Formulae

Not to be copied in any form or distributed or resold
Property of:
Softideas Pvt. Ltd., 5- Sinbai Niwas, Gokhale
Model Colony, Pune-411016
LSw Limestone required per week
RMw
LSw := C L ⋅
100
4
LSw = 4.284 × 10 Tonnes/Week
Qcr Crusher Capacity required
LSw
Qcr :=
Tcrw ⋅ Thd
Qcr = 595 Tonnes / Hrs
Hv Crusher Hopper capacity -( volumetric)
Qcr ⋅ H t
H v :=
BDLS ⋅ 60
H v = 123.958 m3
Feeder for Crusher
Capacity of Crusher feeding devices e.g Apron Feeder, Vibrating Screen etc
should have 20 to 30% over capacity.
Feeder capacity Qcrf T/Hr.
Crusher Capacity =Q cr T/Hr Qcr := 595
Over capacity factor K2 K2 := 1.2
Qcrf := K2⋅ Qcr
T
Qcrf = 714
Hr
T
T
Feeder capacity Qcrf T/Hr. Qcrf = 714
Hr
Transportation from crusher
Crusher should be followed by a Plate conveyor or Impact conveyor of short

length.
This may be followed by Weigh Belt Scale to check crusher output.This is
followed by Belt Conveyor transporting crushed material to the Mix Bed or Raw
Mill Hopper as the case may be.
The capacity of these Transport devices should be having 50% over capacity
(over crusher capacity) This is in view of flushing from Crusher when a big stone is
crushed resulting in rush of material.
Capacity of Transporting equipment after crusher upto Mix Bed including Stacker
is given by Qtcro T/Hr
Qtcro := 1.5 ⋅ Qcr
T
Qtcro = 892.5
Hr
Book-I Chapter 3
Preblending Section
File Name : 1_3_preblending
Topic: Expanded Table Of Contents
1_3_preblending_1 Preblending and Stockpile Equipment Calculations

Book-I Chapter 3
Preblending Section
File Name :
1_3_preblending_1
Topic: Preblending and Stockpile Equipment - Calculations
Calculation of Stockpile Capacity for Raw material (Limestone)
To calculate the capacity of stockpile following steps can be followed.
Step :- 1 Determine Kiln capacity

Step :- 2 Determine weekly requirement of crushed Limestone material
Qdk Kiln Capacity of Clinker Qdk := 4500 Tonnes /

Day
BDLS Bulk density of Stone (limestone) BDLS := 1.2 Tonnes./m3
K1 Factor for converting Clinker to Raw meal K1 := 1.6
CL Total Limestone component as percentage C L := 85 %

of Raw mix
Qcr Crusher capacity Qcr := 565 Tonnes/ Hr
RMd Number of days of Raw Material stock required RMd := 7
Calculation
Qsp Stock pile capacity in Tonnes.
RMw Raw material required per week
RMw := Qdk ⋅ K 1⋅ 7
4
RMw = 5.04 × 10 Tonnes/Week
RMw
LSw := C L ⋅
100
4
Qsp Stock pile capacity in Tonnes -Live Capacity
Qsp := Qdk ⋅ K1⋅ RMd
4
Qsp = 5.04 × 10 Tonnes
Qstacker Stacker Capacity
Qstacker := 1.5 ⋅ Qcr
Qstacker = 847.5 Tonnes/Hr
Stacker / Stacker Belt Capacity = Qstacker = 847.5 Tonnes/Hr

Book-I Chapter 4
Raw Grinding Section
File Name : 1_4_rawgrinding
1_4_rawgrinding_1 Bond Work Index of the various material based on

bond test mill result dry basis
1_4_rawgrinding_2 Calculation of power at Ball Mill shaft for Raw material ,

based on the Bond's work index
1_4_rawgrinding_3 Raw Mill and Auxiliary Equipment Capacity Calculations
1_4_rawgrinding_4 Raw Material Drying - Estimation ofTotal Moisture to be

Evaporated from Feed
1_4_rawgrinding_5 Raw Mill Heat Balance - Evaluation of Hot Gas

Requirement for Drying
1_4_rawgrinding_6 Calculation of Ball Mill Percentage Filling as per

Measurement
1_4_rawgrinding_7 Calculation of Grinding Ball Size
1_4_rawgrinding_8 Specific Heat of Raw Material as a Function of

Temperature
1_4_rawgrinding_9 Estimation of grindability based on the operating
parameters of Mill
1_4_rawgrinding_10 Calculation of Mill Output at Different Fineness of Product
1_4_rawgrinding_11 Calculation of Efficiency of Dynamic Air Separator
1_4_rawgrinding_12 Average Piece Weight ofGrinding Media
1_4_rawgrinding_13 Ball Mill Critical Speed and Ball Charge Calculations
1_4_rawgrinding_14 Verical Roller Mill -- Calculation of Power

1_4_rawgrinding_15n Radiation Loss in Raw Mill Heat Balance

Property of:
Softideas Pvt. Ltd., 5- Sinbai Niwas, Gokhale Nagar Road,
Book-I Chapter 4
File Name : 1_4_rawgrinding_1
Topic: Bond Work Index of the various material based on bond test mill result
dry basis
The Bond index of various material based on the Dry basis -
Bond test mill result is calculated as given below.
Pf Product fineness test result ( 80 % Passing - Range > 90 µ ) , µ Pf := 60
Ff Feed size to test mill ( 80 % passing - Range 0-4 mm ) , µ Ff := 2500
Sc Screen size , ( Normally 90 µ size ) , µ Sc := 90
Pr Finished product per mill revolution , gm / rev Pr := 1.36
Calculation
Ws Bond index , kwh/sh.t dry basis
44.5
W s := kwh/sh.t ( dry basis )
0.23 0.82  10 10 
Sc ⋅ Pr ⋅  − 
 Pf Ff 
W s = 11.261 kwh/sh.t ( dry basis )

Book-I Chapter 4
Topic: Raw Mill Heat Balance - Evaluation of Hot Gas Requirement for Drying
Hot gases required for drying of material in raw grinding in ball mill
The hot gases required for the drying of the feed moisture in the raw material while
grinding in close circuit ball mill is calculated as below.
Ght Hot gases temperature , Ght := 280 deg.c

Ghs Specific heat of hot gases Ghs := 0.34 kcal/deg.c-Nm3
Rt Base temperature R t := 20 deg.c
Amb Ambient air temperature Amb := 35 deg.c
Amb s Specific heat of ambient air Amb s := 0.30 kcal/Nm 3.deg.c
Alt Altitude ( From mean sea level ) Alt := 950 m
Fq Fresh feed quantity Fq := 100 tph
Mf Total fresh feed moisture(surface) Mf := 8 %
Mp Total product moisture)surface) Mp := 2 %
Fs Specific heat of raw material Fs := 0.21 kcal/kg.deg.c
Fa False air percentage Fa := 10 %
P Absorbed mill power P := 3000 kw
Eg Amount of dedusting gases Eg := 150000 m 3/hr
Egt Dedusting gases temperature Egt := 105 deg.c
Egs Specific heat of dedusting gases Egs := 0.31 kcal/Nm 3.deg.c
Ra Surface area for Radiation Losses R a := 185 m2
Rf Radiation Loss R f := 50 kcal/m2.deg.c
difference
Calculations
Gh Required hot gas quantity ( Nm3/hr )
RG Circulating air ( Nm 3/hr )
Heat output :
Step :-1 Heat to raw material
(
Hop := Fq ⋅ 1000 ⋅ Fs ⋅ Egt − R t − 5 ) Kcal/hr
6
Hop = 1.68 × 10 Kcal/hr
Note :The raw material temp. is normally less by 5 deg.c. than the exit gas temperature.
Step :-2 Heat to dedusting gases
( )  Eg 
273
Hog := Eg ⋅ Egs ⋅ Egt − R t ⋅   Kcal/hr
 t + 273 
6
Hog = 2.855 × 10 Kcal/hr
Step :-3 Heat loss due to radiation
(
Hor := R a⋅ R f ⋅ Egt − R t ) Kcal/hr
5
Hor = 7.862 × 10 Kcal/hr
Step :-4 Heat loss to evaporate moisture
Moisture to be evaporated
(
Fq ⋅ 1000 ⋅ Mf − Mp )
W := kg/hr
100 − Mf
W = 6522 kg/hr
(
How := W ⋅ 540 + Egt − Amb ) Kcal/hr
6
How = 3.978 × 10 Kcal/hr
Note :The latent heat of evaporation of water is 540 kcal/kg of water.

Step :-5 Heat loss to false air
Eg ⋅ Fa⋅ Amb s ⋅ Egt − R t( )

Hoa := Kcal/hr
100
5
Hoa = 3.825 × 10 Kcal/hr
Total heat loss
Ho := Hop + Hog + Hor + How + Hoa Kcal/hr
6
Ho = 9.682 × 10 Kcal/hr
Heat inputs :
Step :-1 Heat from fresh feed
(
Hif := Fq ⋅ 1000 ⋅ Fs ⋅ Amb − R t ) Kcal/hr
5
Hif = 3.15 × 10 Kcal/hr
Step :-2 Heat from grinding power
Hip := P ⋅ 816 Kcal/hr
6
Hip = 2.448 × 10 Kcal/hr
Step :-3 Heat from false air
(
Eg ⋅ Fa ⋅ Amb s ⋅ Amb − R t )
Hia := Kcal/hr
100
4
Hia = 6.75 × 10 Kcal/hr
Total heat input
Hi := Hif + Hip + Hia Kcal/hr
6
Hi = 2.83 × 10 Kcal/hr
Note :If the heat input is less than the heat output then only we require hot gases.
Let us solve for hot gases requirement.
Gh := 0 Nm3/hr
(
Gh := root  Ho −  Hi + Gh ⋅ Ghs ⋅ Ght − R t )   , Gh Nm3/hr
4
Gh = 7.75 × 10 Nm3/hr
Gh := if ( Hi < Ho , Gh , 0) Nm3/hr
Gh = 77501 Nm3/hr
Note :If the dedusting gases quantity is less than the hot gases required then either
increase the hot gases temperature or increase the dedusting gases amount and run the
heat balance again.
  273  Fa 
Mg := Eg ⋅   − 1.24 ⋅ W − ⋅ Eg Nm3/hr
  Egt + 273  100 
Mg = 85246 Nm3/hr
Gh = 77501 Nm3/hr
Note := if ( Mg ≥ Gh , "O.K." , "Change the hot gases temp. or the dedusting gases quantity" )
Note = "O.K."
Amount of recirculation gases :
RG := if ( Mg ≥ Gh , Mg − Gh , 0) Nm3/hr
RG = 7745 Nm3/hr
Amount of hot gases required for Drying :
Gh = 77501 Nm3/hr
Book-I Chapter 4
File Name : 1_4_rawgrinding_6r1
Topic: Calculation of Ball Mill Percentage Filling as per Measurement
To calculate the percentage of grinding media filling in the ball mill

based on the empty measured height is as below.
Di Mill inside diameter Di := 4 m

H Empty measured height H := 0 m
H Di
θ r
h a
C.G of Charge
Calculations
F H Percentage
- Empty height
fillinginside linersmedia
of grinding in m
r Radius inside lining
Di
r := m
2
r=2 m
Percentage filling :
 H − r
θ := 2 acos   radians
 r 
θ = 6.283 radians
RMw
LSw := C L ⋅
100
4
Qcr Crusher Capacity required
LSw
Qcr :=
Tcrw ⋅ Thd
Qcr = 595 Tonnes / Hrs
Hv Crusher Hopper capacity -( volumetric)
Qcr ⋅ H t
H v :=
BDLS ⋅ 60
H v = 123.958 m3
Feeder for Crusher
Capacity of Crusher feeding devices e.g Apron Feeder, Vibrating Screen etc
should have 20 to 30% over capacity.
Feeder capacity Qcrf T/Hr.
Crusher Capacity =Q cr T/Hr Qcr := 595
Over capacity factor K2 K2 := 1.2
Qcrf := K2⋅ Qcr
T
Qcrf = 714
Hr
T
T
Feeder capacity Qcrf T/Hr. Qcrf = 714
Hr
Transportation from crusher
Crusher should be followed by a Plate conveyor or Impact conveyor of short

length.
This may be followed by Weigh Belt Scale to check crusher output.This is
followed by Belt Conveyor transporting crushed material to the Mix Bed or Raw
Mill Hopper as the case may be.
The capacity of these Transport devices should be having 50% over capacity
(over crusher capacity) This is in view of flushing from Crusher when a big stone is
crushed resulting in rush of material.
Capacity of Transporting equipment after crusher upto Mix Bed including Stacker
is given by Qtcro T/Hr
Qtcro := 1.5 ⋅ Qcr
T
Qtcro = 892.5
Hr
Book-I Chapter 3
Preblending Section
File Name : 1_3_preblending
1_3_preblending_1 Preblending and Stockpile Equipment Calculations

Book-I Chapter 3
Preblending Section
File Name :
1_3_preblending_1
Topic: Preblending and Stockpile Equipment - Calculations
Calculation of Stockpile Capacity for Raw material (Limestone)
To calculate the capacity of stockpile following steps can be followed.
Step :- 1 Determine Kiln capacity

Step :- 2 Determine weekly requirement of crushed Limestone material
Qdk Kiln Capacity of Clinker Qdk := 4500 Tonnes /

Day
BDLS Bulk density of Stone (limestone) BDLS := 1.2 Tonnes./m3
K1 Factor for converting Clinker to Raw meal K1 := 1.6
CL Total Limestone component as percentage C L := 85 %

of Raw mix
Qcr Crusher capacity Qcr := 565 Tonnes/ Hr
RMd Number of days of Raw Material stock required RMd := 7
Calculation
Qsp Stock pile capacity in Tonnes.
RMw Raw material required per week
RMw := Qdk ⋅ K 1⋅ 7
4
RMw = 5.04 × 10 Tonnes/Week
RMw
LSw := C L ⋅
100
4
Qsp Stock pile capacity in Tonnes -Live Capacity
Qsp := Qdk ⋅ K1⋅ RMd
4
Qsp = 5.04 × 10 Tonnes
Qstacker Stacker Capacity
Qstacker := 1.5 ⋅ Qcr
Qstacker = 847.5 Tonnes/Hr
Stacker / Stacker Belt Capacity = Qstacker = 847.5 Tonnes/Hr

Book-I Chapter 4
File Name : 1_4_rawgrinding
1_4_rawgrinding_1 Bond Work Index of the various material based on

bond test mill result dry basis
1_4_rawgrinding_2 Calculation of power at Ball Mill shaft for Raw material ,

based on the Bond's work index
1_4_rawgrinding_3 Raw Mill and Auxiliary Equipment Capacity Calculations
1_4_rawgrinding_4 Raw Material Drying - Estimation ofTotal Moisture to be

Evaporated from Feed
1_4_rawgrinding_5 Raw Mill Heat Balance - Evaluation of Hot Gas

Requirement for Drying
1_4_rawgrinding_6 Calculation of Ball Mill Percentage Filling as per

Measurement
1_4_rawgrinding_7 Calculation of Grinding Ball Size
1_4_rawgrinding_8 Specific Heat of Raw Material as a Function of

Temperature
1_4_rawgrinding_9 Estimation of grindability based on the operating
parameters of Mill
1_4_rawgrinding_10 Calculation of Mill Output at Different Fineness of Product
1_4_rawgrinding_11 Calculation of Efficiency of Dynamic Air Separator
1_4_rawgrinding_12 Average Piece Weight ofGrinding Media
1_4_rawgrinding_13 Ball Mill Critical Speed and Ball Charge Calculations
1_4_rawgrinding_14 Verical Roller Mill -- Calculation of Power

1_4_rawgrinding_15n Radiation Loss in Raw Mill Heat Balance

Property of:
Book-I Chapter 4
Topic: Bond Work Index of the various material based on bond test mill result
dry basis
The Bond index of various material based on the Dry basis -
Bond test mill result is calculated as given below.
Pf Product fineness test result ( 80 % Passing - Range > 90 µ ) , µ Pf := 60
Ff Feed size to test mill ( 80 % passing - Range 0-4 mm ) , µ Ff := 2500
Sc Screen size , ( Normally 90 µ size ) , µ Sc := 90
Pr Finished product per mill revolution , gm / rev Pr := 1.36
Calculation
Ws Bond index , kwh/sh.t dry basis
44.5
W s := kwh/sh.t ( dry basis )
0.23 0.82  10 10 
Sc ⋅ Pr ⋅  − 
 Pf Ff 
W s = 11.261 kwh/sh.t ( dry basis )

Book-I Chapter 4
Topic: Raw Mill Heat Balance - Evaluation of Hot Gas Requirement for Drying
Hot gases required for drying of material in raw grinding in ball mill
The hot gases required for the drying of the feed moisture in the raw material while
grinding in close circuit ball mill is calculated as below.
Ght Hot gases temperature , Ght := 280 deg.c

Ghs Specific heat of hot gases Ghs := 0.34 kcal/deg.c-Nm3
Rt Base temperature R t := 20 deg.c
Amb Ambient air temperature Amb := 35 deg.c
Amb s Specific heat of ambient air Amb s := 0.30 kcal/Nm 3.deg.c
Alt Altitude ( From mean sea level ) Alt := 950 m
Fq Fresh feed quantity Fq := 100 tph
Mf Total fresh feed moisture(surface) Mf := 8 %
Mp Total product moisture)surface) Mp := 2 %
Fs Specific heat of raw material Fs := 0.21 kcal/kg.deg.c
Fa False air percentage Fa := 10 %
P Absorbed mill power P := 3000 kw
Eg Amount of dedusting gases Eg := 150000 m 3/hr
Egt Dedusting gases temperature Egt := 105 deg.c
Egs Specific heat of dedusting gases Egs := 0.31 kcal/Nm 3.deg.c
Ra Surface area for Radiation Losses R a := 185 m2
Rf Radiation Loss R f := 50 kcal/m2.deg.c
difference
Calculations
Gh Required hot gas quantity ( Nm3/hr )
RG Circulating air ( Nm 3/hr )
Heat output :
Step :-1 Heat to raw material
(
Hop := Fq ⋅ 1000 ⋅ Fs ⋅ Egt − R t − 5 ) Kcal/hr
6
Hop = 1.68 × 10 Kcal/hr
Note :The raw material temp. is normally less by 5 deg.c. than the exit gas temperature.
Step :-2 Heat to dedusting gases
( )  Eg 
273
Hog := Eg ⋅ Egs ⋅ Egt − R t ⋅   Kcal/hr
 t + 273 
6
Hog = 2.855 × 10 Kcal/hr
Step :-3 Heat loss due to radiation
(
Hor := R a⋅ R f ⋅ Egt − R t ) Kcal/hr
5
Hor = 7.862 × 10 Kcal/hr
Step :-4 Heat loss to evaporate moisture
Moisture to be evaporated
(
Fq ⋅ 1000 ⋅ Mf − Mp )
W := kg/hr
100 − Mf
W = 6522 kg/hr
(
How := W ⋅ 540 + Egt − Amb ) Kcal/hr
6
How = 3.978 × 10 Kcal/hr
Note :The latent heat of evaporation of water is 540 kcal/kg of water.

