S.

NO Description Symbol Formula Example

Degree of filling DF 3.2 * P Target: 14-16

Cement Manufacturer's Handbook, (%) (Deff)3 * n * s P: 5500
Kurt E. Peray P: Clinker production, t/d Deff: 4.15
1
Deff: Burning zone effective diameter, m n: 3.8
n: Kiln speed, rpm s: 4
s: Kiln slope, % DF: 16.20
Thermal or Burning zone Loading TL Formula-1: Target: 4.0-5.0
FLS - Kiln manual (Gcal/hr/m ) 2
F * NCV F: 10,000
A * 4179000 NCV: 27,000
F: Fuel rate in kiln, kg/hr A: 13.52
NCV: Net calorific value of fuel, kJ/kg-fuel TL: 4.78
A: Burning zone cross-sectional area, m 2
2
Thermal or Burning zone Loading TL Formula-2: Target: 4.0-5.0
FLS - Kiln manual (Gcal/hr/m ) 2
P*H P: 5,500
A * 24 * 4179 H: 1,190
P: Clinker production, tpd A: 13.52
H: Specific heat consumption in kiln, kJ/kg-clinker TL: 4.83
A: Burning zone cross-sectional area, m 2

Volumetric loading VL P Target: 5.0-5.5

FLS - Kiln manual (tpd/m )3
A*L P: 5,500
3 P: Clinker production, tpd A: 13.52
A: Burning zone cross-sectional area, m 2
L: 68
L: Kiln length, m VL: 5.98
Material residence time in kiln RTK 19 * L Target: 20-25
FLS - Kiln manual (min.) Deff * n * s L: 68
L: Kiln length, mts Deff: 4.15
4
Deff: Burning zone effective diameter, mts n: 3.8
n: Kiln speed, rpm s: 4
s: Kiln slope, % RTK: 20.5
Clinker residence time in cooler RTC 15.805 * A * Ps Target: 20-25

