HEAT BALANCE

Necessity

To Establish the Specific heat

consumption
To Find out the areas of heat losses
To Quantify the losses
Taking
Energy

Steps

to

Conserve

Thermal

Procedure

HEAT BALANCE

CALCULATION

ENERGY FLOWS

MATERIAL FLOWS

BOUNDARY

Boundary

HEAT BALANCE

Material Flow
PH Exhaust

HEAT BALANCE
Outputs
Inputs

Raw meal

Fine Coal

Air

Cooling
Air

Cooler Exhaust

Clinker

Energy Flow

HEAT BALANCE

PH Exhaust
Raw meal

Input
Loss

Radiation
Fine Coal

Air
Reaction
Radiation
Coolin
g Air

Cooler Exhaust
Radiation
Clinke
r

HEAT BALANCE
Measurement Schedule
Surface temperature of Preheater ,Kiln, & Cooler
should be taken before and after trial
Parallel measurement is required for Highly
varying parameters like Gas flow, temperature,
oxygen etc.

IMPORTANT
AN UNINTERRUPTED LONG
TRIAL PERIOD IS ALWAYS
BENEFICIAL

Programme
schedule
Material Flow Measurement
Frequency :- Every 1 Hours

Location

Parameter

Raw meal feed

Temperature Thermo meter

Recirculation dust Weight in Kg

Clinker

Device / Method
Weigh feeder
Solid flow Feeder
Weigh Bridge

Programme
schedule

Lab Analysis
Frequency :- Every 8 Hours

Location

Parameter

Device / Method

Clinker analysis

SiO2 , Al2O3
,Fe2O3

Lab analysis
Orsatt

CaO, MgO, K2O

PH Exhaust Gas

Na2O, SO3, LOI

Coal

O2, CO2, CO

Raw meal

Net CV
H2 O

Programme
Air Flow Measurement schedule
Frequency :- Every 6 Hours

Location

Parameter

PH exhaust

Temperature
C

Cooler fan Air

Cooler Vent air
Primary firing air
Secondary firing
air

Flow in Kg/hr

Device /
Method
o

Thermo meter
Thermocouple

Anemometer
Pitot tube

Plant Data

HEAT BALANCE

Kiln Size
diameter

3.8:50
25

Ambient temperature
Wind speed

::-

1.1
47

Site elevation
MSL

:-

m long
o

Km/hr
m/sec
m from

Material Flow

HEAT BALANCE

A. Kiln feed for 24 hours

Counter

8488
Final reading :
4000
Initial reading: 4488

Difference

T
T

Q:

187

Kiln feed Hourly rate ( Q / 24 ) :

74
TPH
Raw meal Temperature
Raw meal Moisture %

0.16

C
%

HEAT BALANCE

Material Flow
B. Clinker Production
Total weighed ( W ) :

2817.6
117.4

Hourly rate ( W / 24 ) :
Kg per Sec

32.61

C. Raw meal to Clinker factor

KF Average TPH
RMKF = ----------------------------------Hourly Clinker Prod. Rate

T
TPH
Kg /Sec
187

= -------------117.4
= 1.
5928

Material Flow

HEAT BALANCE

D. Recirculation dust (6 hours)

Measured

(W) :

Hourly rate ( W / 6 ) :

45

7.50

T
TPH

Dust in Preheater exit gas in kg /kg clinker

7.5*1000

Dust Hourly rate * 1000

= -- -------------117.4 *
= ----------------------------------1000
Clinker Hourly rate * 1000
Kg dust / Kg
clinker

0.064

HEAT BALANCE

Material Flow
B. Fuel used
Coal + Pet coke
Net Colorific Value :Moisture ( % )

:-

Ash content ( % )

:-

Sulpher S ( % )

