Preheater Outlet gas flow calculation

Gas density

Measurement Volumetric % Molecular Weight

O2 % 3.00% Not measured 32 kg/mole

CO2 % 22.00% Not measured 44 kg/mole
N2 % 75.00% (100-O2-CO2) 28 kg/mole

Gas Density = (O2% X 32 + CO2% X 44 + N2% X 28) / (22.4 x 100)

1.4125 kg/m3 N

Temperature deg C T 380

St pressure mmWg Ps -810
Barometric pressure at Site mmWg Pb 10320

Correction factor Cf = 273 x (Pb +Ps) 0.3847721

(273+T) 10333

Actual Density = Gas Density * Correction factor Cf 0.5434906 kg/m3

Pressure Head Dynamic Pd

28 29 30 31 32 33 34 35
36 31 29 30 31 32 33 34
35 30 28 29 30 31 32 33
30 29 29 30 32 31 30 30

Average Pd 31.16 mmWg

Pitot Tube factor K 0.825

Velocity = KX ((2X9.81XPd)/Actual density) 27.67 m/s

Duct Area = Diameter 3150 mm 7.796 m2

OR
Size 0X 0 0.000 m2

Actual Flow Rate = Velocity X Duct Area 216 m3/s

776547.98 m3/h

Nominal Flow rate= Actual flow rate * Correction factor Cf 298794 Nm3/h

Cliner production 4400 tpd 183.3 tph

Air consumption / kg of clinker 1.6298 Nm3/kg
(preheater)
PREHEATER FAN EFFICIENCY

Fan Outlet pressure -5 mmWg

Fan inlet pressure -830 mmWg

Pressure developed by Fan Outlet - Inlet 825 mmWg

Actual Flow Rate = 776548 m3/h

Air power by Fan = 1745 Kw

(Actual flow rate X Pressure Develpoed / 102/3600)

Fan Power (from Energy meter) Pm 2409 Kw

Cable losses Lc 1%
Motor Efficiency Lmotor 95%
Mechanical efficiency Lmech 99%

Power drawn by Fan Shaft = 2243 Kw

( Pm * L motor*Lmech*(100-Lc)/100)

Fan speed (MAX 990) rpm 970

Fan Damper % 90-100

Control LRS

Fan Efficiency = 78%

(Air power by Fan/Power drawn by Fan Shaft)x100
Mill fan inlet gas flow calculation R Mill Fan 25-07-2009
Gas density

Measurement Volumetric % Molecular Weight

O2 % 21.00% Not measured 32 kg/mole

CO2 % 0.00% Not measured 44 kg/mole
N2 % 79.00% (100-O2-CO2) 28 kg/mole

Gas Density = (O2% X 32 + CO2% X 44 + N2% X 28) / (22.4 x 100)

1.2875 kg/m3 N

Temperature deg C T 90.8

St pressure mmWg Ps -717
Barometric pressure at Site mmWg Pb 10245

Correction factor Cf = 273 x (Pb +Ps) 0.6919509

(273+T) 10333

Actual Density = Gas Density * Correction factor Cf 0.8908868 kg/m3

Pressure Head Dynamic Pd

30.3 31.9 26.1 27.5 28.2 27.1 28.4 26.4
26.3 27.1 26.6 23.4 26.8 18.6 15.5 17.6
18 17.9 15.5 19.1 16.5 20.1 15.9 14.2
20.8 24.7 22.3 24.5 19.8

Average Pd 22.66 mmWg

Pitot Tube factor K 0.834

Velocity = K X ((2X9.81XPd)/Actual density) 18.63 m/s

Duct Area = Diameter 4000 mm 12.571 m2

OR
Size 0X 0 0.000 m2

Actual Flow Rate = Velocity X Duct Area 234 m3/s

843156.45 m3/h

Nominal Flow rate= Actual flow rate * Correction factor Cf 583423 Nm3/h
RAW MILL FAN EFFICIENCY

Fan Outlet pressure -35 mmWg

Fan inlet pressure -871 mmWg

Pressure developed by Fan Outlet - Inlet 836 mmWg

Actual Flow Rate = 843156 m3/h

Air power by Fan = 1920 Kw

(Actual flow rate X Pressure Develpoed / 102/3600)

Fan Power (from Energy meter) Pm 1660 Kw

Cable losses Lc 1%
Motor Efficiency Lmotor 95%
Mechanical efficiency Lmech 99%

Power drawn by Fan Shaft = 1546 Kw

( Pm * L motor*Lmech*(100-Lc)/100)

Fan speed (MAX 990 ) rpm 900

Fan Damper % 100

Control GRR

Fan Efficiency = 124%

(Air power by Fan/Power drawn by Fan Shaft)x100
Bag House fan outlet gas flow calculation
Gas density
Measurement Volumetric % Molecular Weight
O2 % 10.00% Not measured 32 kg/mole
CO2 % 16.00% Not measured 44 kg/mole
N2 % 74.00% (100-O2-CO2) 28 kg/mole

Gas Density = (O2% X 32 + CO2% X 44 + N2% X 28) / (22.4 x 100)

1.3821429 kg/m3 N

Temperature deg C T 88.7

St pressure mmWg Ps 68.4
Barometric pressure at Site mmWg Pb 10245

Correction factor Cf = 273 x (Pb +Ps) 0.7533375

(273+T) 10333

Actual Density = Gas Density * Correction factor Cf 1.04122 kg/m3

Pressure Head Dynamic Pd

23 22 18 25 21 19 22 20

Average Pd 21.25 mmWg

Pitot Tube factor K 0.83

Velocity = K X ((2X9.81XPd)/Actual density) 16.61 m/s

Duct Area = Diameter 4000 mm 12.571 m2

OR
Size X 0.000 m2

Actual Flow Rate = Velocity X Duct Area 209 m3/s

751662.6 m3/h

Nominal Flow rate= Actual flow rate * Correction factor Cf 566256 Nm3/h
BAG HOUSE FAN EFFICIENCY

Fan Outlet pressure -46 mmWg

Fan inlet pressure -620 mmWg

Pressure developed by Fan Outlet - Inlet 574 mmWg

Actual Flow Rate = 751663 m3/h

Air power by Fan = 1175 Kw

(Actual flow rate X Pressure Develpoed / 102/3600)

Fan Power (from Energy meter) Pm 665 Kw

Cable losses Lc 1%
Motor Efficiency Lmotor 95%
Mechanical efficiency Lmech 99%

Power drawn by Fan Shaft = 619 Kw

( Pm * L motor*Lmech*(100-Lc)/100)

Fan speed (MAX 745 ) rpm 700

Fan Damper % 90-100

Control LRS

Fan Efficiency = 190%

(Air power by Fan/Power drawn by Fan Shaft)x100
FALSE AIR INGRESS

1 Based on Gas Analysis

O2 % 7.0% O2 % 8.7%
CO2 % 18.5% CO2 % 16.0%
Equipment
Inlet Outlet

Leakage on O2 basis = (O2 at Outlet - O2 at Inlet) / (21-O2 at Outlet)

13.82%

Leakage on CO2 basis = (CO2 at Inlet - CO2 at Outlet) / (CO2 at Intlet)

13.51%

Average leakage = (Leakage on O2 basis + Leakage on CO2 basis) / 2

13.67%

2 Based on Temperature Measurement

T inlet 200 T outlet 192

Equipment
Inlet Outlet

Ambient Temperature degC 33.5

Leakage on Temp basis = (Inlet-Outlet) / (Outlet-Ambient)

5.05%