU Gas balance in preheater
Over all heat balance, gas balance and mass
balance in the pyro section-6 stage preheater
-74p
MC_V4_B203_Pyro_3BIU BIU
-69p
balance in the pyro section -5 stage
preheater-69p
MC_V4_B203_Pyro_2
-64p
Pyro Processing ( Kiln, Preheater &
Cooler ) Section
MC_V4_B203_Pyro_TOC Book 203
Calculation of grate area and bed height for
clinker cooler
MC_V4_B202_Cooler_3
Clinker cooler gas balance and heat balance MC_V4_B202_Cooler_2BIU BIU
Clinker cooler gas balance and heat balance MC_V4_B202_Cooler_2
Clinker cooler -cooling air calculation MC_V4_B202_Cooler_1
Clinker Cooler Section MC_V4_B202_Cooler_TOC Book 202
MC_V4_B301_Heat_3BIU Calculation of total heat required to evapoate
moisture
Volume-5 : Fluid power
Book 200 Air and Gas Handling
Book 201 MC_V5_B201_Fans_TOC Pneumatics and compressed air systems
Compressed air systems
Pneumatics basics
BIU MC_V5_B201_Fans_1BIU Calculation of mass of gases stored in a
vessel
MC_V5_B201_Fans_1 Calculation of mass of gases stored in a
vessel
Book 300 Process design calculations - support systems
Book 301 MC_V1_B301_Site_TOC Plant Site
BIU MC_V1_B301_Site_1BIU The Barometric pressure at site based on the
The Barometric pressure at site based on the
MC_V1_B301_Site_1
Book 302 MC_V4_B302_Heat_TOC Heat & Combustion
BIU MC_V4_B301_Heat_1BIU Combustion calculations for burning of fuel oil
BIU MC_V4_B301_Heat_2BIU Gaseous fuels- combustion calculations
BIU
BIU MC_V5_B201_Fans_6BIU Calculation of pressure loss and flow through
compressed air pipe lines
MC_V5_B201_Fans_6 Calculation of pressure loss and flow
through compressed air pipe lines
BIU MC_V5_B201_Fans_7BIU Calculation of pipe diameter for flow
MC_V5_B201_Fans_7 Calculation of pipe diameter for flow
Production and distribution of compressed air
BIU MC_V5_B201_Fans_8BIU Calculation of frequency at which
compressor would come on load as
function of system demand.
MC_V5_B201_Fans_8 Calculation of frequency at which
compressor would come on load as
function of system demand.
BIU MC_V5_B201_Fans_9BIU Calculation of consumption of compressed
BIU MC_V5_B201_Fans_2BIU Compressed air pressure in a cylinder to
deliver a desired clamping force
MC_V5_B201_Fans_2 Compressed air pressure in a cylinder to deliver
a desired clamping force
BIU MC_V5_B201_Fans_3BIU Calculation of theoretical power to compress air
polytropically
MC_V5_B201_Fans_3 Calculation of theoretical power to compress air
polytropically
BIU MC_V5_B201_Fans_4BIU Calculation of theoretical power for
isothermal compression of air
MC_V5_B201_Fans_4 Calculation of theoretical power for
isothermal compression of air
BIU MC_V5_B201_Fans_5BIU Calculation of inter-cooler pressure for minimum
power for two stage compression of air
MC_V5_B201_Fans_5 Calculation of inter-cooler pressure for minimum
power for two stage compression of air
Calculation to find pressure range to control number
of starts for compressor for given capacity of receiver
based on operational demand of compressed air
MC_V5_B201_Fans_14
Calculation to find pressure range to control
number of starts for compressor for given
capacity of receiver based on operational demand
of compressed air
MC_V5_B201_Fans_14BIU BIU
Calculation of number of starts for compressor
for given capacity of receiver based on
operational demand of compressed air
MC_V5_B201_Fans_13
Calculation of number of starts for compressor
for given capacity of receiver based on
MC_V5_B201_Fans_13BIU BIU
Calculation of capacity of receiver based on
MC_V5_B201_Fans_12
Calculation of capacity of receiver based on
BIU MC_V5_B201_Fans_9BIU Calculation of consumption of compressed
air in operating a cylinder
MC_V5_B201_Fans_9 Calculation of consumption of compressed
air in operating a cylinder
BIU MC_V5_B201_Fans_10BIU Calculation of reduction in consumption of
compressed air in operating a cylinder with low
pressure supply for retract stroke
MC_V5_B201_Fans_10 Calculation of reduction in consumption of
compressed air in operating a cylinder with low
pressure supply for retract stroke
BIU MC_V5_B201_Fans_11BIU Calculation of consumption of compressed air in
operating a cylinder including effect of pressurising
pipeline between valve and cylinder.
MC_V5_B201_Fans_11 Calculation of consumption of compressed air in
operating a cylinder including effect of pressurising
pipeline between valve and cylinder.
BIU MC_V5_B201_Fans_12BIU
MC_V5_B201_Fans_18 Calculating of extend stroke time for a cylinder as
a function of load to be moved considering
cushioning effects.
Volume-22 : Business Mathematics
Book 200 Funds and assets creation
Book 201 MC_V22_B201_Interest_TOC Interest
BIU MC_V22_B201_Interest_1BIU Calculation of Effective Rate of Interest on an
Investment when Nominal Rate of Interest is
Known
MC_V22_B201_Interest_1 Calculation of Effective Rate of Interest on an
Investment when Nominal Rate of Interest is
Known
BIU MC_V5_B201_Fans_15BIU Estimation of leakage of compressed air , based
on fall in pressure in ring main when the plant is
shut down.
MC_V5_B201_Fans_15 Estimation of leakage of compressed air , based
on fall in pressure in ring main when the plant is
shut down.
BIU MC_V5_B201_Fans_16BIU Calculating compressed air cylinder bore to be
able to develop a desired clamping force
MC_V5_B201_Fans_16 Calculating compressed air cylinder bore to be
able to develop a desired clamping force
BIU MC_V5_B201_Fans_17BIU Calculating cylinder bore and compressed air
consumption to move a load up an incline.
MC_V5_B201_Fans_17 Calculating cylinder bore and compressed air
consumption to move a load up an incline.
BIU MC_V5_B201_Fans_18BIU Calculating of extend stroke time for a cylinder as
a function of load to be moved considering
cushioning effects.
Calculation of Rate of Nominal Interest per Year to
Reach a Certain Future Value on a Fixed Deposit or
Investment and Amount of Recurring Deposit
Separately to Achieve a Desired Total Future Value.
MC_V22_B201_Interest_6
Calculation of Rate of Nominal Interest per Year to
Investment and Amount of Recurring Deposit
Separately to Achieve a Desired Total Future Value.
MC_V22_B201_Interest_6BIU BIU
Calculation of Rate of Nominal Interest per Year,to
Investment and Recurring Deposit Separately or
Together
Calculation of Rate of Nominal Interest per Year,to
Together
Calculation of Future Value of a Fixed Deposit or
Together
Calculation of Future Value of a Fixed Deposit or
Together
Calculation of Rates of Interest on an Investment
when Final Balance After the End of Deposit
Period is Known
Calculation of Rates of Interest on an Investment
when Final Balance After the End of Deposit
Period is Known
Calculation of Nominal Rate of Interest on an
Investment when Effective Rate of Interest is
Known
Calculation of Nominal Rate of Interest on an
Investment when Effective Rate of Interest is
Known
BIU MC_V22_B202_Annuities_4BIU Calculation to find, present value of an annuity
MC_V22_B202_Annuities_4 Calculation to find, present value of an annuity
BIU MC_V22_B202_Annuities_5BIU Calculation to find, equated monthly instalment
to repay a loan
MC_V22_B202_Annuities_5 Calculation to find, equated monthly instalment
to repay a loan
Book 203 MC_V22_B203_Depreciation_TOC Depreciation
Text MC_V22_B203_Depreciation_1TXTIntroduction to Depreciation
Book 202 MC_V22_B202_Annuities_TOC Annuities
BIU MC_V22_B202_Annuities_1BIU Calculation of Payments for a Sinking Fund
MC_V22_B202_Annuities_1 Calculation of Payments for a Sinking Fund
BIU MC_V22_B202_Annuities_2BIU Calculation of Time Required for a Target Amount
in Sinking Fund
MC_V22_B202_Annuities_2 Calculation of Time Required for a Target Amount
in Sinking Fund
BIU MC_V22_B202_Annuities_3BIU Calculation to find, how much money will be in
the Sinking Fund after a certain period.
MC_V22_B202_Annuities_3 Calculation to find, how much money will be in
the Sinking Fund after a certain period.
Volume-23 : New Calculations
Book 200 Miscellaneous
Book 201 MC_V23_B201_Hopper_TOC Hopper design
BIU MC_V23_B201_Hopper_1BIU Calculation of valley angle of a hopper with
square and rectangular cross section, given the
wall angles and vertical height of the pyramidal
part.
MC_V23_B201_Hopper_1 Calculation of valley angle of a hopper with
square and rectangular cross section, given the
wall angles and vertical height of the pyramidal
part.
BIU MC_V23_B201_Hopper_2BIU Calculation of wall angles and valley angles of a
hopper with square and rectangular cross
section, given the opening dimensions and
height of the pyramidal part.
BIU MC_V22_B203_Depreciation_2BIU Depreciation Calculation of Assets by
Straight-line Method
MC_V22_B203_Depreciation_2 Depreciation Calculation of Assets by
Straight-line Method
BIU MC_V22_B203_Depreciation_3BIU Depreciation Calculation of Assets by Reducing
Balance Method
Accelerated Reducing Balance Method
Sum-of-the-Years' -Digits Method
BIU MC_V22_B203_Depreciation_6BIU Depreciation Calculation by Units of Production
Method
Calculation to determine number of refractory
bricks required for a kiln section
MC_V23_B202_Refra_1
Calculation to determine number of refractory
bricks required for a kiln section
MC_V23_B202_Refra_1BIU BIU
Refractory design MC_V23_B202_Refra_TOC Book 202
Calculation of maximum filling height of a silo so
that the lateral pressure does not exceed given
safe value
MC_V23_B201_Hopper_4
Calculation of maximum filling height of a silo so
that the lateral pressure does not exceed given
safe value
MC_V23_B201_Hopper_4BIU
Calculation of lateral pressure on silo wall due to
stored bulk material as function of filling height
and checking the possibility of increasing
capacity by increase of height.
Calculation of lateral pressure on silo wall due to
stored bulk material as function of filling height
and checking the possibility of increasing
capacity by increase of height.
MC_V23_B201_Hopper_3BIU BIU
Calculation of wall angles and valley angles of a
hopper with square and rectangular cross
section, given the opening dimensions and
height of the pyramidal part.
MC_V23_B204_Fuels_1BIU No files here
BIU MC_V23_B204_Fuels_2BIU Burner calculation - 3- channel coal firing burner
MC_V23_B204_Fuels_2 Burner calculation - 3- channel coal firing burner
Book 205 MC_V23_B205_Ducts_TOC Chutes & Ducts
BIU MC_V23_B205_Ducts_1BIU Load analysis of a multi-support saddle mounted tertiary air
duct
MC_V23_B205_Ducts_1 Load analysis of a multi-support saddle mounted tertiary air
duct
Book 203 MC_V23_B203_Kiln_TOC Kiln
BIU MC_V23_B203_Kiln_1BIU Calculation to determine the gap between tyre
and supporting pads
MC_V23_B203_Kiln_1 Calculation to determine the gap between tyre
and supporting pads
BIU MC_V23_B203_Kiln_2BIU Calculation of heat of reaction of clinker based on
laboratory analysis -based on VDZ procedure.
MC_V23_B203_Kiln_2 Calculation of heat of reaction of clinker based on
laboratory analysis -based on VDZ procedure.
Book 204 MC_V23_B204_Fuels_TOC Fuels & combustion
BIU
MC_V23_B207_Preblend_1BIU Calculation of longitudinal and linear blending beds .
MC_V23_B207_Preblend_1 Calculation of longitudinal and linear blending beds .
Book 208 MC_V23_B208_Matrl_TOC Materials properties
BIU MC_V23_B208_Matrl_1BIU Calculation of specific heats of various materials as a
function of temperature
MC_V23_B208_Matrl_1 Calculation of specific heats of various materials as a
function of temperature
BIU MC_V23_B208_Matrl_2BIU Calculation of specific heats of various gases as a function
of temperature
MC_V23_B208_Matrl_2 Calculation of specific heats of various gases as a function
of temperature
Book 206 MC_V23_B206_Dedust_TOC Dedusting systems
BIU MC_V23_B206_dedust_1BIU Calculation to check suitability of existing Glass Bag House
after proposed upgradation of kiln.
MC_V23_B206_Dedust_1 Calculation to check suitability of existing Glass Bag House
after proposed upgradation of kiln.
BIU MC_V23_B206_dedust_2BIU Calculate total pressure a fan must develop to move air in a
dedusting duct fitted with suction hood, filter and nozzle at
discharge end .
MC_V23_B206_dedust_2 Calculate total pressure a fan must develop to move air in a
dedusting duct fitted with suction hood, filter and nozzle at
discharge end .
Book 207 MC_V23_B207_Preblend_TOC Preblending systems
BIU
BIU V0_A001_TablesCharts_8BIU Calculation of Specific Heats of Gases and
Materials as a Function of Temperature
BIU V0_A001_TablesCharts_9BIU Dimension, Units, Variables & Constants,
Degree of Freedom etc
BIU V0_A001_TablesCharts_10BIU Pressure Related Basic Calculations
BIU V0_A001_TablesCharts_11BIU Calculations to Convert Column of Fluid to
Pressure
Text V0_A001_TablesCharts_12TXT Introduction toPsychrometry
BIU V0_A001_TablesCharts_13BIU Bulk Densities of Materials
BIU V0_A001_TablesCharts_14BIU Distributed Loads on Platforms for Civil Design
BIU V0_A001_TablesCharts_15BIU Foundation Pockets Size as a Function of Bolt
Size
Appendix 1 : Tables and charts
MC_V0_A001_TablesCharts_TOC Tables and charts
BIU V0_A001_TablesCharts_1BIU Separation Factor of ESP / Filter Dust
BIU V0_A001_TablesCharts_2BIU Humidity Chart - Finding Dew Point and Humidity
BIU V0_A001_TablesCharts_3BIU Steam Tables - Finding Dew Point and Humidity
V0_A001_TablesCharts_4 Reactivity of coal
BIU V0_A001_TablesCharts_5BIU Charts and Tables-Conversion Tables and
Factors
BIU V0_A001_TablesCharts_6BIU Calculation of Hard Grove Index from Laboratory
Result and conversion .
BIU V0_A001_TablesCharts_7BIU Charts and Tables-Wagner,Sieve.Blaine Relations
MC_V0_A002_Sciencedata_9TXT Properties of Metals - Poission's Ratio
Text MC_V0_A002_Sciencedata_10TXT Properties of Metals - Modulus of Elasticity
Text MC_V0_A002_Sciencedata_11TXT Properties of Metals - Melting Point in
Degrees Kelvin at Atmospheric Pressure
Text MC_V0_A002_Sciencedata_12TXT Properties of Common Solids - Density
Text MC_V0_A002_Sciencedata_13TXT Properties of Common Solids - Specific Gravity
Text MC_V0_A002_Sciencedata_14TXT Properties of Common Solids - Specific Heat
Text MC_V0_A002_Sciencedata_15TXT Properties of Common Solids - Thermal
Conductivity
Text MC_V0_A002_Sciencedata_16TXT Properties of Gases - Specific Gravity
MC_V0_A002_Sciencedata_TOC Scientific data
Text MC_V0_A002_Sciencedata_1TXT Basic Sciences Fundamental Physical
Constants
Text MC_V0_A002_Sciencedata_2TXT Basic Sciences Temperature Scales
Text MC_V0_A002_Sciencedata_3TXT Basic Sciences Periodic Table of Elements
Text MC_V0_A002_Sciencedata_4TXT Calculus Reference Formulae Table of Integral
Formulas
Text MC_V0_A002_Sciencedata_5TXT Properties of Metals - Thermal Conductivity at
Atmospheric Pressure ,250C
Text MC_V0_A002_Sciencedata_6TXT Properties of Metals - Specific Gravity
Text MC_V0_A002_Sciencedata_7TXT Properties of Metals - Co-efficient of Linear
Expansion per Degree C
Text MC_V0_A002_Sciencedata_8TXT Properties of Metals - Electrical Resistivity
Text
Circle
BIU MC_V0_A003_Mensuration_AP_6BIU Inscribed Circle
BIU MC_V0_A003_Mensuration_AP_7BIU Circumscribed Circle
BIU MC_V0_A003_Mensuration_AP_8BIU Sector of a Circle
BIU MC_V0_A003_Mensuration_AP_9BIU Circular Segment
BIU MC_V0_A003_Mensuration_AP_10BIU Regular Polygon
BIU MC_V0_A003_Mensuration_AP_11BIU Inscribed Polygon
BIU MC_V0_A003_Mensuration_AP_12BIU Circumscribed Polygon
BIU MC_V0_A003_Mensuration_AP_13BIU Parabolic Segment
BIU MC_V0_A003_Mensuration_AP_14BIU Ellipse
Text MC_V0_A002_Sciencedata_17TXT Properties of Gases - Specific Heat at 1.0
