Actually you made us understand saving by modifying the coal conveying line if we have to find out same coal conveying line like: before we were maintaining coal phase density 3 kg coal/kg air and after taking action by reducing blower RPM in steady state kiln operation so now phase density 5 kg coal/kg air. by this method we can calculate heat losses.
First you have to check your heat consumption of the plant and then compare with Benchmarking numbers if there is any deviation then compare the cooler losses and preheater losses with standard values- cooler losses -110 to 120 kcal per kg clinker and Preheater losses -105 to 120 kcal per kg clinker.. details discussion will be discussed on Pyro optimisation module.
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@@Asnaniclasses_Cement Sir we are using 100% petcoke with 20% TSR, 5500TPD & 730 SHC. PH heat losses are in higher side (130 to 140 kcal/kg clk.) How could I optimise with stable plant operation? Kindly suggest please
Actually, in AFR the overall oxygen concentration at the preheater outlet is around 4-5 percent with 20-25 percent TSR , therefore, as thumb rule increase in 1 percentage of TSR leads to increase 1 kcal per kg clinker,it means that whatever number you are getting is not bad. Without AFR it should be in the range of 700 kcal per kg clinker but still you can reduce it by increasing top cyclone efficiency upto 97 percentage
If across TDA temp losses 60 degree and we have to find out heat losses, so we can find out TDA air velocity through pitot tube and then to calculate air flow M3/hr and then convert it to kg/hr and after that it can be found out specific air kg/kg clk. So easily it can be calculated heat losses across TAD. This is the right way or not, pls suggest us sir
Generally if you use a pitot tube then it may be bent due to high temperature it's better to divide recuperation air as per it's coal consumption, suppose you re getting 0.80 Name per kg clinker then take 60 percentage of it =.48 Nm3 per kg clinker Heat loss =0.48*1.29*20-0*specific heat of air Considering 20 degrees heat loss
Sir, suppose we have to find out recuperation air, so in my plant total cooler fans are 10 nos. how many fans will be taken for recuperation air. In Static grate area, two fans have been given. Ambient air density becomes 1.293 kg/NM3, is'nt
Total input cooling air-Vent air=Recuperation Air Unit -Nm3/kg clinker Find the individual fans air in Nm3/kg clinker and then add it upto recuperation air Suppose up to the 5th fan you're getting o.75 Nm3/kg clinker then then null point is there in that compartment.
Practically it is not possible..but if it happens still some air will pass through TAD...Secondly insufficient air leads to high CO formations in Calciner leads to reducing conditions in the kiln which increases the coating formation of sulphides...
Very Impressive sir, highly salute
Thank you sir,for this type of valuable class,please carry on this type of topic
Sure
Sir very good morning
Ur explanation is sup
And also tq so much for giving this information sir
Excellent work done
Thanks Sir 🙏
Sir I m process engineer in ultratech cement so ur lectures are so useful for me
Good,you ask your doubt here..stay connected
Thanks sir
Actually you made us understand saving by modifying the coal conveying line
if we have to find out same coal conveying line like: before we were maintaining coal phase density 3 kg coal/kg air and after taking action by reducing blower RPM in steady state kiln operation so now phase density 5 kg coal/kg air. by this method we can calculate heat losses.
If you reduce the blower rpm then you have to check the conveying velocity in the pipeline... therefore before doing it whether it's feasible or not
Sir, thanks for your valuable knowledge sharing ..
Q. What action can we take to reduce specific heat consumption in Pyro system?
First you have to check your heat consumption of the plant and then compare with Benchmarking numbers if there is any deviation then compare the cooler losses and preheater losses with standard values- cooler losses -110 to 120 kcal per kg clinker and Preheater losses -105 to 120 kcal per kg clinker.. details discussion will be discussed on Pyro optimisation module.
@@Asnaniclasses_Cement Sir we are using 100% petcoke with 20% TSR, 5500TPD & 730 SHC. PH heat losses are in higher side (130 to 140 kcal/kg clk.) How could I optimise with stable plant operation? Kindly suggest please
Actually, in AFR the overall oxygen concentration at the preheater outlet is around 4-5 percent with 20-25 percent TSR , therefore, as thumb rule increase in 1 percentage of TSR leads to increase 1 kcal per kg clinker,it means that whatever number you are getting is not bad.
Without AFR it should be in the range of 700 kcal per kg clinker but still you can reduce it by increasing top cyclone efficiency upto 97 percentage
If across TDA temp losses 60 degree and we have to find out heat losses, so we can find out TDA air velocity through pitot tube and then to calculate air flow M3/hr and then convert it to kg/hr and after that it can be found out specific air kg/kg clk. So easily it can be calculated heat losses across TAD.
This is the right way or not, pls suggest us sir
Generally if you use a pitot tube then it may be bent due to high temperature it's better to divide recuperation air as per it's coal consumption, suppose you re getting 0.80 Name per kg clinker then take 60 percentage of it =.48 Nm3 per kg clinker
Heat loss =0.48*1.29*20-0*specific heat of air
Considering 20 degrees heat loss
Sir, suppose we have to find out recuperation air, so in my plant total cooler fans are 10 nos. how many fans will be taken for recuperation air.
In Static grate area, two fans have been given.
Ambient air density becomes 1.293 kg/NM3, is'nt
Total input cooling air-Vent air=Recuperation Air
Unit -Nm3/kg clinker
Find the individual fans air in Nm3/kg clinker and then add it upto recuperation air
Suppose up to the 5th fan you're getting o.75 Nm3/kg clinker then then null point is there in that compartment.
Ambient air density is to be calculated upon the density correction factor
Sir if TAD Wii be blocked then will be the affect? As air has an option to go through secondary air
Practically it is not possible..but if it happens still some air will pass through TAD...Secondly insufficient air leads to high CO formations in Calciner leads to reducing conditions in the kiln which increases the coating formation of sulphides...
Yeah it increases the secondary air volume that leads to reduce the CO tendency at kiln inlet
Heat copy me batao ek sequence me
Kindly, clear your question means aapko kya seekhna hai so that I will clear that topic in the next classes.
sir app bahut chhota likhte hai.