:-

Firing System

:-

Coal Consumed

:-

7797
0.33
1.92
4.15
Indirect
X

Kcal/kg coal
%
%
%

Kg /Kg Clinker

HEAT BALANCE

Material Flow
Clinker Analysis
SiO2
Al2O3
Fe2O3

=
=
=

CaO
MgO
K2 O
Na2O
So3

=
=
=
=
=

LOI

21.56
5.56
4.17
64.19
1.79
0.55

%
%
%

%
%
0.26
%
1.59
%
0.15
%

Basis 1 Kg Clinker
at Temperature 0

Clinker Temperature measure at cooler out let

HEAT BALANCE

Gas Flow Measurement

Primary air

Measuring Equipment
Anemometer - Measure at fan open inlet
Pitot tube
- Measure at intermediate
duct
Data to be measured if Pitot tube
0.250
Dia of the duct
: 0 .049
Area of the duct
: 103.5
Velocity Pressure ( Vp ) :

40

Air temperature
:
Density of standard air : 1.29

m
m2
mm Wc
C
kg/Nm3
o

HEAT BALANCE

Gas Flow Measurement

Pitot tube

It has two coaxial tubes, the inner one has an open

end and the outer one has a closed end. The outer
tube has a small holes on its surface.
The center tube (+) Shows Total Pressure (TP)
The Outer tube (-) Shows Static pressure (SP)
If we connect both tube with manometer it Shows
Velocity pressure (VP)
The measuring point should be in
a straight duct with uniform flow
(5*D before and 2*D after)

HEAT BALANCE

Gas Flow Measurement

Pitot tube

HEAT BALANCE

Gas Flow Measurement

Primary air

47

Barometric pressure = 10333 * 2.71828-0.0001255 * H

10272

=
1.29

mm Wc

10272

800

40
* 273
*
b
+ SP
--------- ---------------0
1.206 273+ T
10333

Density correction =

=
0.98

Velocity
m/Sec

= Kp

103.
5

9.81

40.
2

1.206

VP
* 2 * g
------------------

HEAT BALANCE

Gas Flow Measurement

Primary air
Volume

=
=

0.049

Area

* Velocity

1.970
1.970

Mass
of the air
Kg/sec

40.2

m3 / Sec
1.206

= Volume

2.38

m3 /sec

* Density

Kg/ Sec

Like that we have to take measurement and

calculate the mass of air in all points

Gas Flow - Input

HEAT BALANCE

A. Coal firing Air Flow

2.380
Kiln
Primary air= 0.293
Kg / Sec @ 40
o
C
Calciner air = 2.673 Kg /Sec @ 40 o C
2.673 / 32.61 =
Total air
=
Kg /Sec @ 40 o C
0.82

Kg/Kg Clinker =
B. Cooler Air flow rate6.19
Fan 1 flow
=
9.78 kg / sec
Fan 2 flow
= 18.40 Kg / Sec
Fan 3 flow
= 20.60 Kg /Sec
Fan 4 flow
= 20.60 Kg / Sec
Fan 5 flow
= 77.29 Kg /Sec
Total flow = 77.29/32.61
Kg /Sec
@ 25
=

Gas Flow Out put

HEAT BALANCE

71.09

PH Exhaust mass
Sec
Temperature
Air kg /Kg clinker

=269
=
=

Air Kg /Kg Clinker

Kg /

71.09/32.61 =
2.179
oC

39.95
316
Cooler exhaust mass=
39.95/32.61Kg
= /Sec
1.225
Temperature
=
oC

Orsatt measurement26.30
CO2
O2

=
=

CO

2.80
0.03

%
%
%

Heat Output

HEAT BALANCE

Heat of formation
Heat in Preheater exit
Loss through Gases
Loss through dust
Evaporation of raw meal moisture
Evaporation of Coal moisture
Loss due to Incomplete combustion
Heat in discharge Clinker
Heat in Cooler Exit Gas
Radiation & Convection Losses

Heat Input

HEAT BALANCE

Coal combustion
Heat in raw meal
Heat in cooler Cooling air
Heat in Primary air
Sensible heat

Heat Balance

Total Heat input = Total Heat Output

HEAT BALANCE

Mean Specific Heats Between 0 and ToC

Specific Heat = A + B * T * 10-6 + C * T2 * 10-9
A

CO2

0.196

118

-43

H2 O

0.443

39

28

N2

0.244

22

O2

0.218

30

Air

0.237

23

Raw Meal

0.206

101

-37

Clinker

0.186

54

Coal

0.262

390

20

C 100

Evaporation of water
at

HEAT BALANCE
THEORATICAL HEAT OF FORMATION OF
CLINKER
+
64.29
Hf = + 7.646 * ---% CaO
491.56
+
1.79
+ 6.48 * ---% Mgo
11.59
+
5.57% Al o
+ 2.2 * ---2

