Pre-Heater Cyclone Size
Data Unit S1 S2 S3 S4
Preheater cyclone Volume
(Cylinder + Cone) Effective m(^31137812448) 9,488 9,151
Preheater (Cyclone + Riser +
Meal Chutes) surface area m2^10089 1207898509219
Supply + Fabrication Weight(
including precalciner) Ton^2015211014651475
Preheater Concrete Volume m3 9639 10202 12172 15258
Preheater cyclone loading at
Guaranteed output tpd/m3 0.80 0.58 0.76 0.79
Pressure Drop Across PH mmWG 330 320 296 328
Benefits
Enhanced Potential Capacity % 7.5 28.5 24.1 12.0
Reduction in Pressure Drop mmWG 51 209 160 84
Saving in Absolute Power kW 150 651 531 244
Reduction in SPC Kwh/t 0.50 2.16 1.77 0.81
PH Fan Sp. Power consumption
at guaranteed output Kwh/t 4.39 4.2 4.2^4
Monitory Savings per Annum Lacs/
Annum^65284231106
Extra Investment for Higher Offered Size
Extra Cost of Steel Lacs 50 212 123 59
Extra Cost of Concrete Lacs 73 315 314 189
Total Extra Expense Lacs 123 527 436 249
ROI
Payback in Years Years 1.89 1.86 1.89 2.34
10.2 Conclusions
- It can be seen from the above table that there is a payback in approx. 1.86 -2.34
Years, this has been estimated on additional cost incurred for steel and concrete
due to bigger size preheater and on benefit in reduction in sp. Power consumption
of PH fan on account of reduction in pressure drop across PH. - Lower Volumetric loading indicates future potential on capacity in PH system
and efficient heat transfer in PH thus reduction in thermal loading in the kiln
enabling higher potential of kiln and increased refractory life. - Supplier 3 is offering biggest diameter of cyclones among all but the average
height of S3 cyclone is least, accordingly their volume of PH cyclones is less.