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    Case Study On Cement Kiln Energy Saving

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    The document summarizes a case study on an energy audit conducted at a cement manufacturing plant. The audit found that reducing the temperature of preheater exit gases from 350C to 330C and avoiding the formation of carbon monoxide could result in annual savings of 15.64 kcal/kg of clinker produced. This translates to a savings of 1276 tons of coal per year, worth approximately 88.68 lakh rupees. Recovering heat from waste exhaust streams in this way allows significant energy savings for the plant as well as environmental benefits. Energy audits provide a systematic approach to achieving conservation.

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    Case Study On Cement Kiln Energy Saving

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    engr kazam
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    The document summarizes a case study on an energy audit conducted at a cement manufacturing plant. The audit found that reducing the temperature of preheater exit gases from 350C to 330C and avoiding the formation of carbon monoxide could result in annual savings of 15.64 kcal/kg of clinker produced. This translates to a savings of 1276 tons of coal per year, worth approximately 88.68 lakh rupees. Recovering heat from waste exhaust streams in this way allows significant energy savings for the plant as well as environmental benefits. Energy audits provide a systematic approach to achieving conservation.

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    The document summarizes a case study on an energy audit conducted at a cement manufacturing plant. The audit found that reducing the temperature of preheater exit gases from 350C to 330C and avoiding the formation of carbon monoxide could result in annual savings of 15.64 kcal/kg of clinker produced. This translates to a savings of 1276 tons of coal per year, worth approximately 88.68 lakh rupees. Recovering heat from waste exhaust streams in this way allows significant energy savings for the plant as well as environmental benefits. Energy audits provide a systematic approach to achieving conservation.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    27 views3 pages

    Case Study On Cement Kiln Energy Saving

    Uploaded by

    engr kazam
    The document summarizes a case study on an energy audit conducted at a cement manufacturing plant. The audit found that reducing the temperature of preheater exit gases from 350C to 330C and avoiding the formation of carbon monoxide could result in annual savings of 15.64 kcal/kg of clinker produced. This translates to a savings of 1276 tons of coal per year, worth approximately 88.68 lakh rupees. Recovering heat from waste exhaust streams in this way allows significant energy savings for the plant as well as environmental benefits. Energy audits provide a systematic approach to achieving conservation.

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    6th International Conference on Recent Trends in Engineering & Technology (ICRTET - 2018)

    Case Study on Energy Audit of Cement Plant


    HITESH R. THAKARE
    Mechanical Engineering Department
    SNJB’s Late Sau. K. B. Jain College of Engineering, Chandwad.

    ABSTRACT
    Energy is one of the major inputs for the economic development of any country. However, the scenario of fossil fuel
    reserves does not agree with the ever increasing energy demands of a growing economy. Hence, it becomes highly necessary to
    undertake energy conservation efforts in order to ensure long term sustainability. Present paper discusses a case study wherein
    waster heat recovery has been utilized to save significant amount of energy in a cement manufacturing plant.

    1. INTRODUCTION
    Energy is one of the major inputs for the economic development of any country. In the case of the developing countries,
    the energy sector assumes a critical importance in view of the ever-increasing energy needs requiring huge investments to meet
    them. Coal and other fossil fuels, which have taken three million years to form, are likely to deplete soon. In the last two hundred
    years, we have consumed 60% of all resources as observed from Figure 1.

    Figure1. 1: Consumption of Fossil Fuels over the years [1]


    The usage of energy resources in industry leads to environmental damages by polluting the atmosphere. Few of examples
    of air pollution are sulphur dioxide (SO2), nitrous oxide (NOX) and carbon monoxide (CO) emissions from boilers and furnaces,
    chloro-fluro carbons (CFC) emissions from refrigerants use, etc. For sustainable development, we need to adopt energy efficiency
    measures.
    Energy efficiency is defined as the ratio of energy required to perform a specific service to the amount of primary energy
    used for the process. Improving energy efficiency increases the productivity of basic energy sources by providing given services
    with less energy resources. Energy efficiency is achieved when energy intensity in a specific product, process or area of
    production or consumption is reduced without affecting output, consumption or comfort levels. Energy efficiency is often viewed
    as a resource option like coal, oil or natural gas. It provides additional economic value by preserving the resource base and
    reducing pollution. For example, replacing traditional light bulbs with Compact Fluorescent Lamps (CFLs) means one will use
    only 1/4th of the energy to light a room. Pollution levels also reduce by the same amount. Nature sets some basic limits on how
    efficiently energy can be used, but in most cases our products and manufacturing processes are still a long way from operating at
    this theoretical limit [1].
    Objective
    The objective of present paper is to demonstrate the savings obtained in energy through reduction of waste heat from a
    fluid stream going out of a cement plant. For the sake of confidentiality, only necessary technical details are mentioned here and
    name or other confidential details of the plant are omitted.
    An energy audit of a cement plant was conducted to establish heat balance in a 5 stage Kiln. Flue gas analyzer and pitot
    tube was used to measure the following data at preheater outlet.
    Temperature = 350oC
    Duct area = 3.098 m2.
    Static pressure = -435 mmWC
    Dynamic pressure = 16.9 mmWC
    CO2 = 19.2%
    Oxygen = 6%
    CO = 0.06%
    The atmospheric pressure is 10334 mmWC.