Atm Pressure, 20C, Except as Noted
Text MC_V0_A002_Sciencedata_18TXT Properties of Gases - Molecular Weightat 1.0
Atm Pressure, 20C, Except as Noted
Text MC_V0_A002_Sciencedata_19TXT Properties of Common Liquids - Specific Heat
MC_V0_A003_Mensuration_TOC Mensuration
MC_V0_A003_Mensuration_AP_TOC Areas and perimeters
BIU MC_V0_A003_Mensuration_AP_1BIU Triangle
BIU MC_V0_A003_Mensuration_AP_2BIU Rectangle
BIU MC_V0_A003_Mensuration_AP_3BIU Parallelogram
BIU MC_V0_A003_Mensuration_AP_4BIU Trapezoid
BIU MC_V0_A003_Mensuration_AP_5BIU
MC_V0_A003_Mensuration_VS_6BIU Frustum of Right Circular Cone
BIU MC_V0_A003_Mensuration_VS_7BIU Sphere
BIU MC_V0_A003_Mensuration_VS_8BIU Spherical Cap
BIU MC_V0_A003_Mensuration_VS_9BIU Spherical Triangle
Did you know?(DYK001)
Click here to find out
MC_V0_A003_Mensuration_VS_TOC Volumes and surfaces
BIU MC_V0_A003_Mensuration_VS_1BIU Rectangular Prism
BIU MC_V0_A003_Mensuration_VS_2BIU Parallelepiped
BIU MC_V0_A003_Mensuration_VS_3BIU Right Circular Cylinder
BIU MC_V0_A003_Mensuration_VS_4BIU Pyramid
BIU MC_V0_A003_Mensuration_VS_5BIU Right Circular Cone
BIU
MathCement
MathCement
Preliminaries
MC_V0_B000_Foreword_01TXT
Topic: Foreword by Dr. A.K.Chatterjee
About this topic
Foreword
It was about 40 years back that I had the first opportunities of peeping into cement plants and
tasting the flavours of cement technology. Within the first few years of my professional
exposure, I had realized how complex and dynamic the cement processes were. I understood
that two kilns or two mills of the same design and dimension might not behave in identical
manners even in comparable situations. A quantitative and numerical understanding of the
processes involved was the only way to succeed in achieving the targeted results.
Those days, I had the "Cement Engineers Handbook " by Otto Labahn as my bible for all
numerical appreciation of the unit operations. Although the book provided the procedures of
calculations for a range of problems, I still had to maintain my own diary to apply the
procedures to the actual situation.
In the 70s, apart from the revised editions of the Hand Book by Otto Labahn, I had the added
benefits of the "Cement-Data-Book" by Walter H.Duda, Cement Manufacturers Hand Book by
Kurt E. Peray, etc. While Duda opened up a comprehensive coverage of numerical data,
diagrams, tables and description of processes and machinery, Peray provided a host of
engineering formulae that represented the basic tools for gaining a better understanding of the
cement engineering and technology. Notwithstanding the availability of these publications,
the cement plant engineers and chemists had to undertake the laborious tasks of making their
own calculations with specific input of data. The books provided only the guidelines,
procedures and approaches.
Quite contrary to the past trends, "Mathcement" is a serious endeavour to rescue the cement
plant operational personnel from the above ennui. The modern computer facility and
accompanying software have provided new opportunities of easy computing. M/s Softideas
Pvt.Ltd. have relied on all the past hand books, or at least the majority of them, and
superimposed "Mathcad" on them. The authors of "Mathcement" have tried to identify the
specific computational requirements of the practicing cement engineers and more particularly
of the personnel operating in the cement plants.
Hence,"Mathcement" does not suffer from the strains of exhaustiveness in coverage. On the
contrary, it provides a sharp focus on practical and day-to-day needs of practicing
professionals. The entire e-book has been designed in 4 parts; the first one covers
essentially the unit operations of a plant starting from the limestone quarry to the cement
dispatch as well as the essential requirements of quality checks and raw materials.
D:\MathCement_demo_pdf\MC_V0_B000_Foreword_
01TXT.mcd
Page 1 of 2
Copyright 2000-2005 Softideas Pvt. Ltd.
MathCement
The second part of the book covers all the auxiliaries such as de-dusting, conveyors, fans and
blowers, water, insulation, laboratory and plant site conditions. The third part of the e-book
takes care of the limited number of physical, chemical and thermo-chemical tables that are
essentially required for engineering calculations. The last, but not the least, is the fourth part
of the e-book that takes care of refreshing the readers about some of the essential basics of
cement chemistry.
On the whole, from the e-book "Mathcement", any practicing cement professional will find a
way to solve his or her problem and would obtain the results by the touch of the keyboard only
by putting in the input values specific to his or her requirements. I did not realize earlier that
computations could be so pleasurable, so easy, so rapid and yet, so precise and useful.
I am sure, all the concerned professionals would derive immense benefit from this innovative e-
book named "Mathcement".
Dr.A.K.Chatterjee
Whole-time Director
The Associated Cement Cos.Ltd.
'Cement House', 121, M.K.Road
Mumbai 400 020, India
Mumbai , July 27, 2001
Fri Sep 23 12:58:29 PM 2005
D:\MathCement_demo_pdf\MC_V0_B000_Foreword_
01TXT.mcd
Page 2 of 2
MathCement
MathCement
Introduction
MC_V0_B000_Intro_01TXT
Topic: The nature of mathematics of cement
About this topic
Mathematics of cement is not a distinct branch of cement technology in a way we understand
in our day-to-day interaction.It is rather an approach to technical analysis in which scientists;
engineers and technologists make use of mathematical symbols in the statement of a problem
and then draws upon known mathematical theorems to support reasoning.The approach is thus
applicable to specific subjects dealt in cement technology like crushing, grinding,
pyro-processing and so on.
Every approach to analysis of a problem associated with design, operation or optimisation in
relation to cement is necessarily exemplified by mathematics.We will conventionally use the
term mathematics of cement to cover the entire spectrum of describing problems and solution
techniques using mathematical techniques.The mathematical techniques that are used can
stretch from simple geometry to matrix algebra, differential equations, programming etc.It is our
intention to introduce various fundamental and advanced mathematical techniques to solve
day-to-day technical and operational problems that are faced by cement technologists or
scientists.
MathCement is a registered trade of Softideas Pvt. Ltd., trade name for the topics dealt under
the realm of mathematics of cement.
References
Fri Sep 23 10:38:09 2005
D:\MathCement_demo_pdf\MC_V0_B000_Intro_
01TXT.mcd
Page 1 of 1
MathCement
MathCement
Introduction
MC_V0_B000_Intro_02TXT
Topic: Mathematics of cement as against non-mathematical approach
About this topic
Mathematics of cement is basically an approach to analysis of cement technology and related
problems.Therefore, it does not fundamentally differ from any non mathematical approach to
such analysis.It should be noted that the fundamental purpose of any theoretical analysis,
regardless of its approach, is to arrive at some conclusions from a given set of assumptions or
data via a process of reasoning.The major difference between "mathematical approach" and
"non-mathematical or literary approach" would lie in the fact that in the case of the former, the
assumptions and conclusions are stated in mathematical symbols rather than in words and in
mathematical equations rather than in explanatory text.Also, in case of mathematical
approach, we use mathematical theorem,which exist in abundance to draw upon for reasoning
in place of literary logic. Truly speaking, symbols and words are equivalent.You can see this in
the fact that symbols are mostly expressed in words.It should, therefore, hardly matter which
one is chosen over the other.But we all know that symbols are more convenient in deductive
reasoning and hence they form the basic building blocks of mathematics.
Mathematics has the basic advantage of leading from explicit assumptions and precise
reasoning at every stage of solution.Mathematical theorems normally have the "if-then" form
such that to tap the "then" part, which is the result part of the theorem,one has to make sure
that the "if " part, that is the condition part, conforms to the assumptions made.
Many solutions are well depicted by geometrical modeling.However, geometrical solutions have
their limitations arising out of dimensional limitation.For instance if the number of variables are
three, the graphical treatment of the solution would call for 3-d graph which is difficult to draw .
However, if the number of variables happens to be four or more,making such higher dimensional
graph becomes practically impossible.Thus mathematical equations are better suited to handle
problems involving many variables.
We can, thus, summarise the advantage we get by adopting mathematical approach against
literary approach as follows:
1) Mathematical language of statement are more concise and precise
2) Mathematics provide us with many techniques and theorems to adopt readily
3) It ensures that all assumptions are made explicit
4) It enables treatment of multi-variable situations (n-variables)
Questions are sometimes raised about how realistic mathematical solutions are?. We must
remember that any theoretical approach to an analysis , mathematical or otherwise,falls within
the domain of reality. Thus ,all such treatments are only extracts from real world.It is always
unrealistic to the extent that it fails to take into consideration some of the complex real life
influences.If we could cover real life situations in its entirety, we could then possibly play God.
02TXT.mcd
Page 1 of 2
MathCement
Finally, we may like to compare mathematical approach to a "mode of transportation" to be
used in our journey from a start point to destination point at a fast speed.Assuming that you
would like to go from home to a park which is situated 3 km away, you you normally pick your
car as your mode of transportation so that you can reach your destination fast. You may also
choose to walk the distance to make it a part of your aerobic excercise.Thus, to be able to
reach your conclusions faster, as a theorist, you would prefer to ride the vehicle of ' appropriate
mathematical techniques". It,however, goes without saying that you have to learn to drive this
vehicle and some one has to build the vehicle.The skill you will acquire will serve you in good
stead for a long time come and so it should be worth its while to learn them.We have, on our
part, tried to build a good and friendly vehicle called "MathCement" covering mathematical
approach to solving cement problems in technology and operations.
MathCement is a registered trade-mark of Softideas Pvt. Ltd., trade name for the topics dealt
under the realm of mathematics of cement.
Fri Sep 23 12:59:07 PM 2005
02TXT.mcd
Page 2 of 2
MathCement
MathCement
Mathematical Models
MC_V0_B000_Models_03TXT
Topic: Why create a mathematical model (MathCement model)?
About this topic
We live our life in the real world in all its glory.It is the nature that we observe with awe and
wonder at the marvel of creation.As human beings our thinking brains have always been
inspired to continuously try and convert natural phenomena to the best of our advantage.For
example,we discovered electricity by observing lightning and made it work for us in thousands
of different ways.
There are people in this world for whom the existing solutions are not acceptable.So they look
for newer solutions by first rejecting the existing solution.As the next step they create an
approximation of the real life situation or object which can be experimented with.This
representative of real life situation or object is a model.A model,thus, tries to replicate a real life
situation or object as closely as possible.This model greatly facilitates experiment since it is
much simpler to handle and manipulate without the danger of damaging or hurting the original
real life situation.
Thus scientists can make changes in the model or subject the model to different conditions
and evaluate its effect .They then project, how it would behave when real life situation is
subjected to similar changed conditions.
As a next step, such findings need to be approved by the appropriate authority.Then, after the
approval,they can finally introduce the changes in real life and see how best the predictions are
met.
Thus, through a model, we see the future behaviour of a current real life situation under
controlled conditions. This helps us to take a decision whether to adopt the new solution or not.
When the representative model is built with mathematical symbols and variables are related to
each other by equations to closely represent the assumptions and constraints and applied with
appropriate mathematical theorem leading to conclusions, we have created a mathematical
model.
Now by varying the values of the variables we can foresee the resultant predictive behaviour of
the model.Computer helps us further to arrive at the conclusions very fast. We can thus
analyse the performance of the real life situations very quickly without disturbing the original
object.
MathCement is a registered trade of Softideas Pvt. Ltd., trade name for the topics dealt under
the realm of mathematics of cement.
References
Fri Sep 23 10:44:39 AM 2005
D:\MathCement_demo_pdf\MC_V0_B000_Models_
03TXT.mcd
Page 1 of 5
MathCement
Fri Sep 23 10:44:39 AM 2005
03TXT.mcd
Page 2 of 5
MathCement
References
03TXT.mcd
Page 3 of 5
MathCement
Picture is inserted instead of paste to reduce file size
Page set up- A-4, Margins- Left 1.2in,top & bottom 1in, right 0.75in.
Region check done 10/5/05
Rev 4
Checked for assignment in
symbol area 10/5/05
Rev 3 Spell check done 10/5/05
4p/1h Rev -2 10/5/05 Rev 2 MC_V0_B000_Models_01TXT
SP 3-4/12/02
11 /12/02 Rev 1
4p/2h Rev -0 BIU 3-4/12/02 Rev -0 V1_B0_CH1_Modelling_1
03TXT.mcd
Page 4 of 5
MathCement
03TXT.mcd
Page 5 of 5
V
d
Dumper volumetric capacity required
B
cs
Excavator Shovel Bucket Capacity
(volumetric) based on standard availability
B
n
Number of shovel buckets to fill a Dumper (normal-
3 to 8 )
H
t
Hopper to hold material equivalent to
crusher feed in terms of time
BD
LS
Bulk density of uncrushed stone
(limestone) 1.5 -1.6
Crusher capacity
Q
cr
To find Dumper volumetric capacity
List of parameters used
User defined units
Top
For transporting quarried stone to crushing plant by dumpers, calculate number of dumpers,
vol. capacities, hopper capacity for crusher.
Statement of problem
Results
Calculation algorithm
Input data
Important bookmarks (Double click on linked regions below to go to sections
directly)
Use this worksheet to estimate capacity requirement of dumpers in the quarry
About this topic
Topic: Quarry - Dumper Calculations
MC_V1_B201_quarry_3BIU_r3
Quarry Section
MathCement 2000
D:\MathCement_demo_pdf\MC_V1_B201_quarry_
3BIU_r3.mcd
Page 1 of 6
Crusher capacity
BD
LS
1.5
tonne
m
3
:
H
t
15min :
3 to 8 )
B
n
5 :
B
cs
4.5m
3
:
Standard dumper volumetric capacity
V
ds
25m
3
:
Dumper turn around time
T
dtr
20min :
Top
Calculate required volumetric capacity of
Dumper
V
d
V
d
B
cs
B
n
:
Dumper capacity W
ds
W
ds
Capacity of dumping required
C
dh
Minimum number of Dumpers required to feed
crusher
N
d
Hopper capacity for crusher -( volumetric) based on
desired holding time H
t