21.59

5.116* ----4.18
% Sio2
0.59 * ----0.00
% Fe2O3
Kcal / Kg
10 * % (K2o +
Clinker

Na2O)
Heat of formation H
basis

12.25

110.45

2.46
0.00

402.59

is in Kcal / Kg Clinker on LOI Free

Heat Loss in Dust

HEAT BALANCE

Heat loss in dust =0.06

Wd *0.0230
Shd
* ( Td 0
269
4
5
Tr )
= 3.97 Kcal / Kg Clinker
Wd = Weight of dust in Kg/Kg clinker
Shd = Specific heat of dust in Kcal / Kg
C
Td

= Temperature of Dust in

Tr =0.20
Reference Temperature
in
-6
Shd = A 6 + 101
B
*269T *10 +-37 C
)
= Kcal / Kg o C
0.2305

C2 (20
269
* T * 10-9

HEAT BALANCE

Heat Loss in PH Gases

Exit Gas composition

O2 = 2.8% ; CO2 = 26.3% ; CO =0.03 %

Balance assume as N2 = 100 (2.8+26.3+0.03) =
70.87
%
The volume
of one gram-molecular weight (Atomic
weight) of any gas is 22.4 liters.
Weight of the Gas element
CO2 = (12.011 + (2*16))/22.4 = 1.9647 kg / Nm3
O2 = (2*16)/22.4
Nm3
CO = (12.011+16)/22.4
Kg/Nm3
N2
= (14.0067*2)/22.4
Nm3

= 1.42857 Kg /
= 1.2505
= 1.2505 Kg /

HEAT BALANCE

Heat Loss in PH Gases

Total Weight of the Gas

CO2 = 1.9647 * 0.263

O2

= 0. 516

= 1.42857 * 0.028 = 0.04

CO = 1.2505 * 0.0003
0.000375
N2 = 1.2505 * 0.7087
Total weight per Nm3
1.442275

=
= 0.8859
=

Weight percentage of the Gas

CO2 = 0. 516/1.4422 *100 =35.77
O2

= 0.04/1.4422 * 100 =2.77

CO = 0.000375/1.4422 *100 =
0.026
N2 = 0.8859/1.4422 * 100 =
61.434

HEAT BALANCE

Heat Loss in PH Gases

Specific heat of Gases

CO2 = 0.3577 * (0.196 + 118*269*10-6) = 0.080

O2

= 0.0277 * (0.218 + 30*269*10-6) = 0.0063

N2

= 0.6146 * (0.244 + 22*269*10-6) =0.153

Total Specific heat in Kcal/Kg

= 0.2402

Heat loss in Gas =2.17

Wg *0.2402
Shg
*269
( Td 0
9
Tr )
= Kcal / Kg Clinker
140.85

HEAT BALANCE

Heat Loss in Raw meal moisture

0.0016

1.5928

Total Moisture =0.00254

Raw meal kg/kg clinker * %
moisture
=
Kg water / Kg
clinker
0.00254

597

1.52
Heat of Evaporation
of Raw meal Moisture
= Water Kg/kg clinker * Heat of evaporation
Heat Loss in Fine coal moisture
=
Kcal / Kg clinker
0.0033
X
Total Moisture = Fine
coal
kg/kg clinker * %
0.0033
X
moisture
=
Kg water / Kg
clinker
0.0033 X

597

Heat of
Evaporation
of Fine coal Moisture
1.97
X

HEAT BALANCE

Heat Loss in Incomplete combustion

The heat loss for in complete burning of Carbon

Is 2417 Kcal/kg of CO.
% Weight of CO Gas = 0.026 wt %
Amount of PH exhaust waste gases = 71.09
kg/sec
Amount of CO = 71.09 *(0.026 /100) =0.01848 kg
Kg/sec
of CO Gas per kg of clinker= 0.01848 / 32.61
= 0.0005668 kg/kg
Clinker
Heat Loss in incomplete combustion = 0.0005688 *
2417
= 1.37