Step :-5 Heat loss to false air
Eg ⋅ Fa⋅ Amb s ⋅ Egt − R t( )

Hoa := Kcal/hr
100
5
Hoa = 3.825 × 10 Kcal/hr
Total heat loss
Ho := Hop + Hog + Hor + How + Hoa Kcal/hr
6
Ho = 9.682 × 10 Kcal/hr
Heat inputs :
Step :-1 Heat from fresh feed
(
Hif := Fq ⋅ 1000 ⋅ Fs ⋅ Amb − R t ) Kcal/hr
5
Hif = 3.15 × 10 Kcal/hr
Step :-2 Heat from grinding power
Hip := P ⋅ 816 Kcal/hr
6
Hip = 2.448 × 10 Kcal/hr
Step :-3 Heat from false air
(
Eg ⋅ Fa ⋅ Amb s ⋅ Amb − R t )
Hia := Kcal/hr
100
4
Hia = 6.75 × 10 Kcal/hr
Total heat input
Hi := Hif + Hip + Hia Kcal/hr
6
Hi = 2.83 × 10 Kcal/hr
Note :If the heat input is less than the heat output then only we require hot gases.
Let us solve for hot gases requirement.
Gh := 0 Nm3/hr
(
Gh := root  Ho −  Hi + Gh ⋅ Ghs ⋅ Ght − R t )   , Gh Nm3/hr
4
Gh = 7.75 × 10 Nm3/hr
Gh := if ( Hi < Ho , Gh , 0) Nm3/hr
Gh = 77501 Nm3/hr
Note :If the dedusting gases quantity is less than the hot gases required then either
increase the hot gases temperature or increase the dedusting gases amount and run the
heat balance again.
  273  Fa 
Mg := Eg ⋅   − 1.24 ⋅ W − ⋅ Eg Nm3/hr
  Egt + 273  100 
Mg = 85246 Nm3/hr
Gh = 77501 Nm3/hr
Note := if ( Mg ≥ Gh , "O.K." , "Change the hot gases temp. or the dedusting gases quantity" )
Note = "O.K."
Amount of recirculation gases :
RG := if ( Mg ≥ Gh , Mg − Gh , 0) Nm3/hr
RG = 7745 Nm3/hr
Amount of hot gases required for Drying :
Gh = 77501 Nm3/hr
Book-I Chapter 4
File Name : 1_4_rawgrinding_6r1
Topic: Calculation of Ball Mill Percentage Filling as per Measurement
To calculate the percentage of grinding media filling in the ball mill

based on the empty measured height is as below.
Di Mill inside diameter Di := 4 m

H Empty measured height H := 0 m
H Di
θ r
h a
C.G of Charge
Calculations
F H Percentage
- Empty height
fillinginside linersmedia
of grinding in m
r Radius inside lining
Di
r := m
2
r=2 m
Percentage filling :
 H − r
θ := 2 acos   radians
 r 
θ = 6.283 radians
 1 ⋅ r2 ⋅ θ − r⋅ ( H − r) ⋅ sin  θ   ⋅ 100
  
2  2 
F :=
2
π ⋅r
F = 100 %
Notes :
• The filling ratio for close circuit ball mill is in the range of 26-32 %
• The filling ratio for open circuit ball mill is in the range of 26-32 %
• For single chamber ball mill the filling ratio is in the range of 24-28 %
Book-I Chapter 4
Topic: Calculation of Efficiency of Dynamic Air Separator
Calculation method of separator circulation factor and the separator efficiency based on
the percentage passing of feed, product and coarse at a perticular partical cut off size are
as given below.
S Partical cut off size S := 90 microns
Fb Separator feed passing Fb := 70 percent material

%
below cut size
Pb Separator product passing Pb := 88 %
Cb Separator coarse passing C b := 55 %
Calculations :
Ef Separator Efficiency in %
Cf Circulation Factor
Separator efficiency :
Pb  Fb − Cb 
Ef := ⋅  ⋅ 100 %
Fb  P b − C b 
Ef = 57.1 %
Circulation factor :
 100  ⋅ P b
C f :=  E  F
 f  b
C f = 2.2
Book-I Chapter 4
Topic: Average Piece Weight ofGrinding Media
The average peice weight of the grinding media is calculated as given

below.
Chamber - I
i := 0 .. 7
Average peice weight , gm/peice WI BIi := GIi :=
Specific surface , m2/ton SI 100 32.5

90 29.0
Ball size , mm BIi 80 26.5
Grinding media loading , ton GIi 70 23.9
60 16.4
50 0
40 0
30 0
Chamber - II
j := 0 .. 4
BIIj := GIIj :=
Average peice weight , gm/peice WI
60 23.9
Specific surface , m2/ton SI
50 27.1
Ball size , mm BIi 40 32.3
30 20.8
Grinding media loading , ton GIIi 25 0
Calculations
Peice weight of each ball : Surface area of each ball :
  BI  
3
  BI  
2
2⋅ π ⋅  2⋅π ⋅  
  1000     1000   m2
WIi :=   ⋅ 7.8 ⋅ 1000 kg/peice SIi :=  
 12  8
 7.854 × 10 
−3
 4.084   −3 
   6.362 × 10

 2.977   5.027 × −3 
 2.091  10
 
   3.848 × −3 
 1.401  10 2
kg/peice m
WIi = SIi =  
 0.882  −3
 2.827 × 10 
   
 0.511  −3
 1.963 × 10 
 0.261 
   −3 
 0.11   1.257 × 10 
 7.069 × −4 
 10 
Book-I Chapter 5
Raw Meal Section
File Name : 1_5_rawmeal
1_5_rawmeal_1 Calculation of Blending &Storage Silos and Auxiliary

EquipmentCapacity for Raw-meal Preparation
1_5_rawmeal_2 Calculation of Kiln Feed Raw-meal Systems
1_5_rawmeal_3n Calculation of Kiln Feed Raw-meal Quantity

Property of:
Book-I Chapter 6
Preheating Section
File Name : 1_6_preheating
No files here currently

Book-I Chapter 7
Clinkerisation Section
File Name :
1_7_clinkerisation
1_7_clinkerisation_1 Calculation of Kiln and Auxiliary Equipment Capacities
1_7_clinkerisation_2 Leakages Through Kiln Air Seal
1_7_clinkerisation_3 Calculation of Specific Heats of Clinker as a Function of

Clinker Temperature
1_7_clinkerisation_4 Kiln Retention Time and Related Parameters
1_7_clinkerisation_5 Kiln Sinter Zone Cooling Fans
1_7_clinkerisation_6 Kiln Nose Ring Cooling Fans
1_7_clinkerisation_7n Kiln Tyre / Shell Ovality
1_7_clinkerisation_8n Kiln Capacity check
1_7_clinkerisation_9n Degree of Decarbonation of Raw Meal -Definition
1_7_clinkerisation_10n Degree of Decarbonation of Raw Meal Calculation on

Operating Data
1_7_clinkerisation_11n Reaction Enthalpy -Decarbonation and Clinkerisation
1_7_clinkerisation_12n Theoretical Heat of Clinker Formation - Calculation
1_7_clinkerisation_13n Calculation of Kiln Weight under Operating Conditions
1_7_clinkerisation_14n Calculation of Kiln Torque under Operating Conditions
1_7_clinkerisation_15n Calculation for Kiln Hydraulic Thruster
1_7_clinkerisation_16n Kiln Hydraulic Thruster - A Note
1_7_clinkerisation_17n Kiln Drive Specification

1_7_clinkerisation_18n Calculation of expansion of Kiln in hot condition
Calculation of Temerature Profile of Kiln Shell in hot
1_7_clinkerisation_19n
condition
1_7_clinkerisation_20n Calcination Function

Property of:
Book-I Chapter 7
File Name : 1_7_clinkerisation_7n
Topic: Kiln Tyre / Shell Ovality
Calculation for ovality of Kiln Tyres / Shells

Ovality of Kiln shell beyond acceptable limit can effect life of Refractory lining in the
Kiln.Kiln shell gets rigidity only after a tyre has been mounted. However, in case of loose
tyre there exists a gap between the shell and the tyre at the top of the shell.The ovality of
the shell , therefore cannot be guaranteed.But it is important to machine the tyres
accurately with maximum ovality inside not to exceed 0.2%
Perfect Circle is in
Black of Dia.= D
Y D
Oval shape is in Red
having Major Dia.=X
and Minor Dia. = Y
Percentage ovality calculation
D Diameter of Tyre D := 4.4 m
X Measured max. diameter X := 4.405 m
Y Measured min. diameter Y := 4.395 m

OP Percentage Ovality of Tyre ( % )
X−Y
OP := ⋅ 100 %
D
%
OP = 0.227
Tyre ovality should be practically zero when machined and maximum 0.2% on load
(after erection)
During operation at a specific temperature the shell expand and fit exactly into the
Tyre and in such a state the shell ovality is then max 0.2% i.e same as that of tyre on
load.
If the ovalityof shell, specially under the tyre section is in the range of 0.4 to0.5%,
then the refractory life is adversely affected.
In the manufacturing workshop the Kiln shell ovality should be measured after fixing
the spider rings. Otherwise the shell becomes oval under its own weight.
If the ovality of fabricated shells show an ovality of more than 0.2% even with the
spiders mounted, it will be difficult to align the shells during erection prior to welding
of the shells at site.This is an important considerationwhy ovality of Kiln shells also
should be kept atminimum possible value.
Book-I Chapter 7
Topic: Kiln Capacity check
Calculation of capacity and loads for a given size of Kiln
QK Kiln Capacity evaluation ( T/Day )
D meters -Inside shell Dia.
Burner
d meters -Inside refrectory Dia.
D Inside ( shell ) diameter of the kiln D := 4.8 m
W Refractory thickness W := 200 mm

L Overall length of the kiln L := 70 m
N Kiln speed N := 3.5 rpm
α Angle of repose ( Clinker 35 deg. ) α := 35 deg.
β Kiln slope ( Range 3.0-4.0 ) β := 3 %
Calculations :
R LD Kiln L / D ratio
L
R LD :=
D
R LD = 14.583
K TL Kiln Thermal Load ( k.cal /m2.hr.)
Kiln thermal load is calculated based on total heat input to kiln on open cross sectional
area.This should normally not exceed. 4.5 million k.cal. /m2/hr.but can go upto 6.0
million k.cal. /m 2/hr.
6
K Heat input to Kiln K := 60 ⋅ 10 k.cal. / hr.
d Kiln diameter on refractory ( m )
W
d := D − 2 ⋅ m
1000
d = 4.4
K
KTL := k.cal /m2.hr
2
d
π⋅
4
6
KTL = 3.946 × 10 k.cal /m2.hr
Vi Kiln volume on refractory (internal volume)( m3)
2
d
Vi := π ⋅ ⋅L m3
4
3 m3
Vi = 1.064 × 10
QTH Theoretical output of Kiln ( t/ day of clinker )
Output factor =F1 is a function of the type of kiln F1 := 7

For normal preheater kiln F1 = 3.0
For precalciner kiln F1 is 7 to 7.5
3.283 0.33
QTH := F1 ⋅ D ⋅L t / day
3 t / day
QTH = 4.903 × 10
QSP Specific output of kiln ( t / day /m3)
QTH
QSP := t / day /m3
Vi
QSP = 4.607 t / day /m3

Book-I Chapter 7
Topic: Calculation for Kiln Hydraulic Thruster
For calculation of operating thrust of Kiln it is necessary to first determine the total
operating weight of the kiln . Please refer to file no. 1_7_clinkerisation_13
For a more detailed note on Hydraulic Thruster please refer to file 1_7_clinkerisation_16
F TH
KILN
WK
TYRE
KILN SECTION
C.L of KILN
THRUST ROLLER
WK Total operating weight of Kiln W K := 868 MT
o
θ Let the slope of Kiln be θ := 2
To convert slope from degree to radian = θ1
θ θ
θ 1 := ⋅π ⋅ π = 0.035
180 180
θ 1 = 0.035 radian
FTH The thrust applied by kiln on its downhill movement due to the slope ( MT )
 90 − θ 
FTH := W K ⋅ cos ⋅π  MT
 180 
FTH = 30.293 MT
Normally Thrust Rollers are provided on Pier No. 1 only.However , it is possible to

provide two sets of Thrust Rollers in 1st. and 2nd. piers. Insuch a case the load is
shared equally by each roller.
Thrust rollers are fitted with standard hydraulic thrusting devices of standard ratings.
A typical range is shown below
Std. hyd. unit

17.5 MT
31.5
45.0
63.0
90.0
It should be noted that the Thrust Roller on the upper side of the Tyre is to act only as
stopper to prevent the kiln from riding out of the roller during its upward movement.
Book-I Chapter 7
Topic: Calculation of expansion of Kiln in hot condition
Calculation of expansion of Kiln in hot condition
Support - 1 Support -3
Support - 2
KILN
S0 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10
L1
L2
L3
Let total length of kiln at cold condition be LT m

At designed ambient temp. LT = L Where L is kiln length
The kiln is theoretically divided into n equal section - normally 10 sections and is
denoted by A
The shell temperatures for the sections are either measured or taken from experience
LT LT
LT := 70 n := 10 i := 1 .. n Li := A :=
n n
S represents length of cummulative sections of kiln
S 1 represents length upto end of first first section of kiln and S2 upto end of second
section of kiln and so on
S0 := 0
0 0
 205 
0 0 0 0  210 
1 7 1 7  
Si := Li + Si −1 2 7 2 14  230 
 250 
3 7 3 21
 280 
L=
4 7
S=
4 28  
5 7 5 35 T :=  310 
6 7 6 42  310 
 
7 7 7 49
 310 
8 7 8 56  290 
9 7 9 63  270 
10 7 10 70  
 250 
ta := 0 ambient temp
co eff. of linear expan = 0.01215 per deg. C
0
0 0
1 2.491
Ei := 0.01215 ⋅ ( Ti− 1 − ta)
2 2.551
3 2.794
4 3.037 DX represents expansion of kilnsections
E=
5 3.402
6 3.766 DXi := Li⋅ Ei E1 = 2.491
7 3.766
8 3.766
9 3.523
10 3.28 L1 := 13 L2 := 38 L3 := 58
0
0 0
1 17.435
2 17.86
3 19.561
4 21.262
DX =
5 23.814
6 26.365
7 26.365
8 26.365
9 24.665
10 22.963
The shell is equally divided into n equal sections (n is fixed at n =10 )

Expansion of each section is given by DXi in mm
Expansion of sec. 1 DX1 = 17.435 Expansion of sec. 6 DX6 = 26.365


Kiln Shell Temp. Profile

350
Shell temperature -Deg. C
300
Ti
250
200
0 10 20 30 40 50 60 70
Si
Shell length from feed end - m
Support - 1 Support -3
Support - 2
KILN
S0 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10
L1
L2
L3
Kiln Shell Expansion at each section

30
Expansion - mm
25
DXi
20
15
0 10 20 30 40 50 60 70
Si
Shell lengths from feed end -m
Full Shell sections upto L1
A= 7
 L1 
SS1 := trunc   SS1 = 1
A
ESS1 = 2.491
ML1 := mod(L1 , A) ML1 = 6
ESS1⋅ ML1 = 14.944
DXL11 := DX1 + ESS1⋅ ML1