H
v1
Hopper capacity -( volumetric) based on minimum
turnaround time for dumper -
H
v2
Selected hopper capacity - the higher value between
H
v1
and H
v2

H
v
Maximum possible capacity of each dumper.
W
max
Input data
Estimation of Number of Dumpers and Capacity and hopper capacity.
To find Dumper volumetric capacity
Q
cr
1200
tonne
hr
:
3BIU_r3.mcd
Page 2 of 6
N
d
12 Minimum number of Dumpers required to feed crusher
N
d
12
Function ceil returns the smallest integer
greater than or equal to x. x must be real.
N
d
ceil
Q
cr
1.1
C
dh
,
:
N
d
Minimum number of Dumpers required to feed crusher
Dumpers should be able to feed the crusher
continuously at a rate slightly higher than the crusher
intake.
Next , calculate the number of dumpers required to feed the crusher
C
dh
112.5
tonne
hr
Dumping capacity
C
dh
112.5
tonne
hr
C
dh
W
ds
T
dtr
:
C
dh
Capacity of dumping
T
dtr
20 min
Dumper turn around time- i.e the average time taken by a dumper to laod,travel
to crusher ,unloadand return to loading point -in minutes
Calculate dumping capacity
W
ds
37.5 tonne
W
ds
V
ds
BD
LS
:
Dumper capacity W
ds
V
ds
25 m
3
Standard dumper volumetric capacity
Dumper capacities are determined by manufacturing standard. So select the
nearest standard capacity dumper.
Next , select standard capacity Dumper from
manufacturer catalogue
V
d
22.5 m
3
Required volumetric capacity
of Dumper
V
d
22.5 m
3
3BIU_r3.mcd
Page 3 of 6
Top
Select dumper capacity to fall between W
max
and W
ds
as calculated based on turn around time W
ds
37.5 tonne
W
max
200 tonne
W
max
H
v
2
BD
LS
:
Hopper should hold at least two dumper loads. So check for maximum
capacity of each dumper.
H
v
266.67 m
3
Hopper capacity feeding the crusher
H
v
266.67 m
3
H
v
if H
v1
H
v2
H
v1
, H
v2
, ( ) :
H
v
Selected hopper capacity - the higher value between H
v1
and H
v2

H
v2
266.67 m
3
H
v2
Q
cr
T
dtr
BD
LS
:
H
v2
turnaround time for dumper - that means the hopper
should hold material for the time taken by a dumper
H
v1
200 m
3
H
v1
Q
cr
H
t
BD
LS
:
H
v1
Hopper capacity -( volumetric) based on desired
holding time
Now calculate the capacity of hopper feeding the crusher
3BIU_r3.mcd
Page 4 of 6
V
d
22.5 m
3
Dumper capacity required, based on turn around time W

ds
37.5 tonne
Capacity of dumping required C
dh
112.5
tonne
hr
Minimum number of Dumpers required to feed

crusher based on dumping capacity
N
d
12
Hopper capacity for crusher -( volumetric) based on
desired holding time
H
v1
200 m
3

turnaround time for dumper -
H
v2
266.67 m
3
Selected hopper capacity - the higher value between

H
v1
and H
v2

H
v
266.67 m
3
Maximum possible capacity of each dumper.W

max
W
max
200 tonne
Select dumper capacity to fall between W
max
and W
ds
Top
Results
Given data
Q
cr
1200
tonne
hr
Crusher capacity
BD
LS
1.5
tonne
m
3

H
t
15 min
3 to 8 )
B
n
5
B
cs
4.5m
3
Standard dumper volumetric capacity V

ds
25 m
3
Dumper turn around time T

dtr
20 min
Derived data
Dumper volumetric capacity required
3BIU_r3.mcd
Page 5 of 6
Observation
References
Fri Sep 23 1:34:59 PM 2005
3BIU_r3.mcd
Page 6 of 6
D
pbn
New product size of rock -volume-surface mean dia.
m
n
New feed rate to be tried
P Power required by crusher for current output
m Current mass feed rate to the crusher
D
pb
Product size of rock -volume-surface mean dia.
D
pa
Feed size of rock -volume-surface mean dia.
User defined units
Top
An existing crusher which crushes rocks to reduce volume-surface mean
diameter of feed to a smaller dia. product.These data being known from the
operations log of the crusher, also the corresponding output and power
requirement figures are known.
Find the new power requirement for a new capacity at a different product dia.
Results
Input data
directly)
This is worksheet can be used to supplement calculation of power required to
crush material in an existing crusher at different outputs by using Rittinger's law.
About this topic
Topic: Calculation of power for existing crusher at different
capacities -application of Rittinger's law
MC_V1_B202_Crushing_3BIU
Crushing section
MathCement 2000
D:\MathCement_demo_pdf\MC_V1_B202_Crushing_
3BIU.mcd
Page 1 of 3
Top
P
n
8.52 kW
Power requirement of crusher
at new output as a fresult of
changes in product size
P
n
8.52 kW
P
n
M
fn
K
R
1
D
pbn
1
D
pa
,
:
P
n
Now we like to find new power requirement
K
R
14.58
m
3
s
2
K
R
P
M
f
1
D
pb
1
D
pa
,
:
or
P
M
f
K
R
1
D
pb
1
D
pa
,
=
Let us consider Rittinger's equation:
Top
D
pbn
3.8mm :
New product size of rock -volume-surface mean dia.
M
fn
10
tonne
hr
:
P 8.95kW :
Power required by crusher for current output
M
f
15
tonne
hr
:
Current mass feed rate to the crusher
D
pb
5mm :
Product size of rock -volume-surface mean dia.
D
pa
19mm :
Feed size of rock -volume-surface mean dia.
Input data
3BIU.mcd
Page 2 of 3
Fri Sep 23 1:41:29 PM 2005
1)Chapter on "Size Reduction" - Unit Operation of Chemical Engineering
2)Hallmark Technologies, Pune
References
Observation
Top
P
n
8.52 kW New power requirement
Derived data
D
pbn
3.8mm New product size of rock -volume-surface mean dia.
M
fn
10
tonne
hr
P 8.95 kW Power required by crusher for current output
M
f
15
tonne
hr
Current mass feed rate to the crusher
D
pb
5 mm Product size of rock -volume-surface mean dia.
D
pa
19 mm Feed size of rock -volume-surface mean dia.
Given data
Results
3BIU.mcd
Page 3 of 3
Roll crusher
Top
A roll crusher of given diameters of rolls are set at a certain distance apart to achieve a certain
nip angle.Find the maximum size of particle that can be fed.
Also , knowing the width of the working face of the rolls, and density of feed material , find the
throughput when the crusher runs at a certain speed. Consider real throughput as a percentage
of theoretical throughput.
Results
Input data
directly)
This is worksheet can be used to calculate the throughput in a Roll Crusher.
About this topic
Topic: Calculation of throughput for Roll Crusher
MC_V1_B202_Crushing_5BIU
Crushing section
MathCement 2000
5BIU.mcd
Page 1 of 5
F
va
Half the distance between the roll surfaces
d
Radius of maximum size of feed particle
R
Angular speed of the rolls

Linear velocity of rolls
v
Actual feed rate (mass flow)
M
va
Input data
r 500mm :
Radius of rolls of the crusher
w
r
0.4m :
Width of roll face
Distance between the roll surfaces
S 12.5mm :
Angle of nip
31deg :
User defined units
Hz
1
s
:
r
w
r
Width of roll face
S
Angle of nip

Actual throughput capacity as percent of
theoretical throughput
q
Roll running frequency
f
Feed material density

Theoretical feed rate (volumetric)
F
vth
Actual feed rate (volumetric)
5BIU.mcd
Page 2 of 5
A
s
5000mm
2
Cross sectional area of

material flow through the rolls
A
s
5000mm
2
A
s
S w
r
:
A
s
Now calculate the cross sectional area of
R 25.36mm Radius of maximum size of
feed particle
R 25.36mm
R
r d +
cos
( )
r :
therefore :
cos
( )
r d +
r R +
=

2
:
R Radius of maximum size of feed particle
d 6.25 mm d
S
2
:
d Half the distance between the roll surfaces
R Find the radius of maximum size of feed
particle
Top
2500
kg
m
3
:
f 2Hz : Roll running frequency
q 12% : Actual throughput capacity as percent of
5BIU.mcd
Page 3 of 5
Top
M
va
9.42
kg
s
M
va
9.42
kg
s
M
va
F
va
:
M
va
F
va
3.77 10
3
m
3
s
F
va
3.77 10
3
m
3
s
F
va
q F
vth
:
F
va
F
vth
0.03
m
3
s
F
vth
0.03
m
3
s
F
vth
v A
s
:
F
vth
v 6.28
m
s
v r :
v Linear velocity of rolls
12.57
rad
s
2 f :

5BIU.mcd
Page 4 of 5
Fri Sep 23 1:44:26 PM 2005
1)Chapter on "Size Reduction" - Unit Operation of Chemical Engineering
References
Observation
Top
M
va
9.42
kg
s
v 6.28
m
s
12.57
rad
s
R 25.36mm Radius of maximum size of feed particle

Derived data
2500
kg
m
3
f 2 Hz Roll running frequency

q 12 % Actual throughput capacity as percent of
31 deg Angle of nip
S 12.5 mm Distance between the roll surfaces
Width of roll face
w
r
0.4m
r 0.5m
Given data
Results
5BIU.mcd
Page 5 of 5
Roll crusher
Top
A roll crusher of given diameters of rolls are set at a certain distance apart to achieve a certain
nip angle.Find the maximum size of particle that can be fed.
Also , knowing the width of the working face of the rolls, and density of feed material , find the
throughput when the crusher runs at a certain speed. Consider real throughput as a percentage
of theoretical throughput.
Results
Input data
directly)
This is worksheet can be used to calculate the throughput in a Roll Crusher.
About this topic
Topic: Calculation of throughput for Roll Crusher
MC_V1_B202_Crushing_5
Crushing section
MathCement 2000
5.mcd
Page 1 of 5
R

v
M
va
Input data
r 500 : mm
w
r
0.4 : m
Width of roll face
S 12.5 : mm
Angle of nip
31 : deg
q 12 : %
User defined units
Hz
1
s
:
r
w
r
Width of roll face
S
Angle of nip

q
f

F
vth
F
va
Half the distance between the roll surfaces
d
Radius of maximum size of feed particle
5.mcd
Page 2 of 5
therefore :
R
r d +
cos
( )
r :
R 25.36 mm
Radius of maximum size of
feed particle
R 25.36 mm
Now calculate cross sectional area of
A
s
A
s
S 10
3
w
r
:
A
s
5000 mm
2
Cross sectional area of
A
s
5000 mm
2
f 2 : Hz
Feed material density 2500 : kg/m
3
Top
Find the radius of maximum size of feed
particle
R
Half the distance between the roll surfaces d
d
S
2
: d 6.25 mm
Radius of maximum size of feed particle R
180
:
cos
( )
r d +
r R +
=
5.mcd
Page 3 of 5
F
va
F
va
q
100
F
vth
:
F
va
3.77 10
3
m
3
/s
Actual feed rate (volumetric) F
va
3.77 10
3
m
3
/s
Actual feed rate (mass flow) M
va
M
va
F
va
:
M
va
9.42 kg/s
va
9.42 kg/s
Top
2 f :
12.57 rad/s
Linear velocity of rolls v
v r 10
3
:
v 6.28 m/s
Theoretical feed rate (volumetric) F
vth
F
vth
v A
s
10
6
:
F
vth
0.03 m
3
/s
Theoretical feed rate (volumetric) F
vth
0.03 m
3
/s
5.mcd
Page 4 of 5
Derived data
Radius of maximum size of feed particle R 25.36 mm
12.57 rad/s
Linear velocity of rolls v 6.28 m/s
va
9.42 kg/s
Top
Observation
References 1)Chapter on "Size Reduction" - Unit Operation of Chemical Engineering
Fri Sep 23 1:45:57 PM 2005
Results
Given data
r 500 mm
w
r
0.4 m
Width of roll face
Distance between the roll surfaces S 12.5 mm
Angle of nip 31 deg
q 12 %
Roll running frequency f 2 Hz
2500 kg/m
3
5.mcd
Page 5 of 5
G
1
Gas flow rate at point 1 =G
1
Let us calculate leakage air between two ponts" 1 and 2 "in a system under
suction.The gas flows from 1 to 2.
degC 1 : Metric_ton MT :
MT tonne :
kwh 1kW hr : short_ton ton :
10
6
m :
microns
1
1000
mm :
User defined units
In a raw grinding mill measurement is carried out at inlet (point 1) and outlet (point 2).Gas flow
rate at inlet is measured and gas analysis is done to find oxygen and carbon dioxide content
at both points.
Based on the given data find the rate of false air entry into the mill between inlet and outlet.
False air entry into grinding mill system affects drying operation as well as power
consumption.Excessive false air lowers the temperature of hot gases which affects heat
transfer efficiency and also lowers the heat available for drying of raw material.This is because
heat is required to go into the false air to raise its temperature to mill ext gas temperature.As
also the mill fan has to handle higher quantity of gases, the power consumption goes up.
As more gas volume has to pass through the mill system which results in additional pressure
loss , also adds to additional power consumption for the mill fan. Controlling of false air to
reasonable value is, therefore, very important.
Use this worksheet to calculate possible false air entry raw grinding mill
About this topic
Topic: Calculation of false air coming into grinding mill system
MC_V1_B204_Rawmill_16BIU
Raw Mill Section
MathCement 2000
D:\MathCement_demo_pdf\MC_V1_B204_Rawmill_
16BIU.mcd
Page 1 of 4
CO2 17.2% : Carbon dioxide measured at point
CO2
st1
19.7% : Carbon dioxide measured at point
1 =CO2
st1
O2
st2
9.5% : Oxygen measured at point 2 =O2
st2
O2
st1
8% : Oxygen measured at point 1 =O2
st1
Important: Please enter
values as "0" if
measument is not done
n 1 :
Atleast one set of values
must be available
Number of measurement =n
n=2 if measurement is done for
both Oxygen and carbon dioxide
only Oxygen or Carbon dioxide
G
1
35
m
3
s
: Gas flow rate at point 1 =G
1
Let us calculate leakage air between two points" 1 and 2 "in a system under
Input data
CO2
air
Carbon dioxide in air =CO2
air
O2
air
Oxygen in air =O2
air
CO2
st2
Carbon dioxide measured at point
2 =CO2
st2
CO2
st1
1 =CO2
st1
O2
st2
Oxygen measured at point 2 =O2
st2
O2
st1
st1
n Number of measurement =n
16BIU.mcd
Page 2 of 4
2 =CO2
st2
CO2
st2
17.2% :
Oxygen in air =O2
air
O2
air
21% :
air
CO2
air
0% :
Oxygen and Carbon dioxide in gases at various points in the system can be measured .We
consider, for simplification, that air has 21% Oxygen and 0 % Carbon dioxide by volume.
We can then calculate for difference in values of Oxygen and Carbo dioxide at different points
and evaluate the percentage of false air with ref. to unmixed gases.
For ease of understanding, we call the mixed gases as the mixture of gas and false air and
gas as unmixed gas (without false air).
Percentage of false air will be referred to as percentage of gas (unmixed gas) at first point
(mill entry point for example).
As false air enters it dilutes the hot flue gas supplied to mill for drying purposes.So Oxygen
level goes up and carbon dioxide level goes down.
False air entry between point 1 and point 2 as percentage of gas volume at point 1 is given by
FA
O!_2
based on Oxygen measurement
FA
O1_2
O2
st2
O2
st1
O2
air
O2
st2
:
FA
O1_2
13.04%
FA
CO21_2
based on Carbon dioxide measurement
FA
CO21_2
CO2
st1
CO2
st2
CO2
st2
CO2
air
:
FA
CO21_2
14.53%
16BIU.mcd
Page 3 of 4
Average of measurement FA
1_2
FA
1_2
FA
O1_2
FA
CO21_2
+
n
:
FA
1_2
27.58%
Gas flow rate at point 2 including false air G
2
G
2
G
1
FA
1_2
G
1
+ :
G
2
44.65
m
3
s
Quantity of false air entry between point 1 and 2 =FA

