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.

I want to know about calculation methods of gas and 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 and kiln feed residue up to 22 per cent. How we can improve our clinker quality?

The white cement clinker must be quenched as it falls from the kiln to freeze the clinker minerals in their high temperature form. However, this quenching does not need to be to ambient temperature or anything like that. 600 degrees C is sufficient. Therefore quenching in water sprays to this temperature, leaving some sensible heat in the clinker is possible. However, how much useful heat could then be recovered from the clinker is debatable.

Hot clinker is quenched in water losing useful heat, can you syggest heat recovery without altering process of quenching.