I want to know about calculation mathods of gas & material flow in preheater, pc, kiln, cooler. Further, can you advise why we are getting brown clinker problem in our 2000tpd off-line calciner kiln from which we are recently producing 2500tpd while having 90-91 LSF, 2.26 SM, 1.4 AM.& kiln feed residue up to 22 per cent. How we can improve our clinker quality?

The calculation of gas and material flow in the preheater relies on the principles of stoichoimetry (to assess the combustion gas products from the fuel) and the conservation of mass. In principle what goes into the kiln must come out somewhere and will allow you to prepare a mass balance for the kiln. With regard to the brown clinker you are producing this is most probably caused by having reducing burning conditions in the burning zone of the kiln. This is very bad for clinker quality and fuel efficiency of the kiln. Almost certainly the problem is with the kiln burner and might be solved by adjustment. You must be sure that you maintain at least one per cent oxygen at the kiln inlet.

How can the efficiency of clinker cooler can be be increased without any modifications?

Cooler efficiency is a function of the amount of air that is blown into the cooler for cooling the clinker. You might improve the efficiency by reducing the amount of cooling air. However, you need to develop a model of the cooler to ensure that you have the optimum balance between thermal efficiency and cooling performance.