Process Design Notes

Kiln Comparison Data

3-Stage SP* SF Short*

Wet Long Dry 1-Stage SP 2-Stage SP Conversion 4-Stage SP SF Conversion L/D Kiln
Capacity (Mgd-1m-3) 0.45-0.70 0.45-0.75 0.75-0.85 0.9-1.0 1.0-1.3 1.5-2.0 3.0-4.0 3.0-3.5 3.5-4.7
L/D (inside brick) 38-44 36-41 30-40 32-34 23-26 15-18 15-18 15-22 10-12
Kiln speed, oper (rpm) 1.2 1.35 1.4 1.4 1.5 1.6 2.8 2.8-3.8 2.1
Kiln speed, max (rpm) 1.4 1.6 1.7 1.7 1.75 1.9 3.3 3.3-4.5 2.5
Slope (%) 3.65 3.65 3.0-4.0 3.0-4.0 3.0-4.0 4.0 4.0 3.0-4.0 3.5
Fill (%) 10-13 10-13 10-13 10-13 10-13 10-13 10-13 10-13 10-14

Ovality (%) 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20

Retention time (min) 150-200 120-160 110-140 95-120 70-85 40-45 20-25 20-30 20-25
Hertz pressure 62,000 62,000 62,000 62,000 62,000 62,000 59,000 59,000 59,000
-1
SHC (kcalkg KK ) 1300-2000 1150-1450 1050-1150 1000-1100 900-1000 750-860 750-860 750-860 720-780
KEG temperature (C) 250-300 550-600 650-700 750-800 900-950 1000-1100 1000-1100 1000-1100 1050-1200
Feed moisture (%) 28-35 0.5 0 0 0 0 0 0 0
-1
KEG velocity (ms ) 4-5 4-5 8-10 8-10 8-10 8-10 4-5 4-5 4-5
-1 -2
BZ load (Gcalh m ) 5-6 5-6 4.75-5.75 4.5-5.5 4.25-5.25 4-5 2.5-3.5 2.5-3.5 2-3
Stage 1 exit gas T (C) --- --- 400-425 375-400 375 350 375 375 325-350
Chain section Yes Yes Yes (short) Yes (short) No No No No No

3-Stage SP* SF Short*

Wet Long Dry 1-Stage SP 2-Stage SP Conversion 4-Stage SP SF Conversion L/D Kiln
Capacity (lbmd-1ft-3) 28-44 28-44 47-53 56-62 62-81 94-125 187-250 187-218 218-293
L/D (inside brick) 38-44 36-41 30-40 32-34 23-26 15-18 15-18 15-22 10-12
Kiln speed, oper (rpm) 1.2 1.35 1.4 1.4 1.5 1.6 2.8 2.8-3.8 2.1
Kiln speed, max (rpm) 1.4 1.6 1.7 1.7 1.75 1.9 3.3 3.3-4.5 2.5
Slope (%) 3.65 3.65 3.0-4.0 3.0-4.0 3.0-4.0 4.0 4.0 3.0-4.0 3.5
Fill (%) 10-13 10-13 10-13 10-13 10-13 10-13 10-13 10-13 10-14
Ovality (%) 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
Retention time (min) 150-200 120-160 110-140 95-120 70-85 40-45 20-25 20-30 20-25
Hertz pressure 62,000 62,000 62,000 62,000 62,000 62,000 59,000 59,000 59,000
-1
SHC (MMBtuton KK ) 4.7-7.2 4.1-5.2 3.8-4.1 3.6-4.0 3.2-3.6 3.6-4.0 3.6-4.0 3.6-4.0 3.8-4.3
KEG temperature (F) 500-600 1000-1100 1200-1300 1400-1500 1650-1750 1400-1600 1400-1600 1400-1600 1300-1450
Feed moisture (%) 28-35 0.5 0 0 0 0 0 0 0
-1
KEG velocity (ftmin ) 800-1000 800-1000 1600-2000 1600-2000 1600-2000 1600-2000 800-1000 800-1000 800-1000
BZ load (MMBtuh ft ) -1 -2
1.84-2.21 1.84-2.21 1.75-2.12 1.66-2.03 1.57-1.94 1.47-1.84 0.92-1.29 0.92-1.29 0.74-1.11
Stage 1 exit gas T (F) --- --- 750-800 700-750 700 650 700 700 600-650
Chain section Yes Yes Yes (short) Yes (short) No No No No No