DXL12 := DX1 + DX2 + ESS1⋅ ML1
DXL13 := DX1 + DX2 + DX3 + ESS1⋅ ML1
DXL1 := if(SS1) > 2 , DXL13 , if( SS1 = 1 , DXL11 , DXL 12)
DXL1 = 32.38
 L2 
SS2 := trunc   SS2 = 5
A
ML2 := mod(L2 , A) ML2 = 3
DXL21 := DX1 + DX2 + DX3 + DX4 + ESS2⋅ ML2
DXL22 := DX1 + DX2 + DX3 + DX4 + DX5 + ESS2⋅ ML2
DXL23 := DX1 + DX2 + DX3 + DX4 + DX5 + DX6 + ESS2⋅ ML2
DXL2 = 110.14
 L3 
SS3 := trunc   SS3 = 8
A
ML3 := mod(L3 , A) ML3 = 2

DXL2 = 110.14
DXL31 := DX1 + DX2 + DX3 + DX4 + DX5 + DX6 + DX7 + DX8 + ESS3⋅ ML3
DXL32 := DX1 + DX2 + DX3 + DX4 + DX5 + DX6 + DX7 + DX8 + DX9 + ESS3⋅ ML3
DXL33 := DX1 + DX2 + DX3 + DX4 + DX5 + DX6 + DX7 + DX8 + DX9 + DX10 + ESS3⋅ ML3
DXL3 = 211.228
DXL :=
∑ DX
DXL = 226.658 mm
DXL1 = 32.38 DXL3 = 211.228
DXL2 = 110.14 DXL = 226.658

Book-I Chapter 8
Clinker Cooling Section
File Name :
1_8_clinkercooling
1_8_clinkercooling_1 Calculation of Clinker Transport Equipment Capacity and

Clinker Stockpile
1_8_clinkercooling_2 Calculation of GrateCooler Drive Power
1_8_clinkercooling_3 Calculation of Grate Cooler Recuperation Efficiency -

T.A.Duct Tapping from Cooler
1_8_clinkercooling_4 Calculation of Grate Cooler Recuperation Efficiency -

T.A.Duct Tapping from Kiln Hood
1_8_clinkercooling_5n Calculation of Grate Cooler Offset from Kiln axis

Property of:
Book-I Chapter 8
Clinker Cooling Section
File Name :
1_8_clinkercooling_2
Topic: Calculation of Grate Cooler Drive Power
Grate cooler motor power calculation :
The grate motor power is calculated as below. See Sketch alongside
Pm Grate motor power Pm kw
Ga Grate area Ga := 30 m2
Df Specific cooler grate drive force D f := 11.5 KN/m2
Sl Stroke length Sl := 120 mm
N Max. grate speed ( Shaft speed , rpm ) N := 22 strokes/min
Calculations
F Cooler grate total drive force (Kilo Newton)
F := Ga⋅ D f KN
KN
F = 345
T Torque at ecenctric shaft (KN.m )
Sl
T := F⋅ KN.m
2⋅ 1000
T = 20.7 KN.m
This torque has to be transmitted by Chain wheel
N Maximum RPM of driven sprocket ( strokes per minute )
Shaft power :
2⋅ π ⋅ N ⋅ T
Ps := KW
60
Ps = 47.689 KW
Grate motor power :
Pm := 1.4 ⋅ Ps KW
Pm = 67 KW
Similarly calculate for all grates individually

F
Eccentric
s1/2 o
Eccentric Drive
Gearbox output
Book-I Chapter 9
Cement Grinding Section
File Name :
1_9_cementgrinding
1_9_cementgrinding_1 Calculation of Cement Mill and Auxiliary Equipment
1_9_cementgrinding_2 Calculation of Cement Grindability based on Ziesel Value
1_9_cementgrinding_3 Cement Mill Heat Balance and Calculation of Hot Gas for
Drying
1_9_cementgrinding_4 Calculation of Cement Mill Output as a function of

Grinding Media Load
1_9_cementgrinding_5 Estimation of grindability of Clinker based on the operating

parameters
1_9_cementgrinding_6 Calculation of Water Spray in the Mill for Cooling
1_9_cementgrinding_7n Sizing of Close Circuit Cement Mill
1_9_cementgrinding_8n Cement Mill Output at Different Finenesses
1_9_cementgrinding_9n Cement Mill Cooling Air
1_9_cementgrinding_10n Mill Radiation Loss

1_9_cementgrinding_11n Cement Mill Grinding Performance as a Function of
Surface Generated
1_9_cementgrinding_12n Expected Power Draw of Cement Mill as a Function of
Speed

Property of:
Book-I Chapter 9
File Name : 1_9_cementgrinding_4
Topic: Calculation of Cement Mill Output as a function of Grinding Media Load
Production of the ball mill - Clinker grinding based on Grinding media loading
The theoretical production based on the grindability of the clinker is as given

below.
Pr Production Pr tph
Pf Product fineness Pf := 3200 blaine
Di Ball mill inside diameter Di := 4 m
L Ball mill effective length ( I + II Chamber ) L := 14 m
N Ball mill speed N := 12 rpm
F Percentage filling F := 28 %
G Grindability , Kwh/ton at 3000 blaine G := 30
Kf K factor Kf := 9.55
Calculations
The blaine correction factor :
 ( P f − 3000) 
  ⋅ 0.49
Bf := e
1000 
Bf = 1.103
The grindability at the required product fineness :
Gf := G ⋅ B f Kwh/t .
Kwh/t
Gf = 33.089
The grinding media :
2
π ⋅ Di ⋅ L ⋅ 4.5 ⋅ F
Gm := ton
4 ⋅ 100
Gm = 221.671 ton
The available mill shaft power :
(G m ⋅ Kf ⋅ Di )
P := kw
1.36
P = 3113 kw
The production based on the grindability :
P
Pr := tph
Gf
Pr = 94 tph
Book-I Chapter 9
File Name : 1_9_cementgrinding_8n
Topic: Cement Mill Output at Different Finenesses
Calculation of Mill output at other finenesses
For an operating mill capacity at a certain fineness is known . Following calculation

method predicts expected outputs at other desired finenesses.
Cap Present Mill output Cap := 120 tph
B1 Present fineness of cement acc. to Blaine B1 := 3000 cm2 /gm
B2 Desired fineness of cement acc. to Blaine B2 := 2800 cm2 /gm
Calculations :
Capnew To find what would be new capacity of mill ( tph )
Correction factor = k
B 2− B 1
⋅ 0.213
k := 10 1000
k = 0.907
 Cap , 0 
Capnew := round  
 k 
Capnew = 132 tph

Book-I Chapter 10
Cement Storage Section
File Name :
1_10_cementstorage
1_10_cementstorage_1 Calculation of Cement Transport and Silo and Auxiliary

Equipment

Property of:
Book-I Chapter 10
Cement Storage Section
File Name : 1_10_cementstorage_1
Topic: Calculation of Cement Transport and Silo and Auxiliary Equipment
Many times cement production can be enhanced by grinding coarser than originally
contemplated or by adding Pozzolanic material. Hence it is of great importance to
foresee such possibilities at design stage and design the capacities for maximum
anticipated capacity of the Mill
Step :- 1
To find the capacity of conveyor from Vibrating screen located at discharge of Cement
mill
Transportation of cement from the mill after Vibrating Screen etc.should be designed
for 20 % over capacity w.r.t. mill capacity.
Qcm Max Capacity of Cement Mill Qcm := 120 Tonnes/ hr
F od Over design factor Fod := 1.2
Calculation
Qtr2 Conveyor capacity
Qtr2 := Fod ⋅ Qcm
Qtr2 = 144 Tonnes / Hr.

Step :- 2
To find capacity of Cement silo
Td Capacity in terms of number of days stock Td := 8 days
Th Mill running hours per day Th := 16 Hrs
VBDc Bulk density of cement for volume VBDc := 1.2 Tonnes/m3
Calculation
Qsilo Silo capacity
( Td⋅Qcm ⋅ Th)
Qsilo :=
VBDc
Qsilo = 12800 m3
Step :- 3
To find capacity of Silo Discharge Apparatus
Qp Demand of Packing m/c per hour Qp := 100 Tonnes/Hr
Over design factor (100 %) Fod := 2
Calculation
Qd Silo Discharge Apparatus Tonnes/Hr
Qd := Fod ⋅ Qp
Qd = 200 T/Hr
Note - There should be always a standby discharge apparatus

Book-I Chapter 11
Cement Despatch Section
File Name :
1_11_cmtdespatch
Currently no files here

Book-I Chapter 12
Quality Checks
File Name : 1_12_quality_n
Topic: Expanded Table Of Quality Checks
1_12_quality_1n Loss on Ignition of Kiln Feed Raw Meal
1_12_quality_2n Silica Ratio and Requirement of Components
1_12_quality_3n Alumina Ratio and Requirement of Components
1_12_quality_4n Lime Saturation Factor Calculation
1_12_quality_5n Hydraulic Ratio of Kiln Feed Raw Meal - Calculation
1_12_quality_6n Burnability Factor of Kiln Feed Raw Meal - Calculation
1_12_quality_7n Complex Compounds of Cement Clinker - Calculation by

Bogue's Formulae
Percentage Liquid and Burnability Index Cement Clinker -
1_12_quality_8n
Calculation
Total Carbonate Content in Kiln Feed Raw Meal-
1_12_quality_9n
Calculation
1_12_quality_10n To Calculate Quantity of CaO Required to Attain Specific

Value of Total Carbonate Content in Kiln Feed Raw Meal-
1_12_quality_11n Kiln Dust Loss in Terms of Kiln Feed Raw Meal-and

Apparant Degree of Calcination

Property of:
Book-I Chapter 12
Quality Checks
File Name : 1_12_quality_4n
Topic: Lime Saturation Factor - Calculation
Calculation of Lime Saturation Factor of Kiln feed raw meal ( LSF )
Analysis on Loss Free Basis
PWFe2O3 Percentage of Fe2O3 in Kiln feed raw meal PWFe2O3 := 2.92 %
PWAl2O3 Percentage of Al2O3 in Kiln feed raw meal PWAl2O3 := 5.4 %
PWCaO Percentage of CaO in Kiln feed raw meal PWCaO := 66.01 %
PWSiO2 Percentage of SiO2 in Kiln feed raw meal PWSiO2 := 22.3 %
Calculation
ARRM Alumina Ratio of Raw Meal
PWAl2O3
ARRM :=
PWFe2O3
ARRM = 1.849
Check if the figure ARRM is > 0.64
Condition 1 :-
To find Lime Saturation Factor ( LSF ) When > 0.64
PWCaO
LSF :=
2.8 ⋅ PWSiO2 + 1.65 ⋅ PWAl2O3 + 0.35 ⋅ PWFe2O3
Condition 2 :-
To find Lime Saturation Factor = LSF When < 0.64
PWCaO
LSF :=
2.8 ⋅ PWSiO2 + 1.1 ⋅ PWAl2O3 + 0.7 ⋅ PWFe2O3
By using if statement we can evaluate LSF
 PWCaO PWCaO

LSF := if  ARRM > 0.64 , ,
 2.8 ⋅ PWSiO2 + 1.65 ⋅ PWAl2O3 ...  2.8 ⋅ PWSiO2 ...  ... 
 + 0.35 ⋅ PWFe2O3
 + 1.1 ⋅ PW  
 Al2O3 
 + 0.7 ⋅ PWFe2O3 
 
LSF = 0.912
Book-I Chapter 12
Quality Checks
File Name : 1_12_quality_9n
Topic: Total Carbonate Content in Kiln Feed Raw Meal- Calculation
Calculation of Total Carbonate Content in Kiln Feed Raw Meal
Analysis of Kiln Feed Raw Meal on Raw Basis
PWFe2O3 Percentage of Fe2O3 in Kiln feed raw meal PWFe2O3 := 1.898 %
PWAl2O3 Percentage of Al2O3 in Kiln feed raw meal PWAl2O3 := 3.51 %
PWCaO Percentage of CaO in Kiln feed raw meal PWCaO := 42.907 %
PWSiO2 Percentage of SiO2 in Kiln feed raw meal PWSiO2 := 14.495 %
PWMgO Percentage of MgO in Kiln feed raw meal PWMgO := 1.365 %
PWAlkalies Percentage of Alkalies in Kiln feed raw meal PWAlkalies := 0.413 %
PWSO3 Percentage of SO3 in Kiln feed raw meal PWSO3 := 0.338 %
LOI Loss On Ignition LOI := 35 %
Calculation
TC Total Carbonate (Calculated from Analysis on Raw Basis)
TC := 1.784 ⋅ PWCaO + 2.09 ⋅ PWMgO
TC = 79.399 %
Note if the analysis is given in Loss Free Basis then multiply by conversion factor
=FLFtoR
100 − LOI
FLFtoR :=
100
Conditional Calculation
Let us define Analysis Basis as = BASIS
If analysis is on Raw Basis then
If analysis is on Loss Free Basis then
Define BASIS
BASIS := 1
( )
TC := if  BASIS > 0 , 1.784 ⋅ PWCaO + 2.09 ⋅ PWMgO , FLFtoR ⋅  1.784 ⋅ PWCaO ...  
  + 2.09 ⋅ PW 
  MgO  
TC = 79.399
Book-I Chapter 13
Raw Materials
File Name :
1_13_rawmaterials_n
Topic: Expanded Table Of Raw Materials
1_13_rawmaterials_1n Raw Materials for Cement Production

Property of:
Book-I Chapter 13
Raw Materials
File Name : 1_13_rawmaterials_1n
Topic: Raw Materials for Cement Production
Variable Definitions for Raw materials section
Principle Raw Materials :
Lime stone : principal source of CaCO3 and hence CaO

Clay : principal source of SiO2
Sand stone : principal source of SiO2
Laterite : principal source of Fe2O3
Alumina : principal source of Al2O3
The principle oxides that constitute cement clinker are:
CaO represented by C
SiO2 represented by S
Al 2O3 represented by A
Fe2O3 represented by F
Rest components represented by R
Complex compounds of Cement are represented by :
Tricalciun silicate is represented by C 3S

Dicalcium silicate is represented by C 2S
Tricalcium aluminate is represented by C 3A
Tetracalcium alumino ferrite is represented by C 4AF
Raw materials as analysed in Laboratory are reported as Raw Basis

The final clinker is the product after combustion, during which process, the raw
materials lose gaseous components . Thus the resultant balance material analysis is
reported without possibility of any further loss. This report is termed as loss free
basis.By predicting the anticipated losses , it is possible to report the analysis of raw
material s in Loss Free Basis.
Since the Raw meal is a mix of two or more raw materials, the analysis is indexed to
indicate the belongingness of particular values as follows.
raw material -1 raw material -2 raw material -3 Ash
[ CaO ] C1 C2 C3 C ASH
[ SiO2 ] S1 S2 S3 SASH
[ Al2 ⋅ O3 ] A1 A2 A3 AASH
[ Fe2 ⋅ O3 ] F1 F2 F3 FASH
And So On
[ LOI ] LOI1 LOI2 LOI3 LOIASH
When the total of all components including LOI is 100% then the analysis is reported in
Raw Basis
When the total of all components excluding LOI is 100% then the analysis is reported in
Loss Free Basis.
To convert from one basis to another following steps can be followed
Step :- 1 To convert to Loss Free Basis from Raw Basis
OR
OI := ⋅ 100 %
100 − LOI
Or
Let 100
FRtoLF :=
100 − LOI
Then
O1 := FRtoLF ⋅ OR
OI represents percentage oxide value in Loss Free Basis
OR represents percentage oxide value in Raw Basis

LOI represents percentage lOSS ON IGNITION in Raw Basis
FRtoLF is common factor for conversion fron Raw To Loss Free basis
Step :- 2 To convert from Loss Free Basis to Raw Basis
( 100 − LOI) ⋅ OI
OR := %
100
Or
Let
100 − LOI
FLFtoR :=
100
Then
OR := FLFtoR ⋅ OI
OI represents percentage oxide value in Loss Free Basis
OR represents percentage oxide value in Raw Basis
LOI represents percentage lOSS ON IGNITION in Raw Basis

FLFtoR is common factor for conversion fron Raw To Loss Free basis
Analysis on Loss Free Basis
F Percentage of Fe2O3 in Kiln feed raw meal F := 2.92 %
A Percentage of Al2O3 in Kiln feed raw meal A := 5.4 %
C Percentage of CaO in Kiln feed raw meal C := 66.01 %
S Percentage of SiO2 in Kiln feed raw meal S := 22.3 %
MGO Percentage of MgO in Kiln feed raw meal MGO := 2.1 %
AL Percentage of Alkalies in Kiln feed raw meal AL := 0.635 %
REST Percentage of Rest oxides in Kiln feed raw meal REST := 3.2 %
LOI Percentage of Loss On Ignition in Kiln feed raw meal LOI := 35 %
100 − LOI
FLFtoR :=
100
FLFtoR = 0.65
Analysis on Raw Basis
FR Percentage of Fe2O3 in Kiln feed raw meal FR := FLFtoR ⋅ F %
AR Percentage of Al2O3 in Kiln feed raw meal AR := FLFtoR ⋅ A %
CR Percentage of CaO in Kiln feed raw meal C R := FLFtoR ⋅ C %
SR Percentage of SiO2 in Kiln feed raw meal SR := FLFtoR ⋅ S %
MGOR Percentage of MgO in Kiln feed raw meal MGOR := FLFtoR ⋅ MGO %
ALR Percentage of Alkalies in Kiln feed raw meal ALR := FLFtoR ⋅ AL %
RESTR Percentage of Rest oxides in Kiln feed raw meal RESTR := FLFtoR ⋅ REST %
FR := FLFtoR ⋅ F FR = 1.898
AR = 3.51
AR := FLFtoR ⋅ A
C R := FLFtoR ⋅ C C R = 42.907
SR := FLFtoR ⋅ S SR = 14.495
MGOR := FLFtoR ⋅ MGO MGOR = 1.365
ALR := FLFtoR ⋅ AL ALR = 0.413
RESTR := FLFtoR ⋅ REST RESTR = 2.08
LOI Percentage of Loss On Ignition in Kiln feed raw meal LOI := 35 %