FA G
2
G
1
:
FA 9.65
m
3
s
Results
Quantity of false air entry between point 1 and 2 =FA FA 9.65
m
3
s
Observation
References
16BIU.mcd
Page 4 of 4
n Number of measurement =n
G
1
1
User defined units
In a raw grinding mill measurement is carried out at inlet (point 1) and outlet (point 2).Gas flow
rate at inlet is measured and gas analysis is done to find oxygen and carbon dioxide content
at both points.
Based on the given data find the rate of false air entry into the mill between inlet and outlet.
False air entry into grinding mill system affects drying operation as well as power
consumption.Excessive false air lowers the temperature of hot gases which affects heat
transfer efficiency and also lowers the heat available for drying of raw material.This is because
heat is required to go into the false air to raise its temperature to mill ext gas temperature.As
also the mill fan has to handle higher quantity of gases, the power consumption goes up.
As more gas volume has to pass through the mill system which results in additional pressure
loss , also adds to additional power consumption for the mill fan. Controlling of false air to
reasonable value is, therefore, very important.
Use this worksheet to calculate possible false air entry raw grinding mill
About this topic
Topic: Calculation of false air coming into grinding mill system
MC_V1_B204_Rawmill_16
Raw Mill Section
MathCement 2000
16.mcd
Page 1 of 4
Important:
Please enter
values as "0" if
measument is
not done Oxygen measured at point 1
=O2
st1
O2
st1
8.2 : %
Oxygen measured at point 2
=O2
st2
O2
st2
10 : %
1 =CO2
st1
CO2
st1
19.7 : %
2 =CO2
st2
CO2
st2
17.2 : %
Oxygen in air =O2
air
O2
air
21 : %
air
CO2
air
0 : %
st1
O2
st1
st2
O2
st2
1 =CO2
st1
CO2
st1
2 =CO2
st2
CO2
st2
Oxygen in air =O2
air
O2
air
air
CO2
air
Input data
1
G
1
30 :
m
3
/s
Number of measurement =n
both Oxygen and carbon dioxide
only Oxygen or Carbon dioxide
Atleast one set
of values must
be available
n 1 :
16.mcd
Page 2 of 4
m
3
/s G
2
39.27
G
2
G
1
FA
1_2
100
G
1
+ :
Gas flow rate at point 2 including false air G
2
% FA
1_2
30.9
FA
1_2
FA
O1_2
FA
CO21_2
+
n
:
Average of measurement FA
1_2
% FA
CO21_2
14.53
FA
CO21_2
CO2
st1
CO2
st2
CO2
st2
CO2
air
100 :
FA
CO21_2
based on Carbo dioxide measurement
% FA
O1_2
16.36
FA
O1_2
O2
st2
O2
st1
O2
air
O2
st2
100 :
FA
O!_2
based on Oxygen measurement
As false air enters it dilutes the hot flue gas supplied to mill for drying purposes.So Oxygen
level goes up and carbon dioxide level goes down.
Oxygen and Carbon dioxide in gases at various points in the system can be measured .We
consider, for simplification, that air has 21% Oxygen and 0 % Carbon dioxide by volume.
We can then calculate for difference in values of Oxygen and Carbo dioxide at different points
and evaluate the percentage of false air with ref. to unmixed gases.
For ease of understanding, we call the mixed gases as the mixture of gas and false air and
gas as unmixed gas (without false air).
Percentage of false air will be referred to as percentage of gas (unmixed gas) at first point
(mill entry point for example).
16.mcd
Page 3 of 4
Quantity of false air entry between point 1 and 2 =FA
FA G
2
G
1
:
FA 9.27 m
3
/s
Results
Quantity of false air entry between point 1 and 2 =FA FA 9.27 m
3
/s
Observation
References
Fri Sep 23 2:02:24 PM 2005
16.mcd
Page 4 of 4
CO
2RM
CO
2RM
CO
2
content in Raw Meal
CO
2CM
CO
2CM
CO
2
content in Partially Calcined Meal
MgCO
3RM
MgCO
3RM
Content of MgCO3 in 1 kg. Raw Meal
CaCO
3RM
CaCO
3RM
Content of CaCO
3
in 1 kg. Raw Meal
D Recirculating dust = D kg/kg cl
kgraw 1kg :
kgcl 1kg :
degC 1 :
User defined units
For given data of a kiln calculate apparent degree of calcination and actual degree of
calcination
Use this worksheet to calculate calculate degree of decarbonation of raw meal.
About this topic
Topic: Degree of Decarbonation of Raw Meal -Definition and
calculation
MC_V1_B207_Clinker_9BIU
Clinkerisation Section
MathCement 2000
D:\MathCement_demo_pdf\MC_V1_B207_Clinker_
9BIU.mcd
Page 1 of 4
C
D
CO
2RM
CO
2CM
CO
2RM
:
C
D
Degree of calcination
CO
2CM
4 % CO
2CM
CO
2
CO
2RM
33.96% CO
2RM
CO
2
content in Raw Meal
CO
2RM
33.96%
Mol. wt of CO
2
= 44
Mol.wt. of CaCO
3
=100
Mol. Wt. of MgCO
3
= 84
CO
2RM
CaCO
3RM
44
100
MgCO
3RM
44
84
+
,
:
CO
2RM
Let us denote CO
2
content in Raw Meal
TC 0.77
TC CaCO
3RM
MgCO
3RM
+ :
TC Total carbonate
CO
2CM
4% : CO
2CM
CO
2
MgCO
3RM
0.01
kg
kgraw
: MgCO
3RM
Content of MgCO3 in 1 kg. Raw Meal
CaCO
3RM
0.76
kg
kgraw
: CaCO
3RM
Content of CaCO
3
in 1 kg. Raw Meal
D 0.2
kg
kgcl
: Recirculating dust = D kg/kg cl
Input data
9BIU.mcd
Page 2 of 4
CO
2RM
C
D
88.22%
A more refined definition can be as stated below.
C
DR
1
1 CO
2RM
1
1 CO
2CM
1
1 CO
2RM
1
:
C
DR
91.9 %
By this method the value of C
D
is reported higher
Apparent degree of calcination C
D
:
Degree of calcination is worked out based on the ratio between loss of CO
2
content from
partially calcined raw Meal and total CO
2
content in raw meal .It implies ,therefore, if the
lower the value of balance CO
2
content higher is the degree of calcination.
CO
2
content in Partially Calcined Meal ,CO
2CM
as measured from samples collected from
kiln inlet, is influenced by circulating dust at kiln inlet. This dust is practically 100 percent
calcined and falsely reduces the value of CO
2CM.
This result shows higher degree of
calcination as is termed as apparent degree of calcination C
D
.
To find the nett or actual degree of calcination without the influence of circulating
dust, we employ correction factor:
Recirculating dust = D kg/kg cl kgcl 1kg :
D 0.2
kg
kgcl
nett or actual degree of calcination C

Dnett
C
Dnett
C
D
1 C
D
1
1 C
D
D +
:
9BIU.mcd
Page 3 of 4
References
Observation
C
Dnett
86.19% Nett or actual degree of calcination
Degree of calcination ( refined) apparent
C
DR
91.9 %
C
D
88.22% Degree of calcination -apparent
CO
2RM
33.96% CO
2
content in Raw Meal
TC 77 % Total carbonate
CO
2CM
4 % CO
2
MgCO
3RM
0.01
kg
kgraw
Content of MgCO3 in Raw Meal
CaCO
3RM
0.76
kg
kgraw
Content of CaCO
3
in Raw Meal
D 0.2
kg
kgcl
Recirculating dust
Results
C
Dnett
86.19%
1 C
D
9BIU.mcd
Page 4 of 4
MathCement 2000
Dedusting Systems
MC_V1_B302_Dedust_23
Topic: Sketches for K- Factors - set 3
About this topic
hv = velocity head
9
K
ANGLE CIRCULAR RECTANGULAR
10
20
30
45
60
,
CIRCULAR_K
0.025
0.102
0.218
0.435
0.652
,
RECTANGULAR_K
0.37
0.146
0.310
0.625
0.940
,
D:\MathCement_demo_pdf\MC_V1_B302_Dedust_
23.mcd
Page 1 of 3
10
BASED ON VELOCITY IN BRANCH

ANGLE
K VALUE
K
0.06
0.12
0.18
0.22
0.44
10
20
30
45
60
,
11
PLATE/FLANGE
A B
A B
CIRCULAR K = 0.87 0.48
RECTANGULAR K = 1.25 0.70
23.mcd
Page 2 of 3
12
DD
0.7D 0.7D
K - REFERED TO VELOCITY AT D
WIRE GUARD 5 CM MESH K = 0.25
CONE WITHOUT GUARD CIRCULAR K RECTANGULAR K
10
20
30
45
60
,
CIRCULAR_K
0.42
0.30
0.24
0.20
0.29
,
RECTANGULAR_K
0.53
0.38
0.31
0.29
0.39
,
Observation
References
Fri Sep 23 3:48:53 PM 2005
23.mcd
Page 3 of 3
C
4
C
a
SiO
2
S S
m
S
1
S
2
S
3
S
4
S
a
Al
2
O
3
A A
m
A
1
A
2
A
3
A
4
A
a
Fe
2
O
3
F F
m
F
1
F
2
F
3
F
4
F
a
In this example we determine the proportion of two raw material components
only. LSF is fixed as set point.
Also to be calculated are:
Composition of raw mix and also the composition of clinker as loss free basis
User defined units
MathCement 2000
Laboratory Investigation and
Raw Mix Design Systems
MC_V1_B303_Lab_25BIU
Topic: Raw-mix Design based on Lime Saturation Factor
About this topic
Use this worksheet to design a two component raw mix to attain a desired lime saturation
factor in the raw mix
Raw mix design is a process of determining the quantitative proportions of the components of
Raw mix ensuring that the clinker produced from such mix attain desired chemical and
mineralogical composition.
This method is applicable to two raw material components, with the lime saturation factor
selected for the clinker. To simplify the following calculations, symbols are used for the
designation of the clinker components, the raw materials, and the coal ash; these symbols
are placed in table below.
Calculation symbols for designation of clinker and raw material components
Compounds Clinker Raw mix Raw mat. Raw mat. Raw mat. Raw mat. Coal
No. 1 No. 2 No. 3 No. 4 ash
CaO C C
m
C
1
C
2
C
3
D:\MathCement_demo_pdf\MC_V1_B303_Lab_
25BIU.mcd
Page 1 of 5
Input data
Two raw materials are given with the following composition, (Raw material No. 1
is Limestone, Raw material No. 2 is Marl)
Limestone Clay
SiO
2
S
1
1.42% : S
2
62.95% :
Al
2
O
3
A
1
0.48% : A
2
18.98% :
Fe
2
O
3
F
1
0.38% : F
2
7.37% :
CaO
C
1
52.60% : C
2
1.40% :
MgO
M
1
1.11% : M
2
0.98% :
SO
3
So
1
0.85% : So
2
0.85% :
LOI LOI
1
43.16% : LOI
2
7.47% :
Total
1
S
1
A
1
+ F
1
+ C
1
+ M
1
+ So
1
+ LOI
1
+ :
Total
1
100 %
Total
2
S
2
A
2
+ F
2
+ C
2
+ M
2
+ So
2
+ LOI
2
+ :
Total
2
100 %
Lime saturation factor desired in raw mix
LSF 0.92 :
Two raw materials are given with the following composition, (Raw material No. 1
is Limestone, Raw material No. 2 is Marl)
Constituent Matrl. 1 Matrl2
SiO
2
S
1
S
2
Al
2
O
3
A
1
A
2
Fe
2
O
3
F
1
F
2
CaO
C
1
C
2
MgO
M
1
M
2
SO
3
So
1
So
2
LOI
LOI
1
LOI
2
Rest Balance
R
1
R
2
Lime saturation factor desired in raw mix
LSF
25BIU.mcd
Page 2 of 5
com
2
0.2 com
2
1
x 1 +
:
com
1
0.8 com
1
x
x 1 +
:
com
2
parts of material no.2 in raw mix
com
1
parts of material no.1in raw mix
Where x represents parts of limestone or material no.1 apportioned to one part of
clay or material no. 2
x 4.05
x
2.8 LSF S
2
1.65 A
2
+ 0.35 F
2
+ ( ) C
2
C
1
2.8 LSF S
1
1.65 A
1
+ 0.35 F
1
+ ( )
:
LSF 0.92 Set value of lime saturation factor
With this formula we calculate how many parts of limestone or material no.1 in
the raw mix are apportioned to one part of clay or the material no. 2.
Accordingly we get:
x
2.8 LSF S
2
1.65 A
2
+ 0.35 F
2
+ ( ) C
2
C
1
2.8 LSF S
1
1.65 A
1
+ 0.35 F
1
+ ( )
=
and solving for x:
LSF
x
C
1
C
2
+
x 1 +
1.65
x A
1
A
2
+
x 1 +
0.35
x F
1
F
2
+
x 1 +
+
2.8 x
S
1
S
2
+
x 1 +
=
Inserting into Kind's formula the calculation symbols used previously, we get
25BIU.mcd
Page 3 of 5
So
2c
0
LOI
1c
com
1
LOI
1
: LOI
1c
0.35 LOI
2c
com
2
LOI
2
: LOI
2c
0.01
Total
1c
S
1c
A
1c
+ F
1c
+ C
1c
+ M
1c
+ So
1c
+ LOI
1c
+ : Total
1c
0.8
Total
2c
S
2c
A
2c
+ F
2c
+ C
2c
+ M
2c
+ So
2c
+ LOI
2c
+ : Total
2c
0.2
100% Raw mix
S
m
S
1c
S
2c
+ : S
m
0.14
A
m
A
1c
A
2c
+ : A
m
0.04
F
m
F
1c
F
2c
+ : F
m
0.02
C
m
C
1c
C
2c
+ : C
m
0.42
M
m
M
1c
M
2c
+ : M
m
0.01
So
m
So
1c
So
2c
+ : So
m
0.01
LOI
m
LOI
1c
LOI
2c
+ : LOI
m
0.36
Total
m
S
m
A
m
+ F
m
+ C
m
+ M
m
+ So
m
+ LOI
m
+ : Total
m
1
We now determine analysis of material no. 1and 2 in the raw mix
Limestone x com.1 Clay x com.2
S
1c
com
1
S
1
: S
1c
0.01 S
2c
com
2
S
2
: S
2c
0.12
A
1c
com
1
A
1
: A
1c
0 A
2c
com
2
A
2
: A
2c
0.04
F
1c
com
1
F
1
: F
1c
0 F
2c
com
2
F
2
: F
2c
0.01
C
1c
com
1
C
1
: C
1c
0.42 C
2c
com
2
C
2
: C
2c
0
M
1c
com
1
M
1
: M
1c
0.01 M
2c
com
2
M
2
: M
2c
0
So
1c
com
1
So
1
: So
1c
0.01 So
2c
com
2
So
2
:
25BIU.mcd
Page 4 of 5
Fri Sep 23 4:05:55 PM 2005
References
Observation
com
2
19.79%
com
2
0.2 marl or component 2
com
1
80.21%
limestone or component 1
com
1
0.8
Results
LSF 0.92
LSF
C 1.65 A 0.35 F + ( )
2.8 S
:
The resulting Kind's lime saturation factor is
Total 1 Total S A + F + C + M + So + LOI + :
Now calculating the clinker composition based on raw mix, on loss free basis
f
1
1 LOI
m
: f 1.56
Clinker
S f S
m
: S 0.21
A f A
m
: A 0.06
F f F
m
: F 0.03
C f C
m
: C 0.66
M f M
m
: M 0.02
So f So
m
: So 0.01
LOI 0 :
25BIU.mcd
Page 5 of 5
Vol.percentage of Hydrogen in flue
gas
H
2
[ ] 0.0% :
CO [ ] 0.02% : Vol.percentage of Carbon monoxide
in flue gas
CO
2
[ ] 20.5% : Vol.percentage of Carbon dioxide in
flue gas
O
2
[ ] 3.5% : Vol.percentage of Oxygen in flue gas
Input data
T
K
Temp. of gases in deg. K
T Temp. of gases
Nm3 Nm
3
= kJ 10
3
J :
Nm3 m
3
: degC 1 :
User defined units