1
 Process Design Notes

Raw Grinding

VRM nozzle ring velocity (AChin-Fatt):

80-90 m/s (w/o external recirc) [15,750-17,700 ft/min]
65 m/s (w/ some material recovery ( 15%)) [12,800 ft/min]
40-45 m/s (w/ external recirc ( 25%)) [7,900-8,850 ft/min]

VRM gas flow (Polysius):

1.64 kggas/kgmeal

VRM vibration:
Frame/reducer mounted sensor: 3 mm/s
Housing mounted sensor: 10 mm/s (e.g. Loesche)

VRM (w/ dynamic classifier) exit duct grain loading:

620 g/m3 [270 gr/ft3] (LSingh / Polysius)
500-700 g/m3 [225-300 gr/ft3] (AChin-Fatt / Loesche)
500-700 g/m3 [225-300 gr/ft3] (GLabelle / LVT)

VRM bed depth:

Typical: 3-4 (75-100 mm)
Maximum: 5 (125 mm)
Approximately 3.5% of table diameter (e.g. Loesche LM36 = 3.6 m 0.035 = 125 mm)
Approximately 6-8% of roll diameter (AChin-Fatt)

Power consumption:
VRM: 3-12 kWh/ton (=f(material grindability))
BM: 9-17 kWh/ton

Typical feed size:

VRM: 3-5
BM: 1 max to 80% -

Typical feed moisture:

VRM: > 24%
BM: 2-3% w/o drying capability
6-8% w/ drying capability

Typical product fineness:

80% -200M (75 )
0.1% +50M (300 )

Specific surface area of ball charge:

16-20 m2/Mg (AChin-Fatt)

Ball charge volume:

24-28%

Mill sweep (AChin-Fatt):

Not air-swept: 0.8-1.5 m/s
Semi air-swept: 2.0-3.5 m/s
Fully air-swept: 3.5-6.0 m/s

Operating rotational speed (% of critical): 70-72%

2
 Process Design Notes

Dew point:
Minimum 40F < dry bulb T

Pyroprocess

Clinker production increase = f(Q) or f(SP):

KK2 = KK1 (SP2 / SP1)
KK2 = KK1 (Q2 / Q1)

Specific exit gases flow (=f(SHC, fuel characteristics)):

780-830 kcal/kgKK (2.8-3.0 MMBtu/tonKK): 1.95-2.15 kg/kgKK [1.35-1.50 Nm3/kgKK]
830-890 kcal/kgKK (3.0-3.2 MMBtu/tonKK): 2.10-2.30 kg/kgKK [1.45-1.60 Nm3/kgKK]

Kiln exit static pressure: 1.5-2.5 inWG (suction)

LOI KF LOI sample

100 LOI KF 100 LOI sample
% Calcination = 100%
LOI KF
100 LOI KF

Excess air = O2(final) / (20.9 O2(final)) 100%

False air = (O2(final) O2(initial)) / (20.9 O2(final)) 100% Note: w/ respect to inlet gases

False air = (O2(final) O2(initial)) / (20.9 O2(initial)) 100% Note: w/ respect to outlet gases

ESP operation (combustion / explosion):

Set @ 25% of lower flammability limits
CH4: 25% of 5% (50,000 ppm) = 12,500 ppm
CO: 25% of X% (YYYY ppm) = ZZZZ ppm

Hood velocity:
5-8 m/s (FLS)
5-6 m/s (MMcCabe)
4 m/s (KHD)