Book-I Chapter 14
Cement
File Name : 1_14_cement_n
Topic: Expanded Table Of Cement
1_14_cement_1n Evaluation of combined water in cement

Property of:
Book-I Chapter 14
Cement
File Name :
1_14_cement_1n
Topic: Evaluation of Combined Water in Cement
After hydration of cement water that is chemically combined with the compounds
and form part of the solid is called combined water.There also exists adsorbed
water and free water .
The water that is held at the surface of the cement by surface tensionof gel
particles is called adsorbed water or gel water.
Water that is held in the pores of the solid paste is free water or capillary water.
Let combined water in set and hardened cement be W C gm
Let the quantity of cement be C gms
then W C / C ratio is given by the following formula
WC
= a1 ⋅ [ C 3 ⋅ S ] + a2 ⋅ [ C 2 ⋅ S ] + a3 ⋅ [ C 3 ⋅ A ] + a4 ⋅ [ C 4 ⋅ A ⋅ F ]
C
let us call this ratio = r so that
r = a1 ⋅ [ C 3 ⋅ S ] + a2 ⋅ [ C 2 ⋅ S ] + a3 ⋅ [ C 3 ⋅ A ] + a4 ⋅ [ C 4 ⋅ A ⋅ F ]
Co- efficients are given by the following table ( acc. to Kantro and Copeland)
data :=
0 1 2
0 0.23 0.23 0.23
1 0.17 0.18 0.2
〈 0〉
a1 := data Corresponds to co-efficients when cement is hydrated
for 1 year
〈 1〉 Corresponds to co-efficients when cement is hydrated
a6.5 := data for 6.5 year
〈 2〉
a13 := data Corresponds to co-efficients when cement is hydrated
for 13 year
 0.228   0.234   0.23 
     
a1 =
 0.168 
a6.5 =
 0.178 
a13 =
 0.196 
 0.429   0.504   0.522 
     
 0.132   0.158   0.109 
Valid for t equal to 1,

let the time period of hydration be = t years t := 13 6.5 and 13 only
and let cement constituents be in % [ C 3 ⋅ S ] := 51
[ C 2 ⋅ S ] := 27
[ C 3 ⋅ A ] := 13
i := 0 .. 3
[ C 4 ⋅ A ⋅ F ] := 9
( (
a := if t = 1 , a1 , if t = 13 , a13 , a6.5 ))
[ C3⋅S ] [ C2⋅S ] [ C3⋅A ] [ C4⋅A ⋅F ]
r := a0 ⋅ + a1 ⋅ + a2 ⋅ + a3 ⋅
100 100 100 100
 0.23  a0 = 0.23
r = 0.248
 
a=
 0.196  a1 = 0.196
 0.522  a2 = 0.522
r = 24.789 %   a3 = 0.109
 0.109 
This would mean that after 13 years, the cement has combined water of 24.789 %
of its weight .
Let quantity of cement be C := 10gm
W C := r ⋅ C
W C = 2.479 gm
Book-II Chapter 1
Plant Site Condition
File Name :
2_1_sitecondition
2_1_sitecondition_1 The Barometric pressure at site based on the altitude

and temperautre.

Property of:
Book-II Chapter 1
Plant Site Condition
File Name :
2_1_sitecondition_1
Topic: The Barometric pressure at site based on the altitude and temperautre.
The Baraometric pressure based on the altitude of the site and the ambient temperature is
calculated as given below.
Bp Barometric pressure Bp mm of Hg
Alt Altitude ( Above mean sea level ) Alt := 500 m
Amb Ambient temperature Amb := 35 deg.c
Calculations:
Elevation factor
1
Ef :=
5.255
 1 − 0.0065⋅ Alt 
 
 288 
Ef = 1.061
Site pressure at zero deg.c. temperature
760
P := mm of Hg
Ef
mm of Hg
P = 716
Barametric pressure at ambient temperature
Bp := P⋅  
273
 mm of Hg
 273 + Amb 
mm of Hg
Bp = 635
Book-II Chapter 2
Dedusting Systems
File Name : 2_2_dedusting
2_2_dedusting_1 Estimation of Vent Air Volume
2_2_dedusting_2_1r K- Factors
2_2_dedusting_3 Calculation of Pressure Losses in Ductings
2_2_dedusting_4 Design Parameters for Design of Duct Systems
2_2_dedusting_5 Duct Balancing
2_2_dedusting_6 Glass Bag House -Calculation of Gas Volume as Function

of temperature.
2_2_dedusting_7 GCT and ESP -Calculation of Gas Volume
2_2_dedusting_8n Sizing of Gas Conditioning Tower
2_2_dedusting_9n Electrostatic Precipitator- Deutsch Efficiency Formula
2_2_dedusting_10n Electrostatic Precipitator- Specific Collection Area
2_2_dedusting_11n Electrostatic Precipitator- Performance Evaluation
2_2_dedusting_12n Electrostatic Precipitator- To calculate Migration Velocity
2_2_dedusting_13n Chimney Design

Property of:
Book-II Chapter 2
Dedusting Systems
File Name :
2_2_dedusting_1
Topic: Estimation of Vent Air Volume
ESTIMATION OF VENT AIR VOLUMES
Estimation of vent air volume is the first step in engineering a dust collection system. The
air volume to be vented form any machinery hood or transfer point depends on many
factors such as the physical nature of the material handled, air currents and surges
created by the movement of machinery parts and materials, the type of enclosure
provided. Therefore, certain accepted standards which give rule-of-thumb methods have
to be followed. The following recommended procedures extracted from:
Industrial Ventilation-
Published by American Conference of Government
Industrial Hygienists, U.S.A.
could be used as guideline in estimation of air volumes.
It may be noted here, for guidance, that when the venting volume is expressed in cubic
meters, this refers to actual operating conditions at site under consideration. however, if
the volume is expressed in NM 3, then this volume is to be corrected for actual operating
temperature and altitude above mean sea level.
1. CLOSED TOP BINS:

Volume = K x volume of entering material.
The value of K ranges form 1 (for large bins, low feed rates, coarse feed) to
50 (small bins, high feed rate, fine material).
The minimum rate is 3600 M3/Hr per M2 of bin opening.
2. BUCKET ELEVATORS:
1800 M3/Hr/Sq. Metre of elevator casing section. For elevators over 10 M height,
connect exhaust from both top and bottom.
3. BELT CONVEYORS:
3600 M3/Hr per sq. metre of openings in enclosure, but minimum
1950 M3/Hr/metre belt width for belt speeds under 1 M/sec.
2800 M3/Hr/metre belt width for belt speeds over 1M/sec.
Additional volume for greater than 1 metre fall and dusty material:
1200 M3/Hr for belt width 300 mm to 1000 mm
1700 M3/Hr for belt width above 1000 mm
4. FLAT DECK SCREEN:
3600 M3/Hr/M2 through hood openings, but minimum.
900 M3/Hr/M2 screen area.
5. CYLINDRICAL SCREEN:
1800 M3/Hr/M2 circular cross section of screen, but minimum.
7200 M3/Hr/M2 of enclosure opening.
6. AIRVEYOR & PNEUMATIC SCREW PUMP SYSTEMS:

Multiply free air volume of the system as follows:
For conveying distances upto 150 M --- 1.5 times
For conveying distances over 150 M --- 1.75 times
7. PNEUMATIC GRAVITY CONVEYOR & BLENDING SYSTEMS:

1.0 times free air volume of the system.
8. SCREW CONVEYORS:
If dust tight, ventilate feed point only. Use 1100 M3/Hr per metre of nominal conveyor
diameter corrected for height of fall of feed.
9. CRUSHERS:
At feed end: Minimum of 2700 M3/Hr/M2 of feed hood opening.
At discharge: Measure air current surges and allow 50% excess.
10. ROTARY CRUSHER:

These act as fans. Restrict ingress of air at feed point. Measure air quantity at
discharge and add 50%. (Crusher manufacturer's recommendations to be called for).
11. GRINDING MILLS:

Use the larger of the following:
A. 0.5 M/sec to 0.6 M/sec through the cross section area of the mill.
B. 1 M/sec through each aperture.
C. 8.5 M3/Hr/HP of Raw Mill motor rating.
D. 13 M3/Hr/HP of Cement Mill motor rating.
(N.B. These figures are for operating temperatures of the Mills).
12. MECHANICAL AIR SEPERATORS:
Where cooling or drying is carried out in Separator, use outlet volumes from detailed
calculations. Maximum air volumes at 88 oC are indicated below for Air Separators:
Separator Size *Volume at Sea Level
4.267 M dia. 31,300 M3/Hr
4.877 M dia. 44,000 M 3/Hr
5.486 M dia. 59,500 M 3/Hr
6.096 M dia. 74,000 M 3/Hr
6.706 M dia. 83,300 M 3/Hr
7.315 M dia. 92,700 M 3/Hr
* For any other temperature or altitude, correct volume by applying density
correction factor.
13. GRATE OPENINGS:
A. (Floor or bench dumping - not enclosed)

2700 to 3600 M3/Hr/M2 of grate area.
B. (Enclosed three sides and top)
2700 M3/Hr/M2 of net face area.
14. 60 T/Hr CEMENT PACKER :

i) Packer Guard --- 100 M3/Min.
ii) Top of Packer --- 15 M3/Min.
iii) Control Screen --- 20 M3/Min.
Book-II Chapter 2
Dedusting Systems
File Name : 2_2_dedusting_5
Topic: Duct Balancing
BALANCING OF DUCT SYSTEM RESISTANCE
1. In a ducting network having branch entries or exits, it is essential to balance system

resistance at every joint (i.e., where a branching takes place), in order to obtain desired
flow rate in each branch.
2. In the typical network shown below, balancing

is to be done as follows:
8
6
7 9
Dedusting Network
13
10 12
1
11
Junction Reference Balance Resistance between Resistance
13 11:13 & 12:13 R 13
2 1:2 & (R13+13:2) R2
3 10:3 & (R2+2:3) R3
R 3 + R3,4 + R4,5 = R5
5
5:6 & 5:7 (R5 + R5,6)/ R6 = (R5 + R5,7)/ R7
(R7 + R7,8)/ R8 = (R7 + R7,9)/ R9

7 7:8 & 7:9
Total system resistance = R6=R8=R9
Fan SP = R6 + Outlet VP at '6'
3. Actual Balancing: Typical at junction 13
1. Find volume flow rate - m 3 at temp. Deg. C, at point 11 & 12 (m3/sec, 0C)
2. Select velocities in ducts 11,13&12,13 (m/sec)
3. Select Main & Branch - 11_13 Main, 12_13 Branch entry
4. Find resistance Wg in 11_13&12_13 say R1 & R2 respectively (mm of Wg)

5. Find which is higher resistance - say R1 > R2
6. Find percentage of balance = ((R 1 - R 2)/ R 1) x 100 %
7. Item 6 should be < 20%
8. If item 6 > 20% redo, line with less resistance 12,13. Increase velocity, to find R12 , 13
> R 2 say, now R12_13 = R 3
9. Recheck % balance, i.e., find which resistance is greater between R 3 & R1

say R 3 > R 1
Therefore, % balance = ((R 3 - R 1)/R 3) x 100% < 20% O.K.
10. Now between R 3 & R 1 which are within 20% of balance, R 3 > R 1
11. Now governing resistance is R 3 = R 13 which is resistance in line 12_13
12. Re-evaluate volume flow in line 11_13 for this governing pressure
Vol 11_13 = Qfinal = Qestimated x square root (R 3/R 1)
where R 3 and R 1 are in mm of Wg.
Qestimated = Original estimated volume flow (m3/sec)
Qfinal = actual volume flow or corrected (m3/sec)
13. Now we know volume flow at 13_2 which is Q11_13 + Q12_13=Q13_2

If there is appreciable temp difference between two air current, find volume of mix and
temp.
14. Select velocity in 13_2, which should be velocity in 11_13 & 12_13
15. Find resistance in 13_2 (mm of Wg)
16. Add R 13 to item 15 to get resistance in point 2 = R 13 + R 13_2

17. Find VP in line 13_2 (velocity will depend upon standard pipe)
VP = V2 x Pair/2g mm of Wg (for metric)
18. Find equivalent VP in terms of velocity in line 11_13&12_13, say, line 1&2
respectively
therefore, equivalent VP = VP1_2
=(Q 1 + Q2)2 x Pair / (A1 + A2)2 x 2 g mm of Wg (for metric system)
For metric system: Pair = Kg/m3
Q1 = m 3/sec in Branch 1
Q2 = m 3/sec in Branch 2
A 1 = m 2 - area or Branch 1
A 2 = m2 - area or Branch 2
g = 9.81 m/s 2 - Accelaration due to gravity
19. Find difference between VP in line 13_2 and equivalent VP

i.e., (VP13_2 - VP1_2) < 2.5 mm of Wg
20. If fig in 19 above is > 2.5 mm of Wg then add this to resistance of line 13_2, to get
resistance at point 2
therefore, Pressure at point 2 = R13 + R13_2 + (VP13_2 - VP1_2) mm of Wg
This resistance is added to indicate requirement of extra pressure for accelaration to
higher velocity, required in the line, after a branch has been connected.
21. Proceed for balancing at joint 2 as described for joint 13 and so on, till complete
network is balanced.
Abbreviations used:
R 1_2 - means resistance between point 1 & 2
R2 - means resistance / static pressure at point 2
VP - Velocity Pressure
Book-II Chapter 2
Dedusting Systems
File Name : 2_2_dedusting_9
Topic: Electrostatic Precipitator- Deutsch Efficiency Formula
This example is for understanding of Deutsch Formula and not for evaluation of ESP
efficiency
An appreciation of Deutsch Formula
Efficiency of an ESP is defined by its capacity to remove dust from the carrying gases. If
the gas volume flow rate is constant, the dust concentration at the inlet and at the out let
can be denoted by the following variables.
RO Dust concentration at ESP inlet R O := 60 gms. / m 3
RC Dust concentration at ESP outlet R C := 0.1 gms. / m 3
η Then the efficiency of dust collection
RC
η := 1 −
RO
η = 0.998
We shall assume the following:
1) Dust particles are uniformly distributed over the entire cross sectional area of ESP
2) Dust collected on the plates are not reentrained into the gas stream.
3) Influence of Electric Wind is negligible.
4) Under the influence of Electric field, the charged dust particles move towards the
collecting electrodes at uniform velocity = W cms. / sec.
5) The gas velocity in the ESP = v m/sec. is constant
W V
d
RO
Collecting Electrode
b dx
RC
x
Discharge Electrode
g The amount of dust particle at this space g gms.
RX Let dust conc. at distance x from inlet be R X := 30 gms. /m3

d Let the distance between collecting and d := 0.15 m
discharge electrode be
b Let us denote the electric field height b := 1 m
dx Let us consider an inter electrodes space dx := 0.01 m

of length at a distance = x from inlet.
g := R X ⋅ b ⋅ 2 ⋅ d ⋅ dx
b . 2d . dx is equal to the volume of the inter electrode space of length dx -

considered in m3
g = 0.09 gms.
df Now the elemental collecting area ( m2 )
df := 2 ⋅ b ⋅ dx m2
df = 0.02 m2
Let us now assume that a quantity of dust = dg gms. settle on this elemental area at a
time dt after a time tx ( the time to travel fron inlet to distance = x )
This means , all the dust particles with migration velocity of = W/100 m/sec., within a
distance of W x dt/100 from the two surfaces of collecting area will settle down on the
plates. Since the particles are assumed to be uniformly distributed, the gas volume which
contain all these dust particles = V m 3
quantity of dust = dg gms. settle on this elemental

area at a time dt sec.after a time tx ( the time to dt := .04
travel fron inlet to distance = x )
W Migration velocity W := 13 cm/sec
W
V := 2 ⋅ b ⋅ dx ⋅ ⋅ dt m3
100
−4
V = 1.04 × 10 m3
Since the dust content in this space is RX gms.dust settled =dg
R X = 30
dg := R X ⋅ V
−3 gms.
dg = 3.12 × 10
Since dust is removed from gas , we will assign negative (-) sign to the value of dg
dg := −dg
−3
dg = −3.12 × 10 gms.
dg
k :=
g
k = −0.035
Now let us put the limits of dust loading and time and integrating we get the following
RC
⌠ 1
 dg = −6.397
 g
⌡R
O
RC
⌠ 1
K1 :=  dg
 g
⌡R
O
time tx ( the time to travel fron inlet to distance = x ) tx := 5
tx
⌠
K1 := −
W
dt
 100 ⋅ d
⌡0
Or
 RX  −W
ln   := ⋅ ( tx − 0)
 R O  100 ⋅ d
Or
tx
− W⋅
100⋅ d
R X := R O ⋅ e
Since the gas travels through the total active length of the ESP = L m in total time = t
sec. at a velocity = v m/sec. we have:
L Total length of ESP L := 12 m
v Gas velocity v := 0.8 m/sec
L
t := sec
v
sec
t = 15
RC Dust conc. at outlet (gms. / m3)
−W t
⋅
100 d
R C := R O ⋅ e
gms. / m 3
R C = 0.000136
R C := 1000 ⋅ R C mg / m 3
R C = 0.136 mg / m 3
Or
RC
η := 1 −
RO
η = 0.998
Or
−W t
⋅
100 d
RO ⋅e
η := 1 −
RO
Or
−W t
⋅
100 d
η := 1 − e
Since t= L/v we can write the expression as
−W L
⋅
100 v⋅ d
η := 1 − e
−W L
⋅
100 v⋅ d
e
 −1 ⋅ W ⋅ L  = 2.26 × 10− 6
exp 
 100 ( v ⋅ d) 
η = 0.9999977397
Where
W Migration velocity in ( cm. / sec )
L Total active length of ESP in ( m )
d Distance between Collecting and Discharge Electrodes in ( m )
v velocity of gas in ( m/sec )
η efficiency of collection
Now please refer to evaluation of Sp. Collecting Area = f m2/m3/sec
L
f := W ⋅
v⋅d
So the Deutsche formula can be written as

