Heat & Mass Balance PPT in cement industry version 2.0.pdf
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Updated the Heat & Mass balance module regarding cement Industry Useful For:- 1) Energy Auditors 2) Process Engineers 3) Chemical Engineers
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Heat & Mass Balance PPT in cement industry version 2.0.pdf
- 1. HEAT & MASS BALANCE ANALYSIS IN CEMENT INDUSTRY BY :-NITIN ASNANI CEA-28964(BEE-Certified Energy Auditor) EX-Jaypee/UTCL/CII -12 yrs exp
- 2. Energy & Mass Balance Concept • Define System Boundary • Define Basis-Ex-kg per kg clinker, kg per kg gases mol • After identifying system boundary, evaluate the following parameters are as below:- ➢Identify Input streams ➢Identify Output streams ➢Identify the accumulation & formation inside the process .
- 4. OVERALL MASS BALANCE CONCEPT
- 8. METHDOLOGY
- 12. Cooler Fan Efficiency Calculation
- 18. KILN FEED, Water Spray, Moisture from fuel
- 19. Total Inputs in SYSTEM Boundary-PYRO
- 20. OUTPUT STREAMS ACROSS SYSTEM Boundary
- 24. COOLER Balance with INPUT Cooling Air
- 25. How to find cooler null point?
- 26. How to find cooler null point?
- 27. Preheater GAS Flow sheet
- 28. TOTAL OUTPUT ACROSS SYSTEM BOUNDARY
- 30. OVERALL CONCLUSION-Mass Balance Study
- 31. IMPORTANT KEY POINTS Specific preheater Norms:- 1.30 -1.50(NM3/kg Clinker) Cooler Norms Input Cooling Air - 1.75 -1.80 Nm3/kg Clinker Cooler Vent Air-1- 1.05 N m3/kg clinker Preheater Fan efficiency>80% False air Across Preheater<8% False Air across Cooler ESP without WHRS <7% False Air Across Cooler ESP With WHRS <10% Specific power of cooler fans-3 -4.0 kWh/ton clinker Specific power of preheater fan without WHRS-3-5 kWh/per ton clinker Specific power of Preheater Fan With WHRS-4-7 kWh/ton Clinker Cooler vent fan without WHRS-0.3 - 0.5 kWh/per ton Clinker Cooler Vent Fan with WHRS-0.7 -1.0 kWh/ton clinker
- 32. Radiation losses Input sensible heats System Boundary Kiln feed Fuel Input cooling air Primary air & coal conveying air Preheater gas losses Cooler vent gas losses Return dust heat losses Heat losses through Clinker Heat from fuel
- 33. INPUT SENSIBLE HEAT 1) Sensible heat from cooling air = Input air(kg/clinker) x specific heat x (temperature difference) = 2.36 x 0.237 x(32-0) = 17.87 kcal/kg clinker………………………………….1 Temperature difference= Ambient Temp-Reference Temperature 2) Sensible heat from kiln feed = kiln feed x specific heat x( kiln feed temp-0) = 1.6 x 0.213 x(75-0) = 25.60 kcal/kg clinker………………………..…...2 3) Sensible heat from Primary Air = Primary air(kg air/kg clinker) x Specific heat x (Primary air temp-reference temp) = 0.049 x 0.237 x(32-0) = 0.37 kcal/kg clinker……………………………………3………………..3
- 35. Kiln Feed & Fuel moisture
- 36. Total Input Heat
- 37. OUTPUT HEAT
- 38. OUTPUT HEAT
- 39. Energy Losses due to convection & Radiation
- 40. Energy Losses due to convection & Radiation
- 41. Kiln and TAD radiation Losses Sheet
- 42. Preheater Radiation losses Sheet
- 43. Cooler Radiation Losses Sheet
- 44. INPUT HEAT
- 45. OUTPUT HEAT
- 46. Overall Heat Balance Conclusion
- 47. IMPORTANT KEY POINTS Best Values -6 Stage Preheater- 675 Kcal/kg Clinker 5 Stage-690 kcal/kg clinker Cooler losses-110- 120 kcal/kg clinker Cooler Efficiency with WHRS-65%& Without-70% Preheater outlet Temperature-240- 250 Degree C Radiation Losses- 5-8% Top cyclone efficiency-97.5% Max AFR Utilization-30% by weight Pressure drop across 6 stage preheater-350-450 mmwg By increasing input sensible heat, the energy losses will be reduced AQC Boiler 60-70% Power in WHRS Specific power of Preheater Fan With WHRS-4-7 kWh/ton Clinker Retention time in New calciner-5sec -10 sec Coal phase density-3-4 kg coal/kg air
- 48. Numerical Questions By minimizing the leakages and certain modifications across the preheater system the plant gets the benefit in terms of overall specific heat consumption by 20 kcal/kg clinker NCV of Coal- 6300 kcal/kg coal Clinker production :-5500 TPD; Grinding Cost of Fine Coal- Rs 15000 per tonne Present Specific heat consumption:-750 kcal/kg clinker Calculate the following:- a) Present coal consumption per day b) Coal consumption with improved thermal efficiency & also calculate saving in Rs per day?
- 49. Future modules………… Subscribe my Channel for more videos……………………….. KNOWLEDGE IS POWER OF TODAY, SMALL EFFORTS BRING CHANGES IN THE SOCIETY.. KEEP Subscribing…..!! KEEP Watching……..!! Link for subscribing the channel- http://www.youtube.com/@nitinasn ani08 •FAN AUDIT •APPLICATION OF FAN CURVE •CASE STUDIES… •BAG FILTER DESIGN…. •CALCINER DESIGN •ENERGY AUDIT METHDOLOGY IN CEMENT PLANT… •WHRS OPTIMIZATION & AUDIT & many more…..