Live plant mimics — one tool, many measurements
Integrated engineering tools that place set-points directly on the equipment and calculate every dependent value live. Downloadable Excel reports included.
Absorbed Power
Free mill absorbed and motor shaft power calculator covering ball mill (Slegten and FLS methods), vertical mill (FLS and Loesche) and roller press (FLS).
Open the mimic NEW · DCSBall Charge Design
Free ball charge design calculator \u2014 ball weight, surface area and count per size class, average charge properties, and calculated volume load and free height.
Open the mimic NEW · DCSBall Mill Media Wear
Free ball mill grinding media wear calculator \u2014 projects your new charge gradation after top-up, compared against your target ball size distribution.
Open the mimic NEW · DCSBall Mill Volume Loading
Free ball mill volume loading calculator from free-height measurements, with a saved trend log per mill and typical-range interpretation.
Open the mimic NEW · DCSBlending Efficiency
Free raw material stockpile blending efficiency calculator \u2014 number of layers from stacker speed and pile geometry, checked against the typical 200-300 layer target.
Open the mimic NEW · DCSCement Ball Mill Master Tool
Integrated cement ball mill digital twin with one deterministic recalculation path, operator-side mill controls, measured ball-charge entry in mm, feed/material load effects on operating power and SEC, fan RPM/false-air ventilation, separate intermediate and outlet diaphragm velocities, separator/return modeling, integrated mass balance and calculated gas outlet temperature.
Open the mimic NEW · DCSClinker Cooler Balance
Free grate cooler mass and energy balance calculator across up to 12 fan zones, with cooler loading, cooling air ratio and heat recuperation interpretation.
Open the mimic NEW · DCSCoal Mill Balance
Free coal mill mass and energy balance calculator. Enter your plant data and get an instant balance with closure check, drying efficiency and inleakage interpretation.
Open the mimic NEW · DCSCyclone Efficiency
Free preheater cyclone collection efficiency calculator from cyclone geometry and feed particle size distribution.
Open the mimic NEW · DCSDust Collector Evaluation
Free baghouse dust collector evaluation \u2014 air-to-cloth ratio, can (thimble) velocity and blow pipe sizing, checked against accepted design limits.
Open the mimic NEW · DCSFalse Air
Free false air (inleakage) calculator from a single opening measurement using the orifice flow equation, with velocity, flow and mass flow results.
Open the mimic NEW · DCSFan Curve
Free fan curve calculator using fan affinity laws \u2014 scale a fan's performance curve to new temperature and speed conditions.
Open the mimic NEW · DCSFinish Mill Balance
Free cement (finish) mill mass and energy balance calculator \u2014 closure check and specific heat consumption, for ball mills and vertical roller mills.
Open the mimic NEW · DCSFlame Momentum
Free kiln burner flame momentum calculator \u2014 universal method plus KHD, FLSmidth Duoflex and Novaflam burner-specific methods.
Open the mimic NEW · DCSGas Flow
Free pitot-traverse gas flow calculator \u2014 gas density, velocity, mass flow and normal/actual volumetric flow, with the AMCA 75% rule check.
Open the mimic NEW · DCSKiln Mass Balance
Free kiln solids mass balance calculator with weighting-factor error reconciliation across raw meal, fuel, return dust, clinker, and dust streams.
Open the mimic NEW · DCSKiln Performance Dashboard
Free interactive kiln performance dashboard \u2014 enter your production, geometry and clinker chemistry readings and get SHC, SPC, filling, retention time, thermal loading, LSF, Bogue and coating tendency in one live dashboard.
Open the mimic NEW · DCSKiln Performance Quick Formulas
Free kiln performance formula calculator \u2014 16 standard FLS Kiln Manual formulas covering degree of filling, thermal/volumetric loading, retention time, excess air and more.
Open the mimic NEW · DCSLSF, Silica Ratio, Alumina Modulus & Bogue
Free clinker quality parameter calculator \u2014 LSF, silica ratio, alumina modulus, Bogue phases (C3S/C2S/C3A/C4AF), coating tendency and burning temperature.