−W L
⋅
100 v⋅ d
η := 1 − e
Or
− W⋅f
100
η := 1 − e
Corrollaries
In the process of deriving the basic formula for ESP collection efficiency we can make the
following important observations.
−W L
⋅
100 v⋅ d
η := 1 − e
1) For same efficiency and all other conditions of operations remaining same W/d is a
constant = K1 Or W= K1*d
i.e. W increases in direct linear proportion to d - the distance between collecting and
discharge electrodes.This would , however, mean higher voltage and rating of
Transformer / Rectifier sets
2 ) W / v is a costant i.e W increases in direct proportion of v - velocity of gases.But the

velocity cannot be increased very much as it has negative influence of re- entraining the
dust particles.
Book-II Chapter 3
Laboratory Investigations
File Name : 2_3_laboratory
2_3_laboratory_1 Quantity of Raw Material Samples for Lab. Investigation
2_3_laboratory_2 Coal Samples -A Point of View
2_3_laboratory_3 Purposes of Tests
2_3_laboratory_4 Tests Conducted at Physical Laboratory
2_3_laboratory_5 Chemical Tests
2_3_laboratory_6 Mineralogical Investigations
2_3_laboratory_7 Fuel Investgation
2_3_laboratory_8 Raw Mix Investgation
2_3_laboratory_9 Burnability Investigation
2_3_laboratory_10 Separation of ESP and Filter Dust
2_3_laboratory_11 Volatility

Property of:
Book-II Chapter 3
File Name : 2_3_laboratory_5
Topic: Chemical Tests
Tests Conducted at Chemical Labs:

For ease of understanding a sample Lab report has been referred to:
Summary report/observation:
1) It may be observed that Sulphate Resistant cement is defined as ∼ASTM - Type V
where C 3A ≤ 5% and (C 4AF + 2C 3A) ≤ 20%.
2) Alkali equillibrium factor Q is < 1 (Q=0.71). Hence no alkali by pass is required.

If Chlorine content is > 0.04% then Alkali by pass is necessary (Cl - Free of Loss basis).
Alkali & Sulphates combine to form alkali sulphates.
when Q = 1 all alkalies combine with sulphates. (Equillibrium)
Q > 1 There is excess of SO3.
Q < 1 There is Alkali excess.
SO3
Q= 80
Na 2O
62 + K 2O
94 + Cl
71
where SO3, Na2O etc are % of these present in Clinker (including ash effect) on loss free
basis. 80, 62 etc. represent Molecular weight of SO3, Na2O etc.
3) Influence of fuel ash is significant and reduces Lime standard by 10 points, eg. from
105 in Raw meal to 95 in clinker.
4) Burnability is normally poor with high Quartz content in Raw meal. But due to the fact
that most of the quartz is in size fraction < 90µ, the influence of same on Burnability is
minimum.
5) Raw mix and ESP dust (size fraction 0 - 32µ) show similar chemical composition.
Individual Tests:
All raw materials are assessed interms of colour, structure, hardness in mole's scale,
moisture content on receipt and moisture absorption when kept under water.
Under water storage of material reveals its properties with respect to flowability specially
for clay etc. Crushing strength is determined for crusher selection.
Bulk density of material is determined after crushing the material in laboratory crusher.
This value is used to determine storage value, eg. for stockpile value, Raw material
hopper value etc. The grain size analysis is done after crushing in the Laboratory
crusher to predict grain size distribution after crushing operation in industrial scale and
this information is used in crusher selection & design.
Chemical composition of Raw materials is determined by Atomic Absorption test. This

can also be done by X'ray analysis. Individual components are determined as under:
%SiO2 - By Atomic absorption test (AAS)

%Al2O3 - By Atomic absorption test (AAS)
%TiO2 - Calorimetric - By Photometer
%Fe2O3 - By Atomic absorption test (AAS)
%Mn2O3 - By Atomic absorption test (AAS)
%CaO - Complexometric - Titration
%MgO - By Atomic absorption test (AAS)
%SO3 - (Total Sulphur) LECO
%P2O5 - Calorimetric - By Photometer
%Na2O - By Flame Photometer
%K2O
%Cl - By Titration
Book-II Chapter 3
File Name : 2_3_laboratory_8
Topic: Raw Mix Investgation
Rawmix Design:
One of the most important purpose of various tests is to determine a suitable Raw mix
capable of producing cement of desirable quality. We have already analysed
composition of various raw materials and correctives as well as fuel ash. Following
parameters are fixed:
1) Consider coal ash absorption in clinker as 100%.
2) Set value for lime standard at 95%. This is the most important set value for
determining Raw mix composition so that Lime saturation factor in clinker is 95%.
Normal range 92 - 97% in clinker.
3) Second set point is for Silica ratio (2.4 to 2.8 in clinker).
4)Third set point is for Alumina ratio (1.8 to 2.2 in clinker).
For solving the equations, following rule may apply.
For 2 component mix - 1 set point i.e., Lime saturation factor
3 component mix - 2 set point i.e., Lime saturation factor and Silica ratio
4 component mix - 3 set point i.e., Lime saturation factor, Silica ratio, Alumina
ratio
Normal liquid phase - 22 - 28%

If liquid phase is less, then cement is harder to burn, and produces SRC(Sulphate
resistant cement). Various formulae for different ratios are indicated. If TiO2 and Mn2O3
are separately determined, then TiO2 should be included in Al2O3 and Mn2O3 should be
included in Fe 2O3 for calculating the ratios.
Book-II Chapter 4
Fuels and Fuel Systems
File Name : 2_4_fuel
2_4_fuel_1 Calculation of Capacities in Coal Preparation Section
2_4_fuel_2 Calculation of Coal Analysis and Heat Values of Coal
2_4_fuel_3n Calculation of Combustion air
2_4_fuel_4n Calculation of Products of combustion
2_4_fuel_5n Calculation of Flame Temperature
2_4_fuel_6n Reactivity of Coal as a Function of Fineness

Property of:
Book-II Chapter 4
File Name : 2_4_fuels_2
Topic: Calculation of Coal Analysis and Heat Values Coal
Fuel Analysis and Calculation of Heat Values of Coal
This document covers fuel analysis and heat values calculation for solid fuel and liquid
fuel namely, coal and fuel oil respectively.
If a fuel as received in the plant is analysed without any change in its state then it will be
termed as "Analysis (as received basis)".
Normally ultimate analysis of fuel on as received basis will be available from the
laboratory.
Solid fuel i.e., Coal, in many a case, is dried to a large extent before being fired into the
furnace. Dryers used are capable of drying the surface moisture of coal and the inherent
moisture remains in coal. This is because the temperature of coal is not allowed to
exceed 80-100 0C (to avoid coking and preignition in the pipeline) and at this
temperature, with sufficient heat available only surface moisture can be dried where as to
dry inherent moisture, the coal should be heated to 108 0C. This is not done due to
associated 'Process problems'.
In any material's drying operation, inherent moisture cannot be dried at temperature <
100 0C. Inherent moisture is a function of property of material's degree of being
hydroscopic.
It must be understood that ultimate analysis of coal (as received), indicates the total
moisture content in coal i.e., surface + inherent moisture and so is the case with coal
analysis (as fired). Analysis (dried basis) reports zero percent moisture in coal since all
the moisture is first driven out under controlled heat before analysis is undertaken.
COAL:
1. Of the various rank and types of coal, we shall confine ourselves to Bituminous coal as
available in India.
2. Coal has basically two parts - i) Organic and ii) Inorganic.

Organic part consists primarily of moisture(inherent and free), hydrocarbons, fixed
carbon and the inorganic part consists of minerals like Kaolinite, Pyrite, Rutite. Main
elements in organic part are H2, N2, S, O2 and to some extent Cl etc.
The various types of coal are Peat, Lignite, Brown, Semi Bituminous, Bituminous,
Anthracite, Graphite
On Proximate analysis, H 2O, Ash, volatile matter and fixed carbon are reported. Ash is
non-combus- tible and is generated by minerals minus moisture in clay and CO2 from
carbonate. Organic part gives volatiles, H2O, and fixed carbon.
3. Coal, as received in plant, is termed coal(as received). All coal contains moisture.
Moisture as reported on coal(as received), is total moisture consisting of surface
moisture(due to washing or rain) and inherent moisture(due to property of coal itself to
absorb moisture in humid air). Surface moisture can be dried if left in the air and the coal,
so dried is termed as coal(air dried). If air dried coal is heated under controlled condition
at 108+2 0C, inherent moisture is dried up. Coal so dried is termed as coal(dried or oven
dried). It may be mentioned here, that in industrial drying of coal in dryers, coal is dried in
air, with coal temperature not exceeding 65-80 0C. Through this process of drying only
surface moisture can be dried.
Inherent moisture in coal can vary from 1 to 14% depending on the nature of coal itself.
Coal absorbs water from air and attains saturation level depending upon the humidity
and temperature of surrounding air. Hence, even if coal was dried at 108 0C to remove
inherent moisture it would once again absorb the equivalent quantity of moisture on
storage in hoppers. Hence in industrial application this is wasteful and not practiced.
4. Coal analysis must report total moisture, inherent moisture and surface moisture in
coal (as received).
Proximate Analysis - Typical Report
Basis of report - As received

Surface moisture, H 2O(S) Msur1 := 7.0% Msur1 = 0.07
Inherent moisture, H2O(I) Minh1 := 3.0% Minh1 = 0.03
Total moisture,
H2O=H 2O(S)+H2O(I) Mtot1 := Msur1 + Minh1 Mtot1 = 0.1
Ash A1 := 22.0% A1 = 0.22
Volatiles V1 := 16.0% V1 = 0.16
Fixed Carbon C1 := 52.0% C1 = 0.52
Mtot1 + A1 + V1 + C1 = 1
Generally higher the volatiles, higher is the inherent moisture.
Hence, Analysis of Air Dried Coal is as follows:

Surface moisture, H 2O(S) Msur2 := 0
1
Inherent moisture, H2O(I) Minh2 := Minh1 ⋅ Minh2 = 0.032
1 − Msur1
Total moisture,
H2O=H 2O(S)+H2O(I) Mtot2 := Msur2 + Minh2 Mtot2 = 0.032
1
Ash A2 := A1 ⋅ A2 = 0.237
1 − Msur1
1
Volatiles V2 := V1 ⋅ V2 = 0.172
1 − Msur1
1
Fixed Carbon C2 := C1 ⋅ C2 = 0.559
1 − Msur1
Mtot2 + A2 + V2 + C2 = 1
Analysis of Coal (Dried)

Surface moisture, H 2O(S) Msur3 := 0
Inherent moisture, H2O(I) Minh3 := 0

Total moisture, Mtot3 := Msur3 + Minh3 Mtot3 = 0
H2O=H 2O(S)+H2O(I)
1
Ash A3 := A1 ⋅ A3 = 0.244
1 − ( Msur1 + Minh1)
1
Volatiles V3 := V1 ⋅ V3 = 0.178
1
Fixed Carbon C3 := C1 ⋅ C3 = 0.578
Mtot3 + A3 + V3 + C3 = 1
5. Ultimate analysis of coal is necessary on 'As Received' basis to determine calorific value,
combustion air, products of combustion etc.
Ultimate Analysis --> Typical Report Basis -- As Received

Surface moisture, H 2O(S) msur1 := 7.0% msur1 = 0.07
Inherent moisture, H 2O(I) minh1 := 3.0% minh1 = 0.03
Total moisture,
H 2O=H 2O(S)+H 2O(I) mtot1 := msur1 + minh1mtot1 = 0.1
Ash a1 := 22.0% a1 = 0.22

Carbon, C c1 := 52.0% c1 = 0.52
Hydrogen, H 2 h1 := 4.0% h1 = 0.04
Nitrogen, N 2 n1 := 3.0% n1 = 0.03
Oxygen, O2 o1 := 8.0% o1 = 0.08
Sulphur, S s1 := 1.0% s1 = 0.01
Chlorine, Cl ch1 := 0% ch1 = 0
mtot1 + a1 + c1 + h1 + n1 + o1 + s1 + ch1 = 1
Drying performance in dryer is drying of surface moisture from say 7% to 1%, with
reference to original coal. This would mean - if analysed after drying, the surface
moisture will be more than 1%. This can be seen as below
Ultimate Analysis -- Air Dried

Surface moisture, H 2O(S) (after drying) msur := 1.0% msur = 0.01
Surface Moisture lost after drying msloss := msur1 − msur msloss = 0.06
1
Surface Moisture, H 2O(S) msur2 := msur ⋅ msur2 = 0.011
1 − msloss
Thus it can be seen that in air

dried(in dryer)/ as fired coal has
surface moisture > 1%.
1
Inherent moisture, H 2O(I) minh2 := minh1 ⋅ minh2 = 0.032
1 − msloss
Total moisture, mtot2 := msur2 + minh2 mtot2 = 0.043

H 2O=H 2O(S)+H 2O(I)
1
Ash a2 := a1 ⋅ a2 = 0.234
1 − msloss
1
Carbon c2 := c1 ⋅ c2 = 0.553
1 − msloss
1
Hydrogen h2 := h1 ⋅ h2 = 0.043
1 − msloss
1
Nitrogen n2 := n1 ⋅ n2 = 0.032
1 − msloss
1
Oxygen o2 := o1 ⋅ o2 = 0.085
1 − msloss
1
Sulphur s2 := s1 ⋅ s2 = 0.011
1 − msloss
1
Chlorine ch2 := ch1 ⋅ ch2 = 0
1 − msloss
mtot2 + a2 + c2 + h2 + n2 + o2 + s2 + ch2 = 1
Ultimate Analysis --- Fully Dried
Inherent Moisture, H 2O(I) (after fully drying) minh := 0% minh = 0
Inherent Moisture loss after fully drying is miloss := minh1 − minh miloss = 0.03
1
Surface Moisture, H 2O(S) msur3 := msur ⋅ msur3 = 0.011
1 − ( msloss + miloss)
1
Inherent Moisture, H 2O(I) minh3 := minh ⋅ minh3 = 0
Total Moisture mtot3 := msur3 + minh3 mtot3 = 0.011
1
Ash a3 := a1 ⋅ a3 = 0.242
1
Carbon c3 := c1 ⋅ c3 = 0.571
1
Hydrogen h3 := h1 ⋅ h3 = 0.044
1
Nitrogen n3 := n1 ⋅ n3 = 0.033
1
Oxygen o3 := o1 ⋅ o3 = 0.088
1
Sulphur s3 := s1 ⋅ s3 = 0.011
1
Chlorine ch3 := ch1 ⋅ ch3 = 0
mtot3 + a3 + c3 + h3 + n3 + o3 + s3 + ch3 = 1
In practice we require another derived form of analysis i.e., Coal(as fired) i.e., the state at
which coal is fired in the furnace, after it has been dried (surface moisture) in a dryer.
For efficient furnace operation, it is necessary to dry the coal as far as possible. But
keeping in view what has been stated above, only surface moisture is dried. Thus higher
the inherent moisture, lower will be the net calorific value of coal in as fired condition.
Even surface moisture is not dried fully since very fine coal, if fully dried off surface
moisture, tend to seggregate and create operational problems.
Thus it can be seen that coal as fired may have about 1% surface moisture and all the
inherent moisture. This will depend on the drying performance of the drying unit.
6. Calorific Value:
Gross Calorific Value (dry basis) = Gross on dry (dry basis)
  o2  
gcv1 := 8105.5 ⋅ c2 + 34077.8 ⋅  h2 −  + 2183.3 ⋅ s2
  8  
3
gcv1 = 5.595 × 10 Kcal/kg
Gross Calorific Value (as received) = Gross on wet (as received)

gcv2 := gcv1 ⋅ ( 1 − mtot1)
3
gcv2 = 5.035 × 10 Kcal/kg
Gross Calorific Value (as fired) = Gross on wet (as fired)
gcv3 := gcv1 ⋅ ( 1 − mtot3)
3
gcv3 = 5.533 × 10 Kcal/kg
Net Calorific Value or Net on wet (as fired)
ncv1 := gcv1 ⋅ ( 1 − mtot3) − 586 ⋅ ( mtot3 + 9 ⋅ h3)
3
ncv1 = 5.295 × 10 Kcal/kg
Net Calorific Value or Net on dry (dry basis)
ncv2 := gcv1 − 586 ⋅ 9 ⋅ h2
3
ncv2 = 5.37 × 10 Kcal/kg
Net Calorific Value or Net on wet (as received)
ncv3 := [ gcv2 − 586 ⋅ ( mtot1 + 9 ⋅ h1) ]
3
ncv3 = 4.766 × 10 Kcal/kg
Book-II Chapter 4
File Name : 2_4_fuels_5n
Topic: Calculation of Flame Temperature
A high flame temperature is necessary in the Kiln to attain very quick transfer of heat
from the flame to the refractory in the Sinter Zone by radiation.Since radiation is a
function of 4th power of temperature, it is imperative that higher the temperature of the
flame better is the heat transfer at the sintering zone of kiln where highest temperature is
is required to convert C2S to C3S.
Ash absorbs heat from the flame itself. When the ash content of coal is greater than 20%
there can be significant cooling of the flame.
Cold primary air as also raw meal in case of insufflation (feeding raw meal along with
coal firing through the Burner)cool down the flame.Raw meal also brings down the net
calorific value of fuel and raw meal mixture.
An attempt to calculate the temperature of a flame can be error prone as it is possible
that there can be dissociation of products of combustion.( CO 2 dissociates to CO +O2 )
an endothermic reaction.
Also as the heat released immediately heats up the products of combustion in its vicinity,
the process is assumed as adiabatic.
In an adiabatic flame, the heat of combustion, is used to heat the products of the
combustion.
The products of the combustion include H20 and CO2;as the combustion is in air, the
nitrogen of the air will remain, unconsumed, with the products and, thus, its heat capacity
need to be considered.
Specific heats of gases as function of temp. T

