Math cement module_1

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calculations required for cement preparation machinery

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Math cement module_1

  1. 1. MathCement Module 1 Volume-1 : Cement plant No ofMathCement _2000 process calculations files Process calculation of plant Part -1 sections Book 200 MC_V1_B201_Quarry_TOC Quarry Section 6 MC_V1_B201_Quarry_1BIU Quarry Deposit Estimation MC_V1_B201_Quarry_1 Quarry Deposit Estimation MC_V1_B201_Quarry_2BIU Quarry - Excavator MC_V1_B201_Quarry_2 Quarry - Excavator MC_V1_B201_Quarry_3BIU_r3 Quarry - Dumper Calculations MC_V1_B201_Quarry_3_r3 Quarry - Dumper Calculations MC_V1_B202_Crushing_TOC Crushing Section 12 MC_V1_B202_Crushing_1BIU_ r5 Crusher and Auxiliaries Calculations MC_V1_B202_Crushing_1_r5 Crusher and Auxiliaries Calculations Single Rotor Hammer or Impact MC_V1_B202_Crushing_2BIU Crusher Calculations Single Rotor Hammer or Impact MC_V1_B202_Crushing_2 Crusher Calculations Calculation of power for existing crusher at different capacities - MC_V1_B202_Crushing_3BIU application of Rittingers law Calculation of power for existing crusher at different capacities - MC_V1_B202_Crushing_3 application of Rittingers law Calculation of power for existing crusher but to be used for different / changed material - application of MC_V1_B202_Crushing_4BIU Rittingers law Calculation of power for existing crusher but to be used for different / changed material - application of MC_V1_B202_Crushing_4 Rittingers law Calculation of throughput for Roll MC_V1_B202_Crushing_5BIU Crusher Calculation of throughput for Roll MC_V1_B202_Crushing_5 Crusher Double Rotor Hammer or Impact MC_V1_B202_Crushing_6BIU Crusher Calculations Double Rotor Hammer or Impact MC_V1_B202_Crushing_6 Crusher Calculations MC_V1_B203_Pre- blending_TOC Pre-blending Section 8 MC_V1_B203_Preblending_1BI Preblending and Stockpile Equipment - U Calculations
  2. 2. Preblending and Stockpile Equipment -MC_V1_B203_Preblending_1 CalculationsMC_V1_B203_Preblending_2BI Stockpile capacities-Longitudinal withU trapizoidal cross section Stockpile capacities-Longitudinal withMC_V1_B203_Preblending_2 trapizoidal cross sectionMC_V1_B203_Preblending_3BI Stockpile capacities-Longitudinal withU triangular cross section Stockpile capacities-Longitudinal withMC_V1_B203_Preblending_3 triangular cross sectionMC_V1_B203_Preblending_4BI Stockpile capacities-Kidney shapedU windrows -triangular sectionMC_V1_B203_Preblending_4BI Stockpile capacities-Kidney shapedU windrows -triangular sectionMC_V1_B204_Rawmill_TOC Raw Mill Section 49 Bond Work Index of the various material based on bond test mill resultMC_V1_B204_RawMill_1_r4 dry basis Calculation of Power at Ball Mill Shaft for Raw Material,based on Bonds WorkMC_V1_B204_RawMill_2BIU Index Calculation of power at Ball Mill shaft for Raw material, based on Bonds workMC_V1_B204_RawMill_2 index Raw Mill and Auxiliary EquipmentMC_V1_B204_RawMill_3BIU Capacity Calculations Raw Mill and Auxiliary EquipmentMC_V1_B204_RawMill_3 Capacity Calculations Raw Material Drying - Estimation ofMC_V1_B204_RawMill_4BIU_r total moisture to be evaporated from3 feed Raw Material Drying - Estimation of total moisture to be evaporated fromMC_V1_B204_RawMill_4_r3 feed Raw Mill Heat Balance - Evaluation ofMC_V1_B204_RawMill_5BIU Hot Gas Requirement for Drying Raw Mill Heat Balance - Evaluation of HotMC_V1_B204_RawMill_5 Gas Requirement for Drying Calculation of Ball Mill PercentageMC_V1_B204_RawMill_6BIU Filling as per Measurement Calculation of Ball Mill PercentageMC_V1_B204_RawMill_6 Filling as per MeasurementMC_V1_B204_RawMill_7BIU Calculation of Grinding Ball SizeMC_V1_B204_RawMill_7 Calculation of Grinding Ball Size Specific Heat of Raw Material as aMC_V1_B204_RawMill_8BIU Function of Temperature Specific Heat of Raw Material as aMC_V1_B204_RawMill_8 Function of Temperature Estimation of specific power consumption, at mill shaft, based on the operating parameters of close circuitMC_V1_B204_RawMill_9BIU ball mill
