Material Balance Cement Plant
Material Balance Cement Plant
Material Balance Cement Plant
M2 Loss 5% 0.05
Clay
M1
M3
IN = Loss + OUT
M1 = M2 + M3
15 = 15*0.05 + M3
0.75
M3 = 14.25 kg/day
M5 Loss 5% 0.05
Crusher
M4
M6
IN = Loss + OUT
M4 = M5 + M6
85 = 85*0.05 + M6
4.25
M6 = 80.75 kg/day
IN = OUT + Loss
M3 + M6 = M8 + M7
14.25 + 80.75 = M8 + 0.475
M8 = 94.525 kg/day
Composition of M7 & M8
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert
kg/day 11.591425 3.093675 76.909625 1.315275 1.788375 0.342
Exhaust Gases
Kiln
M8
M9
Analysis of M8
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert
kg/day 11.5 3.08 76.53 1.31 1.78 0.34
Mwt of Component
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3
Mwt 60.06 101.94 100.09 159.68 84.31
Moles of Component
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3
kmol/day 0.192032 0.030196 0.764563 0.008196 0.021106
Analysis of M9
Component C2S C3S C3A C4AF
% 20 60 12 8
Reaction In Kiln
CaCO3 -------------- CaO + CO2 1
MgCO3 ------------- MgO + CO2 2
CaO + Al2O3 ------------- CaO.Al2O3 3
4CaO + 2Al2O3 + CaO.Al2O3 ----------------- 5CaO.3Al2O3 4
5CaO + 3Al2O3 --------------- 5CaO.3Al2O3 5
2CaO + SiO2 -------------- 2CaO.SiO2 6
4CaO + 5CaO.3Al2O3 -------------- 3(3CaO.Al2O3) 7
CaO + 2CaO.SiO2 -------------- 3CaO.SiO2 8
4CaO + Al2O3 + Fe2O3 -------------- 4CaO.Al2O3.Fe2O3 9
3 + 4 ------------- 5
X1 = Y1 = 0.764563 kmol/day
X2 = Y2 = 0.021106 kmol/day
Y3 = 0.384065 kmol/day
X3 = 0.192032 kmol/day
Z4 = 0.032783 kmol/day
Y4 = 0.008196 kmol/day
X4 = 0.008196 kmol/day
Y5 = 0.022001 kmol/day
X5 = 0.007334 kmol/day
Z5 = 0.036668 kmol/day
Y6 = 0.029334 kmol/day
X6 = 0.022001 kmol/day
CaO + 2CaO.SiO2 ----------- 3CaO.SiO2
1 1 1
Z7 Y7 X7
C3S C2S
3CaO.SiO2 2CaO.SiO2
60% 20%
Weigh Ratio 3 1
Mwt 228.3 172.22
Mole Ratio 0.013141 0.005807 weigh ratio / mwt
2.263 1 Divided by 0.005806
kg/day
Component kmol/day Mwt kmol/day * Mwt %
C2S 0.058851 177.22 10.429662 17.3
C3S 0.133181 228.3 30.405208 50.4
C3A 0.022001 270.3 5.946735 10
C4AF 0.008196 485.95 3.982729 6.6
Inert - - 9.520970 15.8
Sum - - 60.285304 100.0
Check
M8 = M9 + Exhaust Gases
94.525 = 60.285304 + 34.577271
94.525 = 94.862575
M9
Cement Mill
M10
5% 0.05 M11
M9 + M10 = M11
M.B of CaSO4:
0.0*M9 + M10 = 0.05M11
M.B of Clinker:
0.0 + M9 = 0.95M11 = 60.285304 kg/day
Basis
100 kg/day ------------- 63.1 kg/day
X kg/day ------------- 3333333.3 kg/day
X = 5282620.2 kg/day
M2 Loss 5% 0.05
Clay 0.75
M1 15 14.25
M3
M5 Loss 5% 0.05
Crusher 4.25
M4 85 80.75
M6