Let us consider a typical flue gas having the following volumetric composition as shown in
input data.
It is known that molal volume of any gas at NTP is 22.4 m
3.
That means, say for example,
oxygen has a molecular weight of 32 .So, 32 Kg. of oxygen will occupy a volume of 22.4m
3
at NTP
Density of a mixture of dry gases at NTP can be calculated by knowing the volumetric
percentages of individual gases present in the mixture.
This worksheet should be used to calculate density of of a mixture of dry and wet gases
About this topic
Topic: Calculation of density of a mixture of dry and wet gases
MC_V1_B304_Fuel_11BIU
Fuels & Combustion
MathCement 2000
D:\MathCement_demo_pdf\MC_V1_B304_Fuel_
11BIU.mcd
Page 1 of 6
MCO [ ] 28 :
MSO
2
[ ] 64 :
Sulphur dioxide
Nitrogen
MN
2
[ ] 28 :
Water vapour
MH
2
O [ ] 18 :
Air (dry)
Mair [ ] 28.965 :
M
V
22.4
m
3
kg
:
Molal volume
Standard density (at 0 degC and 760 mm of Hg)
Density of Oxygen
O2
MO
2
[ ]
M
V
:
O2
1.43
kg
m
3
Density of Carbon dioxide
CO2
MCO
2
[ ]
M
V
:
Vol.percentage of Sulphur dioxide
in flue gas
SO
2
[ ] 5.3% :
Vol.percentage of Nitrogen in flue
gas
N
2
[ ] 70.08% :
Type of gas : Typ = 1 for flue gas,
Typ=2 for air
Typ 1 :
Dew point temperature of the sample gas
t
dew1
59degC :
Caution : please read values of moisture in gas corresponding to dew point in from the graph
in the calculation area.
Constants
Gas Molecular weights
Oxygen
MO
2
[ ] 32 :
Hydrogen
MH
2
[ ] 2 :
Carbon dioxide
MCO
2
[ ] 44 :
Carbon monoxide
11BIU.mcd
Page 2 of 6
air.dry
1.29
kg
m
3
air.dry
Mair [ ]
M
V
:
Density of air (dry)
H2O
0.8
kg
m
3
H2O
MH
2
O [ ]
M
V
:
Density of water vapour
H2
0.09
kg
m
3
H2
MH
2
[ ]
M
V
:
Density of Hydrogen
N2
1.25
kg
m
3
N2
MN
2
[ ]
M
V
:
Density of Nitrogen
SO2
2.86
kg
m
3
SO2
MSO
2
[ ]
M
V
:
Density of Sulphur dioxide
CO
1.25
kg
m
3
CO
MCO [ ]
M
V
:
Density of Carbon monoxide
CO2
1.96
kg
m
3
11BIU.mcd
Page 3 of 6
Density of the dry gas =
gas.dry

gas.dry
O
2
[ ]
O2
CO
2
[ ]
CO2
+ CO [ ]
CO
+ SO
2
[ ]
SO2
+ N
2
[ ]
N2
+ :
gas.dry
1.48
kg
m
3
Dew point temperature = t

dew
data
20
30
40
50
60
70
80
85
0.015
0.028
0.05
0.09
0.155
0.29
0.57
0.95
0.0123
0.024
0.043
0.075
0.13
0.24
0.475
0.73
,
:
t
dew
data
0

: t
dew
Dew point temperature in deg. C
Vap
air
data
1

: Vap
air
Kg of water vapour per Kg of dry air
Vap
gas
data
2

: Vap
gas
Kg of water vapour per Kg of dry gas
with30% Co2
20 30 40 50 60 70 80 90
0.01
0.1
1
Dew pt. temp. - deg.C
K
g

w
a
t
e
r

v
a
p
o
u
r

p
e
r

K
g

d
r
y

a
i
r

/

d
r
y

g
a
s
Vap
air
Vap
gas
t
dew
11BIU.mcd
Page 4 of 6
m
3
/kg dry gas V
vap
0.16 m
3
V
vap
Vap
H2O
:
Volume of vapour V
vap
V
gas1
0.68 m
3
V
gas1
1kg
gas.dry
:
Volume of 1 kg. dry gas V
gas1
Vap 0.13 kg
Vap if Typ 1 = Vap
gas
, Vap
air
, ( ) :
Vapour in air or gas =Vap
read from the graph (approx. value) kg /kg dry gas Vap
gas
0.126kg :
read from the graph (approx. value) kg /kg dry air Vap
air
0.151kg :
t
dew1
59degC
Dew point temperature of the sample gas
Calculation of density of moist gas when dew point temperature is known.
Vap
air
0.077737 =
Vap
gas
0.066117 =
t
dew
46.954 =
Vap
air
0.038542 =
Vap
gas
0.032781 = t
dew
34.885 =
Practice : try reading thse values from the graph:
Use above graph to read out data for water vapour in Kg per Kg of dry air or
gases corresponding to adew point temperature. (hint - Rt. click the mouse on
the graph and select trace)
11BIU.mcd
Page 5 of 6
Density of moist gas
gas.wet
gas.wet
1kg Vap +
V
vap
V
gas1
+
:
All volumes in NTP
NTP - Normal temp. of o deg.C and normal preassure
of 760 mm Hg
gas.wet
1.35
kg
m
3
Results
All volumes in NTP
Density of the dry gas =
gas.dry

gas.dry
1.48
kg
m
3
Density of moist gas

gas.wet

gas.wet
1.35
kg
m
3
Observation
References
Fri Sep 23 4:13:03 PM 2005
11BIU.mcd
Page 6 of 6
b
Bulk density of material
V Belt speed
b Belt width
Angle of inclination for vertical lift
H Vertical lift of the conveyor
L Horizontal run of the conveyor
User defined units
A rubber belt conveyor has been designed convey crushed bulk material material .Depending
upon the layout of the plant the conveyor may run only horizontally or in combination of
horizal travel and vertical lift.
We know the design parameters of the belt and also the material characteristics. Find
1) the total resistance to the movement of the belt
2) effective tension in the belt
3) carrying side and return side tension
4) sag tension
5) power required to drive the belt
This is worksheet can be used to find the basic parameters related to calculation of power
required to drive a rubber belt conveyor.As belt conveyors are extensively used in a cement
plant to carry crushed raw materials and crushed coal over fairly long distances, it will be
useful to check these basic parameters.
About this topic
Topic: Power and tension calculations of rubber belt conveyor -
MC_V1_B305_Convey_12BIU
Conveying Systems
MathCement 2000
D:\MathCement_demo_pdf\MC_V1_B305_Convey_
12BIU.mcd
Page 1 of 8
Mass of carrying side idlers per unit of length
m
ic
Mass of return side idlers per unit of length
m
ir
Secondary resistance co-efficient
K
sr
Efficiency of conveying
n
Drive factor
K
d
Sag of snubbed drive
S
K
s
Sag factor
Fri Sep 23 4:21:48 PM 2005
Input data
Horizontal run of the conveyor
L 80m :
Vertical lift of the conveyor
H 11m :
Angle of inclination for vertical lift
8deg :
m
s
Conveyor carrying rate for design
Width of troughing idlers
W
t_idl
Pitch of troughing idlers
p
t_idl
Width of return idlers
W
r_idl
Pitch of return idlers
p
r_idl
Co- efficient of friction between belt and drum

Belt wrap angle over drum

Belt friction co-efficient

r1
Load friction co-efficient

r2
Transmission efficiency between motor and drive pulley

t
Input by selection
Mass of belt per unit of length
m
b
12BIU.mcd
Page 2 of 8
r2
0.025 :
t
85% :
Input by selection - for selection of some of the following data refer to
earlier file
Mass of belt per unit of length m
b
20
kg
m
:
Mass of carrying side idlers per unit of length m
ic
30
kg
m
:
Mass of return side idlers per unit of length m
ir
2.5
kg
m
:
Secondary resistance co-efficient K
sr
0.9 :
Efficiency of conveying n 90% :
Drive factor K
d
1.9 :
Sag of snubbed drive S 3% :
Sag factor K
s
4.2 :
Fri Sep 23 4:21:48 PM 2005
Belt width b 800mm :
Belt speed V 1.5
m
s
:
b
1000
kg
m
3
:
m
s
8
kg
s
:
Width of troughing idlers W
t_idl
152mm :
Pitch of troughing idlers p
t_idl
1.0m :
Width of return idlers W
r_idl
102mm :
Pitch of return idlers p
r_idl
3.0m :
Co- efficient of friction between belt and drum 0.1 :
Belt wrap angle over drum 240deg :
r1
0.025 :
12BIU.mcd
Page 3 of 8
T
2
6576.46 N
T
2
K
d
T
e
:
T
2
Therefore slack side tension
T
e
3461.3 N
T
e
F
r
:
T
e
Effective tension in the belt
F
r
3461.3 N
F
r
F
H
1 K
sr
+ ( ) F
sl
+ :
F
r
Total resistance to motion
K
sr
0.9 Secondary resistance co-efficient
F
sl
575.32 N
F
sl
m
s
V
g H :
Load slope resistance to motion of belt
F
sl
F
H
1518.93 N
F
H

r1
m
ic
m
ir
+ 2m
b
cos
( )
+ ( ) L g
1
]

r2
m
s
V
g L + :
F
H
Main resistance to belt motion
M
e
5768.86 kg
M
e
m
ic
m
ir
+ 2m
b
cos
( )
+ ( ) L :
M
e
Total effective mass of all movine part are abtained
by summation
12BIU.mcd
Page 4 of 8
V 1.5
m
s
Belt speed
b 0.8m Belt width
8 deg Angle of inclination for vertical lift
H 11 m Vertical lift of the conveyor
L 80 m Horizontal run of the conveyor
Results
P
m
6.11 kW
P
m
T
e
V
t
:
P
m
Motor power rating
Tight side tension T
1
T
1
1 K
d
+ ( ) T
2
:
T
1
19071.75N
Sag tension on carrying side T
sag_c
T
sag_c
K
s
p
t_idl
m
b
m
s
V
+
,
g :
T
sag_c
1043.43 N
Sag tension on return side T
sag_r
T
sag_r
K
s
p
r_idl
m
b
g :
T
sag_r
2471.28 N
Operating power required at driving drum P
o
P
o
T
e
V :
P
o
5.19 kW
t
12BIU.mcd
Page 5 of 8
t
85 %
Mass of belt per unit of length
m
b
20
kg
m
Mass of carrying side idlers per unit of length

m
ic
30
kg
m
Mass of return side idlers per unit of length

m
ir
2.5
kg
m
Secondary resistance co-efficient

K
sr
0.9
Efficiency of conveying
n 0.9
Drive factor
K
d
1.9
Sag of snubbed drive
S 3 %
Sag factor
K
s
4.2
Main resistance to belt motion
F
H
1518.93 N
Load slope resistance to motion of belt
F
sl
575.32 N

b
1000
kg
m
3
m
s
8
kg
s

Width of troughing idlers
W
t_idl
0.15 m
Pitch of troughing idlers
p
t_idl
1 m
Width of return idlers
W
r_idl
0.1m
Pitch of return idlers
p
r_idl
3 m
Co- efficient of friction between belt and drum
0.1
Belt wrap angle over drum
240 deg

r1
0.03

r2
0.03
12BIU.mcd
Page 6 of 8
Fri Sep 23 4:20:12 PM 2005
1)Chapter on Belt Conveyor -Bulk Solids Handling by C.R. Woodcock
and J.S.Mason: Published by Leonard hill
2)Chapter on "Handling of Solids" - Unit Operation of Chemical
Engineering
References
Observation
P
m
6108.17 W Motor power rating
P
o
5191.95 W Operating power required at driving drum
T
sag_r
2471.28 N Sag tension on return side
T
sag_c
1043.43 N Sag tension on carrying side
T
1
19071.75N Tight side tension
T
2
6576.46 N Therefore slack side tension
T
e
3461.3 N Effective tension in the belt
F
r
3461.3 N Total resistance to motion
12BIU.mcd
Page 7 of 8
Input data area locked for demo folder
12BIU.mcd
Page 8 of 8
mmWg
1
13.6
mmHg :
bar 760mmHg :
mmHg mm : mmHg 133.33Pa :
kN 1000N :
User defined units
p v
1
a
1
Throat
Q
d
t
d
Ventury Meter
h
t
v
2
a
2
A horizontal pipeline is carrying water and it is desired to measure the flowrate. The pipeline
is equipped with an in-line ventury meter.Diameter of the pipe is given and the static pressure
before ventury is measured.Throat diameter of ventury is also known and the pressure head at
the throat is also measured. The pressure loss due to friction in the ventury between inlet and
throat is assumed as percentgae of pressure difference.
This worksheet can be used to find the flow rate through a pipeline with the introduction of
ventury meter
About this topic
Topic: Fluid flow - calculation of flow through pipeline with ventury meter
MC_V1_B308_Hydraulics_11BIU
Plant Hydraulics
MathCement 2000
D:\MathCement_demo_pdf\MC_V1_B308_Hydraulics_
11BIU.mcd
Page 1 of 6
Area of cross section at throat of ventury
v
1
Velocity of water at inlet to ventury
v
2
Velocity of water at the throat of ventury
Input data
Static pressure at inlet to ventury
p 150
kN
m
2
:
Static head at throat of ventury -in terms of
column of mercury
h
t
400 mm :
Percentage of pressure loss in ventury
P
loss
3% :
Dia. of pipeline
d 300mm :
d
t
100mm :
Dia. of throat
Density of water

w
1000
kg
m
3
:
Density of mercury

Hg
13600
kg
m
3
:
p
Static head at throat of ventury -in terms of
column of mercury
h
t
Percentage of pressure loss in ventury
P
loss
Dia. of pipeline
d
d
t
Dia. of throat
Density of water