Open the mimic NEW · DCSMax Ball Size Calculator (Bond Formula)
Free maximum ball size calculator for ball mill charge design, using the Bond formula from feed size, work index and mill speed.
Open the mimic NEW · DCSMill Axial Test
Free ball mill axial sampling test tool \u2014 log % retained data along the mill length and see the grinding progression profile.
Open the mimic NEW · DCSMill Sweep
Free ball mill sweep velocity calculator, accounting for grinding media loading and charge swell \u2014 checked against the typical 1.0-1.5 m/s band.
Open the mimic NEW · DCSPHT Exit Gas Composition
Free preheater exit gas composition calculator \u2014 CO2, H2O, SO2, O2 and N2 volumetric composition, gas density and molecular weight, from fuel and kiln feed chemistry.
Open the mimic NEW · DCSPlant Mass Balance & Cost Model \u2014 Quarry to Cement
Flagship Excel model reconciling every stage from quarry through raw mill, kiln and cement mill \u2014 mass balance, electrical SEC, and cascading cost per tonne, all built on balanced (not booked) tonnages.
Open the mimic NEW · DCSPsychrometrics
Free moist air property calculator (ASHRAE equations) from dry-bulb and wet-bulb temperature \u2014 relative humidity, humidity ratio, dew point, enthalpy and density.
Open the mimic NEW · DCSRaw Materials Dryer Balance
Free raw materials dryer mass and energy balance calculator (natural gas firing) \u2014 combustion air, products of combustion, closure check and specific heat consumption.
Open the mimic NEW · DCSRoller Press
Free roller press process calculator \u2014 throughput, nip angle, pressure of fragmentation and specific energy, checked against guide values.
Open the mimic NEW · DCSRosin-Rammler Particle Size Distribution
Free Rosin-Rammler particle size distribution fit from sieve analysis \u2014 slope (uniformity), position parameter and fit quality.
Open the mimic NEW · DCSSeparator Design and Evaluation
Free separator design and evaluation calculator covering static, V-separator, mechanical, circulating and high efficiency separator types, checked against typical design ranges.
Open the mimic NEW · DCSShell Heat Losses
Free kiln, dryer or cooler shell heat loss calculator from a measured shell temperature profile \u2014 radiation and convection losses, with specific loss per unit output.
Open the mimic NEW · DCSTromp Curve
Free separator Tromp curve calculator from feed/fines/rejects particle size analysis \u2014 circulating load, probability of rejection by size, and Imperfection.
Open the mimic NEW · DCSUnit Conversions
Free multi-category unit converter for cement process engineering \u2014 length, pressure, energy, specific energy, flow, temperature and more.
Open the mimic NEW · DCSVariograph (Semivariogram)
Free process variability calculator (semivariogram) from a sample sequence \u2014 classical statistics, experimental semivariogram, and random/trend/cyclic variance breakdown.
Open the mimic NEW · DCSVolatile Balance
Free kiln volatile balance calculator (SO3, K2O, Na2O, Cl) \u2014 in:out ratios, sulfur:alkali molar ratio, and volatilization coefficients against typical ranges.
Open the mimicBuilt for one plant, not a generic template
These two are different from the free calculators below \u2014 they're standalone products built around your plant's full data flow, not a single formula.
Plant Mass Balance & Cost Model
Quarry through raw mill, kiln and cement mill, all reconciled to one balanced truth \u2014 mass, electrical SEC, and a cascading cost per tonne \u2014 not booked figures.
See the full model Free \u00b7 InteractiveKiln Performance Dashboard
An example of what a real kiln control-room dashboard looks like \u2014 production, geometry and clinker chemistry together: SHC, SPC, filling, retention time, thermal loading, LSF, Bogue.
Open the dashboardProcess engineering calculators
Enter real plant data, get an instant result with plain-language interpretation of what it means for your operation. Free — verify your email once and every tool below unlocks.
Coal Mill Balance
Full mass and energy balance around a coal mill, with closure check, drying efficiency and inleakage interpretation.
Open calculatorClinker Cooler Balance
Grate cooler mass and energy balance across 12 fan zones, with cooler loading, cooling air ratio and heat recuperation interpretation.
