⚙️ Vertical Roller Mill — Heat & Mass Balance Calculator
Cement Plant Process Tool | Single-file, browser-only | Design case: 385 t/h raw meal
📥 Feed & Process
🌬️ Gas Streams
🔥 Heat Balance
⚖️ Mass Balance
🏭 Unit Residuals
⚙️ Settings
📦 Raw Meal Feed Composition
| Component | Wet% | Wet Flow (t/h) | Moisture (%) |
Dry Flow (t/h) | Water (t/h) |
|---|---|---|---|---|---|
| TOTAL | — | — | — | — | — |
🌡️ Process Parameters
| Production Capacity | t/h (product) | |
| Feed Material Temperature | °C | |
| Product Temperature | °C | |
| Mill Outlet Gas Temp. | °C | |
| Product Moisture Content | % (wet basis) | |
| Mill Water Injection | m³/hr | |
| Product Residue (+90µm) | % | |
| Separator Efficiency | % | |
| Reference Temperature | °C |
⚡ Power Data
| Equipment | kWh/t | Power (kW) | Speed |
|---|---|---|---|
| Mill Motor | 2675 | — | |
| Fan Motor | 1564 | — | |
| Separator Motor | 12.1 | rpm | |
| Fan Speed | — | — | rpm |
kW = kWh/t × Production Rate (auto-computed)
🌬️ Gas Stream Measurements & Composition
Edit O₂, CO₂, H₂O vol% — N₂ is computed as remainder. Enthalpy computed automatically.
Measured Input
Computed
Editable
| Stream | P (mmWg) |
T (°C) | Composition (vol%) | Flow (Nm³/min) |
Flow (m³/min actual) |
Flow (m³/hr) |
Density (kg/Nm³) |
Mass Flow (kg/hr) |
Enthalpy (Mcal/hr) |
||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| O₂% | CO₂% | H₂O% | N₂% (calc) | MW | |||||||||
🔥 Heat Balance — INPUTS
| Description | Mcal/hr | % |
|---|---|---|
| THERMAL INPUTS | ||
| Heat content — Mill Inlet Gases | — | — |
| ↳ Preheater gas | — | — |
| ↳ Recirculation | — | — |
| Heat content — Feed Materials (dry) | — | — |
| Heat content — Feed Moisture | — | — |
| MECHANICAL INPUTS | ||
| Heat content — Mill Drive | — | — |
| Heat content — Fan Drive | — | — |
| TOTAL INPUTS | — | 100% |
❄️ Heat Balance — OUTPUTS
| Description | Mcal/hr | % |
|---|---|---|
| PRODUCT & GAS | ||
| Heat content — Raw Meal Product | — | — |
| Heat content — Exhaust Gas (to filter) | — | — |
| EVAPORATION | ||
| Latent Heat — Drying (feed moisture) | — | — |
| Latent Heat — Water Injection | — | — |
| UNACCOUNTED | ||
| Heat Loss (radiation, convection, etc.) | — | — |
| TOTAL OUTPUTS | — | 100% |
📊 Heat Balance Summary
| Parameter | Value | Unit | Status |
|---|---|---|---|
| Total Inputs | — | Mcal/hr | — |
| Total Outputs (excl. loss) | — | Mcal/hr | — |
| Unaccounted Heat Loss | — | Mcal/hr | — |
| Heat Loss (%) | — | % | — |
| Heat Consumption (excl. motor) | — | kcal/kg product | — |
| Specific Drying Energy | — | kcal/kg water evap. | — |
⚖️ Solid Mass Balance
| Stream | Mass Flow (t/h) | Status |
|---|---|---|
| INPUTS | ||
| Fresh Feed (wet) | — | — |
| Fresh Feed (dry) | — | — |
| Feed Moisture | — | — |
| Water Injection | — | — |
| Recycle Flow (to mill) | — | — |
| Mill Feed Total (dry) | — | — |
| OUTPUTS | ||
| Product (dry) | — | — |
| Product (moisture in product) | — | — |
| Water Evaporated | — | — |
| Separator Reject (gross) | — | — |
| Mass Balance Residual | — | — |
📈 Circuit Performance
| Circulation Factor | — | — |
| Separator Efficiency | — | % |
| Specific Power — Mill | — | kWh/t |
| Specific Power — Fan | — | kWh/t |
| Total Specific Power | — | kWh/t |
| Drying Capacity (feed moisture) | — | t water/hr |
| Water Evaporation Rate | — | kg/kg feed |
🌊 Water Balance
| WATER IN | |
| Feed moisture | — |
| Water injection | — |
| Moisture in hot gas (H₂O) | — |
| WATER OUT (t/h) | |
| In exhaust gas (vapor) | — |
| In product | — |
| Water balance residual | — |
🏭 Unit Operation — VRM (Vertical Raw Mill)
| Parameter | In | Out | Residual | Unit |
|---|---|---|---|---|
| Mass (dry solid) | — | — | — | t/h |
| Mass (water) | — | — | — | t/h |
| Energy | — | — | — | Mcal/hr |
🌀 Unit Operation — Dynamic Separator
| Parameter | In (t/h) | Product Out | Reject Out |
|---|---|---|---|
| Mass (dry) | — | — | — |
| Circulation factor | — | ||
🌪️ Unit Operation — Cyclone / Dust Collector
| Parameter | Value | Unit |
|---|---|---|
| Gas flow to filter | — | Nm³/min |
| Gas temperature at fan inlet | — | °C |
| Cyclone pressure drop | 155 | mmWg |
| Gas energy (cyclone outlet) | — | Mcal/hr |
🏗️ Unit Operation — Hot Gas Duct / Preheater Connection
| Parameter | Value | Unit |
|---|---|---|
| Preheater gas flow (measured) | — | Nm³/min |
| Preheater gas temperature | — | °C |
| Gas enthalpy (preheater) | — | Mcal/hr |
| Hot gas damper opening | % open | |
| Recirculation damper | % open |
📤 Unit Operation — Stack / Exhaust
| Stream | Flow (Nm³/min) | Temp (°C) | O₂% | Mass Flow (kg/hr) | Enthalpy (Mcal/hr) | Status |
|---|---|---|---|---|---|---|
| Gases to Filter/Stack | — | — | — | — | — | — |
⚙️ Thermodynamic Settings
| Cp solid (raw meal) | kcal/(kg·°C) | |
| Cp liquid water | kcal/(kg·°C) | |
| Cp steam (H₂O vapor) | kcal/(kg·°C) | |
| Latent heat of evaporation (T_ref) | kcal/kg | |
| Mill drive thermal efficiency (η) | — (0–1) | |
| Fan drive thermal efficiency (η) | — (0–1) |
Gas Cp Coefficients: Cp = a + b·T [kcal/(kg·°C)]
| Gas | a (const.) | b (×10⁻⁵/°C) | MW (g/mol) |
|---|---|---|---|
| N₂ | 28 | ||
| O₂ | 32 | ||
| CO₂ | 44 | ||
| H₂O | 18 |
🧪 Reaction Chemistry (Optional)
Enable calcination reactions occurring in the preheater or mill. These add endothermic heat to the energy balance.
| CaCO₃ → CaO + CO₂ (decarbonation) | |
| CaCO₃ fraction in feed | |
| Calcination degree in mill | |
| ΔH_rxn (endothermic, +ve) | |
| ΔH = 427 kcal/kg CaCO₃ = 3190 kcal/kg CO₂ released | |
Note: For raw grinding mills, calcination in the mill itself is typically <2%. The preheater cyclones do most calcination. Set calcination degree = 0 to exclude from mill energy balance.