This document presents a training program on heat and mass balance. It defines heat balance as calculating heat inputs and outputs of a system. The purpose is to establish heat consumption, identify heat loss areas, and improve heat economy. It discusses types of heat, specific heat, heat of formation, flow measurement, and calculating heat inputs and outputs of kilns and coolers. Heat balance ensures heat inputs equal outputs and is used to analyze efficiency and opportunities for improvement.

1. A
Presentation
Of
Training Program
On
HEAT AND MASS BALANCE
Held at
RTC NIMBAHERA
By:- ANIL KUMAR
SUDHIR KR. LIMBA
JKC Production

2. WHAT IS HEAT BALANCE?
“The heat balance calculation is basically
a calculation where heat inputs and
outputs are measured, calculated and
compared.”

3. THE PURPOSE OF HEAT BALANCE
1. ESTABLISH THE SPECIFIC HEAT CONSUMPTION
OF THE STABLY OPERATING KILN.
2. COLLECT INFORMATION ABOUT WHERE THE
HEAT LOSSES OCCUR IN THE SYSTEM.
3. IDENTIFY WHERE ATTENTION IS NEEDED TO
IMPROVE HEAT ECONOMY OF THE KILN.
4.TODAY WHEN FUEL COST ARE SO HIGH, IT’S A
TOOL TO REVIEW WHERE OUR SYSTEM IS
INEFFICIENT.

4. HEAT BALANCE
ΣHeatin = ΣHeatout
a = b+c+d
Theoretical
Requirement(b)
Avoidable Losses (d)
Energy Input (a)
Unavoidable Losses (c)

5. TWO TYPES OF HEAT
Q = m cp (T-Tr)
Q = sensible heat in kcal/kg clinker
m = Specific mass of material, kg/kg clinker
cp = specific heat of material at temp. T, kcal/kg0c
T = temp. Of material, 0c
Tr = reference temp. 00c
LATENT HEAT
Linked to modification by chemical
reaction, change in state and change
in structure
SENSIBLE HEAT
Absorbed or released by a
substance

6. SPECIFIC HEAT
The specific heat is the amount of heat per unit mass required
to raise the temperature by one degree Celsius.
Cp (Kcal/kg centi) = A + BxTx10-6 + CxT2x10-9
A B C
Co2 0.196 118 -43
H2o 0.443 39 28
N2 0.244 30 0
O2 0.218 23 0
Air 0.237 101 0
Raw meal 0.206 54 -37
Clinker 0.186 23 0
Hot gas 0.237 390 0
Coal 0.262 39 0

7. HEAT OF FORMATION OR HEAT OF REACTION
1. The heat of reaction is the difference between the heat absorbed in
decarbonation of limestone and heat released in forming the clinker
minerals.
CaCO3 CaO + CO2
Q = 2.2 A + 6.48 M + 7.646 C – 5.1165 S – 0.59 F
Q = heat of formation in kcal/kg clinker
A = % Al2O3, M = % MgO, C = % CaO , S = % SiO2 ,
F = % Fe2O3 + % P2O5
2. The Raw Meal chemistry affects the reaction heat, the heat absorbed
by the process gets bigger as the LSF of minerals rises.
3. Standard value of Heat of Reaction = 390-420 Kcal/kg cl

8. FLOW MEASUREMENT
1. Gas Density:- Constituents of Preheater Gas-
ρn = Σ Mol wt of Gas x Gas% = Kg/Nm3
Gas Vol at NTP
ρ (Kg/m3)= ρn [273 / (273+T)]*[(Patm + Ps)/10336]
Where ρn = Kg/Nm3 , Patm=Site pressure
Ps= Static Pressure, T=Temp in 0C
CO2 O2 N2 CO
Molecular
Wt
44 32 28 28
Gas% 26 3.5 70.5 0
Density
(Kg/Nm3)
0.5 0.1 0.9 0.0

9. 2. Velocity (m/sec):-
V= K√ (2*g*Pd)/ρ
Where K= Pitot tube constant, g = Acc. of gravity
Pd = Dynamic Pressure, ρ=Corrected density
3.Flow:-
Flow (m3/sec)= Velocity (m/s)*Area of Duct (m2)
4.Mass Flow:-
Mass Flow (Kg/Sec) = Flow (m3/sec)*ρ (Kg/m3)
5.Specific Mass(M):-
M (Kg/Kg Cl) = (Kg/sec)*3600 / (Cl TPH)*1000

10. HEAT BALANCE OF KILN SYSTEM
Radiation loss,Q8
Fuel, Q1 Clinker, Q4
Feed, Q2 Dust, Q5
Air, Q3 Waste Gas, Q6
Exhaust Air, Q9
Total Heat Input = Total Heat Output
Q1 + Q2 + Q3 = Q4 + Q5 + Q6 + Q7 + Q8 + Q9
Kiln Clinkerization Q7

11. HEAT INPUT IN KILN CALCULATION
1. HEAT OF COAL COMBUSTION = Cv * X
Where X= Coal Consumption, Kg/ Kg clinker
Cv = Calorific Value of coal , Kcal/Kg Coal
2. Heat in kiln feed:
Q= Mf * Cpf * (Tf – Tr)
Where Mf= Amount of kiln feed, Kg / Kg clinker
Cpf = Specific heat of kiln feed
Tf = Temp of kiln feed in 0C
Tr = Reference temp
3. Heat in cooling air:
Q= Mco * Cp * (Tco – Tr)
Where Mco= Mass of cooling air, Kg/ Kg of clinker
Cp= Specific heat of cooling air , Kcal/ Kg 0C
Tco = Temp of cooling air

