Material out = Material in + Generation - Consumption - Accumulation

Accumulation = 0 (Steady State)

Generation & Consumption = 0 (No Chemical Reaction)
Material out = Material in
Dry Basis 100 kg/day
85%
85
15%
15

L/S
Clay

M2

Loss

kg/day
kg/day
5%

0.05

Clay
M1
M3

Component
%

IN
M1
15

=
=
=
=

Loss
M2
15*0.05
0.75
14.25

M3
SiO2
70.69

+
+
+

OUT
M3
M3

kg/day

Al2O3
14.91

CaCO3
4.5

Fe2O3
6

MgCO3
1.5

M5

Loss

5%

0.05

Inert
2.4

Crusher
M4
M6

Component
%

IN
M4
85

=
=
=
=

Loss
M5
85*0.05
4.25
80.75

M6
SiO2
1.88

+
+
+
kg/day

Al2O3
1.2

CaCO3
94.45

Fe2O3
0.57

OUT
M6
M6

MgCO3
1.95

Inert
0

M8
Raw Mill
M3
M6
Loss

M3
14.25

IN
+
+

M6
80.75
M8

OUT
M8
M8
94.525

+
+
+
kg/day

Loss
M7
0.475

Composition of M7 & M8
SiO2
Al2O3
CaCO3
Fe2O3
MgCO3
11.591425 3.093675 76.909625 1.315275 1.788375

Component
kg/day

Component
%

=
=
=
=

Concentration of Composition in Mixture

SiO2
Al2O3
CaCO3
Fe2O3
12.20
3.2565
80.96
1.38

M7
0.5%
0.005

MgCO3
1.88

Inert
0.342

Inert
0.36

Exhaust Gases
Kiln
M8
M9
IN
M8
94.525

=
=
kg/day

OUT
M9

+
+

Component
kg/day

SiO2
11.5

Analysis of M8
Al2O3
CaCO3
3.08
76.53

Component
Mwt

SiO2
60.06

Mwt of Component
Al2O3
CaCO3
101.94
100.09

Moles of Component

Exhaust Gases
Exhaust Gases

Fe2O3
1.31

MgCO3
1.78

Fe2O3
159.68

MgCO3
84.31

Inert
0.34

Component
kmol/day

SiO2
0.192032

Component
%

C2S
20

Component
Mwt

C2S
172.22

Al2O3
0.030196

CaCO3
Fe2O3
MgCO3
0.764563 0.008196 0.021106

Analysis of M9
C3S
C3A
60
12

C3S
228.30

C3A
270.18

C4AF
8

C4AF
485.95

Reaction In Kiln
CaCO3 -------------- CaO + CO2
MgCO3 ------------- MgO + CO2
CaO + Al2O3 ------------- CaO.Al2O3
4CaO + 2Al2O3 + CaO.Al2O3 ----------------- 5CaO.3Al2O3
5CaO + 3Al2O3 --------------- 5CaO.3Al2O3
2CaO + SiO2 -------------- 2CaO.SiO2
4CaO + 5CaO.3Al2O3 -------------- 3(3CaO.Al2O3)
CaO + 2CaO.SiO2 -------------- 3CaO.SiO2
4CaO + Al2O3 + Fe2O3 -------------- 4CaO.Al2O3.Fe2O3
3 + 4 -------------