  3. 3. Estimation of specific power consumption, at mill shaft, based on the operating parameters of close circuitMC_V1_B204_RawMill_9 ball mill Calculation of mill power demand forMC_V1_B204_RawMill_10BIU_ desired output at specified feed andr3 product sizes, based on Bond Index. Calculation of mill power demand for desired output at specified feed andMC_V1_B204_RawMill_10_r4 product sizes, based on Bond Index.MC_V1_B204_RawMill_10_1BI Calculation of mill output for differentU feed and product sizes Calculation of mill output for differentMC_V1_B204_RawMill_10_1 feed and product sizes Calculation of Efficiency of Dynamic AirMC_V1_B204_RawMill_11BIU Separator Calculation of Efficiency of Dynamic AirMC_V1_B204_RawMill_11 Separator Average Piece Weight of GrindingMC_V1_B204_RawMill_12BIU Media Average Piece Weight of GrindingMC_V1_B204_RawMill_12 Media Ball Mill Critical Speed and Ball ChargeMC_V1_B204_RawMill_13BIU Calculations Ball Mill Critical Speed and Ball ChargeMC_V1_B204_RawMill_13 CalculationsMC_V1_B204_RawMill_14BIU_ Vertical Roller Mill -- Calculation ofr4 Power Vertical Roller Mill -- Calculation ofMC_V1_B204_RawMill_14_r4 PowerMC_V1_B204_RawMill_15BIU_ Radiation Loss in Raw Mill Heatr3 Balance Radiation Loss in Raw Mill HeatMC_V1_B204_RawMill_15_r3 Balance Calculation of false air coming intoMC_V1_B204_RawMill_16BIU grinding mill system Calculation of false air coming intoMC_V1_B204_RawMill_16 grinding mill system Calculation of water pressure at nozzle over material bed of Vertical Roller MillMC_V1_B204_RawMill_17BIU with supply from overhead tank Calculation of water pressure at nozzle over material bed of Vertical Roller MillMC_V1_B204_RawMill_17 with supply from overhead tank Calculation of retention time of materialMC_V1_B204_RawMill_18BIU in a two compartment ball mill Calculation of retention time of materialMC_V1_B204_RawMill_18 in a two compartment ball mill Rosin-Rammler equation -calculation ofMC_V1_B204_RawMill_19BIU_ predicted residue on sieve and variatonr1 calculations
  4. 4. Rosin-Rammler equation -calculation of predicted residue on sieve and variatonMC_V1_B204_RawMill_19_r1 calculations Calculation of mean diameter of fineMC_V1_B204_RawMill_20BIU ground particles Calculation of mean diameter of fineMC_V1_B204_RawMill_20 ground particlesMC_V1_B204_RawMill_21BIU_ Calculation of auxiliary drive rating ofr1 Ball Mill for raw grinding Calculation of auxiliary drive rating ofMC_V1_B204_RawMill_21_r1 Ball Mill for raw grindingMC_V1_B204_RawMill_22BIU_ Calculation of makeup charge or ballr2 mills Calculation of makeup charge or ballMC_V1_B204_RawMill_22_r2 millsMC_V1_B204_RawMill_23BIU_ Calculation of wear rate of grindingr1 balls in ball mills Calculation of wear rate of grindingMC_V1_B204_RawMill_23_r1 balls in ball mills Calculation of Recirculation Air in RawMC_V1_B204_RawMill_24BIU Grinding Vertical Roller Mill Calculation of Recirculation Air in RawMC_V1_B204_RawMill_24 Grinding Vertical Roller MillMC_V1_B205_Blending_TOC Blending and Storage Section 8 Calculation of Blending & Storage Silos and Auxiliary Equipment Capacity forMC_V1_B205_Blending_1BIU Raw-meal preparation Calculation of Blending & Storage Silos and Auxiliary Equipment Capacity forMC_V1_B205_Blending_1 Raw-meal preparationMC_V1_B205_Blending_2BIU_r Calculation of Kiln Feed Raw-meal3 Systems Calculation of Kiln Feed Raw-mealMC_V1_B205_Blending_2_r3 Systems Calculation of Kiln Feed Raw-mealMC_V1_B205_Blending_3BIU Quantity Calculation of Kiln Feed Raw-mealMC_V1_B205_Blending_3 QuantityMC_V1_B205_Blending_4BIU_r Calculation of blending factor by2 methods of standard deviation Calculation of blending factor byMC_V1_B205_Blending_4_r2 methods of standard deviationMC_V1_B206_Kilnfeed_TOC Kiln-feed Section 2MC_V1_B206_Kilnfeed_1BIU_r Locating feeding point of material into3 Preheater Gas ducts Locating feeding point of material intoMC_V1_B206_Kilnfeed_1_r3 Preheater Gas ducts Clinkerisation (kiln,pre-MC_V1_B207_Clinker_TOC heater)Section 49
