CHAPTER 1 INTRODUCTION

1.1 Title of Project

Energy analysis of the Waste Heat Recovery System in the Cement Production Plants.
1.2 Problem Statement
Thermax Limited is global leader providing a range of engineering solutions to the energy
and environment. As a part of sustainable development & Energy harnessing it is
continuously developing new and innovative technologies in both domestic and global
market.
The objective of this project is to understand & study the Cement Industry and its global
impact & its effects which lead to the waste heat recovery system wherein more & more
energy wastage from a cement plant can be utilized and harnessed for different processes of
the plant itself. This overall will conserve the fuel utilization & also save the environment
from the harmful effects. Thus, we will be doing an energy analysis of the referred plant &
see how much energy can be produced (MW) & utilized for the plant itself.
1.3 Scope of the Project
The scope of proposed project consists following objectives:
a. Study of Cement production industry & different types of process being processed in.
b. Study of the Cement production process.
c. Study of Waste heat recovery system & applications.
d. Study of the Waste heat recovery application in cement firms & Advantages.
e. Energy potential & heat duty calculation for various boiler components.
f. Conclusion and results.
The cement clinker production sector is a substantially energy intensive industry
accounting for 50-60% of the production costs while is currently contributing
about 5% to the global anthropogenic emissions . Thermal energy demands
depend on the age of the plant and on the specific process but ranges between
3000 and 6500 MJ/tone clinker. The average specific energy consumption is
about 2.95 GJ per ton of cement produced for well-equipped advanced kilns,
while in some countries the consumption exceeds 5 GJ/ton. The electric energy
demand ranges from 90 to 150 kWh per cement ton In a typical cement plant,
25% of the total energy used is electricity and 75% is thermal energy. However,
the process is characterized by significant heat losses mainly by the flue gases
and the ambient air stream used for cooling down the clinker. About 35% - 40%
of the process heat is lost by those waste heat streams . Approximately 26% of
the heat input to the system is lost by dust, clinker discharge, radiation from the
kiln and pre-heater surfaces, and convection from the kiln and pre-heaters .A

heat recovery system could be used to increase the efficiency of the cement
plant and thus lower the CO2 emissions. Moreover, it would reduce the amount
of waste heat to the environment and lower the temperature of the exhaust
gases . Waste heat can be captured from combustion exhaust gases, heated
products, or heat losses from systems.
The process of manufacture of cement can be divided into three basic steps,
preparation of raw materials, pyroprocessing to produce clinker, and grinding
and blending clinker with other products to make cement. The raw materials
obtained from the quarry are crushed, ground and mixed as a slurry in the wet
process and a powder in the dry process. This mixture is then fed into a calciner
and preheater before being fed into the kiln, for pyroprocessing (clinker
formation). The kiln reaches temperatures greater than 1450. The clinker
nodules produced and any additives are then ground to the desired fineness in
the cement grinder. Pyroprocessing consumes 99% of the fuel energy while
electricity is mainly used to operate both raw material (33%) and clinker (38%)
crushing and grinding equipment. Pyroprocessing requires another 22% of the
electricity hence it is the most energy intensive step of the production process.
Continually, to improve energy use profitability and competitiveness, many
effectual technologies in energy use by industry were adopted. A significant
number of studies have been concentrated on the analysis of energy and its
utilization in cement industry. Among them, there are very important and
constructive papers.
First Indian cement plant has commenced production in 1914 at Porbandar,
Gujarat. Large quantities of cement had to be imported for meeting the deficit.
The country now is the second largest producer of cement in the world. India is
now exporting large quantities of cement and clinker. India should increase its
cement production significantly. However, cement industry is considered as one
of the large energy consuming industry. Cement industry has been consuming
high amounts of energy for many years. For producing clinker normally rotary
kilns are widely used in cement plants. Significant amount of coal is burnt to
carry out the kiln processing. Each tone of cement produced releases
approximately 1 tone of CO2.The major part of the CO2 emissions from the
production of cement is released from the calcination of limestone (50%) and
from the combustion of fuels (40%). About 35% to 40% of the process heat is lost
from those waste heat streams.
Energy crisis on one hand, and increase in generation of CO2 on other hand, are
the two major issues, which are being discussed worldwide, these days. In
addition, due to the perpetual increase in energy prices, one has to think of ways
& means of conserving depleting fossil fuels/ reducing generation of CO2. All
possible means of saving energy, which otherwise, went un-arrested/ un-used in
the energy intensive industries, hence, are being explored. In cement industry,
energy corresponds to the major cost head of operating expenses. An
appreciable amount of energy can be conserved by optimizing the plant
operation, and by recovering waste heat from the preheater and cooler gases.

This saved energy can be converted into electrical energy, by installing waste
heat recovery boilers/ turbine.
The Kyoto Protocol permits flexibility to developing countries to start emissionreduction projects, and hence to earn credits termed as Certified Emission
Reduction (CER) credits. Each CER credit is equivalent, in its weightage, to one
tonne of CO2, which in turn would be considered towards meeting a countrys
own Kyoto Target. This mechanism is termed as the Clean Development
Mechanism (CDM).The waste and effective energy is audited and the exhaust
waste gases before and after the installation of WHRPP are evaluated. Its effect
on cement production and water consumption are also discussed.