5
S. NO Description Symbol Formula Example

Emperical Formula (min.) P A: 100

5 A: Cooler grate cross-sectional area, m 2 Ps: 70
Ps: Static pressure at clinker droping area, mB P: 5,500
P Clinker production, tpd RTC: 20.1
True CO2 in kiln exit gas TCO2 100 * ( CO2 + CO ) Target: -
Cement Manufacturer's Handbook, (vol.%) 100 + ( 1.89 * CO ) - ( 4.78 * O2 ) CO2: 36.5
6 Kurt E. Peray CO2: Kiln exit gas CO2, vol.% CO: 0.002
CO: Kiln exit gas CO, vol.% O2: 4.2
O2 : Kiln exit gas O2, vol.% TCO2 45.7
Excess air EA 79 * O2 Target: 10-15
FLS - Kiln manual (%) 0.21 * ( 100 - CO2 ) - O2 O2: 2.8
7
O2: O2 content in gas, vol% CO2: 26.5
CO2: CO2 content in gas, vol% EA: 17.5
Radiation heat losses RHL 16.716 * 10 * ( T - t )
-8 4 4
Target: -
FLS - Kiln manual (kJ/hr/m ) 2
T: Radiating body temperature, K T: 517
8
t: Ambient air temperature, K t: 305
RHL: 10,496
Convection heat losses CHL 335.7 * ( ( T + t ) / 2 ) -0.724
*(T-t) 1.333
Target: -
FLS - Kiln manual (kJ/hr/m ) 2
T: Radiating body temperature, K T: 443
9
t: Ambient air temperature, K t: 308
CHL: 3,174
Forced convection heat losses FCHL 117.14 * ( ( T + t ) / 2 ) -0.351
*v 0.805
*D -0.195
*(T-t) Target: -
(when wind speed > 3.0 m/s) (kJ/hr/m ) 2
T Radiating body temperature, K T: 525
FLS - Kiln manual t Ambient air temperature, K t: 302
10
v Wind speed, m/s v: 5
D Radiating body diameter, m D: 4.15
FCHL: 8,725
%Ash absorption in clinker AA CC * Ash Target: -
Simple mathematical calculation (%) P CC: 26
11 CC: Coal consumption, tph Ash: 15
S. NO Description Symbol Formula Example
11
Ash: Ash content in fuel (as fired basis), % P: 208
P: Clinker production, tph AA: 1.88
Raw Mix:Clinker ratio RMCK 100 - %AA Target: -
(dust to kiln) - 100 - LOI AA: 1.74
12
Simple mathematical calculation AA: %Ash absorption, % LOI: 35.58
LOI: Loss on ignition of raw mix, % RMCK: 1.525
Raw Mix:Clinker ratio RMCS ( 100 - %AA ) * 100 Target: -
(dust to silo) - ( 100 - LOI ) * ( 100 - DL ) AA: 1.74
13 Simple mathematical calculation AA: %Ash absorption, % LOI: 35.58
LOI: Loss on ignition of raw mix, % DL: 8.5
DL: Dust losses from preheater, % RMCS: 1.667
Heat of reaction HR [ ( 4.282 * CaCO3 * RMCK ) + ( 3.085 * MgCO 3 * RMCK ) Target: -
or (kJ/kg clinker) + ( 222 * Al2O3 / ( 100 - LOI ) ) + ( 11.6 * CH2O * RMCK ) CaCO3: 75.1
Theoretical heat required to produce - ( 511.6 * SiO2 / ( 100 - LOI ) ) - ( 59 * Fe2O3 / ( 100 - LOI ) ) RMCK: 1.53
1 kg of clinker - ( 1000 * ( K2O + Na2O ) / ( 100 - LOI ) ) MgCO3: 1.6
or - ( 79 * C * RMCK ) - ( 32 * S * RMCK ) ] * 4.179 LO:I 34.5
Clinkerisation heat CaCO3: CaCO3 content in kiln feed, % Al2O3: 4.17
(including Heat of combustibles) RMCK: Kiln feed:Clinker ratio, - CH2O: 1.05
FLS - Kiln manual MgCO3: MgCO3 content in kiln feed, % SiO2: 13.47
14 LOI: LOI content in kiln feed, % Fe2O3: 2.41
Al2O3: Al2O3 content in clinker, % K2O: 0.38
CH2O: Water of crystalisation in kiln feed, % Na2O: 0.27
SiO2: SiO2 content in clinker, % C: 0.2
Fe2O3: Fe2O3 content in clinker, % S: 0.04
K2O: K2O content in clinker, % HR: 1,625
Na2O: Na2O content in clinker, %
C: Carbon content in kiln feed, %
S: Sulphur as pyrites in kiln feed, %
False air w.r.t. mix FAMO ( O2mix - O2gas ) * 100 Target: 5-7
(based on O2 analysis) (%) 21 - O2gas O2mix: 3.6
15
S. NO Description Symbol Formula Example
15
FLS - Communition Manual O2mix: O2 content in mixture of gas, vol.% O2gas: 2.8
O2gas: O2 content in unmixed gas, vol.% FAMO: 4.4
False air w.r.t. gas FAGO ( O2mix - O2gas ) * 100 Target: 5-7
(based on O2 analysis) (%) 21 - O2mix O2mix: 3.6
16
FLS - Communition Manual O2mix: O2 content in mixture of gas, vol.% O2gas: 2.8
O2gas: O2 content in unmixed gas, vol.% FAGO: 4.6
False air w.r.t. mix FAMC ( CO2gas - CO2mix ) * 100 Target: 5-7
(based on CO2 analysis) (%) CO2gas CO2mix: 32.1
17
FLS - Communition Manual CO2mix: CO2 content in mixture of gas, vol.% CO2gas: 34.5
CO2gas: CO2 content in unmixed gas, vol.% FAMC: 7.0
False air w.r.t. gas FAGC ( CO2gas - CO2mix ) * 100 Target: 5-7
(based on CO2 analysis) (%) CO2mix CO2mix: 32.1
18
FLS - Communition Manual CO2mix: CO2 content in mixture of gas, vol.% CO2gas: 34.5
CO2gas: CO2 content in unmixed gas, vol.% FAMC: 7.5

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