  5. 5. Calculation of Kiln and AuxiliaryMC_V1_B207_Clinker_1BIU_r3 Equipment Capacities. Calculation of Kiln and AuxiliaryMC_V1_B207_Clinker_1_r3 Equipment Capacities.MC_V1_B207_Clinker_2BIU_r3 Leakages through Kiln Air SealsMC_V1_B207_Clinker_2_r3 Leakages through Kiln Air Seals Calculation of Specific Heats of ClinkerMC_V1_B207_Clinker_3BIU as a Function of Clinker Temperature Calculation of Specific Heats of ClinkerMC_V1_B207_Clinker_3 as a Function of Clinker Temperature Kiln Retention Time and RelatedMC_V1_B207_Clinker_4BIU Parameters Kiln Retention Time and RelatedMC_V1_B207_Clinker_4 ParametersMC_V1_B207_Clinker_5BIU_r3 Kiln sinter zone cooling fansMC_V1_B207_Clinker_5_r3 Kiln sinter zone cooling fans Calculation of nose ring cooling air forMC_V1_B207_Clinker_6BIU_r3 kiln inlet Calculation of nose ring cooling air forMC_V1_B207_Clinker_6_r3 kiln inletMC_V1_B207_Clinker_7BIU Kiln Tyre / Shell OvalityMC_V1_B207_Clinker_7 Kiln Tyre / Shell OvalityMC_V1_B207_Clinker_8BIU_r4 Kiln Capacity checkMC_V1_B207_Clinker_8_r4 Kiln Capacity check Degree of Decarbonation of Raw MealMC_V1_B207_Clinker_9BIU -Definition and calculation Degree of Decarbonation of Raw MealMC_V1_B207_Clinker_9 -Definition and calculation Degree of Decarbonation of Raw MealMC_V1_B207_Clinker_10BIU Calculation on Operating Data Degree of Decarbonation of Raw MealMC_V1_B207_Clinker_10 Calculation on Operating Data Reaction Enthalpy -Decarbonation andMC_V1_B207_Clinker_11BIU Clinkerisation Reaction Enthalpy -Decarbonation andMC_V1_B207_Clinker_11 Clinkerisation Theoretical Heat of Clinker Formation -MC_V1_B207_Clinker_12BIU Calculation Theoretical Heat of Clinker Formation -MC_V1_B207_Clinker_12 Calculation Calculation of kiln mass underMC_V1_B207_Clinker_13BIU operating conditions Calculation of kiln mass underMC_V1_B207_Clinker_13 operating conditions Calculation of Kiln Torque underMC_V1_B207_Clinker_14BIU Operating Conditions Calculation of Kiln Torque underMC_V1_B207_Clinker_14 Operating ConditionsMC_V1_B207_Clinker_15BIU_r3 Calculation for Kiln Hydraulic ThrusterMC_V1_B207_Clinker_15_r3 Calculation for Kiln Hydraulic Thruster
  6. 6. MC_V1_B207_Clinker_16TXT Kiln Hydraulic Thruster - A NoteMC_V1_B207_Clinker_17BIU Kiln Drive SpecificationMC_V1_B207_Clinker_17 Kiln Drive Specification Calculation of expansion of Kiln in hotMC_V1_B207_Clinker_18BIU condition Calculation of expansion of Kiln in hotMC_V1_B207_Clinker_18 condition Calculation of Temerature Profile of KilnMC_V1_B207_Clinker_19BIU Shell in hot condition Calculation of Temerature Profile of KilnMC_V1_B207_Clinker_19 Shell in hot conditionMC_V1_B207_Clinker_20BIU Calcination FunctionMC_V1_B207_Clinker_20 Calcination Function Calculation of false air infiltration intoMC_V1_B207_Clinker_21BIU kiln preheater system Calculation of false air infiltration intoMC_V1_B207_Clinker_21 kiln preheater systemMC_V1_B207_Clinker_22BIU Calculation of Alkali Bypass SystemMC_V1_B207_Clinker_22 Calculation of Alkali Bypass System Calculation of Range of Bypass Quantity of Gases from Kiln to LimitMC_V1_B207_Clinker_23BIU Alkali concentration in Clinker Calculation of Range of Bypass Quantity of Gases from Kiln to LimitMC_V1_B207_Clinker_23 Alkali concentration in Clinker Correlation Between Central Chord Angle or Charge Angle and Degree ofMC_V1_B207_Clinker_24BIU Filling of Kiln Correlation Between Central