HEAT BALANCE

Heat Loss in Cooler Exhaust air

Heat loss in Air
Tr )

1.22
=
Wg

* Shg
0.2443

= 94.57

0.23

Shg = A 7 + B
*316T
23
= Kcal / Kg
0.2443

*(
316

Td 0

Kcal / Kg Clinker

*10-6
o

Heat Loss in Clinker discharge

Heat loss in Air
Tr )
0.18

=1.0
Wm
= 23.10

* Shg
0.1925

*(
120

Td 0

Kcal / Kg Clinker

Shcg = A 6 + 54
B
*120T *10-6
= Kcal / Kg o C
0.1925

HEAT BALANCE
Surface Losses
Radiation
Q = 4 * 10

( TS4 _ Ta4)

where,

Q - Heat in Kcal / hr m2
TS - Surface temperature in Kelvin's
Ta - Ambient temperature in Kelvin's

Surface Losses

HEAT BALANCE

Natural Convection
Q = 80.33 * ( TS + Ta )
---------2

Forced Convection

- 0.724

* (TS Ta) 1.333

Q = 28.03 * (TS + Ta) -0.351 * V

0.805

* D-0.195 * (Ts-Ta)

----------------

2
Where Q = Heat in Kcal / M2 . Hr
Ts = Surface temperature in o K
Ta = Ambient temperature in o K

V = Wind velocity in m/sec

D = Dia meter of the measured surface in m

Radiation Loss

HEAT BALANCE

Surface temp of kiln outlet( 2 m) =165

C
Ambient temp
= 25
C
8
4
4T 4 )
4
Q1 = 4 4* 10
* -8 10
*
(T
*
((165+273)
S
a(25+273) )
Wind Speed is less than 3 m / sec
Q1

= 1157

= 809

Kcal/ [Link]

Q2 = 80.33*( T43
+298
Ta
S
8
---------2
Q2

- 0.724

Kcal/ [Link]

* (43TS 298
Ta ) 1.333
8

HEAT BALANCE

Surface Losses - Kiln

From Kiln Surface
Outle Area
t m m2
Temp
o
K

Losses Kcal/h.m2
Radiation Convectio
n

Total
Loss
Kcal/h.m2

24

438

1157

809

1966

47184

24

524

2700

1414

4114

98736

24

525

2723

1421

4145

99480

44

24

566

3790

1712

5502

132048

46

24

562

3675

1684

5358

128592

48

24

526

2747

1428

4175

100200

50

24

524

2700

1414

4114

98736

Total Losses in Kcal /Hr

Losses
Kcal/h

A* B

2482738

Surface Losses - PH
Cyclones

HEAT BALANCE

Kiln Surface

Losses
Kcal/h.m2

Losses
Kcal/h

Area
m2

Radiati
on

Total
Loss
Convec Kcal/h.m
2
tion

A* B

Tem
poK

Stage-1
Cylinder

80

360

416

332

748

60037

Cone

28

386

646

494

1140

32213

Top

10

364

443

352

795

Meal pipe

12

429

1164

789

1953

23011

Raiser duct

15

369

491

387

878

13508

Stage-2

8322

Surface Losses
Kiln Loss =

HEAT BALANCE

248273
Kcal/h
* 24 h * 1.05
=
8
22.2
Production
TPD *1000
2817.6

Kcal
/Kg
Clinker

1.05 is for to compensate heat loss from live rings

407469
Kcal/h
* 24 h
6
Production TPD *
2817.6
1000

PH Loss =

Cooler Loss

= 34.7

Kcal
/Kg
Clinker

= 5 Kcal/ Kg Clinker

Tertiary duct Loss = 2.6 Kcal/ Kg Clinker

Total Surface Losses = 22.2 + 34.7 + 5 + 2.6

Kcal /Kg
4.5
Clinker

HEAT BALANCE

Heat of Coal Combustion

= Kcal
/Kg Coal * XCoal consumed = 7797 X
7797

Heat in Raw meal

=1.59
Wm

Heat in put

* 0.213
Shg

= 25.06
0.20

Shd = A 6 + 101
B
= 0.213

* 74T

Kcal / Kg

* 74
( Td 0 Tr )

