Grate cooler thermal Analysis.ppt
Transcript of Grate cooler thermal Analysis.ppt
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By
Abdul Manan
13103046
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Mass Balance Analysis
Global Mass Balance kiln system
Grate Cooler Mass Balance
Balance Energy of Grate Cooler
Eficiency Thermal
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Suspension Preheater
Kiln Feed 273 ton/h
Coal 8124.3 kg/h
Primary Air coal 28 m3/min
Natural Gas 3630.75 kg/h
Rice Husk (RH) 11.8 ton/h
Primary Air RH 68 m3/min
Grate Cooler Measurement
Clinker Ratio 1.76
Air Cooler Rate 5900 m3/min
Exhaust Air rate 7.44 m/s
Tin Grate Gooler 1450C
Tout grate cooler 103C
Texhaust air 241CTsecondary air 950C
T3rd air 950C
Tambient 32C
Kiln
Coal 8124.3 kg/h
Primary Air 40 m3/min
Raw Material
Composition % w.t
CaO 44.04
SiO2 12.91
Al2O3 3.23
Fe2O3 2.11
MgO 1.19
SO3 0.27
H2O 0.8
Lost of Ignition 35.45
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Coal (Proximate Analysis)
Composition % w.t
Whole
Water
3.6
Ash 19.3
Volatile
Matter
41.4
Fixed
Carbon
35.7
Coal (Ultimate Analysis)
Composition % w.t
C 71.2
H 4.5
O 21.9
N 0.9
S 0.7
Rice Husk
Composition % w.t
C 38.3
H 4.36
O 35.45
N 0.83
Ash 20.6
H20 8.3
Natural Gas
Composition % w.t
CH4 58.37
C2H6 4.78
C3H8 3.49
C4H10 1.6
C5H12 0.59
C6H14 0.49
N2 2.77
CO2 27.91
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Flow Input (Kg/h) Output (Kg/h)
Kiln Feed
Coal (SP)
Coal (Kiln)
Rise husk
Natural Gas
Cooler Air
Primary Air SP
Primary Air Kiln
Primary Air Rise Husk
Clinker Out
Gas out
CO2 Calcination
Steam
Return Dust
Exhaust Air
273,000
4,890
6,990
11,800
3,285
410,640
1,766
2,523
4,289
155,114
234,514
85,273
2,184
35,202
206,249
Total 719,003 718,536
Loss mass 647
Global Mass Balance
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Flow Input (Kg/kg clinker) Output (Kg/ kg clinker)
Kiln Feed
Coal (SP)
Coal (Kiln)
Rise husk
Natural Gas
Cooler Air
Primary Air SP
Primary Air Kiln
Primary Air Rise Husk
Clinker Out
Gas out
CO2 Calcination
Steam
Return Dust
Exhaust Air
1,7600
0,0315
0,0451
0,0761
0,0212
2,6474
0,0135
0,0163
0,0277
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1,0000
1,5119
0,5497
0,0141
0,2269
1,3297
Total 4,6365 4,6323
Loss mass 0,0042
Global Mass Balance
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Flow Input (Kg/kg Clinker) Output (Kg/kg Clinker)
Air Cooler
Leak Air
Clinker+ kiln cooler ash
Clinker Out
Exhaust Air
3rdAir
2ndAir
Kiln Cooler Ash
2,6474
0,0080
1,1000
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1,3297
0,9150
0,4107
0,1000
Total 3,7553 3,7553
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Flow Input (kcal/kg Clinker) Output (Kg/kg Clinker)
Air Cooler
Leak Air
Clinker+ kiln cooler ash
Clinker Out
Exhaust Air
3rdAir
2ndAir
Kiln Cooler Ash
Heat Loss
20,08
0,06
422,67-
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-19,26
77,87
218,18
97,93
22,427,16
Total 442,81 442,81
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t =
=
76.4 %=
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firebrick
grate cooler wall
grate plate
Leak Air
Causes of Heat loss:
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Conclusion
Termal Efficiency of Grate Cooler is 76.4%
Grate Cooler is working properly based on
(Duda,W.H.Cement Data Book.1986)
Suggestion
Evaluate the Thermal Efficiency periodically
Raplace grate plate periodically
Raplace fire brick periodically
Repair the leakage