QUESTIONNAIRE FOR PYROPROCESSING
MODIFICATION
COMPANY NAME
LOCATION AND
ADDRESS
1
Plant Altitude (M)
Relative Humidity (%)
Ambient Temperature Range (oC)
Describe Kiln System and specify type
Long, wet
4-stage SP
4-STAGE SP
5-stage Precalciner
6-Stage Precalciner
Others
Existing clinker production
DESIGN
3000
MTPD
Long, dry
4-stage Precalciner
4-stage W/riser duct
Burning
NORMAL
4400
MAXIMUM
MTPD
4500
MTPD
Existing fuel consumption
NORMAL
810
MAXIMUM
kcal/kg
820
kcal/kg
PREHEATER
5
How many strings are there in your preheater? :- ONE
How many stages are there in your preheater? :-FOUR
What are the different vessel diameters?
Stage 1 (Top)
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6 (Bottom)
String One
6300 MM
7400 MM
8200MM
8200MM
---------
String Two
Please enclose a sketch of Cyclone and provide dimensions as per Annexure I.
What are the inlet and outlet areas of each vessel?
String One (m2)
Stage 1 (Top)
Stage 2
Stage 3
String Two
(m2)
IN 10.57662 M2
OUT 7.0225 M2
IN 12.1104 M2
OUT 10.75 M2
IN 14.4648 M2
OUT 12.1922 M2
Stage 4
Stage 5
Stage 6 (Bottom)
8
IN 18.29 M2
OUT 12.1922M2
------This data is essential and please fill completely.
Are there any crisscrossing? If yes, please explain
NO
Type of Precalciner
Size : Diameter (m) x Height (m)
% Calciner Achieved :
LOI of Raw Meal to Kiln:
% of fuel fired in Precalciner
Quantity of fuel fired in Precalciner (TPH):
:- 8.2M DIA. X 11.36M
:- 90%
:- 35%
:- 60-65%
:- 15-20 (TPH)
10
If system does not have a calciner, is there any firing in the riser duct?
N.A.
If yes, what percentage?
11
Please provide a pressure and temperature profile across the preheater in each stage.
Preferably attach a sketch showing exactly the measurement points.
12
A.
Preheater Fan (provide fan characteristic curves) String I
Static Pressure (mmWG or in WG)
Design
802 MMWG
Operating
800 MMWG
Volume (am3/Hr or ACFM)
712800 M3/HR
730000 M3/HR
Temperature (oC or oF)
390C
390C
Fan Drive Type
Fan Drive kW (Design & Absorbed)
Fan Drive Max. Amps
COUPLING
GEARED GC109 TRULINE
2500KW
252 AMP
2350KW
230AMP.
Fan Drive Normal Amps
230 AMP.
230AMP.
Normal Fan Damper & Speed
100% DAMPER
991 RPM
VARIABLE
SPEED
Specify as Damper Controlled or
Variable Speed
12
3.15 M. for
68.14 M. Length
100% DAMPER
920RPM
3.15 x 3.81
oblong dia for 38
M. from bottom
& remaining
30.14 M. length
duct dia is 3.15
M.
B.
Down comer duct diameter
C.
Preheater Fan (provide fan characteristic curves) String II N.A.
Design
Static Pressure (mmWG or in WG)
Volume (am3/Hr or ACFM)
Temperature (oC or oF)
Fan Drive Type
Fan Drive kW (Design & Absorbed)
Fan Drive Max. Amps
Fan Drive Normal Amps
Operating
Normal Fan Damper & Speed
Specify as Damper Controlled or
Variable Speed
Down comer duct diameter
FUEL FIRED IN PRE CALCINER
13
Give typical analysis and heating values for each. Please specify as low heat value
or high heat value.
(As fired)
(As fired)
Solid Fuel
Fuel
Indonesian Coal
Type
%
Type
Volatile Matter
40%
%
%C
Fixed Carbon
%
%H
Sulphur
0.75
%
%O
Water
TOTAL 18.0% %
%H2O
Ash
14%
%S
HHV (dry basis)
6050
kcal/kg
%Ash
LHV
kcal/kg
NCV
kcal/kg
NOTE: If more than one type of fuel is fired simultaneously, please specify fuel
split. Ultimate analysis is important and please fill all the data.
B
Maximum and minimum raw coal moisture content
MAXIMUM MOISTURE CONTENT 12-15 % MINIMUM MOISTURE CONTENT
9-10%
Do you use waste derived fuels (fires, solvents, etc.,)? If so please specify type and
give typical analysis and heating value for each.
Do you use waste derived fuels (fires, solvents, etc.,)? If so please specify type and
give typical analysis and heating value for each.
N.A.
D
If solid fuels are burned, what type of firing system exists for kiln and calciner?
(e.g. Direct, Indirect, Semi direct, FK pump). Provide sketch if possible..
INDIRECT WITH F.K.PUMP
15-20
Capacity of Pre calciner Firing System (TPH)
Type of Fuel Metering System
IMPACT SANKHYO FLOW
METER
14
Is there a tertiary duct from cooler / kiln hood to precalciner
T.A.DUCT FROM COOLER
Yes
No
Yes
Tertiary Air Duct Take off
No
Kiln Hood
TAKE OFF FROM COOLER
Cooler
What size is the duct?
