MATHCEMENTreg;-PYRO, A MATHEMATICAL MODEL TO ESTABLISH HEAT, GAS AND MASS BALANCE IN THE PYRO PROCESSING SECTION OF MODERN CEMENT PLANTS

摘要

Live-Math technique, based on mathematical software Mathcad® has been used to develop a mathematical model to represent combined functioning of preheater, precalciner, kiln and grate-cooler. The basic process parameters are inputted in the model. Initial calculations are based on certain assumptions of fuel efficiency, temperature of the tertiary air, circulating dust at kiln inlet, calcinations function etc. Mass balances at various preheater stages are carried out starting from the lowermost stage. It then calculates gas flow rate at each stage followed by stage wise heat balance calculation. Heat balance provides the temperature profile across the preheater. The model makes validation checks. The user can control the looping calculation by changing the assumed fuel efficiency to converge on the conditionality satisfaction. The model shifts to grate cooler and establishes cooler function to evaluate the temperature of tertiary air which then is re-entered in the calculation of preheater. Calculations are repeated till conditions are satisfied. The advantage of using this model is seen in its power to present all calculation steps in real mathematical notation and in live format. It presents investigative possibility in plant operation and design by allowing the users to manipulate data and operating conditions.