Temp. of gases in flame =T
C PN2(T) Sp. heat of N2 at temp. T
C PCO2(T) Sp. heat of CO2 at temp. T
C PH2O(T) Sp. heat of H2O at temp. T

The formulas to the left, from
Noggle,
Physical Chemistry (3rd Ed)
are valid up to 3000 K.
5
−3 −6 2 0.88⋅ 10
CpN2( T) := 25.79 + 8.09⋅ 10 ⋅ T − 1.46⋅ 10 ⋅ T +
2
T
5
−3 −6 2 7.97⋅ 10
CpCO2( T) := 41.58 + 15.6⋅ 10 ⋅ T − 2.95⋅ 10 ⋅ T −
2
T
5
−3 −6 2 2.20⋅ 10
CpH2O( T) := 26.06 + 17.7⋅ 10 ⋅ T − 2.63⋅ 10 ⋅ T +
2
T
Ultimate Analysis of coal (BY WEIGHT):

C1
Carbon = C % C1 := 46.99 c2 := c2 = 0.47
100
H1
Hydrogen =H2 % H1 := 2.82 h2 := h2 = 0.028
100
N1
Nitrogen = N2 % N1 := 1.03 n2 := n2 = 0.01
100
S1 −3
Sulphur =S % S1 := 0.5 s2 := s2 = 5 × 10
100
O1
Oxygen =O 2 % O1 := 2.16 o2 := o2 = 0.022
100
H2O1
Moisture =H2O % H2O1 := 5 h2o2 := h2o2 = 0.05
100
ash
Ash =ash % ash := 40 ash2 := ash2 = 0.4
100
Total moisture (surface)= mtot3 mtot3 := 0.04
Calorific Value:
Gross Calorific Value (dry basis) = Gross on dry (dry basis)
gcv1 := 8105.5⋅ c2 + 34077.8 ⋅  h2 −

o2  
 + 2183.3⋅ s2
  8  
3
gcv1 = 4.689 × 10 Kcal/kg
Gross Calorific Value (as fired) = Gross on wet (as fired)
gcv3 := gcv1⋅ ( 1 − mtot3)

3
gcv3 = 4.501 × 10 Kcal/kg
Calculation of flame temp. T o C
3
Calorific value of coal as fired =gcv3 gcv3 = 4.501 × 10 k.cal / kg. coal
Air for combustion ATH1 kg. / kg. coal ATH1 := 6.992 kg. / kg. of coal
Quantity of coal F kg. F := 1.0 kg.of coal
Flue gas quantity (products of combustion) Vf V f := 7.577 kg. / kg. of coal
Ash content per kg. fuel =ash2 ash2 = 0.4 kg. / kg. of coal
Sp. heat of ash Sash k.cal. /kg. o C Sash := 0.2

k.cal. /kg. o C
Sair := 0.24
Sp. heatof air =Sair k.cal. /kg. o C k.cal. /kg. o C
Temp. of air - primary and secondary tair := 600 o C

mix. tair o C
Sp. heat of coal Scoal k.cal. /kg. o C Scoal := 0.25

k.cal. /kg. o C
Temp. of Coal t coal o C tcoal := 25 o C

Sflg := 0.26
Sp. heat of flue gas Sflg k.cal. /kg. o C k.cal. /kg. o C
Flame temperature = T o C
gcv3 + ATH1⋅ Sair⋅ tair + F⋅ Scoal⋅ tcoal o C

T :=
V f ⋅ Sflg + ash2⋅ Sash
T = 2690 o C
Book-II Chapter 5
Conveying Systems
File Name : 2_5_conveying
2_5_conveying_1 Vertical Bucket Elevator -Power and Filling
2_5_conveying_2 Deep Bucket or Deep Pan type Conveyors -Power and

Filling
2_5_conveying_3 Screw Conveyor
2_5_conveying_4 Belt Conveyor -Length of Conveyor Belt in a Roll
2_5_conveying_5n Belt Drives -Length of Drive Belt
2_5_conveying_6n Troughed Belt Conveyor-Calculation of Capacity

Property of:
Book-II Chapter 5
Conveying Systems
File Name : 2_5_conveying_3nr1
Topic: Screw Conveyor
Capacity Calculation as a Function of Geometry and speed of Screw Conveyor
The capacity of a screw conveyor depends upon average cross sectional areaof the flow
of material in the trough and the material speed,These depend on trough diameter,the
screw lead and speed.
Pitch of the screw is normally equal to the diameter or upto 0.8 times the screw diameter.
Standard dia. of screw range from 0,15 to 0.6 m but can go up in special cases to 1000mm
or more.
As a thumb rule pitch should be atleasr 12 times the average piece size of material.and 4
time the maximum size of material
Gradient =β degree C factor = C
 0   1 
5   0.9 
 
β := 10

C := 0.8

   
 15   0.7 
 20   0.65 
   
Screw speed is selected as followes
60
n :=
For light and non abrasive material
D
45
For heavy and non abrasive material n :=
D
30
For heavy and abrasive material n :=
D
Q Throughput ( tph ) Q tph
Bd Bulk density , ton/m3 Bd := 1.25 ton/m3
n Screw speed , rpm n := 20 rpm
Sp Screw Pitch , mm Sp := 300 mm
D Diameter of Trough D := 300 mm
L Length of Screw L := 5 m
C Factor for variation of material cross section C := 1

For horizontal flow C=1 : At 200 gradient C= 0.65)
ξ Filling factor ( varies between 0.75 to 0.85 ) ξ := 0.8
Calculations :
F Average cross sectional area of the material flow ( m 2 )
2
π ⋅D
F := ⋅ξ ⋅ C m2
4 ⋅ 1000⋅ 1000
F = 0.057 m2
v Speed of movement of the material along the axis ( m/s )
n
v := Sp ⋅ m/s
1000 ⋅ 60
v = 0.1 m/s
Q Capacity of the conveyor ( t/h )
Q := F ⋅ v ⋅ Bd ⋅ 3600 t/h
Q = 25.447 t/h
Power requirement calculation:
N HS Power at shaft for horizontal conv.
 1.2  Flour , Cereal, Saw dust

Friction factor C1  
C 1 :=
 1.6  Pulverised Coal
 2.5  Lump Coal
  Cement , Gypsum, clay, Ash,
 4  Lime
C 1 := 4
Q⋅ L
N HS := C 1 ⋅
367
N HS = 1.387
kW
N gs Power at shaft If the screw has to move material in a gradient ( kW)
H Lift of the screw H := 0.3 m
H Q ⋅L
N gs := Q ⋅ + C1⋅
367 367
N gs = 1.408 kW
Ref . Materials Handling Equipment by M.P.Alexandrov

Book-II Chapter 6
Fans and Blowers
File Name : 2_6_fans
2_6_fans_1 Calculation of Fan Motor Power
2_6_fans_2 Calculation of Fan Volume Rating
2_6_fans_3n Design of Large Fans -Requirement of Motor Data

2_6_fans_4n Calculation of Expansion of Fan shaft -During Hot Condition

Property of:
Book-II Chapter 6
Fans and Blowers
File Name : 2_6_fans_1
Topic: Calculation of Fan Motor Power
The motor power of fan based the design parameters.
The calculation of the motor power of fan based on the design parameters is as given
below .
Fv Fan volume Fv := 220000 m3/hr
Fp Fan static pressue Fp := 38 mbar
Fe Fan efficiency Fe := 80 %
Gd Density of the gases Gd := 0.630 kg/m3
Gd.l Dust load in the gases Gd.l := 50 gm/m 3
Calculations :
Fan consumed power without dust load :
( Fv ⋅Fp⋅ 10) ⋅ 100

Fsp := kw
102 ⋅ Fe⋅ 3600
10 is the factor to convert m bar to

mm of wg.
Fsp = 285 kw
Fan consumed power considering the dust load :
 Gd.l 
 Gd + 
 1000 
Fsp.d := Fsp ⋅ kw
Gd
Fsp.d = 307 kw
Fan motor power
Fl Factor for losses in Fl := 1.12

belt/coupling
Mmp := Fsp.d ⋅ Fl kw
Mmp = 344 kw
Book-II Chapter 7
Raw-mix Design
File Name : 2_7_rawmix
2_7_rawmix_1 Raw-mix Design for Two Components
2_7_rawmix_2 Raw-mix Design based on Hydraulic Module
2_7_rawmix_3 Raw-mix Design based on Lime Saturation Factor
2_7_rawmix_4 Raw-mix Design based on Lime Saturation Factor and

Silica Ratio
2_7_rawmix_5 Raw-mix Design - Calculation of Coal Ash Absorption
2_7_rawmix_6 Raw-mix Design - Calculation with Four Components
2_7_rawmix_7 Raw-mix Calculation with to meet Potential Clinker

Compounds
2_7_rawmix_8 Calculation of Potential Clinker Composition

Property of:
Book-II Chapter 7
Raw-mix Design
File Name : 2_7_rawmix_1
Topic: Raw-mix Design for Two Components
Raw mix design is a process of determining the quantitative proportions of the components
of Raw mix ensuring that the clinker produced from such mix attain desired chemical and
mineralogical composition.
Calculation for two components

In this simple method we determine the proportion of two raw material components only.
CaCO 3 is fixed as set point.
Example:
In this method, the proportion of limestone with certain percentage of CaCO3, and
proportion of clay with with certain percentage of CaCO3 are determined, to get a raw
mix with a certain desired CaCO3 content
% of CaCO 3 content desired in Raw Mix R := 76
% of CaCO 3 content in Limestone L := 89
% of CaCO 3 content in Clay C := 31
Parts of CaCO3 excess in Lime stone l := L − R

l = 13
Parts of CaCO3 deficient in clay c := R − C
c = 45
P Proportion of Limestone to Clay
Parts of Limestone c = 45 c
P :=
Parts of Clay l = 13 l
P = 3.462
Therefore, to get a raw mix with a CaCO 3 content of 76%, 45 parts of limestone
should be mixed with 13 parts of clay. Thus the proportion of the components in
the raw mix, i.e., limestone:clay =45:13 =3.462 : 1,
Book-II Chapter 7
Raw-mix Design
Topic: Raw-mix Design based on Lime Saturation Factor
Calculation based on the Lime saturation factor
Calculation of raw mix composition based on the lime saturation factor using Kind's
saturation factor.
Given 2 raw materials, Kind's lime saturation module is:
CaO − (1.65 ⋅ Al2 O3 + 0.35 ⋅ Fe2 O3 )

KS k = = 0.92
2.8 ⋅ SiO2
Limestone Clay
SiO2 S1 := 1.42 S2 := 62.95
Al 2O3 A1 := 0.48 A2 := 18.98
Fe2O3 F1 := 0.38 F2 := 7.37
CaO C 1 := 52.60 C 2 := 1.40
MgO M1 := 1.11 M2 := 0.98
SO3 So1 := 0.85 So2 := 0.85
LOI LOI1 := 43.16 LOI2 := 7.47
Total1 := S1 + A1 + F1 + C 1 + M1 + So1 + LOI1 Total1 = 100
Total2 := S2 + A2 + F2 + C 2 + M2 + So2 + LOI2 Total2 = 100
Inserting into Kind's formula the calculation symbols used previously, we get
xC1 + C2  xA1 + A2 xF + F2 
− 165
. + 0.35 1 
x +1  x +1 x +1 
KS k =
 xS + S 2 
2.8 1 
 x +1 
and solving for x:
x=
( 2.8KSk S2 + 165
. A2 + 0.35F2 ) − C2
=−
C2 − ( 28 . A2 + 0.35F2 )
. KSk S2 + 165
C1 − ( 28 . A1 + 0.35F1 )
. KSk S1 + 165 C1 − ( 28 . A1 + 0.35F1 )
. KSk S1 + 165
With this formula we calculate how many parts of limestone in the raw mix are
apportioned to one part of clay. Accordingly we get:
we know that KSk := 0.92
( 2.8 ⋅KSk ⋅ S2 + 1.65 ⋅A2 + 0.35 ⋅F2) − C 2

x := x = 4.054
C 1 − ( 2.8 ⋅ KSk ⋅ S1 + 1.65 ⋅ A1 + 0.35 ⋅ F1)
Thus 4.054 parts of limestone are apportioned to one part of clay:
x 1
pl := pl = 0.802 pc := pc = 0.198
x+1 x+ 1
Limestone x 0.8020 Clay x 0.1980
S1c := pl ⋅ S1 S1c = 1.139 S2c := pc ⋅ S2 S2c = 12.456
A1c := pl ⋅ A1 A1c = 0.385 A2c := pc ⋅ A2 A2c = 3.756
F1c := pl ⋅ F1 F1c = 0.305 F2c := pc ⋅ F2 F2c = 1.458
C 1c := pl ⋅ C 1 C 1c = 42.192 C 2c := pc ⋅ C 2 C 2c = 0.277
M1c := pl ⋅ M1 M1c = 0.89 M2c := pc ⋅ M2 M2c = 0.194
So1c := pl ⋅ So1 So1c = 0.682 So2c := pc ⋅ So2 So2c = 0.168
LOI1c := pl ⋅ LOI1 LOI1c = 34.62 LOI2c := pc ⋅ LOI2 LOI2c = 1.478
Total1c := S1c + A1c + F1c + C 1c + M1c + So1c + LOI1c Total1c = 80.213
Total2c := S2c + A2c + F2c + C 2c + M2c + So2c + LOI2c Total2c = 19.787

100% Raw mix
Sm := S1c + S2c Sm = 13.595
Am := A1c + A2c Am = 4.141
Fm := F1c + F2c Fm = 1.763
C m := C 1c + C 2c C m = 42.469
Mm := M1c + M2c Mm = 1.084
Som := So1c + So2c Som = 0.85
LOIm := LOI1c + LOI2c LOIm = 36.098
Totalm := Sm + Am + Fm + C m + Mm + Som + LOIm Totalm = 100
Now calculating the clinker composition as of raw mix free of loss due to ignition
100
f := f = 1.565
100 − LOIm
Clinker
S := f ⋅ Sm S = 21.274
A := f ⋅ Am A = 6.48
F := f ⋅ Fm F = 2.759
C := f ⋅ C m C = 66.46
M := f ⋅ Mm M = 1.697
So := f ⋅ Som So = 1.33
LOI := 0
Total := S + A + F + C + M + So + LOI Total = 100
The resulting Kind's lime saturation factor is
C − ( 1.65 ⋅ A + 0.35 ⋅ F)
KSk := KSk = 0.92
2.8 ⋅ S
Book-II Chapter 7
Raw-mix Design
Topic: Calculation of Potential Clinker Composition
Oxide contents and potential composition
The calculation to find the required amount of potential clinker compounds showed that
small quantity fluctuations in the proportioning of the raw components, with their
resultant small differences in the oxide contents, cause large fluctuations in the potential
phase composition of the clinker and consequently, as in this case, the reduction of
C 3S-content by 50%, and an increase in C 2S-content of 100%. This is also shown below
in the compilation of three different clinkers with small differences in the oxide contents,
and the resulting large fluctuations in the calculated phase composition.
Clinker analysis and potential compound composition

