ENERGY CONSERVATION IN CEMENT INDUSTRY

By G.V.S.Santhosh Kunal Sharma

WHAT IS THE NEED OF ENERGY CONSERVATION?

 TO OVERCOME : Worldwide Energy Crisis Environmental Degradation

ENERGY CONSUMPTION IN CEMENT PRODUCTION

 Cement industry consumes much energy Cement industry is also noted for great percentage of energy costs and total production costs Energy can be conserved by Preventing of leakage in kilns Modifying the equipment to recover heat from the preheater and cooler Effective use of industrial waste material

Energy Consumption
Percentage of Energy cost in Portland Cement production cost is 20-30% Reduction in energy cost increases company profits because of decrease in manufacturing costs

90% or more fuel consumed for clinker burning. 40% of electrical energy consumed for finish grinding , Little under 30% consumed for raw material process and 30% for clinker burning process

PROMOTION OF ENERGY CONSERVATION TECHNIQUE

Good Housekeeping
Elimination of minor wastes Review of operation standards More effective management Improvement of employees For Example Efforts include management to prevent unnecessary lighting of electric lamps, idle operation of motors, Repair of steam leakage and heat insulation

Equipment Improvement
Minor modifications of existing production line to provide waste heat recovery equipment and gas pressure recovery equipment Replacement by advanced equipment For example gases in clinker cooling process can be used to run the turbines

Process Improvement
To reduce energy consumption by substantial modification of production process by technological development Accompanied by large equipment investment Modernization of process provides energy conservation, high quality and improved product yield which results in manpower saving

Energy conservation Technique

Raw material process Selection of raw material Management of fineness Use of industrial wastes(fly ash) Replacement of fan rotor Improvement of temperature and pressure control system From wet process to dry process

Clinker burning Process

Prevention of stop due to failure Selection of fuel Prevention of leak Use of industrial waste material (waste tires and slag) Recovery of preheater exhaust gas Recovery of cooler exhaust gas From wet process to dry process

Finish Process Management of fineness Improvement of grinding equipment Efficient labor

ENERGY MANEGEMENT

Choice of Raw Material and Fuel

By expansion of stock yard or the adoption of a pre blending system, there are a number of possibilities that inexpensive raw material with low purity or substitute raw material excelling in grindability will be found Various industrial waste and by-products can be used in cement industry For example: Coal ash, Molding sand, Waste tire, oil and China clay

Waste Heat Recovery Power Generation

 Pre heater exhaust gas has about 20% of heating value brought in by the fuel Cooler exhaust gas has 14% These residual heating values can be used to dry raw materials end to generate electricity This private power generating system will reduce the running and production cost which results in energy conservation

Equipment Investment
When an investment is made not only with the view to energy conservation but also to produce combine effects including increase in production and the stabilization of operation can be achieved Invested capital is also recovered early

CONCLUSION
Since energy cost of total cement production cost is large, energy conservation is an important matter in technical improvement activities The cement production cost depends on the adopted production process Dry process consumes less energy than wet process

CONCLUSION
The timing of the investment of process improvement must be carefully determined taking into consideration the budgetary condition of enterprises and the outlook of cement market Before improving a process, the activities of Good Housekeeping and Equipment improvement should be applied to promote energy conservation.

THANK YOU