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Specialized Tools · Kiln · No. 01

Where does the heat of your kiln go?

The heat crept up 20 kcal/kg this month and nobody can say where it went. On a 5,000 t kiln that is about 17 t of coal every day, burnt for nothing. The O2 drifted, the cooler exhaust got hotter, the kiln factor moved: each one alone looks small, and together they are the bill.

What it savesFinds the kilocalories above target, and puts a daily cost on them.

US$30One-time · yours to keep
See the sample report (PDF)
  • Excel 2013 or later, Windows and Mac
  • No macros, no internet
  • Updates for life
  • Updates for life
  • Your name on every sheet
Your figures in: every result graded GOOD, WATCH or ACT, Today against What if

How this file helps

Find out if it is happening to you, how much it costs, and what to correct.

1Find outThe full balance of the kiln: every kilocalorie in, and where each one leaves.
2MeasureThe heat above target in dollars a day and in tons of fuel, and what one point of O2 or 10 degrees at the exit costs.
3CorrectThe largest loss first, with the check to make. The What-if shows the gain before the kiln is touched.

What it gives you

Every kilocalorie accounted for.

The heat of every fuel, main burner and calciner, per kg of clinker
The full balance in and out: preheater gas, cooler exhaust, clinker, radiation
The cooler efficiency and the cost of one more point of O2
What if: lower O2 or a cooler exhaust cooler, before touching the kiln

See it working

Worked on a demonstration plant.

Your figures in: every result graded GOOD, WATCH or ACT, Today against What if
Your figures in: every result graded GOOD, WATCH or ACT, Today against What if
The chart drawn for you, ready for the report
The chart drawn for you, ready for the report
What to do first, and why
What to do first, and why

Worked out for you

7 results from the figures you already measure.

Heat consumption and the heat above targetIts cost a day, in dollars and in tons of fuelPreheater gas volume and excess airHeat leaving with the gas, the cooler exhaust and the clinkerRadiation and not measuredCooler efficiencyLoss-free kiln feed factor

What is inside the file

Kiln Heat BalanceYour figures in, Today and What if side by side, every result graded, two charts, and what to do first.
MethodHow every result is obtained, and the references each grade is read against.
LicenseYour name, your company and your email, in the heading of every sheet.

What you need

  • 1Clinker made, kiln feed factor and its LOI
  • 2The fuels and their rates
  • 3Preheater exit O2 and temperature
  • 4Cooling air and the cooler temperatures
Industry methodsThe methods used across the cement industry, worked out step by step.
Graded, not just calculatedEach result is marked GOOD, WATCH or ACT against the usual range, with the reason.
Ready for the reportPrint-ready pages with the charts drawn for you.
Yours to keepOne price, no subscription. Use it again and again.

Questions

Before you buy

Can I see it before I buy?

Yes. The sample report shows the whole first sheet of the file, worked on a demonstration plant: every result, the charts and what to do first.

Does it need the internet or macros?

No. It works on Excel 2013 or later, on Windows or Mac, with no macros and no connection. Nothing to install.

Can I use it for several kilns?

Yes. Save one copy per kiln and per test. The file is yours to use for as long as you like.

What is the What-if column?

Type a new figure beside today's and see every result change, before anything is changed in the plant.

Who may use my copy?

One engineer or one plant. Your name is written on every sheet.

How do I pay?

Press Buy. We reply on WhatsApp and by email with the bank details. When the payment arrives, your copy is ready to download from this page.

Where does the heat of your kiln go?

Have the answer with your next figures.

US$30One-time · yours to keep
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More in the Kiln package

The other files of this package

Kiln Gas, False Air, Fans and Stack, a worked example
Kiln · No. 02
Kiln Gas, False Air, Fans and Stack

Is your ID fan moving kiln gas, or leaked air?

The ID fan is at its limit and the kiln cannot take more feed. Very often the fan is pulling air that leaked in through doors, flaps and joints, not kiln gas.

What it savesTurns the air leaking into the tower back into capacity for feed.

  • Excess air at the kiln inlet, the calciner outlet and the preheater exit
  • The false air between them, and what one point of O2 costs a day
US$30one-time · yours to keepSee the file →
Kiln Loading, Burner and Condition, a worked example
Kiln · No. 03
Kiln Loading, Burner and Condition

Is your kiln working in the band of its type?

Free lime jumps, the coating falls and the burning zone shell runs hot. The flame, the kiln speed and the load decide it, and they are rarely checked together.

What it savesKeeps the burning zone and the flame where the clinker is made, not the shell.

  • Residence time, filling and loads against kilns of the same type
  • The flame of the main burner: primary air, tip velocity, momentum
US$30one-time · yours to keepSee the file →
Raw Mix, Clinker and Volatile Cycles, a worked example
Kiln · No. 04
Raw Mix, Clinker and Volatile Cycles

How much more chlorine will your kiln take before it blocks?

The lowest cyclone blocks again and the kiln stops. Chlorine and sulfur circulate unseen until they condense, and every ton of new alternative fuel adds to them.

What it savesTells how much alternative fuel the chemistry will take, before the cyclones find out.

  • LSF, moduli and the clinker phases from the kiln feed
  • The heat of clinker formation for the heat balance
US$30one-time · yours to keepSee the file →

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