Constituent Clinker I % Clinker II % Clinker III %
SiO2 S1 := 20.0 S2 := 21.8 S3 := 20.0
Al 2O3 A1 := 7.0 A2 := 7.6 A3 := 5.5
Fe2O3 F1 := 3.0 F2 := 3.3 F3 := 4.5
CaO C1 := 66.0 C2 := 63.0 C3 := 66.0
Rest
Balance R1 := 4.0 R2 := 4.3 R3 := 4.0
Total1 := S1 + A1 + F1 + C1 + R 1 Total1 = 100

p 1 := 4.071⋅ C1 − 7.600⋅ S1 − 6.718⋅ A1 − 1.430⋅ F1 p 2 := 4.071⋅ C2 − 7.600⋅ S2 − 6.718⋅ A2 − 1.430⋅ F2

q 1 := 8.602⋅ S1 + 5.068⋅ A1 + 1.078⋅ F1 − 3.071⋅ C1 q 2 := 8.602⋅ S2 + 5.068⋅ A2 + 1.078⋅ F2 − 3.071⋅ C2
r1 := 2.650⋅ A1 − 1.692⋅ F1 r2 := 2.650⋅ A2 − 1.692⋅ F2
s1 := 3.043⋅ F1 s2 := 3.043⋅ F2
p 3 := 4.071⋅ C3 − 7.600⋅ S3 − 6.718⋅ A3 − 1.430⋅ F3
q 3 := 8.602⋅ S3 + 5.068⋅ A3 + 1.078⋅ F3 − 3.071⋅ C3
r3 := 2.650⋅ A3 − 1.692⋅ F3
s3 := 3.043⋅ F3
Compound Clinker I % Clinker II % Clinker III %

C 3S p 1 = 65.37 p 2 = 35.017 p 3 = 73.302
C 2S q 1 = 8.064 q 2 = 36.125 q 3 = 2.079
C 3A r1 = 13.474 r2 = 14.556 r3 = 6.961
C 4AF s1 = 9.129 s2 = 10.042 s3 = 13.694
The chemical compositions of three different clinkers have been listed above. The oxide
contents do not vary widely; but the calculated potential compositions show considerable
differences. Therefore, when calculating the composition of the raw mix, it should be
taken into consideration that a variation of 1% in the CaO-content causes a variation in
the tricalcium silicate content by about 10-14% and, vice-versa, a fluctuation in the
C 3S-content by 1%, causes a corresponding increase or decrease in the CaO-content by
1/14 = 0.07%, or a change in the CaCO3-content of the raw mix by 0.07 × 1.78 = 0.12%.
If the CaO-content is kept constant and the values for the other oxides change, there is a
corresponding change in contents of the resulting clinker minerals.
Also one and the same clinker can show different calculated potential compound
compositions, when on the one hand, one calculates with only the four main oxides, and
on the other hand when including also the auxiliary components which participate in the
formation of minerals. For a nume- rical presentation of this fact, the following clinker
analysis may be used for calculation.
Oxide Clinker
SiO2 S := 22.5
Al 2O3 A := 5.0
Fe2O3 F := 2.5
TiO2 T := 0.5
Mn2O3 Mn := 0.3
CaO C := 63.0
MgO Mg := 1.8
K 2O K := 0.4
Na 2O Na := 0.4
SO3 So := 2.6
Insoluble Ins := 0.5
LOI LOI := 0.5

Total := S + A + F + T + Mn + C + Mg + K + Na + So + Ins + LOI Total = 100
p := 4.071⋅ C − 7.600⋅ S − 6.718⋅ A − 1.430⋅ F
q := 8.602⋅ S + 5.068⋅ A + 1.078⋅ F − 3.071⋅ C
r := 2.650⋅ A − 1.692⋅ F
s := 3.043⋅ F
The calculated potential composition is:
C 3S p = 48.308
C 2S q = 28.107
C 3A r = 9.02
C 4AF s = 7.607
Total := p + q + r + s Total = 93.042
p
The ratio of C 3S : C 2S is = 1.719
q
i.e., 1.719 : 1
The auxiliary components contribute to the following formation of minerals:
K K 2SO4; the rest of SO3 to CaSO4
SO3 CaSO4
TiO2 CaO TiO2
Na 2O 8 CaO Na2O3 3Al 2O3 (C 8NA3)
Mn2O3 4 CaO Al 2O3 Mn2O3 (C 4AMn)
CaO free
Considering the mineral formation as quoted above, the potential clinker composition is:
%
CaO - free 1.0
K 2SO4 0.74
CaSO4 3.84
CaO TiO2 0.86
C 8NA3 5.27
MgO 1.80
C 4AF 7.61
C 4AMn 0.92
C 3A 3.28
C 3S 37.89
C 2S 36.29
Total 99.50
A comparison of the two results shows wide differences in the potential composition of
the same clinker. Also the ratio C 3S : C 2S has changed and is roughly 1 : 1, according to
the second method of calculation. Differences in potential composition are the result of
differences in the mineral formations used for the calculation.
Book-II Chapter 8
Plant Water
File Name : 2_8_water
2_8_plantwater_1n Quality of Plant Cooling Water

Property of:
Book-II Chapter 9
Insulation
File Name : 2_9_Insulation
2_9_insulation_1 General Specifications for Insulation in Cement Plant

Property of:
Book-III Useful Tables-1
Basic Sciences
File Name : 3_1_UT_v8
3_1_UT_1 Basic Sciences Fundamental Physical Constants
3_1_UT_2 Basic Sciences Temperature Scales
3_1_UT_3 Basic Sciences Periodic Table of Elements
3_1_UT_4
3_1_UT_5 Calculus Reference Formulae Table of Integral Formulas
3_1_UT_6 Properties of Metals - Thermal Conductivity at Atmospheric

Pressure ,250C
3_1_UT_7 Properties of Metals - Specific Gravity
3_1_UT_8 Properties of Metals - Co-efficient of Linear Expansion per

Degree C
3_1_UT_9 Properties of Metals - Electrical Resistivity
3_1_UT_10 Properties of Metals - Poission's Ratio
3_1_UT_11 Properties of Metals - Modulus of Elasticity
3_1_UT_12 Properties of Metals - Melting Point in Degrees Kelvin at

Atmospheric Pressure
3_1_UT_13 Properties of Common Solids - Density
3_1_UT_14 Properties of Common Solids - Specific Gravity
3_1_UT_15 Properties of Common Solids - Specific Heat
3_1_UT_16 Properties of Common Solids - Thermal Conductivity

3_1_UT_17 Properties of Gases - Specific Gravity
3_1_UT_18 Properties of Gases - Specific Heat at 1.0 Atm Pressure, 20ºC, Except as
Noted
3_1_UT_19 Properties of Gases - Molecular Weightat 1.0 Atm Pressure, 20ºC,

Except as Noted
"Copyright 1999 by MathSoft, Inc. Reprinted by permission of MathSoft, Inc."

Property of:
Basic Sciences
File Name : 3_1_UT_1_v8
Topic: Fundamental Physical Constants
Universal Constants
m
Velocity of light in vacuum c := 299792458⋅
sec
−7 newton
Permeability of vacuum µ 0 := 4 ⋅ π ⋅ 10 ⋅
2
amp
− 12 farad
Permittivity of vacuum ε0 := 8.854187817⋅ 10 ⋅
m
3
− 11 m
Newtonian constant of G := 6.67259 ⋅ 10 ⋅
2
gravitation kg⋅ sec
− 34
Planck's constant (h) h := 6.6260755⋅ 10 ⋅ joule⋅ sec
Electromagnetic Constants
− 19
Elementary charge e := 1.60217733 ⋅ 10 ⋅ coul
− 15
Magnetic flux quantum Φ 0 := 2.06783461 ⋅ 10 ⋅ weber
− 24 joule
Bohr magneton 9.2740154⋅ 10 ⋅
tesla
− 27 joule
Nuclear magneton 5.0507866⋅ 10 ⋅
tesla
Atomic Constants
−3
Fine structure constant α := 7.29735308 ⋅ 10
−1
Rydberg constant R := 10973731.534⋅ m
− 10
Bohr radius a0 := 0.529177249⋅ 10 ⋅m
− 18
Hartree energy Eh := 4.3597482⋅ 10 ⋅ joule
2
Quantum of −4 m
3.63694807 ⋅ 10 ⋅
circulation sec
Electron
− 31
Electron mass me := 9.1093897⋅ 10 ⋅ kg
Electron specific 11 coul

−1.75881962 ⋅ 10 ⋅
charge (electron kg
charge to mass ratio)
Electron Compton − 12
2.42631058 ⋅ 10 ⋅m
wavelength
− 15
Classical electron radius re := 2.81794092 ⋅ 10 ⋅m
− 26 joule
Electron magnetic moment 928.47701⋅ 10 ⋅
tesla
Muon
− 28
Muon mass mµ := 1.8835327⋅ 10 ⋅ kg
Proton
− 27
Proton mass mp := 1.6726231⋅ 10 ⋅ kg
Ratio of proton mass to

1836.152701
electron mass
Proton Compton − 15
1.32141002 ⋅ 10 ⋅m
wavelength
− 26 joule
Proton magnetic moment 1.41060761 ⋅ 10 ⋅
tesla
Proton gyromagnetic 4 rad

26751.5255 ⋅ 10 ⋅
ratio sec⋅ tesla
Neutron
− 27
Neutron mass mn := 1.6749286⋅ 10 ⋅ kg
Neutron Compton
− 15
wavelength 1.31959110 ⋅ 10 ⋅m
Physico-Chemical Constants
23 −1
Avogadro constant N A := 6.0221367⋅ 10 ⋅ mole
Atomic mass − 27
AMU := 1.6605402⋅ 10 ⋅ kg
constant
coul
Faraday constant 96485.309⋅
mole
joule
Molar gas constant 8.314510⋅
mole⋅ K
− 23 joule
Boltzmann's constant kb := 1.380658⋅ 10 ⋅
K
Molar volume of ideal liter

22.41410⋅
gas at STP mole
−8 watt
Stefan-Boltzmann σ := 5.67051 ⋅ 10 ⋅
2 4
constant m ⋅K
− 16 2
First radiation constant 3.7417749⋅ 10 ⋅ watt⋅ m
Second radiation constant 0.01438769 ⋅ m⋅ K
Data from CRC Handbook of Chemistry and Physics, 73nd edition,

edited by David R. Lide, CRC Press (1992).
Basic Sciences
Topic: Temperature Scales
While the internationally accepted SI system of units calls for Kelvin

as a temperature unit, other commonly used temperature scales
include Celsius, Fahrenheit, and Rankine.
Variables
Absolute temperature (Kelvin): T
Formulas
T
Celsius (°C) scale: TC = − 273.15 °C
K
9
Fahrenheit (°F) scale: TF = 32 + ⋅ TC °F
5
Absolute temperature (Rankine): TR = (TF + 459.67) ⋅ R
 9 ⋅ T  ⋅R
TR =  5 K
 
Example: The ice point Tice is the temperature at which ice and
air-saturated water are in equilibrium at atmospheric pressure. The
steam point Tstm is the temperature at which steam and liquid water
are in equilibrium at atmospheric pressure. These temperatures are:
Ice point (Celsius): Tice_C := 0.00 °C
Steam point (Celsius): Tstm_C := 100.00 °C
Find the corresponding temperatures in the Fahrenheit, Kelvin,

and Rankine scales.
Ice Point
Fahrenheit
9
Tice_F := 32 + ⋅ Tice_C
5
Tice_F = 32 °F
Kelvin
Tice_K := ( Tice_C + 273.15) ⋅ K
Tice_K = 273.15 K
Rankine
 9 Tice_K 
Tice_R :=  ⋅ ⋅R
5 K 
Tice_R = 491.67 R
Steam Point
Fahrenheit
9
Tstm_F := 32 + ⋅ Tstm_C
5
Tstm_F = 212 °F
Kelvin
Tstm_K := ( Tstm_C + 273.15 )⋅ K
Tstm_K = 373.15 K
Rankine
 9 Tstm_K 
Tstm_R :=  ⋅  ⋅R
5 K 
Tstm_R = 671.67 R Rankine

Basic Sciences
Topic: Periodic Table of Elements
Inert
Alkali Metals Gases
Alkaline Earth Metals Nonmetals Halogen-

s
Transition Elements (Heavy Metals)
Lanthanide Series
Actinide Series
Basic Sciences
Topic: Properties of Metals - Co-efficient of Linear Expansion per Degree C
Expansion Expansion
Coefficient Coefficient
(-106) (-106)
Metal Metal
Aluminum 25 Osmium 5
Antimony 9 Platinum 9
Beryllium 12 Plutonium 54
Bismuth 13 Potassium 83
Cadmium 30 Rhodium 8
Chromium 6 Selenium 37
Cobalt 12 Silicon 3
Copper 16.6 Silver 19
Gold 14.2 Sodium 70
Iridium 6 Tantalum 6.5
Iron 12 Thorium 12
Lead 29 Tin 20
Magnesium 25 Titanium 8.5
Manganese 22 Tungsten 4.5
Molybdenum 5 Uranium 13.4
Nickel 13 Vanadium 8
Niobium 7 Zinc 35
Data from CRC Handbook of Tables for Applied Engineering

Science, 2nd edition, edited by R. Bolz and G. Tuve, CRC
Press (1973).
Basic Sciences
Topic: Properties of Common Solids - Density
Density Density
Material (gm/cm3) Material (gm/cm3)
Agate 2.6 Paper 0.93

Alabaster, carbonate 2.73 Paraffin 0.89
Alabaster, sulfate 2.29 Peat blocks 0.84
Albite 2.64 Pitch 1.07
Amber 1.09 Porcelain 2.4
Amphiboles 3.1 Porphyry 2.8
Anorthite 2.75 Pulp board 0.19
Asbestos 2.4 Pyrite 5.0
Asbestos slate 1.8 Quartz 2.65
Asphalt 1.3 Resin 1.07
Basalt 2.7 Rock salt 2.18
Beeswax 0.97 Rubber, hard 1.19
Beryl 2.70 Rubber, soft, commercial 1.1
Biotite 2.9 Rubber, soft, pure gum 0.92
Bone 1.9 Sandstone 2.25
Brick 1.8 Serpentine 2.57
Butter 0.87 Silica, fused transparent 2.21
Calamine 4.3 Silica, translucent 2.07
Calcspar 2.7 Slag 2.9
Camphor 0.99 Slate 3.0
Caoutchouc 0.96 Soapstone 2.7
Cardboard 0.69 Spermaceti 0.95
Celluloid 1.4 Starch 1.53
Cement, set 2.9 Sugar 1.59
Chalk 2.4 Talc 2.8
Charcoal, oak 0.57 Tallow, beef 0.94
Charcoal, pine 0.36 Tallow, mutton 0.94
Cinnabar 8.12 Tar 1.02
Clay 2.2 Topaz 3.6
Coal, anthracite 1.6 Tourmaline 3.1
Coal, bituminous 1.4 Wax, sealing 1.8
Cocoa butter 0.90 Wood:
Coke 1.4 Alder 0.55
Copal 1.09 Apple 0.75
Cork 0.24 Ash 0.75
Cork linoleum 0.54 Balsa 0.13
Corundum 4.0 Bamboo 0.36
Diamond 3.27 Basswood 0.46
Dolomite 2.84 Beech 0.80
Ebonite 1.15 Birch 0.64
Emery 4.0 Blue gum 1.00
Epidote 3.37 Box 1.06
Feldspar 2.65 Butternut 0.38
Flint 2.63 Cedar 0.53
Fluorite 3.18 Cherry 0.80
Galena 7.5 Dogwood 0.76
Gamboge 1.2 Ebony 1.22
Garnet 3.78 Elm 0.57
Gas carbon 1.88 Hickory 0.77
Gelatin 1.27 Holly 0.76
Glass, common 2.6 Juniper 0.56
Glass, flint 4.4 Larch 0.53
Glue 1.27 Lignum vitae 1.25
Granite 2.70 Locust 0.69
a
Graphite 2.51 Logwood 0.91
Gum arabic 1.35 Mahogany, Honduras 0.66
Gypsum 2.32 Mahogany, Spanish 0.85
Hematite 5.1 Maple 0.69
Hornblende 3.0 Oak 0.75
Ice 0.917 Pear 0.67
Ivory 1.88 Pine, pitch 0.84
Leather, dry 0.86 Pine, white 0.43
Lime, slaked 1.35 Pine, yellow 0.49
Limestone 2.72 Plum 0.72
Linoleum 1.18 Poplar 0.43
Magnetite 5.1 Satinwood 0.95
Malachite 3.9 Spruce 0.59
Marble 2.72 Sycamore 0.50
Meerschaum 1.14 Teak, Indian 0.77
Mica 2.9 Teak, African 0.98
Muscovite 2.88 Walnut 0.67
Ochre 3.5 Water gum 1.00
Opal 2.2 Willow 0.50
a Some values reported as low as 1.6.
Data from CRC Handbook of Tables for Applied Engineering Science,

2nd edition, edited by R. Bolz and G. Tuve, CRC Press (1973).
Basic Sciences
Topic: Properties of Gases - Molecular Weightat 1.0 Atm Pressure, 20ºC, Except as Noted
Molecular
Gas Weight
Acetylene 26.04
Air (mixture) 28.966
Ammonia (NH3) 17.02
Argon (Ar) 39.948
Butadiene (C4H6) 54.09
n-Butane (C4H10) 58.12
1-Butene (butylene) C4H8 56.108
Carbon dioxide (CO2) 44.01
Carbon monoxide (CO) 28.011
Chlorine (Cl2) 70.906
Deuterium (D 2) 2.014
Ethane (C2H 6) 30.070

