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1 SURVEY OF CHEMICAL EMISSIONS Table 44. Partial Description of Potential Energy Savings in Cement Production Process Modification Energy Savings Transport of kiln feed and finished cement Use of mechanical conveyors instead of pneumatic systems. 2 kWh/ton (note 1) Blending of kiln feed Use of gravity silos instead of compressed air or mechanical systems. 0.9-2.3 kWh (note 1) Wet process Replacement of tube mill with wash mill. 5-7 kWh/ton Dry process Use of roller mills instead of ball mills. 6-7 kWh/ton Dry process Avoiding vibration trips for vertical mills. 0.8-1.0 kWh/ton Classifiers or separators for both raw material feed and finished product Use high-efficiency classifiers or separators. 2.5-3.4 kWh/ton Clinker production – all kilns, process control (note 2) Better process control results in heat recovery, material throughput, lower emissions. 2.5-5% energy savings Kiln combustion (note 3) Improved combustion systems. 2-10% fuel savings and increase in output of ~ 5-10% Firing system Use of indirect firing. Fuel savings of 130-190 kBtu/ton of clinker Oxygen enrichment in kiln Unlikely to result in energy savings Seals Upgrading of seals (Maihar cement, India). Fuel savings of 10 kBtu/ton clinker Kiln shell heat loss reduction Use of better insulating refractories. Reduce fuel usage by 100-340 kBtu/ton. Also improves reliability and reduces start-up energy needs Kiln drives Highest efficiencies for synchronous motors using single pinion drive with air clutch and synchronous motor. Electricity savings of 0.5 kWh/ton clinker. Replacement of dc drive with ac results in ~ 1% reduction in electricity use. Fuels Use of waste derived fuels. – tires, carpet and plastic wastes, paint residue, dewatered sewage sludge, filter cake. (Note 4) Energy savings of 500 kBtu/ton clinker Cooling of clinker Conversion to reciprocating grate cooler – large capacity, efficient heat recovery. 8% fuel savings, but extra electricity of 2.7 kWh/ton clinker Clinker production, wet process Conversion of wet process to semi-dry process by using slurry drier. Reduce fuel consumption by 1.4 MBtu/ton clinker Clinker production, wet process Conversion of wet process to semi-wet process (filter press system). Fuel savings 1MBtu/ton. Added electricity consumption of 3-5 kWh/ton. Clinker production, wet process Conversion of wet process to pre- heater/pre-calciner kiln. Fuel savings of 2.7-2.9 MBtu/ton. High cost of conversion. Note 1: This does not decrease emissions in the plant, unless electricity is generated in-house. Note 2: Several case studies listed – ABB LINKman system by Blue Circle Industries UK, Process Perfector of Pavillion Technologies Inc, fuzzy logic control systems by Krupp Polysius (Germany), Mitsui Mining (Japan), Ash Grove (Oregon, U.S.). Note 3: Several case studies listed – Blue Circle Industries, Gyro-Therm Technology developed by University of Adelaide. Note 4: Cement kiln efficient way to recover energy from waste. High temperature and long residence time destroy organics. Since 1990, > 30 plants gained approval to use tires. 42PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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