Cyclone p:
1st stage: 5-6 inWG
2nd stage: 8-10 inWG
3rd stage:8-10 inWG
4th stage: 10-12 inWG

Bypass:
-
Heat penalty (4-stage SP): 5% BP 1% KF
-
16,000-22,000 Btu/tonKK per % BP

Volatiles:
-
KK S/Alk molar ratio 0.8-1.2 (can be higher as long as sulfur (SO3) comes out in KK)
-
Typical equilibrium time = 150 kiln retention time [LSingh]
-
Volatilization approx. 15-20 gr/ft3
-
Chlorides:
o < 0.015-0.040% of inputs (raw basis)

3
 Process Design Notes

o < 1.0% of kiln inlet (raw basis)

o < 0.07% in fuel
o kiln inlet approx. 50 s inputs
o precipitate / condense @ 900-1200F (475-650C)

Clinker cooler cooling air requirement:

Reciprocating grate cooler: 2.8-3.2 kgair/kgKK
S-F cross-bar cooler: 2.2 kgair/kgKK (as advertised; realistically 2.5)

Secondary (+ tertiary) air mass (=f(1 air, NCA, SHC, EA)):

Direct-fired system: 0.9-1.2 kgair/kgKK
Indirect-fired system: 1.2-1.5 kgair/kgKK
SA / TA proportioned according to fuel split & EA

Clinker cooler (grate) loading:

Older grate cooler: 30-40 Mg/d/m2
Modern grate cooler: 40-50 Mg/d/m2

Kiln nose cooling fan [HTseng / Polysius]:

725 acfm/ft-
SP = 7-8 inWG
v = 4,500-5,000 ft/min
Manifold v approx 50-60% of nozzle velocity to ensure uniform air distribution

Burner tip velocities:

Conveying air: 20-50 m/s (80 m/s if single channel burner)
Axial air: 80-170 m/s
Swirl air: 50-90 m/s
Gas: 200 m/s

Typical kiln feed densities (Peray p. 178):

Preheat zone 75 lb/ft3 (1,200 kg/m3)
10% calcined 73 lb/ft3 (1,170 kg/m3)
20% calcined 70 lb/ft3 (1,120 kg/m3)
40% calcined 65 lb/ft3 (1,040 kg/m3)
80% calcined 60 lb/ft3 (960 kg/m3)
Burning zone 92 lb/ft3 (1,475 kg/m3)

Estimated kiln feed angle of repose (Peray p. 178):

Preheat zone 45
10% calcined 27
20% calcined 24
40% calcined 21
80% calcined 18
Burning zone 50

Kiln chain unit weight (per Magotteaux):

3 : 5.9 lb/ft
7/8 3 : 8.6 lb/ft
1 3 : 12.52 lb/ft

Typical chain system design criteria (LSingh):

Chain Zone
% kiln length, including bare inlet section 20 30
Location of curtain from feed zone () 1.0 2.0

4
 Process Design Notes

Total chain wt
% of daily production (ton/d) 8.0 12.0
ton chains / ton KK 2.1 to 2.5
Specific surface area (ft2 / ft3 of chain zone) 2.6 to 3.7
Length of dust curtain chains (ft / ft kiln ) 0.66 to +0.77

Kiln chain weight installed (per Duda):

Wet process: 120 kgchain/MgKK/d
Dry process: 105-110 kgchain/MgKK/d

Fuel volatile matter:

-
Decreased VM results in decreased reaction, ergo increased CO (combat via finer grinding & higher
temperatures)
-
Typical values:
o Coal (bituminous): 25-40%
o Coal (anthracitic): 5-15%
o Coke (delayed): 8-18%
o Coke (fluid): 3.7-7.0%

Typical gross heating values and LHV:HHV ratios:

-
Coal: 12,000 Btu/lbm 0.970
-
Coke: 14,000 Btu/lbm 0.980
-
TDF: 13,700 Btu/lbm (whole tire w/ 13-15% steel) 0.960
-
Fuel oil: 138,000 Btu/gal 0.945
-
Natural gas: 1,050 Btu/scfm 0.905

