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Article history:
Received 5 August 2011
Received in revised form
21 June 2012
Accepted 27 June 2012
Available online 9 August 2012
Grate coolers are widely used in cement industries to recover heat from hot clinker, coming out from the
rotary kiln. This study focuses on improving the energy, exergy and recovery efciencies of a grate
cooling system through the optimization of its operational parameters such as masses of cooling air and
clinker, cooling air temperature, and grate speed. It has been found that the energy and recovery energy
efciencies of a cooling system can be increased by 1.1% and 1.9%, respectively, with every 5% mass
increases of cooling air. Similarly, it has been estimated that energy and recovery energy efciencies can
be increased by 2.0% and 0.4% with every 5% increase of cooling temperature. The exergy and its recovery
efciencies found to be increased by 3.6% and 2.2%, respectively, for the same condition. Energy efciency
and energy recovery efciencies are increased by 3.5% and 1.4% with every 9.1% increase of grate speed.
Using heat recovery from the exhaust air, energy and exergy recovery efciencies of the cooling system
found to be increased by 21.5% and 9.4%, respectively. It has been found that about 38.10% and 30.86%
energy cost can be saved by changing mass ow rate of clinker and mass ow rate of cooling air,
respectively.
2012 Elsevier Ltd. All rights reserved.
Keywords:
Energy efciency
Exergy efciency
Grate clinker cooling
1. Introduction
The cement production is one of the most energy intensive
industries and accounts for about 30e40% of the production cost.
Nearly 5% of the total global industrial energy is used by the cement
industries [1,2]. Therefore, various energy saving techniques can be
applied to reduce energy used by this type of industry [3e5].
A grate clinker system is used in cement production and clinker
burning system consists of a clinker cooler, the rotary kiln, and the
suspension pre-heater [6]. A clinker cooler reduce the temperature
of the clinker, and grind and recover energy from the sensible heat
of the hot clinker by heating the cooled air. Four different types of
clinker coolers (i.e. grate, planetary, shaft, and rotary coolers) are
used to cool the hot clinker. A grate cooler has been proven to
recover more heat than the other types of coolers. For large capacity
plants, a great cooler is preferred one [7]. Fig. 1 presents the
schematic of a typical grate clinker cooler.
In a grate cooler, the clinker comes out of the rotary kiln at
a high temperature of 1380 C and it is cooled by fresh incoming air
Nomenclature
C
CCE
CS
CSC
E
_
m
T
Q_ pc
Q_ oc
Q_ exh
ES
EC
665
Subscripts
ca
Cooling air
cl,ck
Clinker
a
Air
as
Secondary air
at
Tertiary air
oc
Outlet clinker
exh
Exhaust air
d
Destruction
in
Input
out
Output
ic
Inlet clinker
2. Methodology
2.1. Energy and exergy analyses
The energy analysis is a traditional approach, which uses energy
balance to estimate energy use in various energy conversion
processes. Energy and exergy are different in the sense that exergy
is only conserved in a reversible process, but it is always consumed
in an irreversible process [17]. An exergy analysis is a thermodynamic approach to identify the types, locations and magnitudes of
thermal losses. Hence, exergy analysis will consequently allow the
evaluation and improvement of the thermodynamic systems
design [7]. Consequently, this analysis provides information on the
maximum savings that could be achieved through the improved
processes [18,19].
2.2. Energy and exergy input data
Specic heat capacities, mass and temperature are the necessary
input parameters to analyze the energy, exergy and recovery efciencies of the grate clinker cooler. These are taken from studies
performed by Rasul et al. [2], Kolip and Fevzi [3] and Mundhara and
Sharma [20]. Table 1 shows the summary of the input and output
666
Table 1
Summary of input and output data of a grate clinker cooler [2,3,20].
No.