    647 | ICRTET0125 www.ijream.org © 2018, IJREAM All Rights Reserved.


    International Journal for Research in Engineering Application & Management (IJREAM)
    Special Issue – ICRTET-2018 ISSN : 2454-9150

    Atmospheric temperature = 20oC.


    Assume pitot tube constant = 0.85
    Production rate of clinker = 55 TPH
    Feed for kiln = 88.5 TPH
    percentage of return dust in pH gas = 6.8 %
    Coal cost = Rs. 6.95/- per kg.
    Operating hours = 8000 per year.
    Net calorific value of coal = 5,356 kCal.kg
    Specific heat of PH gas = 0.25 kcal/kg oC,
    Specific heat of return dust = 0.23 kcal/kg oC.
    We need to calculate heat loss due to formation of CO, from preheater return dust as well as exit gas. Later on the preheater exit
    gas temperature was reduced to 330oC as well as CO formation was avoided. This also helped in significant annual monetary
    saving, as explained in the following texts.
    Preheater gas density at STP conditions
    = (%O2 x MO2)+ (%CO2 x MCO2)+ (%(N2+CO) x MCO)/(22.4 x 100)
    = (6 x 32) + (19.2 x 44) + (74.74+0.06)x28/(22.4 x 1000)
    = 1.398 kg/Nm3
    Gas density at given temperature and pressure
    = STP Density x 273 x (10334+Pstatic)/((273+T)x10334)
    = 1.393 x 273 x (10334 – 435)/((273+350)x10334)
    = 0.587 kg/Nm3
    Preheater gas velocity calculation
    = Pitot tube const x √(2 g Pd / density)
    = 0.85 x √(2 x 9.81 x 16.9/0.585)
    = 20.19 m/sec
    Flow rate of preheater gas using continuity equation
    = duct area x velocity
    = 3.098 x 20.22
    = 62.55 m3/sec
    = 62.55 x 3600 x 0.587 / 1.398
    = 94550 Nm3/hr
    Thus, specific volume of preheater gas is obtained as
    = 94550/55000
    = 1.72 Nm3/kg of clinker
    Now we can calculate heat loss due to exit gas from preheater
    = mass of gas x specific heat x temperature difference
    = 1.72 x 1.398 x 0.25 x (350-20)
    = 198.37 kCal/kg of clinker
    Now we can calculate heat loss through return dust
    = mass of dust x specific heat x temperature difference
    = percentage of return dust/100 x clinker factor x specific heat x temperature difference
    = (6.8/100) x (88.5/55) x 0.23 x (350 – 20)
    = 8.3 kCal/kg of clinker
    Now we can calculate heat loss through formation of CO in the process
    = mass of CO x 67636
    = specific volume of preheater gas x %CO/(22.4 x 1000) x 67636
    = 1.72 x 0.06/(22.4 x 1000) x 67636
    = 3.12 kCal/kg of clinker
    Afterwards, exit temperature of preheat exit gas was proposed to be reduced to 330oC. in this scenario, the corresponding
    heat losses have been estimated as follows. Also, the case of avoiding the formation of CO was taken into account.
    Now we can calculate heat loss due to exit gas from preheater
    = mass of gas x specific heat x temperature difference
    = 1.72 x 1.398 x 0.25 x (330-20)
    = 186.35 kCal/kg of clinker
    Saving in heat loss for this condition = 197.95 – 186.35 = 12.02 kCal/kg of clinker
    Now we can calculate heat loss through return dust
    = mass of dust x specific heat x temperature difference
    = percentage of return dust/100 x clinker factor x specific heat x temperature difference
    = (6.8/100) x (88.5/55) x 0.23 x (330 – 20)
    = 7.8 kCal/kg of clinker
    Saving in heat loss for this condition = 8.3 – 7.8 = 0.5 kCal/kg of clinker
    Hence, total saving in thermal energy = 12.02 + 0.5 + 3.12 = 15.64 kCal/kg of clinker
    Because of this, the saving in coal obtained = 15.64 /5356 = 0.00292 kg/ kg of clinker
    6th International Conference on Recent Trends in Engineering & Technology (ICRTET - 2018)

    Saving obtained in coal on annual basis


    = 0.0029 x 55 TPH x 8000 hours/year
    = 1276 x 103 kg/year
    = 1276 ton per year
    = 1276 x 103 x 6.950
    = Rs. 88,68,200/- per year

    CONCLUSION
    It was observed that recovering the substantial amount of energy from waste exhaust stream can result in significant
    amount of saving. Such a energy saving is beneficial to the company as well as to the environment. More importantly, energy
    audit is a systematic approach towards achieving energy conservation.

    REFERENCES
    [1]. Guide books for Energy Auditor’s Certification Examination by BEE, New Delhi.

    649 | ICRTET0125 www.ijream.org © 2018, IJREAM All Rights Reserved.

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