12. HEAT INPUT IN KILN CALCULATION
4.Heat in primary air:
Q= Mp * Cp * ( Tp – Tr)
Where Mp = Mass of Primary Air, Kg / Kg Clinker
Cp = Specific Heat of Primary Air , Kcal/Kg 0C
Tp = Temp of Primary Air
Tr = Reference Temp
5.Sensible Heat of Fuel:
Q= Mf * Cpf * ( Tf – Tr)
Where Mf = Mass of fuel, Kg/ Kg of clinker
Cpf = Specific Heat of Fuel Kcal / Kg 0C
Tf = Temp of fuel
Tr = Reference Temp

13. HEAT OUTPUT CALCULATION FROM KILN
1.Heat out from Preheater exit/return dust :
Q = Md * Cpd * ( Td – Tr )
Where Md = Mass of Return Dust Kg / Kg of clinker
Cpd =Specific heat of return dust Kcal/ kg 0C
Td = Temp of return dust
2. Heat out from Preheater Exit Gases :
Q= Me * Cpe * ( Te – Tr)
Where Me = Mass of Exit gases, Kg/ Kg of clinker
Cpe =Specific heat of kiln exit gases, kcal/kg 0C
Te = Temp of exit gases

14. HEAT OUTPUT CALCULATION FROM KILN
3. Heat out from cooler exhaust air:
Q = Mce * Cpce * ( Tce – Tr)
Where Mce = Mass of cooler exit air , kg / kg clinker
Cpce = Specific heat of cooler exit air Kcal / kg 0C
Tce = Temp of cooler exit air
4. Heat out from clinker of cooler discharge:
Q = Mc * Cpc * ( Tc – Tr)
Where Mc = Mass of clinker, Kg / Kg of clinker
Cpc = Specific heat of clinker Kcal/ kg 0C
Tc = Temp of discharge clinker

15. SURFACE LOSSES
1. Radiation Losses
2. Convection Losses
Radiation Losses:
Qrad= 4.87x10-8xδ (T4-T0
4)
T = Shell Temp 0K
T0= Reference temp 00K
δ= Emissivity of steel (0.85)

16. Convection Losses
1. Free Convection:-
QFC = 80.33 x [(T+T0)/2]-0.724x (T-T0)1.333
T= Shell temp 0K
T0= Reference temp 00K
Free convection used at < 3 m/sec of wind velocity.
2. Forced Convection:-
QFD = 28.03x [(T+T0)/2]-0.351xV0.805xD-0.195x (T-T0)
T= Shell temp 0K,
T= Reference temp 00K
V=Wind velocity >3m/sec
D= dia of measured object

17. Heat In
Mass
Kg/Kg Cl
Cp
Kcal/Kg0C
Temp
0C
Sp.Energy
Kcal/Kg Cl
Sensible heat of Kiln feed 1.6 0.211 50 16.88
Sensible heat of Coal 0.1224 0.283 50 1.73
Sensible heat of Cooling air 2.35 0.283 35 19.60
Sensible heat of Primary air 0.033 0.283 35 0.28
Sensible heat of Transport air 0.075 0.283 50 0.89
Sensible heat of False air 0.224 0.237 35 1.86
Energy from fuel 703
Total Heat In 4.41 744
EXAMPLE OF HEAT BALANCE
Kiln feed=150 TPH , Clinker=99.67 TPH , Coal=8.48 TPH

18. Heat Out
Heat loss through clinker 1 0.192 120 23.0
Heat loss through PH exit gases 1.95 0.24 231 108.3
Heat loss through vent air 1.380 0.243 313 105.3
Heat loss through dust 0.08 0.228 231 4.2
Heat of reaction 416.0
Radiation loss through cooler 6.0
Radiation loss through kiln 30.0
Radiation loss through Preheater 35.0
TAD(Assumed) 5.0
Heat of moisture evaporation 6.0
Total heat out 4.41 738.5
Sp heat consumption 697
Heat Error % 0.8%

19. Heat In
Mass
Kg/Kg Cl
Cp
Kcal/Kg0C
Temp
0C
Sp.Energy
Kcal/Kg Cl
Sensible heat of Kiln feed 1.505 0.210 70 22.10
Sensible heat of Pt Coke 0.111 0.264 70 2.05
Sensible heat of Cooling air 2.15 0.264 22 11.32
Sensible heat of Primary air 0.035 0.239 22 0.18
Sensible heat of fresh air (By pass) 0.033 0.239 22 0.17
Energy from fuel 853.86
Total Heat In 889.68
KILN HEAT BALANCE OF JKC
Kiln feed=55 TPH , Clinker=36.55 TPH , Pet coke=4.04 TPH

20. Heat Out
Heat loss through clinker 1 0.186 100 18.88
Heat loss through PH exit gases 2.74 0.246 330 222.27
Heat loss through vent air 1.368 0.239 260 85.09
Heat loss through By Pass 0.109 0.246 305 8.18
Heat of reaction 400.41
Radiation loss through cooler 5.0
Radiation loss through kiln 38.37
Radiation loss through PH 35.00
TAD(Assumed) 4.0
Heat of moisture evaporation 0.076 0.444 30 50.81
Total heat out 869.00
Sp heat consumption 847.0
Heat Error % 2.3%

21. HEAT BALANCE OF COOLER SYSTEM
Cooling air
Clinker In
Surface Losses
Sec. Air
Vent Air
Clinker Out
T Air

22. RECUPERATION EFFICIENCY OF COOLER
Recuperation Efficiency: -
=( Heat Recycle to kiln/ Heat input by cooler)*100%
= [ (Hsa + Hta)/ Hin ) ]* 100%

23. THANK YOU