Condition
Material
Cp (kJ/kg C)
Temperature, T ( C)
Entropy, s s0 (kJ/kg K)
Enthalpy h h0 (kJ/kg)
1
2
3
4
5
6
Input
Hot Clinker
Cooling air
Secondary air
Tertiary air
Cooled clinker
Exhaust gas
1.00
2.55
0.45
0.42
1.00
1.68
1.06
1.01
1.14
1.13
0.92
1.03
1300
45
850
650
115
220
1.7618
0.0658
1.5124
1.2775
0.2430
0.5185
1351.5
20.2
940.4
705.2
82.8
200.8
Output
E_ in
E_ out
(1)
_ cl Ccl Tcl1 Ta m
_ a Ca Tac Ta
Ein Q_ ic Q_ ca m
E_ out Q_ as Q_ at Q_ oc Q_ exh
_ as Ca Tas Ta m
_ at Ca Tat Ta
m
(3)
_ cl Coc Toc Ta m
_ exh Ca Texh Ta
m
To estimate the efciency of the cooler and the amount of
energy that can be recovered from the cooler, following equations
are used. Energy efciency is the ratio between the amount of
energy output and input of the system and can be expressed as
[18,21]:
P_
E
hI P _out
Ein
(4)
The recovery energy efciency of the secondary and tertiary air can
be expressed as [2]:
Q_
r
hrecovery;cooler _
Q ic Q_ ca
(5)
_
Ex
in
_ out Ex
_
Ex
d
(6)
The steady state exergy balance, using exergy destruction for the
open system of clinker cooling (Fig. 4), is thus stated as [17,22]:
_
_
_ ca Ex
_ as Ex
_ at Ex
_
_ oc Ex
Ex
Ex
d Ex
exh
ic
_
_ ck eic m
_ a ea
0Ex
d m
_ as eas m
_ at eat m
_ a;exh eexh
_ ck eoc m
m
(2)
(7)
The exergy efciency hP;I denes all exergy input as the exergy
consumed, and all exergy output as the exergy utilized and can be
expressed as [18]:
_
Ex
0h
;I
_ as Ex
_ at Ex
_
_ oc Ex
Ex
cooling air preheater and primary air pre-heater) has been estimated here. The amount of cost savings through the associated
with the recovered energy can be estimated using Eq. (10):
CS ES EC
h;I _ out
Exin
_
_
Ex
ic Exca
CCE
h;II
_
Ex
recovered
_
Ex
in
_ as eas m
_ at eat
m
_
_ ca
Ex
Ex
(9)
(12)
ic
In this case, both the kinetic and potential exergies are neglected
[17,22]. Realistically, there is a part of the output exergy, which
remains unused, i.e. the exergy that is dissipated to the environment. In this case, exergy efciency can be expressed as [9]:
h;1
(11)
(8)
exh
0h;II
667
_ out Ex
_ waste
Ex
_Ex
(10)
in
Table 2
Energy input and output of a clinker cooler [2].
Sym.
Description
Formula used
_
Ex
ic
Exergy of clinker
from kiln to cooler
Exergy of cooling air
Recovery exergy of
kiln secondary air
Recovery exergy rate
of tertiary air from cooler
Exergy of clinker at
cooler outlet
Exergy of cooler exhaust air
_ ck hck;out ho To sck;out so
m
_ ca
Ex
_ as
Ex
_ at
Ex
_ oc
Ex
Fig. 4. Exergy ow schematic of a grate clinker cooler [17].
_
Ex
exh
_ a hca ho To sca so
m
_ as has ho To sas so
m
_ at hat ho To sat so
m
_ ck hck;in ho To sck;in so
m
_ exh hck;exh ho To sexh so
m
668
Table 3
Energy analysis summary of the base case clinker cooler [1,2,20,22].
Condition
Material
Temperature, T, C
Heat, Q kJ/kg cl
% Of energy
Energy efciency
of cooler, hcooler, I (%)
Input
Hot clinker
Cooling air
Secondary air
Tertiary air
Cooled clinker
Exhaust gas
Unaccountable losses
1300.0
45.0
850.0
650.0
115.0
220.0
1351.5
51.5
423.2
296.6
82.8
337.4
262.9
96.3
3.7
30.2
21.1
5.9
24.1
18.7
81.3
51.3
Output
_
_
_
_
_
_
_
T0 Sgen Ex
d Exic Exca Exoc Exas Exat Exexh
(13)
Based on second law analysis, the exergy efciency of this system is
summarized in Table 4.
Similar to energy efciency, the exergy efciency (53.8%)
represents the overall performance of the grate clinker cooling
system. However, exergy contained in the exhaust gas and the
cooled clinkers are still considered to be recovered regardless of the
end use. The exergy efciency of the grate clinker cooling system is
relatively low compared to its energy efciency (81.3%). This
conrms that at the given conditions of the systems surroundings,
not all energy contained within the system can be converted to
useful work. The exergy of the system is always destroyed in the
irreversible clinker cooling process, for which its constituents are
brought to a state of equilibrium with the surroundings. Sgt et al.
[14] also studied cement plant in Turkey and found that 51% of the
initial energy was lost in their calculations. Authors found that
thermal energy losses could be reduced using natural gas instead of
coal.
The exergy recovery efciency of the system is much lower
(43.2%) than the energy recovery efciency (51.3%). This is because,
for exergy recovery efciency, only the exergy recovered and used
at other processes of clinker production, is taken into account.
Similar to the energy recovery efciency, the exergy recovery efciency of the system also plays a signicant role in the improvement of the clinker cooler. Exergy recovery efciency represents
the real room for improving the system.
3.3. Changing the operational parameters: mass ow rate of cooling
air
3.3.1. Change in the rst and second law efciencies of the grate
clinker cooling system
Variations in mass ow rate of cooling air will lead to a change in
the outlet temperature of clinker, due to an increase or decrease in
cooler
(%)
Table 4
Summary of the input and output results of exergy parameters.
Condition
Material
Temperature, T, C
Input
Hot clinker
Cooling air
Secondary air
Tertiary air
Cooled clinker
Exhaust gas
Exergy destroyed or losses
1300.0
45.0
850.0
650.0
115.0
220.0
826.0
1.7
220.4
136.7
10.4
77.8
382.2
53.8
43.2
46.2
Output
Fig. 5. Variation in rst and second law efciencies of grate clinker cooler with
increments in mass ow rate of cooling air.
669
Table 5
The additional fan electrical energy requirements for every 5% increase in mass ow rate of the cooling air [18].
Material
Original mass ow
rate (kg/kg clinker)
Fan motor
power (kW)
Energy requirement
per day (kWh)
Cooling air
Secondary air
Tertiary air
Exhaust air
Total
2.55
0.45
0.42
1.68
2.68
0.48
0.45
1.76
0.13
0.02
0.02
0.08
21,563
11,912
9781
20,000
27.6
15.2
12.5
25.6
81
442
244
200
410
1296
670
_ avg T2 T1
Q_ cooling air mc
kg
kJ
1:007 K 334 K 318 K
2:55
kg ck
kg
41:1
Fig. 6. Variation in rst and second law efciencies of grate clinker cooler with change
in temperature of cooling air.
kJ
kg ck
Taking the total sensible heat contained within the exhaust air
for the base case clinker cooler to be 337.2 kJ/kg ck, the fraction of
heat that is returned to heat the cooling air found to be about 12.2%.
From the analysis, it is apparent that 12.2% of the sensible heat
contained within the exhaust air is used to preheat the incoming
cooling air from 45 C to approximately 60 C. The specic heat of
the air is taken at an average temperature of 52.5 C. This analysis
was performed under the assumption that no heat was lost during
the heat transfer.
Fig. 7. Variation in rst law efciencies of grate clinker cooler with decrement in mass
ow rate of clinker.
same amount of heat from the clinker and therefore the air
temperature remains constant. But as the heat input is decreasing,
the clinker temperature also decreases.
On the other hand, the increase in rst law efciency actually
represents the increased ratio of cooling air to clinker at an instant,
as well as the increase in time for the heat transfer process to take
place. More cooling air with a given amount of clinker to cool and
time for the heat transfer process to take place correspond to better
heat transfer and recovery rates. An optimum value of mass ow
rate of clinker is required so that the recovery of energy has
a maximum amount in the cooler at a reasonable plant output.
Fig. 7 also shows an improvement over second law efciency of
the system with a decrease of mass ow rate of the clinker. For
every 5% decrease in mass ow rate of clinker, the clinker cooler
experiences approximately 2.9% increase in exergy efciency and
exergy recovery efciency each. In this case, the improvement in
second law efciency of the system is comparable to its rst law
counterparts. As previously discussed, the increase in these efciencies represents the improvement in the rates of heat transfer
and heat recovery, due to the increased amount of cooling air per
unit clinker and to the prolonged amount of time for the heat
transfer process to occur. The main task of cooler is to cool down
the hot clinker to the lowest possible temperature and at the same
time the cooling air should be preheated to a temperature level
such that we need the lowest energy input for the burning process
in rotary kiln. Decreasing the mass ow rate of clinker, will improve
the systems rst and second law efciencies, but at the expense of
clinker output of the plant.
3.5.2. Energy requirement for decrement in the mass ow rate of
clinker
It is proven from the analysis performed by Mundhara and
Sharma [20] that decreasing the mass ow rate of clinker will result
in the increase of the rst and second law efciencies of the clinker
cooling system. Evidently decreasing the mass ow rate of clinker
would also translate to a decrease in plant output per unit time. It is
noted that the reduction in mass ow rate of clinker is not similar to
increase of the mass ow rates of cooling air, secondary air, tertiary
air and exhaust air by the same percentage. This is because heat
transfer rate is also affected by the amount of time that the clinker
spends inside the cooler, and not only by the relative mass ow
rates of the air to the clinker.
The decrease in mass ow rate of clinker would also affect the
mass ow rates of the other processes in the cement production
plant, as these processes are sequential. The main processes of
interest are the calcination process and the burning process,
because they are energy consumers and are directly related to the
clinker cooling process. As such, the mass ow rates of clinker in
those processes are not highly affected by the change in mass ow
rate of clinker in the cooling process.
Taking the plant output of 3000 tons of clinker per day, and
187.5 tons of clinker per hour, the three processes, i.e. calcination,
burning and cooling, would have to be run for an extended period
of 0.84 h, or 50.5 min to reach the plant output rate mentioned.
