| Cement Kiln HMB Engine
Industrial Pyroprocessing Simulation & Diagnostic Platform
Converged · 0 iters
📊 Dashboard
🌀 Cooler
🔧 TAD
🌫️ ESP
🔥 Heat Balance
⚖️ Mass Balance
💧 Streams
🔬 Combustion
📐 Sankey
🔄 Solver
🔍 Diagnostics
📄 Reports
Sp. Heat Consumption
—
kcal/kg clinker
—
Clinker Production
—
Tonnes / Day
Total Coal Rate
—
TPH
WHRS Recovery
—
MW
PH Exhaust Loss
—
kcal/kg (% of Input)
Cooler Exhaust Loss
—
kcal/kg
R&C Total Loss
—
kcal/kg
Heat of Reaction
—
kcal/kg (% unavoidable)
Thermal Efficiency
—
%
Cooler Efficiency
—
%
False Air
—
%
TAD Leakage
—
%
🔍 Active Diagnostics
🔴 Heat Outputs — kcal/kg clk
🟢 Heat Inputs — kcal/kg clk
💨 Cooler Air Distribution
🌡️ Key Process Temperatures
🌀 Cooler Fan Flow Calculation
Fan-wise Flow Summary
Cooler Performance Metrics
Cooler Compartment Air Distribution
Cooler Heat Recovery Analysis
🔧 Tertiary Air Duct (TAD) Analysis
TAD Flow Calculation
TAD Heat Loss & Efficiency
TAD Pressure Profile
Leakage Analysis
🌫️ ESP / Baghouse Fan Analysis
Fan Performance
Gas Flow & Leakage
ESP Heat Loss
Heat of Reaction: Q = 4.11·Al₂O₃ + 6.48·MgO + 7.646·CaO - 5.1165·SiO₂ - 0.59·Fe₂O₃ [kcal/kg]
Sensible Heat: Q = m × ∫Cp(T)dT = m × [a·T + 0.5·b·T²] [kcal/hr]
Coal Heat: Q = m_coal × NCV_blend [kcal/hr]
Assumptions: Cp coefficients from Perry's Chemical Engineers' Handbook. T_ref = 0°C.
🔴 Heat Output Components
| # | Component | kcal/kg clk | Mkcal/day | % Share | Reducible | Benchmark | Priority |
|---|
🟢 Heat Input Components
| # | Component | kcal/kg clk | Mkcal/day | % Share | Stream Type |
|---|
❄️ Cooler Heat Balance
| Component | kcal/kg clk | % Share |
|---|
Mass Balance: Σm_in = Σm_out ± tolerance [kg/hr]
CO₂ from Calcination: m_CO₂ = m_CaCO₃ × (44/100) = m_CaO × 1.786 × 0.44 [kg/hr]
Air Density: ρ = 1.293 × (273/(273+T)) × (P/760) [kg/Nm³]
⚖️ System Mass Balance (kg/hr basis)
| Stream | kg/hr | TPH | TPD | kg/kg clk | Unit / Source |
|---|
Mass In
Mass Out
💨 Air Flow Summary
| Air Stream | kg/hr | % of Total | Nm³/kg clk |
|---|
💧 All Process Streams
| Stream Name | Type | Mass Flow (kg/hr) | Temp (°C) | O₂ % | CO₂ % | N₂ % | H₂O % | Enthalpy (kcal/kg) | H̊ (kcal/hr) |
|---|
Stoich. O₂: O₂ = C×(32/12) + H×8 + S×1 - O [kg/kg fuel]
Theoretical Air: A_th = O₂ / 0.232 [kg/kg fuel]
Actual Air: A_act = A_th × (1 + excess_air) [kg/kg fuel]
CO₂ prod: CO₂ = C × (44/12) [kg/kg fuel]
H₂O prod: H₂O = H × 9 [kg/kg fuel]
🔬 Fuel Composition (proximate)
⚗️ Combustion Air Requirement
🔥 Combustion Products
| Product | kg/kg fuel | Nm³/kg fuel | Total (kg/hr) | Vol% |
|---|
💨 Flue Gas Composition at Each Stage
| Location | Temp °C | O₂ % | CO₂ % | N₂ % | H₂O % | SO₂ % |
|---|
🏭 3D Kiln Process Overview
📐 Heat Distribution — Proportional Flow Diagram
Heat & Mass Flow — Kiln System
🏭 Process Unit Summary
🌀 Preheater
🔥 Kiln
❄️ Cooler
🔄 Multi-Variable Solver — Energy Balance Closure
Tolerance: 0.1% | Method: Newton-Raphson with Line Search
Solver Config
Convergence History
Unknown Variables Solved
🔍 Intelligent Diagnostic Engine
Critical Issues
Warnings
Recommendations & Action Items
Data Validation Results
📄 Report Generation & Export
Export Options
Report Preview
Click a button above to generate a report preview.
Reports include:
- All input parameters with validation status
- Complete heat balance with formulas
- Complete mass balance with stream details
- Combustion stoichiometry
- Diagnostic findings and recommendations
- Cooler, TAD, and ESP analysis