Coal/coke fineness (FLSmidth):

Recommended Fineness of Coal/Coke for Kiln and Calciner

30

25

20
Normal T calciner
%R 90 m

15 High T calciner
Kiln burner
10

0
0 5 10 15 20 25 30 35 40 45 50
% Volatiles (ash and m oisture free)

Solid fuel fineness (PAlsop):

0.5% %VM 200M

Coal/coke residual moistures (FLSmidth):

Anthracite coal and pet coke: 0.5-1.0%
Bituminous coal: 1.5-2.5%
Lignite coals: 8-12%

5
 Process Design Notes

Coal mill air:fuel ratio (for drying):

Smaller vertical mills:
Larger vertical mills:
Ball mills:
2.0-2.5 lbair/lbfuel @ 55 HGI
1.0-1.7 lbair/lbfuel @ 100 HGI
1.5 lbair/lbfuel @ 55 HGI
1.0 lbair/lbfuel @ 100 HGI
0.8-1.0 lbair/lbfuel (lower for lighter materials) (HRoser / KVS)

Coal mill (VRM) exit duct grain loading:

350-380 g/m3 [150-165 gr/ft3] (AChin-Fatt)

Separator (HES) product grain loading:

300-500 g/m3 [125-225 gr/ft3] (GLabelle / LVT)
Maximum 600 g/m3 [260 gr/ft3] before see negative impact on separator performance

Mill sweep (fuel ball mill):

Semi air-swept: 1.0-2.0 m/s (typical 1.5)
Fully air-swept: 1.0-2.0 m/s (typical 1.5) [note: CEMEX Brooksville 0.5 m/s]
KVS: 2,500-3,000 fpm (13-15 m/s) thru discharge trunnion opening

HES rotor peripheral speed:

vT = r = r 2 / t
16-19 m/s (AChin-Fatt)
14 m/s (GLabelle)

Ball mill discharge duct exit velocity:

16 m/s minimum (KVS MGallimore)

Microscopy:
Heating rate = f(alite size); target = 15-35 m
Small = too fast
Large = too slow
Residence time = f(belite size); target = 25-40 m
Small = too short
Large = too long
Maximum temperature = f(alite birefringence); target > 3.6
Cooling (quenching) rate = f(belite color); target > 3.6

Calcination:
Reaction starts ~ 700C (1,292F)
Reaction fully underway ~ 800C (1,472F)

Combustibles in kiln feed:

Organic (volatile) C ~ 250-350C (482-662F)
Inorganic (fixed) C ~ 650-900C (1,202-1,652F)

Secondary firing:
1 s retention time in preheater 20% back end firing

VRM grinding pet coke (need to increase friction to increase capacity):

Increase dam ring height
Add water
Increase mill speed

6
 Process Design Notes

Finish Grinding

(BSA1 / BSA2)n = ton/h2 / ton/h1 = kWh/ton1 / kWh/ton2

n = 1.3 for HES
n = 1.6 for 1st gen sep

Separator efficiency (bypass):

1st generation: 40-60%
2nd generation: 20-40%
3rd generation: 8-20%

Separator (1st generation) clearances:

Gap between blade top and drum cover: -
Blade extension under drum cover: 1-2

Separator (HES) feed concentration (Qf/Qa):

O-Sepa: 2.5 kg/m3 [1100 gr/ft3] (higher because of distribution table)
SEPAX: 2.0 kg/m3 [875 gr/ft3] (lower because fully air-swept)

Separator circulating factor, C:

C = Rejects (ton/h) / Fines (ton/h) = [fines (x) feed (x)] / [feed (x) rejects (x)]
CL = Feed (ton/h) / Fines (ton/h) = [fines (x) rejects (x)] / [feed (x) rejects (x)]
C = CL 1
Typical C for 1st generation: 200-600% (low end of range for lower Blaine)
Typical C for 3rd generation: 100-200% (low end of range for lower Blaine)