Dia 2650 mm OD x 67322 mm length
Type of Damper in Tertiary Air Duct : No
Pressure drop in Tertiary Air Duct (mmWg)
15
Drawings to be enclosed for Preheater modification
1) GA of Preheater building
2) Floor plans of Preheater building with openings
KILN
16
Kiln Dimensions
A)
Length (m)
67.07M
Kiln Speed (rpm)
Diameter (m)
4.572M
Kiln Slope (%)
Year Commissioned
1982
Kiln Drive HP
B)
Installed Power
522
KW
C)
Operating Power
337
KW
D)
Drive details
Main Gear
Number of teeth
Face Width
Helix angle
Min.
Operating
Max.
0.40
4.0
4.0
4.0%
700HP
UNIT
NO.
MM
DEGREE
256
775
6 18 RH
Pinion
Normal pressure angle
Tooth hardness
Normal module or diametrical pitch
DEGREE
BHN
MM
25
200-220
1.0/25.4
Quantity
Number of teeth
Face Width
Helix angle
Normal pressure angle
Tooth hardness
Normal module or diametrical pitch
Bearing Size
NO
NO
MM
DEGREE
DEGREE
HB
MM
Bearing centerline to centerline
dimension
MM
1.0
19
787.4
6 18 LH
25
310-360
25.4
23152CA/C3
/W33
1621.66
Low Speed
Coupling
UNIT
Manufacturer
Size
Rating
CONCORD
GC-D-2014C
KW
Main Reducer
Manufacturer
Size of model
Ratio
Power rating
Service factor
KW
FLENDER
SZN 710(SPL)
20.628:1
745.7
2.4
High Speed
Coupling
Manufacturer
WELLMAN
BIBBY
432-B
2.4 HP/RPM
Size
Rating
Main Motor
Full Speed rpm
Full power rating
Auxiliary Drive
Clutch or
Decoupling
Device
n-1
KW
1150
525
KW
MARLON CO.
USA
CESU-12M,
SIZE - 75
29.8
Manufacturer
Size
Rating
Servicing factor
Auxiliary Reducer
Manufacturer
Size or model
Ratio
Power rating
Service factor
KW
FALK
CORPORATION
75 CB3-12A
39.28:1
29.8
1.22
Backstop
Manufacturer
Size
Rating
N-m
MARLAND USA
CEBMAG-5C-W
245 AT CAM
SHAFT
Service factor
Auxiliary Motor
Speed
Power
RPM
KW
1460
29.8
E) REFRACTORY
Calcination
R-63 & HA60
220MM
Type
Thickness
Sintering
HA-70
220MM
Cooling
S-65 ALMAG-85
220MM
F) THRUST ASSEMBLY:
Type
: VERTICAL THRUST ROLLER 26 x 8 SIZE
G) THRUST ASSEMBLY:
Feed End
: VERTICAL THRUST ROLLER 26 x 8 SIZE
Discharge End
: VERTICAL THRUST ROLLER 26 x 8 SIZE
FUEL FIRED IN KILN
17
Give typical analysis and heating values for each. Please specify as low heat value
or high heat value.
(As fired)
(As fired)
Solid Fuel
Fuel
Type
INDONESIAN %
Type
Volatile Matter
40
%
%C
Fixed Carbon
%
%H
Sulphur
0.75
%
%O
Water
TOTAL 18%
%
%H2O
Ash
6.7%
%
%S
HHV (dry basis) 6050
kcal/kg
%Ash
LHV
kcal/kg
NCV
kcal/kg
NOTE: If more than one type of fuel is fired simultaneously, please specify fuel
split. Ultimate analysis is important and please fill all the data.
Do you use waste derived fuels (fires, solvents, etc.,)? If so please specify type and
give typical analysis and heating value for each.
NO
18
If solid fuels are burned, what type of firing system exists for kiln?
(e..g. Direct, Indirect, Semi direct, FK pump). Provide sketch if possible.
INDIRECT WITH F.K.PUMPS
Type of Kiln Burner
Capacity of Kiln Burner
Design NCV of fuel
% of Fuel fired in Kiln
Quantity of fuel fired (TPH)
40
6000
35-40%
7-8(TPH)
What is percentage of kiln primary air?
M.KCal./Hr.
K.Cal./Kg.
12%
volume
m3/Hr or
ACFM
3
Primary air fan capacity 13000. m /Hr. 32*C mmWG
19
a)
b)
c)
d)
e)
f)
Drawings:
General Arrangement drawing of Kiln
General Arrangement drawing of Kiln hood Layout
General Arrangement drawing of Fire hood
General Arrangement drawing of Feed end seal arrangement
General Arrangement drawing of Discharge end seal Arrangement
General Combined Arrangement drawing of Cooler, Kiln & Pre heater
20
OPERATING DATA
Kiln inlet
Pressure
20-40 mmWG
Temperature
1050-1100 oC
Kiln hood
5-7 mmWG
850 900 oC
COOLER
21
Cooler Dimensions
Make:
Type:
Size:
