Energy audit and conservation opportunities for pyroprocessing unit of a typical dry process cement plant

G. Kabir, A.I. Abubakar and U.A. El-Nafaty

Energy, 2010, vol. 35, issue 3, 1237-1243

Abstract: Cement production process has been highly energy and cost intensive. The cement plant requires 8784 h per year of the total operating hours to produce 640,809 tonnes of clinker. To achieve effective and efficient energy management scheme, thermal energy audit analysis was employed on the pyroprocessing unit of the cement plant. Fuel combustion generates the bulk of the thermal energy for the process, amounting to 95.48% (4164.02 kJ/kgcl) of the total thermal energy input. Thermal efficiency of the unit stands at 41%, below 50–54% achieved in modern plants. The exhaust gases and kiln shell heat energy losses are in significant quantity, amounting to 27.9% and 11.97% of the total heat input respectively. To enhance the energy performance of the unit, heat losses conservation systems are considered. Waste heat recovery steam generator (WHRSG) and Secondary kiln shell were studied. Power and thermal energy savings of 42.88 MWh/year and 5.30 MW can be achieved respectively. Financial benefits for use of the conservation methods are substantial. Environmental benefit of 14.10% reduction in Greenhouse gases (GHG) emissions could be achieved.

Keywords: Cement plant; Clinker; Energy audit; Pyroprocessing; Rotary kiln; Thermal energy (search for similar items in EconPapers)
Date: 2010
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Citations: View citations in EconPapers (15)

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Persistent link: https://EconPapers.repec.org/RePEc:eee:energy:v:35:y:2010:i:3:p:1237-1243

DOI: 10.1016/j.energy.2009.11.003

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