Separator (HES) exit duct grain loading (to D/C):

Slag: 400-500 g/m3 [175-225 gr/ft3] (GLabelle / LVT)
Cement: 500-700 g/m3 [225-300 gr/ft3] (GLabelle / LVT)
Cement: 0.75 kg/m3 (AChin-Fatt) [325 gr/ft3]

Separator (HES) rotational speed ():

20 m/s (for BSA = 3600 cm2/g)
O-Sepa 2 rpm/50 cm2/g

Tromp Curve (FLSmidth):

Cut size: particle size corresponding to the Tromp-value 50% (depends on rotor speed and fineness level;
ideally on the steepest part of the curve)
Slope (): slope of the curve in the interval 25-75%, e.g. P25/P75
Normal ranges: HES > 0.5
2nd gen 0.3-0.4
1st gen 0.25-0.35
Bypass (): Tromp value at lowest point on curve
Normal ranges: HES 5-15%
2nd gen 20-40%
1st gen 30-60%

Tromp curve shape affected by:

Material load: excessive loading results in increased bypass and lower value
Airflow: insufficient airflow results in higher bypass value and lower value
Circulation factor: increase in circulation factor leads to increase in the bypass value
Grinding aid: the use of grinding aid may counteract agglomeration, resulting in reduced bypass value
and increased sharpness of separation

7
 Process Design Notes

Slot sizes:
C1: 6-8 mm
C2: 8-10 mm

Slot open area:

6-8% of effective area (AChin-Fatt/Fuller) [excluding center screen]
15% of effective area (PAlsop) [including center screen]

Material size at division head:

4% +2mm (5% +8M)

Material size at mill discharge:

1600-1800 cm2/g (approx half of final product BSA)
5% +30M

FM ball charge surface area:

C1: 9.5-10.5 m2/Mg (3.0-3.5 lbm/ball)
C2: 26-29 (AChin-Fatt) or 28-33 (JBump) or 35-38 (PAlsop) m2/Mg
Mono: 18-20 m2/Mg (AChin-Fatt)

Power consumption (=f(feed size)):

BM: 32-36 kWh/ton (ideal); 34-38 kWh/ton (typical) [1-1 feed F80]
BM: 35-40 kWh/Mg (ideal); 37-42 kWh/Mg (typical) [25-38 mm feed F80]

Specific power consumption (LSingh):

Mill w/ conventional separator: 1.0 (BSA/100) = kWh/ton
Mill w/ high efficiency separator: 0.9 (BSA/100) = kWh/ton
Mill w/ HES and roller press: 0.75 (BSA/100) = kWh/ton

Fluorescein mixture:
2 g fluorescein per Mg/h total mill feed
600-800 ml alcohol
2.5 kg mill feed (proportioned for raw KK, gyp and returns)

Fluorescein analysis:
100 ml beakers (10-20)
5 g material
50 ml distilled water

Grinding aid consumption (8.5 lb/gal):

T-I: 0.9-1.1 lbm/toncement
T-III: 1.2-1.4 lbm/toncement

Typical allowance in tube mill shell length (AChin-Fatt):

Feed end liners 75 mm
Central diaphragm 500 mm
Discharge diaphragm 350 mm

Typical shell liner thickness (AChin-Fatt):

Lifting (step) liner 95 mm
Classifying liner 90 mm
Lifting (compt 2) 63 mm
DUO-3 (compt 2) 50 mm

8
 Process Design Notes

Torque factor in 2nd compt ( in FLS power consumption equations) (AChin-Fatt):

Classifying liners 0.65
Lifting liners 0.67
DUO-3 liners 0.66

Ball mill absorbed power design notes (AChin-Fatt):

