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ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN

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This paper highlights the efforts taken by the author in developing an Energy Model for the pyro-processing of Clinker production in a dry-process rotary cement kiln. In this paper this Energy Model is applied to a state of the art cement plant in a Far East Asian country. However this Energy Model is also applicable to all the modern dry process cement kilns. This model is based on actual field input data and site observations.

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ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN

  1. 1. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN Presented by VEN V. VENKATESAN, PE, CEM VGA Engineering Consultants, Inc.
  2. 2. Presenter <ul><li>Ven is working in the field of energy management for the past 33 years. </li></ul><ul><li>A Master’s degree holder in Chemical Engineering, with specialization in Plant Design, he has conducted Energy Audits over 120 energy intensive process industries located around the world and identified energy savings worth over $100 millions/yr. </li></ul><ul><li>Worked as Energy Manager in a Petroleum refinery and also in an integrated Steel Mill complex. </li></ul><ul><li>Twice awarded certificates of appreciations by US Dept. of Energy, for outstanding leadership & exceptional skills. </li></ul><ul><li>For more details about Ven, kindly visit: http://www.vgaec.com </li></ul>
  3. 3. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN <ul><li>The main raw material for the cement manufacturing is the Lime stone. Pyro-procesing is a 2-step process (Calcination and Clinkerization) through which powdered limestone is converted into clinker. The CO2 in limestone is removed during Calcination & the powdered mass is fused into lumps at temperatures of 2600 o F during Clinkerization. </li></ul><ul><li>The Pyro-processing (PP) section of a dry-process cement plant consists of the following major equipment </li></ul><ul><li>1. Cyclone Preheaters (4 - 6 stages of cyclones preheating the feed) </li></ul><ul><li>2. Pre Calciner (where fuel-fired flash furnaces complete the Calcination) </li></ul><ul><li>3. Rotary Kiln (where the calcined-powder is fused into Clinkers) </li></ul><ul><li>4. Grate Cooler (where the Clinker is cooled for further handling) </li></ul>
  4. 4. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN Simplified block diagram of Pyro-processing
  5. 5. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN Equipment line-up of Pyro-processing
  6. 6. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN <ul><li>The energy model is a mathematical model, where the operating process parameters are linked to the energy consumption of Pyro-procesing (PP) </li></ul><ul><li>Typical operational parameters in the PP section are: </li></ul><ul><li>- Raw Meal feed rate to the Kiln system, </li></ul><ul><li>Fuel firing rates at Precalciner & at the Rotary Kiln, </li></ul><ul><li>Total air supply to the PP section </li></ul><ul><li>Operating temperatures maintained at the PP section </li></ul><ul><li>Energy Model is useful to analyze & evaluate the operational improvements at the PP section. </li></ul>ENERGY MODEL OF PYRO-PROCESSING
  7. 7. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN
  8. 8. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN
  9. 9. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN Sankey diagram from the Pyro-processing Energy Model
  10. 10. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN <ul><li>The energy model is useful to analyze / evaluate the operational improvements at the Pyroprocessing (PP) section. </li></ul><ul><li>Typical operational improvements in the PP section are: </li></ul><ul><li>- Increase feed rate, by minimizing the false air ingress in the Preheaters </li></ul><ul><li>Increase feed rate, by controlling the excess air at Kiln & PC burners </li></ul><ul><li>Maximize the secondary & tertiary air temperatures, by optimizing the Cooler air balance-point </li></ul><ul><li>- Minimize the radiation losses, by fixing with improved insulation </li></ul>UTILIZATION OF THE ENERGY MODEL
  11. 11. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN
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  16. 16. ENERGY MODELING OF THE PYROPROCESSING OF CLINKER IN A ROTARY CEMENT KILN <ul><li>Any Questions ? </li></ul>

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