w
Density of mercury

Hg
Flow rate
Q
a
1
Area of cross section at inlet to ventury
a
2
11BIU.mcd
Page 2 of 6
ph
p
1
g
p
2
g
=
v
2
2
2 g
v
1
2
2 g
p
1
g
p
2
g
,
1 P
loss
( ) =
ph 20.74m
ph p
1h
p
2h
:
Difference of static pressure head
p
p
2h
5.44 m
p
2h
h
t
Hg
w
:
h
pt
pressure head at throat in terms of water column
p
1h
15.3 m
p
1h
p
w
g
:
h
p
pressure head at inlet in terms of water column
p
1
g
p
2
g
,
1 P
loss
( )
v
2
2
2 g
v
1
2
2 g
=
or
p
1
g
v
1
2
2 g
+
p
2
g
v
2
2
2 g
+ P
loss
p
1
g
p
2
g
,
+ =
substituting for "loss"
loss P
loss
p
1
g
p
2
g
,
=
p
1
g
v
1
2
2 g
+
p
2
g
v
2
2
2 g
+ loss + =
Since the pipe and ventury are horizontal there is no difference in geodatic heights.
We can write the Barnoulli's equation between inlet and throat of ventury:
11BIU.mcd
Page 3 of 6
Solving for v
2
using Solve Block of Mathcad
v
2
ph
( )
1 P
loss
( )
a
2
a
1
v
2
,
2
2 g
+
1
1
1
1
]
2 g =
Substituting in eqn 1 and rewriting:
Substituting for v
1
and rewriting the equation 1, we get expression for v
2
:
v
1
a
2
a
1
v
2
=
a
2
0.01 m
2
a
2

d
t
2
4
:
a
1
0.07 m
2
a
1

d
2
4
:
v
1
a
2
a
1
v
2
=
v
2
velocity of water at the throat of ventury
v
1
velocity of water at inlet to ventury
a
2
area of cross section at throat of ventury
area of cross section at inlet to ventury
a
1
where:
a
1
v
1
a
2
v
2
=
from equation of continuity
ph
( )
1 P
loss
( ) 20.11m
----------------------------eqn 1
v
2
2
2 g
v
1
2
2 g
ph
( )
1 P
loss
( ) =
or
11BIU.mcd
Page 4 of 6
Hg
13600
kg
m
3
Density of mercury
w
1000
kg
m
3
Density of water
d
t
100 mm Dia. of throat
d 300 mm Dia. of pipeline
P
loss
3 % Percentage of pressure loss in ventury
h
t
400 mm Static head at throat of ventury -in terms of
column of mercury
p 150
kN
m
2
Results
Q 0.16
m
3
s
Q v
2
a
2
:
Q Flow rate
v
1
2.22
m
s
v
1
a
2
a
1
v
2
:
v
2
19.99
m
s
v
2
Find v
2
( ) :
use function Find
v
2
ph
( )
1 P
loss
( )
a
2
a
1
v
2
,
2
2 g
+
1
1
1
1
]
2 g =
Given
v
2
6
m
s
: guess value:
11BIU.mcd
Page 5 of 6
Flow rate
Q 0.16
m
3
s
a
1
0.07 m
2
area of cross section at inlet to ventury

area of cross section at throat of ventury
a
2
0.01 m
2
v
1
2.22
m
s
velocity of water at inlet to ventury

v
2
19.99
m
s
velocity of water at the throat of ventury

Observation
References Civil Engineering Hydraulics :page 81 -fluid flow concepts
Fri Sep 23 5:01:54 PM 2005
11BIU.mcd
Page 6 of 6
water
column
h
p
Vapour pressure of fluid at the given
temperature
h
fit
Cummulative head loss due to pipe
fittings and friction in terms of height
of water column
water
column
Sp. weight of fluid flowing in the pipe

v Flow velocity in suction pump
z
1
Vertical height of centre line of pump
suction line above the water level in
the ground water tank
g Gravitational constant
MathCement 2000
Used Gloval variable
to display results
along side input data
Plant Hydraulics
MC_V1_B308_Hydraulics_20BIUa
Topic: Calculation of Net Positive Suction Head (NPSH) for pump located
above reservoir level.
About this topic
This worksheet can be used to calculate Net Positive Suction Head before a pump, which is
used for pumping water from a reservoir and delivering to a discharge tank.Pump is located so
that the centre line is above the water level in the reservoir
A pump is required to pump water from a ground level reservoir to an elevated tank.The
location of the pump above the reservoir and also the height of the tank are given. Pumping
rate in the suction line is known. The details of head losses due to pipe fittings and friction in
the suction line is also known.The atmospheric pressure, temperature of water under suction
and corresponding specific weight and vapour pressure are given.
Calculate NPSH for the pump.
User defined units
kN 1000N : kPa 1000 Pa :
mmHg 133.33Pa :
bar 760mmHg :
mmWg
1
13.6
mmHg :
20BIUa.mcd
Page 1 of 4
NPSH 7.12 m
Net Positive Suction Head
Result preview
p 101356Pa
Static pressure on the fluid surface
Used Gloval variable
to display results
along side input
data. Caution: Don't
redefine global
variable within the
body of calculations
to avoid confusion.
h
p
0.654m
temperature in terms of height of
water column
water
column
h
fit
1.1m
Cummulative head loss due to pipe
of water column
water
column
9830.11
N
m
3
v 1.1
m
s
Flow velocity in suction pump

z
1
1.5 m
Vertical height of centre line of pump suction
line above the water level in the ground water
tank.Caution: Use (-) sign if water level
below pump centreline
g 9.81
m
sec
2
Gravitational constant
Input data
NPSH
Net Positive Suction Head
p
Static pressure on the fluid surface
20BIUa.mcd
Page 2 of 4
h
fit
1.1m Cummulative head loss due to pipe
of water column
9830.11
N
m
3
v 1.1
m
s
Flow velocity in suction pump
z
1
1.5 m Vertical height of centre line of pump
suction line above the water level in
the ground water tank
g 9.81
m
s
2
Gravitational constant
Results
NPSH can be thus interpreted as the total suction head above the vapour pressure
of the fluid
NPSH 7.12 m
note : z
1
is subtracted if the water
level is below the pump centre line
NPSH
p
v
2
2g
+
,
z
1
+ h
fit
h
p

NPSH is given by the following equation
Discharge tank
Suction line Ref. line
Pump
z
1
Ground tank
20BIUa.mcd
Page 3 of 4
temperature
h
p
0.65 m
Static pressure on the fluid surface p 101356Pa
Net Positive Suction Head NPSH 7.12 m
Observation
References Fluid Mechanics for Engineering Technology by Irving Granet pp 290
Fri Sep 23 5:04:35 PM 2005
20BIUa.mcd
Page 4 of 4
MathCement_PYRO
Kiln & Preheater Section
MC_V4_B201_KilnPH_7BIU
Topic: Mass Balance in multiple preheater stages
Caution - switch to manual calculation mode ( deselect math>automatic calculation) .Since the length
of this calculationis very big -you maynot get consistant result under automatic mode of
calculation.
About this topic
In this topic we have worked out detailed procedure for calculating mass balance of multiple
stages of preheater .The example is based on the following:
1) preheater with 5 stages ( count from bottom most cyclone)
2) precalciner
3) Tertiary air through separate duct.
4) Tertiary air tapped from kiln hood
5) Fuel type is coal,oil or gas
Convention
A suspension type cyclone preheater is divided into stages.In our calculation we will call the
lowest stage as stage 1 and subsequent higher stages as 2, 3 ,4 etc.A stage consists of a
cyclone,the gas duct leading to the cyclone and meal chute below the cyclone.
Feed / Meal
Dust Gas
Meal
Cycl one separ at or
Gas duct
Hot gas Dust
Typi cal cycl one st age
D:\MathCement_demo_pdf\MC_V4_B201_KilnPH_
7BIU.mcd
Page 1 of 14
F 0.005
kg
kg_rawmeal
:
Reaction enthalpy( heat ) of clinker - R
W
R
W
450
kcal
kgcl
:
Starting temperature of decarbonation - T
A
T
A
1063K :
End temperature for decarbonation - T
E
T
E
1163K :
Circulating dust load at kiln inlet -S
OE
S
OE
0.3
kg
kgcl
:
Bypass quantity of gases at kiln inlet - BY
BY
ntp
0.00m
3
:
Percent fuel firing in precalciner -V
C
V
C
55% :
Cyclone efficiency -stage wise
Cyclone efficiency -stage 1-
st1

st1
70% :
st2

st2
70% :
st3

st3
80% :
User defined units
B-IU Calculation using Mathcad's built-in units
This calculation use Mathcad's builtin units.So you will not find conventional
unit conversion factors in the equations used.
Mio_tonne 10
6
tonne : kgcl kg : kg_rawmeal kg :
kg_coal kg : kg_CO
2
[ ] kg : degC 1 :
kg_fuel kg : kg_ash kg : cu_m
ntp
m
3
:
All temperatures in Kelvin =K K 273 degC + =
Input Data
Loss on ignition of raw meal - GV
GV 0.35 :
Moisture in raw meal -F
7BIU.mcd
Page 2 of 14
F
pc
0.102
kg_fuel
kgcl
kg. fuel / kg.cl F

pc
V
C
F
req
:
Fuel fired to precalciner -F
pc
F
req
0.19
kg_fuel
kgcl
F
req
f
H
u
:
Fuel requirement -F
req
f
797
kcal
kgcl
f
797
kcal
kgcl
f
797
kcal
kgcl
:
Let's assume fuel efficiency ,i.e heat release by
fuel per unit mass of clinker -
f
H
th
420
kcal
kgcl
H
th
R
W
30
kcal
kgcl
:
Theoretical heat of formation of clinker -H
th
Calculation
We start with certain assumed values of
1) Fuel consumption
2) Temperature of tertiary air
Establish preheater bottom stage conditions.Then calculate mass balance of
individual stages to find the unknowns.
F
ash
30% : Ash in fuel -F
ash
H
u
4300
kcal
kgcl
: Heat value of fuel to precalciner and kiln - H
u
st5
92% : Cyclone efficiency -stage 5-
st5
st4
80% : Cyclone efficiency -stage 4-
st4
7BIU.mcd
Page 3 of 14
RM
CO2
GV
c
RM
F
:
CO
2
in kiln feed raw meal - RM
CO2
kg_CO
2
[ ] 1 kg
Assume total loss on ignition is entirely due to release of CO
2
from raw meal
RM
F
1.48
kg_rawmeal
kgcl
RM
F
1 ASH
tot
1 GV
c
:
Raw meal requirement for producing clinker -RM
F
GV
c
0.36
GV
c
1
1
1
1 GV
1
1 ASH
tot
1 +
,
:
Loss on ignition ,corrected for ash -GV
c
ASH
tot
0.06
kg_ash
kgcl
ASH
tot
F
ash
F
req
:
Total ash absorbed in clinker - ASH
tot
ASH
kiln
0.03
kg_ash
kgcl
ASH
kiln
F
ash
F
kiln
:
Ash going into kiln with fuel -ASH
kiln
See sketch 1_1_kiln_7_drg2
ASH
pc
0.03
kg_fuel
kgcl
ASH
pc
F
ash
F
pc
:
Ash going into precalciner with fuel -ASH
pc
F
kiln
0.08
kg_fuel
kgcl
F
kiln
F
req
F
pc
:
Fuel fired to kiln -F
kiln
7BIU.mcd
Page 4 of 14
kg
MI
1
M
1
st1
:
Quantity of material entering cyclone 1 - MI
1
M
1
1.35
kg
kgcl
M
1
RM
ki
S
OE
+ :
Material at discharge chute of cyclone -1 / preheater stage 1- M
1
S
OE
0.3
kg
kgcl
Quantity of circulating dust at kiln inlet -S

OE
RM
ki
1.05
kg
kgcl
RM
ki
RM
cal.kiln
1 LOI
ki
:
Quantity of raw meal at kiln inlet - RM
ki
LOI
ki
0.07
LOI
ki
T
E
t
kf.rm
T
E
T
A
GV
c
:
Loss on ignition of raw meal at kiln inlet -LOI
ki
Loss on ignition as linear relation to temperature difference between start and end
temperature of decarbonation
t
kf.rm
1143K
t
kf.rm
1143K :
Assume temperature at kiln inlet for calcined raw meal - t
kf.rm
RM
cal.kiln
0.975
kg
kgcl
RM
cal.kiln
1 ASH
kiln
:
Raw meal quantity fully calcined (loss free basis)in kiln -RM
cal.kiln
RM
CO2
0.54
kg_CO
2
[ ]
kgcl
7BIU.mcd
Page 5 of 14
M
2
2.06
kg
kgcl
M
2
MI
1
CO2
pc
+ ( ) MI
1ash
S
OE
+ ( ) :
Quantity of material discharged through meal chute from cyclone stage 2 -
M
2
CO2
pc
0.46
kg
kgcl
CO2
pc
RM
CO2
RM
ki.co2
:
CO2 released in precalciner -CO2
pc
RM
ki.co2
0.08
kg
kgcl
RM
ki.co2
RM
ki
RM
cal.kiln
:
CO2 in raw meal entering kiln -RM
ki.co2
This is calculated by calculating the presence of CO2 in raw meal entering the kiln
and then subtracting it from total amount of CO2 present in raw meal feed.
CO2 released in precalciner -
MI
1CO2
1.02
kg
kgcl
MI
1CO2
RM
ki
MI
1ash
:
The quantity of raw meal that has lost CO2 in precalciner- MI
1CO2
MI
1ash
0.03
kg
kgcl
MI
1ash
ASH
pc
:
Ash coming into raw meal from precalciner -MI
1ash
S
1
0.58
kg
kgcl
S
1
MI
1
1
st1
( ) :
Dust at exhaust from cyclone stage 1- S
1
MI
1
1.93
kg
kgcl
7BIU.mcd
Page 6 of 14
S
OE
0.3
kg
kgcl
RM
ki
1.05
kg
kgcl
RM
cal.kiln
0.97
kg
kgcl
ASH
pc
0.03
kg
kgcl
ASH
kiln
0.03
kg
kgcl
RM
ki.co2
0.08
kg
kgcl
S
2
MI
2
M
3
S
1
M
2
MI
1
ASH
pc
SO
E
ASH
kiln
M
1
RM
ki.co2
RM
ki
RM
cal.kiln
M
1
1.35
kg
kgcl
MI
2
2.95
kg
kgcl
M
2
2.06
kg
kgcl
S
2
0.88
kg
kgcl
S
1
0.58
kg
kgcl
S
2
0.88
kg
kgcl
S
2
MI
2
1
st2
( ) :
2
MI
2
2.95
kg
kgcl
MI
2
M
2
st2
:
2
7BIU.mcd
Page 7 of 14
S
3
293.45
kg
kgcl
kg / kg.cl S
3
MI
3
1
st3
100
,
:
3
MI
3
295.82
kg
kgcl
MI
3
M
3
st3
100
:
3
M
3
2.37
kg
kgcl
M
3
MI
2
S
1
:
M3
S
3
0.59
kg
kgcl
S
3
MI
3
1
st3
( ) :
3
MI
3
2.96
kg
kgcl
MI
3
M
3
st3
:
3
M
3
2.37
kg
kgcl
M
3
MI
2
S
1
:
Quantity of material discharged through meal chute from cyclone stage 3
- M3
7BIU.mcd
Page 8 of 14
S
4
MI
4
1
st4
( ) :
Dust at exhaust from cyclone stage 4- S4
MI
4
368.67
kg
kgcl
MI
4
M
4
st4
:
4
M
4
294.94
kg
kgcl
M
4
MI
3
S
2
:
M
4
M
2
2.06
kg
kgcl
S
1
0.58
kg
kgcl
st2
70 %
S
2
0.88
kg
kgcl
MI
2
2.95
kg
kgcl
M
3
2.37
kg
kgcl
M
2
2.06
kg
kgcl
st3
80 %
MI
3
295.82
kg
kgcl
S
3
293.45
kg
kgcl
7BIU.mcd
Page 9 of 14
S
4
MI
4
1
st4
( ) :
S
4
73.73
kg
kgcl
Quantity of material discharged through meal chute from cyclone