For dry grinding raw mill, add power for the drying compartment
For air swept raw mill, increase the calculated power draw by 1.08
For wet grinding raw mill, decrease the calculated power by 0.75 to 0.9 (low for lower % solids)
For wet grinding raw mill, use balls no less than 1" in 2nd compt as finer balls tends to float
For slag grinding mill, decrease the calculated power draw by 0.95
Typical power losses:
Gear & Pinion 3.5%
Reducer 1.5%
Motor 3.0%

Ball volume (%) 113 126 (H / D)

Ball mill operating rotational speed (% of critical): 75-78%

Dust Collection

Air-to-cloth ratio:
Pulse Jet (process D/C): 4.0-4.5 acfm/ft2
Pulse Jet (nuisance D/C): 5.0-6.0 acfm/ft2
R/A: 2.0-2.5 acfm/ft2
Star bags: 4.0-4.5 acfm/ft2
Pleated elements: 4.0-4.5 acfm/ft2

D/C can (or thimble) velocity: < 250 ft/min

D/C p:
Pulse Jet: 3.5-4.5 inWG (bags blinded at 7 inWG)
R/A: 2.0-3.0 inWG (bags blinded at 5 inWG)
Star bags: 4.0-5.0 inWG (bags blinded at 7 inWG)

D/C off-time: 8-15 s (higher the better; low off-time contributes to internal bag wear)
D/C on-time: 0.10-0.12 s (dependent on bang)

Blow pipes:
Number of holes per pipe 16
Hole : hole areas pipe cross-sectional area
1 pipe (sched 40): I.D. = 1.610, A = 2.036 in2
1 pipe (sched 40): I.D. = 1.380, A = 1.496 in2
1 pipe (sched 40): I.D. = 1.049, A = 0.864 in2
pipe (sched 40): I.D. = 0.824, A = 0.533 in2
Stagger firing sequence: e.g. 1-4-7-10-2-5-8-11-3-6-9-12-etc.

Gravel Bed Filter (GBF):

Gas flow per module: 20,000 acfm [LSingh]
Based on 128 acfm/ft2 total filter area (comes to 15,000 acfm) [Rexnord]
Backflush flow: 8,400 acfm (some specs call for 7800 acfm) [Rexnord, Lurgi]
Based on 145-150 acfm/ft2 (flux), 9 ft screen, 2.5-3.0 ft dip tube, 57-59 ft2 screen area
Lower: improper cleaning
Higher: blow gravel out

9
 Process Design Notes

Design p: 8-9 inWG (typical is 9-12 inWG)

Gravel bed depth: 4.5 in
Rake clearance above screen: 3/8 in
Design inlet grain loading: 4-6 gr/ft3

Cyclone dimensioning:
4V
d
2.6 n3,600

where: d = nominal cyclone diameter [m]

V = total airflow [m3h-1]
n = number of cyclones [---]

Fans

Fan power:
P [kW] = Q [m3/s] p [kPa] / [%]
BHP [hp] = Q [cfm] SP [inWC] / 6356 / [%]
( = static efficiency)

Note: fan p is total pressure difference across fan

Fan laws:

Density Change Speed Change Size Change

Q2 = Q1 Q2 = Q1 (N2 / N1) Q2 = Q1 (D2 / D1)3
p2 = p1 (2 / 1) p2 = p1 (N2 / N1)2 p2 = p1 (D2 / D1)2
P2 = P1 (2 / 1) P2 = P1 (N2 / N1)3 P2 = P1 (D2 / D1)5

Note: valid only for speed changes up to 25% because of assumption that fan efficiency remains constant

Tip speed, u:
u [fpm] = D [ft] N [rpm]

Rule of thumb for calculating fan total pressure w/ straight impeller vanes:
0.6 u 2
p total
g

where: ptotal = fan total pressure [Pa]

= gas density [kgm-3]
u = tip speed [ms-1]
g = gravitational constant [9.80665 ms-2]

Wheel inertia:
wr2 [lbmft2] = W [lbm] (0.35 D [ft])2

Round duct equivalent of rectangular duct:

Dr 1.2655
ab 3
ab

10
 Process Design Notes

Environmental

Dioxin / Furan formation

450-800F (230-425C)

Water injection (NOx control):

~ 1 gpm per ton of fuel
10-15% NOx reduction

SNCR:
Up to 85% NOx reduction
0.40-0.80 USD/tonKK

Auxiliary Equipment

HEX tube design: 2000-2500 fpm tube velocity (HTseng)

Conditioning (spray) tower:

air-to-water pressure ratio: > 1.1:1 (empirical @ DEM)
air-to-water pressure bias: 10-35 psi (supercedes above note based on LYO & BAL)
air rqmt: 95-110 acfm/lance
inlet duct: 15 slope (to the vertical)
ensure nozzles / spray pattern doesnt overlap (creates large droplets)
soft mist spray desirable, hard spattering spray undesirable

Engineering / Miscellaneous

Pipe conveying velocities: 3,500-4,000 fpm (18-20 m/s) to transport fine material (raw meal, clinker dust, cement)

Pyroline conveying velocities [PAlsop]:

Upper limits:
Through cooler grate: 5 m/s
Kiln hood: 6 m/s
Under cooler bull nose: 15 m/s
Burning zone (1,450C): 9.5 m/s
Kiln feed end transition (1,000C): 13 m/s
Preheater riser duct: 24 m/s
Preheater gas ducts: 18 m/s
Lower limits:
Tertiary air duct: 25 m/s
Pulverized coal conveying: 20 m/s [PAslop]; 16 m/s [GLabelle, Pillard]

Ball mill conveying velocities [Lafarge]:

Discharge trunnion: 23-25 m/s (max)
Discharge housing: 4-5 m/s
Discharge duct: 10-15 m/s

Steel erection: $3.00/lb steel (stiffeners, etc. multiply by 1.25-1.75) [HTseng]

Refractory installation: $1.75/lb refractory [MGower]
Refractory demolition: $0.44/lb refractory [MGower]

Power consumption by P (damper or other):

kW = Q (ft3/min) 0.30483 (ft3 to m3) / 60 (s/min) P (inWC) 0.24884 (inWC to kPa)
note: Pa = kgm-1s-2 and W = kgm2s-3

11
 Process Design Notes

Motors:
If designed for 0.8 PF () and a given hp, can incr to 1.0 and get more hp as long as stay below FLA
kVA = 3 E I /1000
kW = 3 E I /1000
= kW / kVA = cos ( = phase angle)

Transfer point dust collection vent line sizing:

Assume 1 ft3 per 1 ft/min belt speed (???)
e.g. 24 belt = 24 6 (height of air above belt) = 2 = 1 ft2 1000 ft/min = 1000 cfm

Hardness scales:
Solid fuels: Hardgrove grindability index (HGI) lower value represents harder to grind material
Minerals: Mohs scale (1 = talc, 10 = diamond)
Metals and alloys (penetration tests):
Brinell hardness number (HBN)
Rockwell hardness test (Rc) [note: scales A, B, C, D, E, F, G) higher value = harder
Also: Vickers, Meyer, Meyer-Vickers, Knoop

Kiln nose ring cooling air flow (HTseng / Polysius):

Total air flow requirement = 725 acfm/ft-kiln [Duda approx 20% higher]
Nozzle velocity = 4,500-5,000 ft/min
Fan SP = 6.5-8.0 inWG
Manifold velocity approx 50-60% nozzle velocity

Kiln shell/tire thermal gradient (T between the two):

Typical (floating tire): 180C
Modern (splined/fixed tire): 360C

Calculation of shaft diameters (Polysius):

N
M d 71,620
n

where: Md = torque [cmkg]

N = power [hp]
n = rotational speed [rpm]

Md
d 3
0.2 K d

where: d = shaft diameter [cm]

Kd = torsional stress [kgcm-2]
Wrought iron 120
Mild steel 200-400
Forged steel 300-480
Cast iron 160-320

12