1
2
3
4
5
6
7
8
9

Moles of Components By the Reaction

CaCO3
---------------------1
0.764563
X1

Y1

MgCO3 ---------------------1
0.021106
X2

Y2

CaO
1
X1
=

MgO
1
X2
=

CO2
1
Y1

0.764563 kmol/day

CO2
1
Y2

0.021106 kmol/day

CO2
Weigh of CO2

=
=

Y1

2CaO
2
Y3

SiO2
1
0.192032

Y3
X3

=
=

0.3840649 kmol/day
0.192032 kmol/day

4CaO
4
Z4

Al2O3
1
Y4

Z4
Y4
X4

=
=
=

0.032783
0.008196
0.008196

kmol/day
kmol/day
kmol/day

5CaO
5
Z5

3Al2O3
3
Y5

+
Y2
kmol/day * Mwt

----------------------

Fe2O3
1
0.008196

----------------------

=
=

0.785668 kmol/day
34.577271 kg/day

2Ca.SiO2
1
X3

----------

4CaO.Al2O3.Fe2O3
1
X4

5CaO.3Al2O3
1
X5

3(3CaO.3Al2O3)
3
X6

Y5 = Total moles of Al2O3 - Y4

Y5
X5
Z5

4CaO
4
Y6
Y6
X6

=
=
=

0.022001 kmol/day
0.0073335 kmol/day
0.0366675 kmol/day

5CaO.3Al2O3
----------1
X5 =
0.007334
=
=

0.029334 kmol/day
0.0220005 kmol/day

CaO
1
Z7

2CaO.SiO2
1
Y7

-----------

3CaO.SiO2
1
X7

From outlet % Analysis

Weigh Ratio
Mwt
Mole Ratio

C3S
3CaO.SiO2
60%
3
228.3
0.013141
2.263
X7
X7
X7

2CaO.SiO2 Excess
2CaO.SiO2 Excess

Inerts in
MgO
CaO Excess

----------------------------

Amount of Inerts

=
=

weigh ratio / mwt

Divided by 0.005806

=
=
=

SiO2 kmol/day *2.263 / (2.263+1)

0.133181 kmol/day
Y7
=
Z7
=
0.133181

=
=

SiO2 kmol/day* (1/2.263+1)

0.058851 kmol/day

The amount of CaO excess

The amount of CaO excess
The amount of CaO excess

Amount of Inerts

C2S
2CaO.SiO2
20%
1
172.22
0.005807
1

Inert in

=
=
=

Outlet
Reactant
CaCo3
Y3+Z4+Z5+Y6+Z7
0.148532 kmol/day

MgO

CaO Excess

Analysis of inlet
Moles of component * Mwt
CaO Excess * Mwt

0.340290
9.520970

+
kg/day

0.8509874

8.3296929

% Analysis of the clinker

Component
C2S
C3S
C3A
C4AF
Inert
Sum

kmol/day
0.058851
0.133181
0.0220005
0.008196
-

Mwt
177.22
228.3
270.3
485.95
-

=
=
=

M9
60.285304
94.862575

kg/day
kmol/day * Mwt
10.429662
30.405208
5.946735
3.982729
9.520970
60.285304

%
17.3
50.4
10
6.6
15.8
100.0

Check
M8
94.525
94.525

+
+

Exhaust Gases
34.577271

M9
Cement Mill
M10
5%

0.05

M10

M11

From the Mill:

Balance:
M9

M11

M.B of CaSO4:
0.0*M9 + M10 = 0.05M11
M.B of Clinker:
0.0 + M9 = 0.95M11 = 60.285304 kg/day
M11 = M9 / 0.95 = 60.285304 / 0.95
M11

63.458215

kg/day

M10

3.172911

kg/day

Real Quantities
Converted Balance
Annual Production
Working Days
1000000

ton/year

100
X

kg/day
kg/day

1000000
300

ton/year
day/year

3333333.3

kg/day

------------63.1
------------- 3333333.3

kg/day
kg/day

Basis

5282620.2

kg/day

M``
=
X*M / 100
M`` : Real quantities
X : the amount of clay and lime stone which produce 1000000 ton/day

M2
0.75

Clay

Loss

M1

15

M``

X*M / 100

M1``
M2``
M3``

=
=
=

792393
39619.651
752773.38

kg/day
kg/day
kg/day

M5
4.25

Loss

Crusher
M4

85

5%

0.05
14.25
M3

5%

0.05
80.75

M6