stage 5 - M
5
M
5
MI
4
S
3
:
M
5
75.22
kg
kgcl

5
MI
5
M
5
st5
:
MI
5
81.76
kg
kgcl

5
S
5
MI
5
1
st5
( ) :
S
5
6.54
kg
kgcl
Quantity of material entering through meal chute to gas duct to cyclone

stage 5 as fresh feed - M
feed
M
feed
MI
5
S
4
:
M
feed
8.02
kg
kgcl
7BIU.mcd
Page 10 of 14
kg
M
1
1.35
kg
kgcl
Material at discharge chute of
cyclone -1 / preheater stage 1- M
1
S
OE
0.3
kg
kgcl
Quantity of circulating dust at kiln
inlet -S
OE
RM
ki
1.05
kg
kgcl
Quantity of raw meal at kiln inlet - RM
ki
RM
cal.kiln
0.975
kg
kgcl
Raw meal quantity fully calcined
(loss free basis)in kiln -RM
cal.kiln
RM
F
1.48
kg_rawmeal
kgcl
Raw meal requirement for producing
1kg. clinker -RM
F
ASH
tot
0.06
kg_ash
kgcl
Total ash absorbed in clinker - ASH
tot
ASH
kiln
0.03
kg_ash
kgcl
Ash going into kiln with fuel -ASH
kiln
ASH
pc
0.03
kg_ash
kgcl
Ash going into precalciner with fuel
-ASH
pc
Results
S
3
293.45
kg
kgcl
M
4
294.94
kg
kgcl
st4
80 %
MI
4
368.67
kg
kgcl
S
4
73.73
kg
kgcl
M
5
75.22
kg
kgcl
st5
92 %
M
feed
8.02
kg
kgcl
MI
5
81.76
kg
kgcl
S
5
MI
5
st5
M
feed
Cyclone stage -5
M
5
S
4
MI
4
st4
S
3
Cyclone stage -4
M
4
S
5
6.54
kg
kgcl
7BIU.mcd
Page 11 of 14
Dust at exhaust from cyclone
stage 3- S
3
S
3
293.45
kg
kgcl
Quantity of material discharged through

meal chute from cyclone stage 4 - M
4
M
4
294.94
kg
kgcl
Quantity of material entering cyclone 4 -

MI
4
MI
4
368.67
kg
kgcl
Dust at exhaust from cyclone stage 4-

S4
S
4
73.73
kg
kgcl

5
M
5
75.22
kg
kgcl
Quantity of material entering cyclone

5 - MI
5
MI
5
81.76
kg
kgcl
Dust at exhaust from cyclone

stage 5- S
5
S
5
6.54
kg
kgcl
Quantity of material entering through meal

chute to gas duct to cyclone stage 5 as
fresh feed - M
feed
M
feed
8.02
kg
kgcl
We can now establish the overall mass balance as shown in the sketch below:
Quantity of material entering cyclone 1
- MI
1
MI
1
1.93
kg
kgcl

1
S
1
0.58
kg
kgcl
Ash coming into raw meal from

precalciner -MI
1ash
MI
1ash
0.03
kg
kgcl
The quantity of raw meal that has lost

CO2 in precalciner- MI
1CO2
MI
1CO2
1.02
kg
kgcl

2
M
2
2.06
kg
kgcl
Quantity of material entering cyclone 2

- MI
2
MI
2
2.95
kg
kgcl
Dust at exhaust from cyclone stage

2- S
2
S
2
0.88
kg
kgcl
Quantity of material discharged

through meal chute from cyclone
stage 3 - M3
M
3
2.37
kg
kgcl
Quantity of material entering

cyclone 3 - MI
3
MI
3
295.82
kg
kgcl
7BIU.mcd
Page 12 of 14
Observation
S
1
0.58
kg
kgcl
ASH
pc
0.03
kg_fuel
kgcl
ASH
kiln
0.03
kg_ash
kgcl
RM
ki
1.05
kg
kgcl
M
1
1.35
kg
kgcl
RM
cal.kiln
0.975
kg
kgcl
S
OE
0.3
kg
kgcl
MI
1
1.93
kg
kgcl
S
2
0.88
kg
kgcl
M
2
2.06
kg
kgcl
MI
2
2.95
kg
kgcl
S
3
293.45
kg
kgcl
M
3
2.37
kg
kgcl
MI
3
295.82
kg
kgcl
M
4
294.94
kg
kgcl
S
4
73.73
kg
kgcl
MI
4
368.67
kg
kgcl
M
5
75.22
kg
kgcl
S
5
6.54
kg
kgcl
MI
5
81.76
kg
kgcl
M
feed
8.02
kg
kgcl
1 kg. clinker
RM
ki
ASH
kiln
RM
ki.co2
ASH
pc
M
1
S
OE
MI
1
M
2
S
1
MI
2
M
3
S
2
M
4
MI
3
S
3
MI
4
M
5
S
4
MI
5
S
5
7BIU.mcd
Page 13 of 14
Observation
References
Fri Sep 23 5:38:13 PM 2005
7BIU.mcd
Page 14 of 14
mbar 100Pa : mmWg
1
13.6
mmHg :
kmol 1000mol : mbar 0.01
lbf
in
2
degC 1 bar 760mmHg :

mbar 100
N
m
2
:
mmHg 132.95 Pa
mmHg
1
25.4
in_Hg :
Nm3 m
3
: in_Hg 3376.86 Pa
User defined units
Top
Consider a compressor to be delivering a certain volume compressed of air expressed in
terms of FAD (free air delivery) at a certain pressure. The compression takes place
polytropically and the polytropic index is given. Calculate theoretical power requirement for
compressing the air to the desired pressure.
Results
Input data
directly)
This worksheet can be used to calculate the power requirement for compressing air
polytropically. It should be remembered that polytropic type of compression which falls
between isothermal and adiabatic or isentropic follows the rule: P V
n
constant =
n represents polytropic index and normally lies between 11.0 and 1.4 covering all types of
changes in volume .
About this topic
Topic: Calculation of theoretical power to compress air polytropically
MC_V5_B201_Fans_3BIU
Pneumatics and Compressed
Air Systems
MathCement_Fluid Power
D:\MathCement_demo_pdf\MC_V5_B201_Fans_
3BIU.mcd
Page 1 of 4
Free air delivery
V
fad
3
m
3
min
:
Gauge pressure of compressed air
P
g
7bar :
Atmospheric pressure
P
b
1bar :
Top
Polytropic equation to be followed for calculation
P V
n
constant =
It follows, then,
P
1
V
1
n
P
2
V
2
n
=
Work done
W
1
W
1
n
n 1
P
2
V
2
P
1
V
1
( ) =
where
P
1
represents initial pressure of air (absolute)
V
1
represents initial volume of air
Polytropic index of compression
n
Free air delivery
V
fad
P
g
P
b
Compressed volume of air flow
V
2
Theoretical requirement of power
W
p
Work done in compressing air
W
1
Input data
Polytropic index of compression
n 1.3 :
3BIU.mcd
Page 2 of 4
V
2
0.61
m
3
min
Compressed volume of air flow
Derived data
P
g
7 bar Gauge pressure of compressed air
V
fad
3
m
3
min
Free air delivery
n 1.3 Polytropic index of compression
P
b
1 bar Atmospheric pressure
Given data
Results
Top
W
p
13.48kW
W
p
W
1
:
W
p
So, theoretical requirement of power
W
1
13.48kW
W
1
n
n 1
P
2
V
2
P
1
V
1
( ) :
Therefore , work done
V
2
0.61
m
3
min
V
2
V
1
P
1
P
2
,
1
n
:
P
2
8 bar
V
1
3
m
3
min
V
1
V
fad
: P
2
P
b
P
g
+ :
P
1
1 bar P
1
P
b
:
In our example we can write
V
2
represents final volume of air
P
2
represents final pressure of air (absolute)
3BIU.mcd
Page 3 of 4
min
Theoretical requirement of power W
p
13.48kW
Work done in compressing air W
1
13.48kW
Top
Observation
References
Fri Sep 23 5:26:51 PM 2005
3BIU.mcd
Page 4 of 4
P
g
mbar 100Pa : mmWg
1
13.6
mmHg :
lbf
in
2

mbar 100
N
m
2
:
mmHg 132.95 Pa
mmHg
1
25.4
in_Hg :
Nm3 m
3
: in_Hg 3376.86 Pa
User defined units
Top
Consider a compressor delivering compressed air at a certain rate at a defined gauge
pressure. The average demand of the system is less than the capacity. Allowable lower limit
of gauge pressure of compressed air is known. The receiver capacity is also given. As the
receiver pressure falls to lower limit the compressor comes on load and continues till the
pressure reaches the upper limit. For the given set of data, find
1) how many times the compressor will come on load per hour. Assume temperature of air is
kept constant
Results
Input data
directly)
This worksheet can be used to calculate how many times a compressor will come on load to
meet a certain demand of compressed air.
About this topic
Topic: Calculation of frequency at which compressor would come on load
as function of system demand.
Air Systems
8BIU.mcd
Page 1 of 5
Average system demand for
compressed air (f.a.d.)
Q
con
7
m
3
min
:
Minimum gauge pressure of
compressed air
P
gmin
6bar :
Receiver volume
V
r
6m
3
:
Top
Average maximum pressure in pipeline
in absolute scale
P
1abs
P
1abs
P
g
P
b
+ :
P
1abs
8 bar
Average minimum pressure in pipeline
in absolute scale
P
2abs
P
2abs
P
gmin
P
b
+ :
P
2abs
7 bar
Let's calculate the volumes of free air stored in the
receiver of compressed air at the maximum and
minimum gauge pressure.
P
g
Atmospheric (barometric) pressure
P
b
Flow rate of compressed air in terms
of free air delivery
Q
Q
con
Minimum gauge pressure of
compressed air
P
gmin
Input data
P
g
7bar :
P
b
1bar :
Q 10
m
3
min
:
8BIU.mcd
Page 2 of 5
t Charging time
Q
chg
3
m
3
min
Q
chg
Q Q
con
:
So the difference between delivery and consumption
would equal volume charged by the compressor in unit
time
Q
con
7
m
3
min
The circuit consumes per unit time

Q 10
m
3
min
The compressor can deliver per unit time

The compressor comes on load when the pressure falls
to lower limit value and goes off load when the pressure
reaches the upper limit value.
V
diff
6 m
3
V
diff
V
r1
V
r2
:
V
diff
Thus the difference in free air volume
stored in the receiver at maximum and
minimum pressure
V
r2
42 m
3
V
r2
P
2abs
V
r
P
b
:
V
r2
Free air volume at minimum gauge
pressure
V
r1
48 m
3
V
r1
P
1abs
V
r
P
b
:
V
r1
Free air volume at maximum gauge
pressure
8BIU.mcd
Page 3 of 5
Top
Note : If the cycle time is too short leading to very frequent start stop operation for
compressor, consider increasing the receiver capacity or extend range of maximum and
minimum pressure.
N
st
21
N
st
1hr
t
cyc
:
N
st
So the number of times the
compressor would come on load per
hour
t
cyc
2.86 min
t
cyc
t t
disch
+ :
Thus total time between the
compressor going on load or cycle
time
t
cyc
t
disch
0.86 min
t
disch
V
disch
Q
con
:
t
disch
Discharge time from receiver
Q
con
System consumption rate for
compressed air
V
disch
6 m
3
V
disch
V
diff
:
V
disch
Volume available for discharging
On the other hand the receiver discharges compressed
air thus reducing its pressure
t 2 min
t
V
diff
Q
chg
:
8BIU.mcd
Page 4 of 5
Fri Sep 23 5:28:41 PM 2005
Power Pneumatics by Michalel J. Pinches and Brian J. Callear References
Observation
Top
N
st
21 So the number of times the
compressor would come on load per
hour
t
cyc
2.86 min Thus total time between the
compressor going on load or cycle
time
t
disch
0.86 min Discharge time
t 2 min Charging time
Derived data
V
r
6 m
3
Receiver volume
P
gmin
6 bar Minimum gauge pressure of
compressed air
Q
con
7
m
3
min

Q 10
m
3
min
P
b
1 bar
P
g
7 bar Gauge pressure of compressed air
Given data
Results
8BIU.mcd
Page 5 of 5
mbar 100Pa : mmWg
1
13.6
mmHg :
lbf
in
2

mbar 100
N
m
2
:
mmHg 132.95 Pa
mmHg
1
25.4
in_Hg :
Nm3 m
3
: in_Hg 3376.86 Pa
User defined units
Top
A cylindrical actuator can receive compressed air under varying pressure within a range. The
minimum sustained gauge pressure is given. Find the minimum bore for the cylinder required
to develop a force to be applied on a mechanical work piece.
Results
Input data
directly)
This worksheet can be used to calculate the required bore of a cylinder in a compressed air
system to activate the piston so that a predefined force can be developed to clamp a
workpiece .Minimum cylinder pressure is known and also the atmospheric pressure is
known and cylinder efficiency is known. The compressed air entering the cylinder at a certain
pressure transmit the same pressure on to the piston. More and more compressed air come
into the cylinder, as the piston moves, to maintain the pressure. The system is used to
transmit the force through the piston rod. Cylinder bore being fixed ,the force can reduce in
case of falling pressure. Calculation ,therefore, should be carried out for minimum sustained
pressure..
About this topic
Topic: Calculating compressed air cylinder bore to be able to develop a
desired clamping force
Air Systems
16BIU.mcd
Page 1 of 3
d
4 A
cy
:
rewriting
A
cy
d
2
4
=
d
Let diameter of cylinder
A
cy
61.86cm
2
A
cy
F
P
gmin
Eff
:
A
cy
We first determine area of cross
section of cylinder required to be
acted on
Top
F 3000N :
Force required to be transmitted by
piston rod
P
gmin
5bar :
Minimum sustained pressure in cylinder
Eff 96% :
Cylinder transmission efficiency
Input data
d
Bore of the cylinder
F
Force required to be transmitted by
piston rod
P
gmin
Minimum sustained pressure in cylinder
Eff
Cylinder transmission efficiency
13.6
16BIU.mcd
Page 2 of 3
Fri Sep 23 5:31:28 PM 2005
References
Observation
Top
A
cy
61.86cm
2
Area of cross section of cylinder
d 88.75mm Bore of the cylinder
Derived data
F 3000N Force required to be transmitted by
piston rod
P
gmin
5 bar Minimum sustained pressure in cylinder
Eff 96% Cylinder transmission efficiency
Given data
Results
Top
Select nearest standard cylinder bore
d 88.75mm
16BIU.mcd
Page 3 of 3
month
yr
12
:
USD 48Rs
USD
Rs
Rs_to_USD
:
Rate of exchange USD to Rupees =Rs_to_USD
Rs_to_USD
1
48
:
Rs 1
User defined units
Top
Surplus fund is invested in a fixed deposit with a bank. Bank pays a nominal yearly rate of
interest. The principal is compounded at monthly or predefined frequency.
Given the final balance amount at the end of the deposit period, find nominal rate of yearly
interest and also effective rate of interest.
Results
Input data
directly)
When you save money in a bank or invest in finance scheme a certain fixed sum, you earn
interest. Interest rates are normally indicated on yearly basis and is called nominal interest.
The principal amount invested, however, increase every month as interest amount is credited.
It is also normal that new monthly balance including interest earned in the previous month
earns interest. This is known as compounding of interest (earning interest on interest) which
results into higher effective earning. In this worksheet, you workout effective rate of interest
and nominal rate of interest when the final balance at the end of the deposit period is known.
About this topic
Topic: Calculation of Rates of Interest on an Investment when Final
Balance After the End of Deposit Period is Known
MC_V22_B201_Interest_3BIU
Interest
MathCement_Business
D:\MathCement_demo_pdf\MC_V22_B201_Interest_
3BIU.mcd
Page 1 of 4
P
r
151049Rs :
Effective rate of interest
Top
Total duration of deposit
d
t
d
t
n
n
y
: n 18
n
y
12
1
yr
d
t
1.5yr
YI
Nominal rate of yearly interest
Balance at the end of the period of deposit
P
r
P
r
P 1
YI
n
y
+
,
n
=
YI
P
r
P
,
1
n
1
1
1
1
1
]
n
y
:
YI 15.4393
%
yr