Kcal / Kg Clinker

*10-6 +-37 C
o

74
*2

T2 * 10-9

HEAT BALANCE

Sensible heat of fuel

Heat in put

Shd

= WXm *0.2776
Shg
* 40
( Td 0 Tr )
= 11.1 Kcal / Kg Clinker
X
0.26
= A 2 + 390
B
* 40T *10-6
= Kcal / Kg o C
0.2776

Heat in Primary air

=0.08
Wm

Heat in put

* 0.238
Shg

= 0.80
0.23

Shd = A 7 + B
23
= 0.238

* 40T

Kcal / Kg

Kcal / Kg Clinker

*10-6
o

* 40
( Td 0 Tr )

HEAT BALANCE

Heat in Cooling air

Heat in put

=2.37
Wm

*0.2375
Shg

= 14.07
0.23

Shd = A 7 + B
* 25T
23
= Kcal / Kg
0.2375

* 25
( Td 0 Tr )

Kcal / Kg Clinker

*10-6
o

Total Heat inputs

= 7797 X+25.06+14.07+0.8+11.1 X
= 7808.1 X+39.93

Total Heat outputs

= 402.5+3.97+140.85+23.1+94.57+1.52+1.97
X+1.37+61.9

Heat Consumption

HEAT BALANCE

Total Heat input = Total Heat output

7808.1 X +39.93 = 729.78 + 1.97 X
7806.13 X
X

= 689.85

= 689.85 / 7806.13 = 0.08837

Kg Coal / Kg Clinker

Heat Consumption 0.08837 * 7797

=689.04 Kcal / Kg clinker

HEAT BALANCE
Heat In put

Kcal /Kg
Clinker

Heat through Coal

Combustion

689.04

94.39

Sensible heat in Raw meal

25.06

3.43

Sensible heat in Fuel

0.98

0.13

Sensible Heat in Air

14.87

2.03

Total Heat In put 729.95

100 %

Heat Out put

Kcal /Kg
Clinker

Heat in PH exit Gases

140.85

19.29

Heat in PH exit Dust

3.97

0.54

Heat of reaction

402.5

55.14

Cooler exhaust air

94.57

12.95

Heat in Clinker discharge

23.1

3.16

Heat in H2O evaporation

1.69

0.23

Radiation Loss

61.9

8.48

Material Balance
Material

HEAT BALANCE
In (Kg)

Out (Kg)

Clinker

1.000000

Coal Ash

0.001700

Raw mix to Clinker

1.528000

0.529700

Water from Raw mix

0.002550

0.002550

Water from Coal

0.000029

0.000029

Total

1.532279

1.532279

Co2 from Raw mix

HEAT BALANCE
Excess air
Excess air in Preheater Exhaust
=

79 * 2.8
O2
--------------------------------0.21 * (100 26.3
CO2 ) 2.8
O2

= 14.85 %

False air
If the Excess air is more than 18 % , that air is
consider as False air
=(Excess air % - 18 %) * PH exit Volume

HEAT BALANCE
Excess air

For Efcient burning some excess

air will be allowed

0.7 % to 3.5 %

3
2
1
0

10

3.5 %

False Air
Zone

%
Oxygen

Excess Air
Zone

Normal O2 level
Insufcient Air
Zone

15

% Excess

2
Air0

25

Optimum O2 level
1.0 % to 1.5 %
% Excess air

0.7 %
30

5.0 to

7.5 %

HEAT BALANCE
False air

Air leakage through an aperture of area A

(M2) with pressure differential DP (mmwg)
can be approximately calculated from
Volume M3/hr = 8900 * A *

DP

Hole size 150 mm dia = 0.01767 M2

System pressure at hole = 120 mm WC
DP = 120

= 10.95mm Wc

False air Volume = 8900 * 0.01767 * 10.95

= 1722 M3 / Hr