Materials flow values are instrumental in many industries for controlling and simulating processes, designing new equipment as well as modifying existing plants. They are sometimes impossible to determine by direct measurement in an operating plant due to the very high temperatures. This study attempted to overcome the difficulties associated with this measurement by proposing a new method to calculate materials flow of a double-string suspension preheater type of cement plant with separate line and in-line calciners (SLC-I), with heat balance error less than 1%. This study was divided into two sequential parts, with the first part presented in this paper. The methodology of the first part was to solve the conservation law of the main clinker plant equipment, supported by Bogue’s equation, the heat of calcination, and the thermodynamic properties of the related materials. The least-square method was employed for solving the overdetermined system equations obtained in the second part. The results of the first part were: the ratio of heat formation to specific heat consumption was 52.13% (> 50%), and the gas exhausted from the plant yielded more than 117 MW heat equivalent, which can potentially be recovered for electricity production.

In many industries, energy auditing is important as the basis for controlling processes and designing additional equipment or modifying an existing plant. However, it requires detailed data of the materials flow, which often cannot be determined easily by direct measurement due to high-temperature limitations. This paper presents the second part of an integrated study to perform energy auditing in a separate line and in-line calciners (SLC-I) type cement plant. The second part of this study, as presented in this paper, focused on the materials flow calculation for eight separate cyclones and two calciners. The least square method was employed for solving the obtained overdetermined system equations. Using the operation data from Part 1 of the study, calculation of the detailed materials flow in each cyclone was executed. The results showed that the separation efficiency of cyclones 1A, 2A, 3A, 4A and 1B, 2B, 3B, 4B was 93.86%, 89.80%, 84.41%, 81.98% and 93.96%, 88.70%, 88.53%, 80.72% respectively and the estimated calcination percentage of kiln feed coming out of the ILC and the SLC was 85.3% and 56.3%, respectively. These values are impossible to be measured directly in the cyclones and calciners during plant operation.