Open calculatorBall Mill Volume Loading
Log free-height measurements per mill and track loading % over time, with typical-range interpretation.
Open calculatorFalse Air
Quantify inleakage at a single opening from pressure and geometry, using the orifice flow equation.
Open calculatorAbsorbed Power
Mill absorbed and motor shaft power for ball mills, vertical mills and roller presses \u2014 5 industry methods in one tool.
Open calculatorUnit Conversions
Instant multi-category unit converter \u2014 length, pressure, energy, flow, temperature and more. No sign-up needed.
Open converterPsychrometrics
Moist air properties (ASHRAE) from dry-bulb and wet-bulb temperature \u2014 humidity, dew point, enthalpy, density.
Open calculatorGas Flow
Pitot-traverse gas flow \u2014 density, velocity, mass and volumetric flow, with the AMCA 75% distribution check.
Open calculatorBall Charge Design
Ball weight, surface area and count per size class, calculated volume load, and typical-range interpretation.
Open calculatorShell Heat Losses
Radiation and convection heat loss from a measured kiln, dryer or cooler shell temperature profile.
Open calculatorDryer Balance
Raw materials dryer mass and energy balance (natural gas firing), with combustion air, products of combustion and closure check.
Open calculatorBall Mill Media Wear
Project your new ball charge gradation after top-up, size by size, against your target distribution.
Open calculatorTromp Curve
Separator circulating load and probability of rejection by size, from feed/fines/rejects particle size analysis.
Open calculatorVariograph
Process variability breakdown (semivariogram) from a sample sequence \u2014 random vs. trend vs. cyclic variance.
Open calculatorVolatile Balance
Kiln SO3/K2O/Na2O/Cl balance \u2014 in:out ratios, sulfur:alkali molar ratio, and volatilization coefficients.
Open calculatorDust Collector Evaluation
Baghouse air-to-cloth ratio, can velocity and blow pipe sizing, checked against accepted design limits.
Open calculatorFinish Mill Balance
Cement mill mass and energy balance with closure check and specific heat consumption, for ball mills and VRMs.
Open calculatorMill Sweep
Ball mill sweep velocity through the open cross-section, checked against the typical 1.0-1.5 m/s band.
Open calculatorPHT Exit Gas Composition
Preheater exit gas composition, density and molecular weight from fuel and kiln feed chemistry, cross-checked against measured O2.
Open calculatorSeparator Design and Evaluation
5 separator types \u2014 static, V-separator, mechanical, circulating, high efficiency \u2014 checked against typical design ranges.
Open calculatorFlame Momentum
Kiln burner flame momentum \u2014 universal method, plus KHD, FLSmidth Duoflex and Novaflam burner-specific methods.
Open calculatorCyclone Efficiency
Preheater cyclone collection efficiency from geometry and feed particle size distribution.
Open calculatorBlending Efficiency
Stockpile blending layer count from stacker speed and pile geometry, checked against the typical 200-300 layer target.
Open calculatorKiln Mass Balance
Kiln solids mass balance with weighting-factor reconciliation across raw meal, fuel, dust and clinker streams.
Open calculatorQuality Parameters
LSF, silica ratio, alumina modulus, Bogue phases, coating tendency and burning temperature from clinker oxide analysis.
Open calculatorKiln Performance Quick Formulas
16 standard FLS Kiln Manual formulas \u2014 degree of filling, loading, retention time, excess air and more, with targets.
Open calculatorFan Curve
Scale a fan performance curve to new temperature and speed conditions using fan affinity laws.
Open calculatorMax Ball Size
Theoretical maximum top-up ball size (Bond formula) from feed size, work index and mill speed.
Open calculatorRoller Press Tools
Throughput, nip angle, pressure of fragmentation and specific energy, checked against guide values.
Open calculatorRosin-Rammler PSD
Particle size distribution fit from sieve analysis \u2014 slope, position parameter and fit quality.
Open calculatorMill Axial Test
Log axial sampling % retained data and see the grinding progression profile along the mill.
Open calculatorMore tools
More calculators added regularly.