Chord Angle or Charge Angle and Degree ofMC_V1_B207_Clinker_24 Filling of Kiln Calculation of fresh cooling air and water to reduce the temperature of kiln (alkali) bypass gases before release toMC_V1_B207_Clinker_25BIU atmosphere Calculation of fresh cooling air and water to reduce the temperature of kiln (alkali) bypass gases before release toMC_V1_B207_Clinker_25 atmosphereMC_V1_B208_ClCooling_TOC Clinker Cooling Section 8 Calculation of Grate Cooler DriveMC_V1_B208_ClCooling_2BIU Power Calculation of Grate Cooler DriveMC_V1_B208_ClCooling_2 Power Calculation of Grate Cooler Recuperation Efficiency -T.A. DuctMC_V1_B208_ClCooling_3BIU Tapping from Cooler Calculation of Grate Cooler Recuperation Efficiency -T.A. DuctMC_V1_B208_ClCooling_3 Tapping from Cooler
  7. 7. Calculation of Grate Cooler Recuperation Efficiency -T.A. DuctMC_V1_B208_ClCooling_4BIU Tapping from Kiln Hood Calculation of Grate Cooler Recuperation Efficiency -T.A. DuctMC_V1_B208_ClCooling_4 Tapping from Kiln Hood Calculation of Grate Cooler Offset fromMC_V1_B208_ClCooling_5BIU Kiln axis Calculation of Grate Cooler Offset fromMC_V1_B208_ClCooling_5 Kiln axisMC_V1_B209_Clstore_TOC Clinker Storage Section 2 Calculation of Clinker Transport Equipment Capacity and ClinkerMC_V1_B209_Clstore_1BIU Stockpile Calculation of Clinker Transport Equipment Capacity and ClinkerMC_V1_B209_Clstore_1 StockpileMC_V1_B210_Cement_TOC Cement Grinding Section 26 Calculation of Cement Mill and AuxiliaryMC_V1_B210_Cement_1BIU Equipment Calculation of Cement Mill and AuxiliaryMC_V1_B210_Cement_1 Equipment Calculation of Cement GrindabilityMC_V1_B210_Cement_2BIU based on Ziesel Value Calculation of Cement GrindabilityMC_V1_B210_Cement_2 based on Ziesel Value Cement Mill Heat Balance andMC_V1_B210_Cement_3BIU Calculation of Hot Gas for Drying Cement Mill Heat Balance andMC_V1_B210_Cement_3 Calculation of Hot Gas for Drying Calculation of Cement Mill Output as aMC_V1_B210_Cement_4BIU function of Grinding Media Load Calculation of Cement Mill Output as aMC_V1_B210_Cement_4 function of Grinding Media Load Estimation of grindability of ClinkerMC_V1_B210_Cement_5BIU based on the operating parameters Estimation of grindability of ClinkerMC_V1_B210_Cement_5 based on the operating parameters Calculation of Water Spray in the MillMC_V1_B210_Cement_6BIU for Cooling Calculation of Water Spray in the MillMC_V1_B210_Cement_6 for CoolingMC_V1_B210_Cement_7BIU Sizing of Close Circuit Cement MillMC_V1_B210_Cement_7 Sizing of Close Circuit Cement Mill Cement Mill Output at DifferentMC_V1_B210_Cement_8BIU Finenesses Cement Mill Output at DifferentMC_V1_B210_Cement_8 FinenessesMC_V1_B210_Cement_9BIU Cement Mill Cooling AirMC_V1_B210_Cement_9 Cement Mill Cooling AirMC_V1_B210_Cement_10BIU Mill Radiation Loss
  8. 8. MC_V1_B210_Cement_10 Mill Radiation Loss Cement Mill Grinding Performance as a MC_V1_B210_Cement_11BIU Function of Surface Generated Cement Mill Grinding Performance as a MC_V1_B210_Cement_11 Function of Surface Generated Expected Power Draw of Cement Mill MC_V1_B210_Cement_12BIU as a Function of Speed Expected Power Draw of Cement Mill MC_V1_B210_Cement_12 as a Function of Speed MC_V1_B210_Cement_13BIU_ Clinker grinding mill - calculation of r2 capacity and power Clinker grinding mill - calculation of MC_V1_B210_Cement_13_r2 capacity and power Cement Storage and Dispatch MC_V1_B211_Cmtstore_TOC Section 4 Calculation of Cement Transport and MC_V1_B211_Cmtstore_1BIU Silo and Auxiliary Equipment Calculation of Cement Transport and MC_V1_B211_Cmtstore_1 Silo and Auxiliary Equipment Evaluation of effect of weighing MC_V1_B211_Cmtstore_2BIU accuracy of packing m/c Evaluation of effect of weighing MC_V1_B211_Cmtstore_2 accuracy of packing m/cEnd of Module - 1

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