P
Principal amount invested
r
Yearly nominal rate of interest
Number of compounding periods
n
Duration of each compounding period of deposit
d
Input data
P 120000 Rs :
Number of compounding periods
n 18 :
Number of compounding periods in a year
n
y
12
yr
:
Final balance at the end of deposit period
3BIU.mcd
Page 2 of 4
n 18 Number of compounding periods
P 120000Rs
Given data
Results
Top
APY 16.58%
APR 16.58%
APY R : APR R :
Annual percentage of return (APR) or annual percentage yield (APY) provided n=12
n 18
Number of compounding done during the period of deposit =n
r 0.01
1
month
r
YI
12
month
yr
:
r Monthly rate of nominal interest
YI 15.44
%
yr
R 16.5801 %
R
YI
n
y
1 +
,
n
y
yr
1 :
Rewriting
YI R 1 + ( )
1
n
y
yr
1
1
1
]
n
y
=
R Effective rate of interest
yr
3BIU.mcd
Page 3 of 4
Fri Sep 23 5:11:56 PM 2005
The Mathcad treasury: Interest rates, Mathsoft Engineering and education Inc.
References
Observation
Top
r 1.29
%
month
Monthly rate of nominal interest
P
r
1.51 10
5
Rs Balance at the end of deposit period
R 16.58% Effective rate of interest
YI 15.44
%
yr
Nominal yearly interest
Derived data
P
r
151049Rs Final balance at the end of deposit period
n
y
12
1
yr
Number of compounding periods in a year
3BIU.mcd
Page 4 of 4
month
yr
12
:
USD 48Rs
USD
Rs
Rs_to_USD
:
Rs_to_USD
1
48
:
Rs 1
User defined units
Top
Determine the current value of a machine that you can afford to purchase.
You approach a bank and find out the rate of interest they would be charging annually.
Your budget permits a certain monthly payments that can be made over a certain period of
time. You want to buy a machine now, with the help of a bank loan.
Results
Input data
directly)
You can then determine the current value of a machine that you can afford to purchase.
You can approach a bank and find out the rate of interest they would be charging annually.
When your budget permits a certain monthly payments that can be made over a certain
period of time, you may attempt to buy a machine now, with the help of a bank loan.
About this topic
Topic: Calculation to find, present value of an annuity
MC_V22_B202_Annuities_4BIU
Annuities
MathCement_Business
D:\MathCement_demo_pdf\MC_V22_B202_Annuities_
4BIU.mcd
Page 1 of 4
P 4yr :
Period of repayment of borrowed fund
Monthly savings to be deposited to bank
m 200Rs :
Top
We shall base our calculation on the formula to calculate future value of an
ordinary annuity.
Monthly rate of interest
YI 12%
r
YI
12
:
r 1 %
Monthly deposit to be made to bank = m
Number of deposits to bank =n
n P
12
yr
:
n 48
V m
1 r + ( )
n
1
r
:
V 12244.52 Rs
month
12
:
Final sum of money paid i.e total outgo
V
YI
Yearly rate of interest
P
Monthly rate of interest
r
Monthly savings to be deposited to bank
m
n
Number of deposits to bank
Input data
YI 12% :
4BIU.mcd
Page 2 of 4
m 200Rs Monthly savings to be deposited to bank
P 4yr
YI 12%
Given data
Results
Top
V
p
7594.79 Rs
V
p
Find V
p
( ) :
V
p
1 r + ( )
n
m
1 r + ( )
n
1
r
1
1
]
=
Given
V
p
567 :
guess value for V
p
Solve for V
p
V
p
1 r + ( )
n
m
1 r + ( )
n
1
r
1
1
]
=
or
V V
p
1 r + ( )
n
=
We can now write the following equation
So we can define the present value of an annuity as the amount that we can borrow ,knowing
the amount of monthly payments, the rate of interest and the number of payments or
installments.
Let the present value be V
p
But this is the total outgo of your fund over the repayment period and does not mean that you
can buy a machine of this current value. To find out the amount of money the bank will
advance as a loan, which will be in tern the current value of the machine you can purchase ,
you have to find the current value of this annuity.
V 12244.52 Rs
So the future value of the annuity is =V
4BIU.mcd
Page 3 of 4
Derived data
Final sum of money paid to fund V 12245 Rs
Present value of the annuity, or the amount of loan fund
to purchase the machine
V
p
7595Rs
Top
Observation
References
Mathematics all around, by Thomas L. Pirnot, Chapter 6.3 -Annuities
Fri Sep 23 5:19:37 PM 2005
4BIU.mcd
Page 4 of 4
life Total expected useful life
cost Total cost of procurement of machine / asset
month
yr
12
:
USD 48Rs
USD
Rs
Rs_to_USD
:
Rs_to_USD
1
48
:
Rs 1
User defined units
Top
Also find the book value after a certain defined period
A cement company decides to buy a hammer crusher to crush coal. It is decided to use
reducing value depreciation method for depreciation calculation. For the given data find the
depreciation value.
Results
Input data
directly)
Use this worksheet to calculate depreciation of machinery or other assets by reducing
balance method
About this topic
Topic: Depreciation Calculation of Assets by Reducing Balance Method
MC_V22_B203_Depreciation_3BIU
Depreciation
MathCement_Business
D:\MathCement_demo_pdf\MC_V22_B203
_Depreciation_3BIU.mcd
Page 1 of 6
Book value = cost - accumulated depreciation
i 0
life
yr
.. :
i
Let us represent number of completed years by variable
Depreciation

D
p
7.69 %
using 1 in place of 100 due to Mathcad built in units
D
p
1
life
yr
:
D
p
Depreciation percent by straight-line method
Depreciation_percent
100
Expected_useful_life
=
Depreciation percent by straight-line method
Assuming that depreciation will be calculated only at
the end of the year
D
tot
900 Rs
D
tot
cost V
salvage
:
Total amount to be depreciated over the lifetime
D
tot
Top
t
y
3yr :
Define the period after which book value should
be found
V
salvage
100Rs :
Expected salvage value at the end of useful life
life 13yr :
Total expected useful life
cost 1000Rs :
Total cost of procurement of machine / asset
Input data
V
salvage
Expected salvage value at the end of useful life
Page 2 of 6
D
ty
cost BV
n
:
D
ty
Depreciation during the defined period
BV
n
786.53 Rs
dividing by "yr" to delete unit n
t
y
yr
:
BV
n
To find the book value after a particular period replace
the value of n vis-a-vis t
y
in the input data block
indexed variable
BV
1
923.08 Rs
indexed variable
BV
0
1000Rs
BV
i
1000
923.08
852.07
786.53
726.02
670.18
618.62
571.04
527.11
486.57
449.14
414.59
382.7
353.26
Rs
BV
i 1 +
BV
i
D
i 1 +
:
D
i 1 +
BV
i
D
p
:
D
i
Book value at the end of 1st. year is calculated by
subtracting the depreciation from the cost at the
beginning of the year or the procurement cost.
BV
1
BV
1
cost cost D
p
: subscripted variable
BV
1
923.08 Rs subscripted variable
Book value after 2nd year is calculated by subtracting
depreciation from the depreciated value at the end of
the previous year
BV
2
BV
2
BV
1
BV
1
D
p
: subscripted variable
BV
2
852.07 Rs subscripted variable
We can, therefore, make the following generalised
equation
BV
0
cost : indexed variable
BV
i 1 +
BV
i
BV
i
D
p
:
Depreciation at end of each year
Page 3 of 6
D
ty
213.47 Rs
i
D
i
646.74 D
tot
900
Following condition is applied to balance total depreciation by considering the
salvage value to be true and the calculated depreciation on declining balance
D
n
if
i
D
i
D
tot
0 D
n
i
D
i
D
tot

,
+ , D
n
i
D
i
D
tot

,
,
1
1
]
:
D
i
0
76.92
71.01
318.8
60.5
55.85
51.55
47.59
43.93
40.55
37.43
34.55
31.89
29.44
Rs
D
0
0
D
1
76.92Rs
D
3
318.8Rs
i
D
i
900 D
tot
900
D
n
318.8
Recalculate book values due to adjustment in depreciation
BV
i 1 +
BV
i
D
i 1 +
:
BV
1
923.08
BV
i
1000
923.08
852.07
533.27
472.77
416.92
365.37
317.78
273.85
233.31
195.88
161.33
129.44
100
Rs
Page 4 of 6
References
Observation
Top
D
i
0
76.92
71.01
318.8
60.5
55.85
51.55
47.59
43.93
40.55
37.43
34.55
31.89
29.44
Rs
Depreciation values after each year of operation
BV
n
533.27 Rs Book value after the desired period
Total amount actually depreciated over the lifetime
i
D
i
900 Rs
D
tot
900 Rs Total amount to be depreciated over the lifetime
Derived data
t
y
3yr : Define the period after which book value should
be found
V
salvage
100Rs : Expected salvage value at the end of useful life
life 13yr : Total expected useful life
cost 1000Rs : Total cost of procurement of machine / asset
Given data
Results
Top
Page 5 of 6
References
Business mathematics by Charles D. Miller, Stanley A. Salzman, Gary Clendeman
Fri Sep 23 5:21:45 PM 2005
Page 6 of 6
Recent research shows that many industrial wastes
can be successfully used as replacement of cement
in preparation of concrete.This can reduce current (2005)
demand for cement by 25%.This will serve to minimise
disposal problem associated with such industrial wastes
and reduce global energy demand.
Source: World Cement: January 2005
Cement substitute
Working with cement and concrete consumes 40% of
the global energy demand.And a reduction of cement and
concrete usage by up to 25% by alternative material
could save 10% of total energy requirements.This also
means a reduction of 400 million MT of CO
2
release per
annum.
Source: World Cement: January 2005
Energy and environment
Fans used in cement plants are mostly of centrifugal
type.The flow characteristics, through a fan, are governed
by three basic rules:
1) Flow rate is proportional to speed.
2) Pressure developed is a square function of speed.
3) Power required varies as cube of speed.
Source:
Fan laws
Atomic weight of any element, when expressed in
grams, contains 6.02X10
23
numbers of atoms of that
element.Thus, 16 gm of Oxygen or 14 gm of Nitrogen will
have equal number of their respective atoms and this
number will be equal to 6.02X10
23
,

also called Avagadro
Number.
Source:
Atomic weight and Avagadro Number.
Atomic weight of any element, when expressed in
grams, contains 6.02X10
23
numbers of atoms of that
element.Thus, 16 gm of Oxygen or 14 gm of Nitrogen will
have equal number of their respective atoms and this
number will be equal to 6.02X10
23
,

also called Avagadro
Number.
Source:
Atomic weight and Avagadro Number.
Average pressure exerted by Earth's atmosphere, at sea
level, is equal to the pressure exerted by a 760mm tall
column of Mercury at its base, .This pressure is called
"Normal atmospheric pressure" or "Standard
atmospheric pressure" and has a value of 101325 Pa
(Pascals).It's also expressed as 1 atm or 1kgf/cm
2
Source:
Natural gas is a mixture of hydrocarbon gases mainly of
Methane.But it may also contain Ethane, Propane,
Butane and Pentane.It is called natural gas as it occurs
naturally in nature, under the Earths' surface. Natural gas
is a fossil fuel like coal and is formed from the remains of
plants, animals and micro-organisms under intense
pressure and heat over millions of years.
Source:
Gaseous fuels -Natural gas
Natural gas, which erupts through fissures in the earth's
crust, from below the surface of the Earth can ignite due
to natural phenomenon like lightning.Such resultant fires
awed the early civilization.Early Greeks assigned divinity
to such natural spring of fire and created a temple around
one such eruption. This is known as Oracle of Delphi.
Source:
"D:\Mathcement_July05\Images\oracle at delphi"
Gaseous fuels -Natural gas
There are only three classes of equipment in a cement
plant. These are 1) Conveying equipment, 2) Storage
equipment and 3) Process equipment.
Again process equipment can be classified in two two
types i.e. 1)Physical process,(when composition of
incoming material does not change during the process)
2) Chemical process(when composition of incoming
material changes during the process).
Source:
Equipment classes

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Table of contents (This file)

Dumper capacity required, based on turn around time W

Minimum number of Dumpers required to feed

Hopper capacity -( volumetric) based on minimum

Selected hopper capacity - the higher value between

Maximum possible capacity of each dumper.W

Hopper to hold material equivalent to

Standard dumper volumetric capacity V

Dumper turn around time T

Angular speed of the rolls

Feed material density

Cross sectional area of

R 25.36mm Radius of maximum size of feed particle

f 2 Hz Roll running frequency

Angular speed of the rolls

Feed material density

Quantity of false air entry between point 1 and 2 =FA

nett or actual degree of calcination C

BASED ON VELOCITY IN BRANCH

Density of Carbon dioxide

Dew point temperature = t

Density of moist gas

Mass of carrying side idlers per unit of length

Mass of return side idlers per unit of length

Secondary resistance co-efficient

Conveyor carrying rate for design

area of cross section at inlet to ventury

velocity of water at inlet to ventury

velocity of water at the throat of ventury

Flow velocity in suction pump

kg. fuel / kg.cl F

Quantity of circulating dust at kiln inlet -S

Quantity of material discharged through meal chute from cyclone

Quantity of material entering cyclone 5 - MI

Dust at exhaust from cyclone stage 5- S

Quantity of material entering through meal chute to gas duct to cyclone

Quantity of material discharged through

Quantity of material entering cyclone 4 -

Dust at exhaust from cyclone stage 4-

Quantity of material discharged through

Quantity of material entering cyclone

Dust at exhaust from cyclone

Quantity of material entering through meal

Dust at exhaust from cyclone stage 1- S

Ash coming into raw meal from

The quantity of raw meal that has lost

Quantity of material discharged through

Quantity of material entering cyclone 2

Dust at exhaust from cyclone stage

Quantity of material discharged

Quantity of material entering

degC 1 bar 760mmHg :

degC 1 bar 760mmHg :

The circuit consumes per unit time

The compressor can deliver per unit time

Average system demand for

degC 1 bar 760mmHg :

List of parameters used

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