Table 6 presents the additional amount of energy consumed for the
clinker cooling system for every 5% decrease in mass ow rate of
clinker, i.e. to run at an extended period of 0.84 h.
From Table 6, it is shown that the grate clinker cooler will
consume a total of 3525 kWh of energy to run for an additional
period of 50.5 min a day. It can be seen that the exhaust fans require
more energy compared to the cooling air fans, as well as the
secondary and tertiary air fans. Fan power consumption is based on
volumetric ow rate, and not only on the mass ow rate of air.
Hotter air on the exhaust side has lower density compared to the
cooler air on the air intake side, consequently causing the fans at
671
Table 6
Additional energy requirement for the grate clinker cooler for every 5% decrease in
mass ow rate of clinker.
Power consumer
Power
consumption (kW)
Additional energy
requirement per day (kWh)
1153
717
549
1174
200
400
3794
969
602
461
987
168
336
3523
Fig. 8. Variation in rst and second law efciencies of grate clinker cooler at different
grate speeds.
672
Table 7
Calculation of base cooler grate motor power.
Surface area, Ga (m2)
Number of
strokes, N
Stroke
length, s (mm)
Torque
T f s=2 1000 (kN m)
Shaft power,
Ps 2pNT/60 (kW)
Actual power,
Pa 1.4 Ps (kW)
30
11.5
22
120
345
20.7
47.7
66.8
affect the amount of heat recovery of the system, and hence, the
rst law efciency.
Air outlet temperatures will rst increase with grate speed until
they reach a certain maximum level, and drop thereafter. The
reason behind this is that, as the grate speed is increased; the
residence time of clinker will decrease, giving less time for the
given amount of cooling air to absorb the heat from the hot clinker.
This consequently leads to lower heat transfer between the two
mediums. However, as grate speed is increased, the clinker bed
height will decrease, leaving more surface area of the hot clinker
exposed to the cooling air, which consequently leads to higher rate
of heat transfer. This opposing effect causes the rst law efciencies
of the system to be at a maximum at a certain speed, and for this
case, it corresponds to the grate speed after 18.2% speed increment
from the base case.
Even though increasing grate speed results in generally air
outlets with higher temperature, the amount of energy that is able
to be recovered through secondary and tertiary air supersedes the
amount of heat losses to the surroundings via convection and
radiation. This is generally true up to about 27.3% of grate speed
increment. Further increment in grate speeds results in a certain
amount of heat losses to the surroundings through convection and
radiation, starting to overcome the increased heat transfer efciency between the two mediums in the cooler, which causes lower
rst law efciencies of the system.
Similar to the trend in rst law efciencies, Fig. 8 also signies
maximum second law efciencies after 18.2% increment in grate
speed. The exergy efciency and the exergy recovery efciency of
the system have values of 60.1% and 46.5%, respectively, at this
very speed. However, on the other hand, the energy efciency
and the energy recovery efciency increase 7.1% and 2.8%,
respectively.
Higher exergy recovery efciency improvement compared to
energy recovery efciency improvement at the optimum speed
signies that the internal exergy destruction during the process is
minimized more than the external exergy destruction. The second
Fig. 9. Variation in rst law recovery efciencies of grate clinker cooler with varying
parameters.
Fig. 10. Variation in second law recovery efciencies of grate clinker cooler with
varying parameters.
Fig. 11. Energy diagram of the grinding mill for the process of raw material drying [27].
Table 8
Energy savings and improvement of energy recovery efciency for different operating parameters.
Operating
parameters
Average
Energy saved (kJ/kg ck)
improvement
In energy
recovery
efciency
Mass ow
2.32
rate of cooling air
Cooling air
0.14
temperature
Mass ow rate
2.88
of clinker
Grate speed
0.77
Total
34.01
30.86
13.31 10.12
23.43
21.26
23.98 18.01
41.99
38.10
4.75
6.02
64.58 45.83
10.77
9.78
30.86 100.00
673
(14)
Using the data available in the Fig. 11 and Eq. (14), the heat recovery
by the cooled air is estimated to be 153.7 kW.
Table 9
Cost savings for different operating parameters.
Operating parameters
Average improvement
Rotary kiln
Pre-calciner
Total
Contribution (%)
2.32
0.14
2.88
0.77 (up to 18.2% optimization)
0.105
0.062
0.112
0.022
0.301
0.054
0.047
0.084
0.028
0.213
0.159
0.109
0.196
0.050
0.514
30.86
21.26
38.10
9.78
100.00
674
Acknowledgements
The authors would like to acknowledge the nancial support
from the High Impact Research Grant (HIRG) scheme (UM-MoHE)
project (project no: UM.C/HIR/MoHE/ENG/40) to carry out this
research.
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