Ethyl chloride (C2H5Cl) 64.515
Ethylene (ethene) C2H4 28.054
Fluorine (F2) 37.996
Helium (He) 4.0026
Hydrogen (H2) 2.016
Hydrogen chloride (HCl) 36.461
Hydrogen sulfide (H2S) 34.076
Krypton (Kr) 83.80
Methane (CH4) 16.044
Methyl chloride (CH3Cl) 50.488
Neon (Ne) 20.179
Nitric oxide (NO) 30.006
Nitrogen (N2) 28.0134
Nitrous oxide (N2O) 44.012
Oxygen (O2) 31.9988
Ozone (O3) 47.998

Propane (C 3H 8) 44.097
Propylene (C3H6) 42.08
Sulfur dioxide (SO2) 64.06
Xenon (Xe) 131.30
Data from CRC Handbook of Tables for Applied Engineering Science,

2nd ed., edited by R. Bolz and G. Tuve, CRC Press (1973).
Book-IV Pop ups
Cement Properties
File Name :
4_4_pop_cmtproperties_n
Pop_cmtproperty_1_oxides Cement Properties -Oxides
Pop_cmtproperty_2_C3S Cement Properties - Major

Constituents-Tricalcium silicate
Pop_cmtproperty_3_C2S Cement Properties - Major

Constituents-Dicalcium silicate
Pop_cmtproperty_4_C3A Cement Properties - Major
Constituents-Tricalcium aluminate
Pop_cmtproperty_5_C4AF Cement Properties - Major

Constituents-Tetracalcium aluminoferrite
Pop_cmtproperty_6_gypsum Cement Properties - Minor Constituents-Gypsum
Pop_cmtproperty_7_freelime Cement Properties - Minor Constituents-Free lime
Pop_cmtproperty_8_magnesia Cement Properties - Minor Constituents-Magnesia
Pop_cmtproperty_9_alkalies Cement Properties - Minor Constituents-Alkali

oxides
Pop_cmtproperty_10_titanium Cement Properties - Minor
Constituents-Titanium dioxide
Pop_cmtproperty_11_P2O5 Cement Properties - Minor
Constituents-Phosphorous pentoxide
Pop_cmtproperty_12_setting Cement Properties-Setting and Harding of Cement
Pop_cmtproperty_13_1_hydration Cement Properties -Influences of age on rate

of hydration
Pop_cmtproperty_13_2_hydration Influences of Composition of cement on rate of

hydration
Pop_cmtproperty_13_3_hydration Influences of fineness of cement on rate of

hydration
Pop_cmtproperty_13_4_hydration Influences of water / cement ratio on
hydration
Pop_cmtproperty_13_5_hydration Influences of temperature on hydration
Pop_cmtproperty_13_6_hydration Influences of admixtures on hydration

Property of:
Book-IV Chapter 4 Pop up files:
File Name :
Cement Properties
Pop_cmtproperty_1_oxides
Cement Properties -Oxides
Approximate Composition of Portland Cement
Oxide Composition (wt. %)
[ CaO ] 60 - 67
[ SiO2 ] 17 - 25
[ Al2⋅ O 3 ] 3-8
[ Fe2⋅ O 3 ] 0.5 - 6.0
[ MgO ] 0.1 - 5.5
[ Na2⋅ O + K2⋅ O ] 0.5 - 1.3
[ TiO2 ] 0.1 - 0.4

[ P2⋅ O 5 ] 0.1 - 0.2
[ SO 3 ] 1-3
File Name :
Cement Properties
Pop_cmtproperty_5_C4AF
Cement Properties - Major Constituents-Tetracalcium

aluminoferrite
Tetracalcium aluminoferrite
[ C 4⋅ A⋅ F ] ranges from 5% to 10 % in ordinary portland

cement average being about 8 %
[ C 4⋅ A⋅ F ] is a complex compound consisting of 4

parts of CaO , 1 part of Al2O3 and 1 part of
Fe2O3.
C 4AF is known to react with water
instantaneously resulting in flash set of
cement within a few minutes. and is
accompanied by release of heat of
hydration of about 420 J /gm. Its strength
attainment is quite uncertain and can be
very low like C3A or very high as C3S
CS - Compressive Strength- N/mm2
day - Number of days
 1   0.2 
   
 3   0.4 
 7   1 
 28   2 
   
day := 
60 
CS := 
3.7 
 90   4.8 
 135   5.5 
   
 180   5.7 
 270   5.8 
   
 360   5.9 
6
Compressive Strength - N/ mm2
CS
2
According to Bogue
0
0 100 200 300 400
day
Days
Compressive Strength of C4AF

File Name :
Cement Properties
Pop_cmtproperty_10_titanium
Cement Properties - Minor Constituents-Titanium dioxide
Titanium dioxide
[ Ti ⋅ O 2 ]
Though present in small quantity ranging from 0.1 to
0.4% titanium dioxide does not have any significance
influence on properties of cement.
File Name :
Cement Properties
Pop_cmtproperty_13_4_hydration
Cement Properties -Influences of Water/ -Cement ratio on

rate of hydration -
Influences of water / cement ratio on hydration
The ration of water mixed with cement is defined as W/C

ratio. As the ratio is higher, it ensures that that there is
sufficient availability of water to hydrate the cement
particles.
As the initial rate of hydration is high, the effect of varying

w/c ratio donot show any perceptable difference at the
initial period.But as the time passes and the rate of
hydration falls the differences are seen i.e at higher w/c
ratio the the average rate of hydration is higher.
Book-IV Pop ups
Cement Quality Tests
File Name : 4_5_pop_cmtqtests_n
Pop_CmtTests_1_compressive Cement Quality Tests-Compressive Strength
Pop_CmtTests_2_Setting Cement Quality Tests-Setting Times

Pop_CmtTests_3_Workability Cement Quality Tests-Workability
Pop_CmtTests_4_Soundness Cement Quality Tests-Soundness
Pop_CmtTests_5_Hydration Cement Quality Tests-Heat of hydration

Property of:
Quality tests
File Name : Pop_CmtTests_1_compressive
Cement Quality Tests-Compressive Strength
Compressive Strength
Description
It is the resistance to load under compression . A

morter or concrete is prepared as per standards
(BS4550 for UK). Water, cement, fine aggregate ,
course aggregate are mixed and standard mould s
are prepared. The moulds are kept immersed in
water.This is the most important property of
commercial cement . Higher fineness contribute to
early strength andalso higher strength of cement.
Air entrained in concrete ,if abnormal , the mix must
be rejected. Compaction of concrete in the mould is
of great importance.
Test
Compressive strengths are failure strengths of
cement moulds kept under water for curing and
development of strength. Tests are usually carried
out after 3days, 7days and 28days. The strengths
achieved are known as 3day strength, 7day
strength and 28day strength respectively. For OPC
min. strength as per BS12 are 13N/mm2 after
3days, 29N/mm2 after 28days.
Book-IV Pop ups
Pressure
File Name : 4_6_pop_pressure_n
Pop_Pressure_1_def Pressure- definitions

Property of:
Book-IV Pop ups
Psychrometry
File Name :
4_7_pop_psychrometry_n
Pop_Psychro_0_psychrometry Psychrometry
Pop_Psychro_1_wet_dry_bulb Psychrometry-Dry Bulb -Wet Bulb
Pop_Psychro_2_wetBulbDep Psychrometry-Wet Bulb Depression
Pop_Psychro_3_1_sphumidity Psychrometry-Specific Humidity
Pop_Psychro_3_RH Psychrometry-Relative Humidity
Pop_Psychro_4_DewPt Psychrometry -Dew Point Temperature
Pop_Psychro_5_relations Psychrometry- Psychrometric Relations
Pop_Psychro_7_DryWetAir Psychrometry-Dry Air-Water Vapour and Wet Air-
Pop_Psychro_8_enthalpy Psychrometry-Enthalpy of Moist Air

Property of:
Psychrometry
File Name : Pop_Psychro_1_wet_dry_bulb
Psychrometry-Dry Bulb -Wet Bulb
Dry Bulb Temperature
The temperature of air,as measured by any

ordinary thermometer is indicator of Dry Bulb
Temp. of air.
Wet Bulb Temperature
When the bulb of the thermometer is wrapped by a

wet cloth and kept continuously moist during the
measurement period, the temperature so indicated
is Wet Bulb Temp.
File Name : Pop_Psychro_4_DewPt
Psychrometry
Psychrometry -Dew Point Temperature
Dew Point Temperature
When a given volume of air, containing certain

quantity of water vapour is made to cool continuously,
it reaches a temperature when it cannot hols the
water vapour any more. The air ,for the given quantity
of water vapour attains its saturation temp.The water
vapour now starts condensing as temp. is lowered
any further.This temperature is called the Dew Point
Temperature.
How to read from Steam Table

Dew point temp. can be directly obtained from the
Steam Table. This can be read as saturation
temp.corresponding to the partial pressure of water
vapour in the air.If say the partial pressure of water
vapour is P v then we can read the dew point temp.as
the saturation temp.of steam corresponding to the
pressure Pv
Book-IV Pop ups
General Topics
File Name : 4_8_pop_gentopics_n
Pop_Gen_1_Dimension Dimension
Pop_Gen_2_Units Units
Pop_Gen_3_Variables Variables and Constants
Pop_Gen_4_Deg. of Freedom Degree of Freedom Analysis
Pop_Gen_5_def. deg. freedom Degree of Freedom of a Problem - A Definition
Pop_Gen_6_equations Equations

Property of:
File Name : Pop_Gen_1_Dimension
General Topics
Dimension
A dimension is an attribute of a physical object which

qualifies a measured value. Fundamentally, all
measurement of physical objects somehow relate to Mass
(M), Length (L) and Time (T). These are, therefore, known
as Basic or Fundamental Dimension.All other attributes of
an object can be expressed in terms of the fundamental
dimensions. by using physical principles.
File Name : Pop_Gen_4_Deg.ofFreedom
General Topics
Degree of Freedom Analysis
A degree-of-freedom (DF) analysis is an accounting of the

variables associated with a problem and the facts and
relations available to determine values for those variables.
To analyse a problem it necessary to check the classes of
variables,theiir relationship,and the other information that
are available.
Book-V Charts & Tables
Steam
File Name : 5_1_charts_steam_n
chartsandtables_1_steamtables Charts and Tables - Steam Tables

Property of:
Book-V Chapter 1 Pop up files: General Topics
File Name : chartsandtables_1_steamtables
Charts and Tables - Steam Tables
Steam Tables
Steam tables are very useful to determine psychrometric properties ofhumid air. From the tables
below ,we can determine dew point temperature, humidity and partial pressure and their
correlation.
Table of Humidity of a Saturated Gas

Total Pressure 1013 mbar
dataair :=
0 1 2 3 4
0 20 23.37 14.7 18.99
1 21 24.85 15.66 20.24
2 22 26.42 16.68 21.55
3 23 28.08 17.76 22.94
4 24 29.82 18.89 24.4
5 25 31.66 20.09 25.96
6 26 33.6 21.37 27.6
7 27 35.64 22.74 29.34
8 28 37.79 24.17 31.18
9 29 40.04 25.67 33.12
10
11
Column "0" has data on Dew Point Temp.

Column "1" has data on Partial pressure of Steam
Column "2" has data on Humidity of Steam in terms of gms / kg.. of dry air
Column "3" has data on Humidity of Steam in terms of gms / Nm3 of dry air
〈〉
X := dataair 0 deg C
〈〉
Y := dataair 1 mbar
〈〉 gms
Z1 := dataair 2 density of dry air 1.29 kg/Nm3
kg⋅ dry air
〈〉 gms
Z2 := dataair 3
3
Nm dry air
To find dew point temperature =TD deg. C for given partial pressure of water vapour Pvs mbar
Let partial pressure of water vapour in saturated air be Pvs kg / cm2 Pvs := 0.033 kg / cm 2
Or
Pvs := 1000⋅ Pvs mbar
Pvs = 33 mbar
fit( Pvs) := linterp(Y , X , Pvs) TD := fit(Pvs) deg. C
fit( Pvs) = 25.691
TD = 25.691 deg. C
To find from table , humidity = w1 gms /kg. dry air Function " linterp" reads the value
of third argument Pvs in the
fit1( Pvs) := linterp(Y , Z1 , Pvs) column named by first argument
by linear interpolation.Then reads
w1 := fit1( Pvs) off the corresponding value from
fit1( Pvs) = 20.974 the column named by the second
argument.Column data should be
in acsending order for
w1 = 20.974 gms /kg. dry air
interpolation to work.
To find from table , humidity = w2 gms /Nm3 dry air
fit2( Pvs) := linterp(Y , Z2 , Pvs)
fit2( Pvs) = 27.093 gms /Nm3 dry air w2 := fit2( Pvs)
w2 = 27.093 gms /Nm3 dry air

13 /3/01
Refer pp 37 in bookDust load measurements

in Gas Flows-- Lurgi
Book-V Charts & Tables
Reactivity of Coal
File Name : 5_4_charts_reactivity_n
chartsandtables_4_coalreactivity Charts and Tables- Reactivity of Coal

Property of:
Book-V Chapter 4 Pop up files: General Topics
File Name : chartsandtables_4_coalreactivity
Charts and Tables- Reactivity of Coal
Reactivity of Coal
T sec Burnout time of coal
O LOSS % Loss of O2
DATA :=
0 1 2
0 0 0 0
1 2 3 1
〈〉 〈〉
O LIGNITE := DATA 1 O ANTHRA := DATA 2
〈〉
T := DATA 0
Coal Reactivity Chart

4 4
3
Loss of Oxygen
O LIGNITE
O ANTHRA 2
0
0
0 10 20 30 40
0 T 40
Time in sec
Lignite 40 % R on 90 mic.
Anthracite -15 5 Ron 90 mic.

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Qcr Crusher Capacity required

Qcr = 595 Tonnes / Hrs

Hv Crusher Hopper capacity -( volumetric)

Feeder for Crusher

Feeder capacity Qcrf T/Hr.

Crusher Capacity =Q cr T/Hr Qcr := 595

Over capacity factor K2 K2 := 1.2

Qcrf := K2⋅ Qcr

Transportation from crusher

Crusher should be followed by a Plate conveyor or Impact conveyor of short

Qtcro := 1.5 ⋅ Qcr

File Name : 1_3_preblending

Topic: Expanded Table Of Contents

1_3_preblending_1 Preblending and Stockpile Equipment Calculations

Calculation of Stockpile Capacity for Raw material (Limestone)

To calculate the capacity of stockpile following steps can be followed.

Step :- 1 Determine Kiln capacity

Qdk Kiln Capacity of Clinker Qdk := 4500 Tonnes /

K1 Factor for converting Clinker to Raw meal K1 := 1.6

CL Total Limestone component as percentage C L := 85 %

Qcr Crusher capacity Qcr := 565 Tonnes/ Hr

RMd Number of days of Raw Material stock required RMd := 7

Qsp Stock pile capacity in Tonnes.

RMw Raw material required per week

LSw Limestone required per week

Qsp := Qdk ⋅ K1⋅ RMd

Qstacker Stacker Capacity

Qstacker := 1.5 ⋅ Qcr

Qstacker = 847.5 Tonnes/Hr

Stacker / Stacker Belt Capacity = Qstacker = 847.5 Tonnes/Hr

Raw Grinding Section

File Name : 1_4_rawgrinding

Topic: Expanded Table Of Contents

1_4_rawgrinding_1 Bond Work Index of the various material based on

1_4_rawgrinding_2 Calculation of power at Ball Mill shaft for Raw material ,

1_4_rawgrinding_3 Raw Mill and Auxiliary Equipment Capacity Calculations

1_4_rawgrinding_4 Raw Material Drying - Estimation ofTotal Moisture to be

1_4_rawgrinding_5 Raw Mill Heat Balance - Evaluation of Hot Gas

1_4_rawgrinding_6 Calculation of Ball Mill Percentage Filling as per

1_4_rawgrinding_7 Calculation of Grinding Ball Size

1_4_rawgrinding_8 Specific Heat of Raw Material as a Function of

1_4_rawgrinding_11 Calculation of Efficiency of Dynamic Air Separator

1_4_rawgrinding_12 Average Piece Weight ofGrinding Media

1_4_rawgrinding_13 Ball Mill Critical Speed and Ball Charge Calculations

1_4_rawgrinding_14 Verical Roller Mill -- Calculation of Power

Not to be copied in any form or distributed or resold

Raw Grinding Section

File Name : 1_4_rawgrinding_1

The Bond index of various material based on the Dry basis -

Bond test mill result is calculated as given below.

Pf Product fineness test result ( 80 % Passing - Range > 90 µ ) , µ Pf := 60

Ff Feed size to test mill ( 80 % passing - Range 0-4 mm ) , µ Ff := 2500

Sc Screen size , ( Normally 90 µ size ) , µ Sc := 90

Pr Finished product per mill revolution , gm / rev Pr := 1.36

W s = 11.261 kwh/sh.t ( dry basis )

Raw Grinding Section

File Name : 1_4_rawgrinding_5

Ght Hot gases temperature , Ght := 280 deg.c

Gh Required hot gas quantity ( Nm3/hr )