summer training ppt on energy optimization in cement industry. by roshan dhaker maharishi arvind college jaipur

1. A
Presentation on J.K. Cement Ltd.
Maharishi Arvind Institute of Engineering & Technology ,
Mansarover Jaipur
Submitted by
Roshan Lal Dhaker
(13EMTEE043)
Electrical Engineering
Submitted to :
K.C. Modi (HOD)
Electrical

2. Introduction to
•J.K.Cement started commercial
production in May 1975 in Nimbahera
•J.K. Cement Ltd is an affiliate of
the J.K. Organisation
•which was founded by Lala
Kamlapat Singhania.

3. Continuous…
• J.K. stands for juggilal kamlapath
singhania.
• Today J.K. Cement has an installed
grey cement capacity of 10.5 MTPA
making it one of the leading
manufacturers in the country.

4. POWER PLANTS AT JK
• J.K. Cement installed first a power plant of
140MW in the year 1987 at Bamania.
• J.K Cement installed a waste heat recovery
power plant 23MW to its different locations.
• 23MW thermal plant in Nimbahera

5. CEMENT manufacturing process
• The product obtained by mixing together
calcareous (calcium carbonate or lime) and
argillaceous (alumina) or other silica and iron
oxide bearing materials, burning them at a
clinkering temperature and grinding the
resulting clinker.
• When it is mixed with water it forms a paste
which hardens and binds aggregates (sand,
gravel and/or crushed rock) together to form a
hard durable mass called concrete.

6. Raw materials of cement
• Main materials:
– Limestone
– Clay
• Additional materials
– Aluminium& Iron
– Gypsum

7. THE CEMENT MANUFACTURING PROCESS
1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted
from the quarry.
Quarry face
1. BLASTING 2. TRANSPORT
3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are
transported to the plant by conveyor. The plant stores the materials before they are
homogenized.
quarry
3. CRUSHING & TRANSPORTATION
2. TRANSPORT : The raw materials are loaded into a dumper.
crushing
conveyor
dumper
storage at
the plant
loader

8. THE CEMENT MANUFACTURING PROCESS
1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.
1. RAW GRINDING
Raw grinding and burning
2. BURNING
2. BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can
be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is
rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to
make cement.
conveyor
Raw mix
kiln
cooling
preheating
clinker
storage at
the plant
Raw mill

9. THE CEMENT MANUFACTURING PROCESS
1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary
additives and cementitious materials can also be added to make a blended cement.
1. GRINDING
Grinding, storage, packing, dispatch
2. STORAGE, PACKING, DISPATCH
2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in
bulk or in bags to its final destination.
clinker
storage
Gypsum and the secondary additives are added
to the clinker.
silos
dispatch
bags
Finish grinding

10. Energy optimization in cement
manufacturing
• Cement producers are large consumers of
thermal and electrical energy
• Efforts to reduce demands by using higher
efficiency equipment and substituting fuels
• To optimize the overall performance of a
cement manufacturing unit requires a plant
wide automation strategy

11. 1. Energy Conservation and its Management has become a prime
factor for the nation, society and individual due to high cost and
non availability of energy.
Why Important?
2. Non awareness of latest technologies and methods, non-
conventional energy sources and renewable energy sources and
how to run the plant and equipment in an energy efficient manner.

12. • Crushers
– Powers of the drives typically vary from 500 kW to 3000 kW.
– a very high start-up torque.
– The drive is typically supported by a flywheel in the drive train.
• Separators
−2.8 – 3.8 kWh electric energy per tonne of raw material can be saved.
– Motors are often used in braking mode to guarantee fast and accurate
speed control and also during stopping of the rotating separator.
12
Cement Processing Equipment

13. • Conveyors
– a cost-efficient alternative for transportation
– not only for transportation of limestone but they are
also needed for transportation of stones, raw meals.
13

14. • Fans
– used practically in all stages of the producing
cement and consume 30% of all electric energy
– Typical motor powers vary between 20kW and
2000kW.
– Fans can be propelled by a constant speed motor
with damper or vane or by a variable speed drive
14

15. Variable Speed Drives – an electrical
energy saver
• In the cement manufacturing process large fans
draw air through the kiln, mills and filters to an
exhaust stack
• Many smaller fans push the air into the grate
cooler to reduce the temperature of the hot
clinker leaving the kiln
• these airflows have to be adjusted and
controlled as atmospheric conditions

16. Continuous...
• fixed speed motor is the least energy efficient
solution and the application of variable speed
drives (VSD) the most energy efficient.

17. Optimized solution for Grate Coolers –
Multi drive
1. Approximately 10 percent of the electrical energy required to
produce one ton of clinker is needed to cool it.
2. It therefore makes good sense to give careful thought to the choice
of drive system for the cooler.
3. One such choice is the Multi drive which is often referred to as an
“optimized drive solution for the cooler area”.
4. It offers all of the benefits of VSD and eliminates – in an
economical sense – many of the drawbacks of single drives. Unlike
single drives (which have to have their own rectifier, DC link and
inverter), the Multi drive system generates the required DC voltage
in a “central” unit and feeds it onto a common DC bus to which the
single, independently operated inverters are connected.

18. Some of the benefits of such a system
• Reduced cabling due to the single power entry for
multiple drives.
• Energy-saving motor-to-motor braking which is
required depending on the grate cooler type.
• Reduced space requirement Elimination of the
low voltage distribution used for single drives or
dampers and direct online motors in cases of
replacement.
• Cost effective reduction of harmonics using an
active front end supply unit or at least a 12-pulse
line supply.

19. Energy monitoring using Knowledge
Manager (KM)
• Production tracking and reporting Process.
• operations monitoring and reporting.
• Material storage management.
• Energy and emission reporting

20. Thermal energy savings using Expert
Optimizer
• note:- Burning zone temperature (BZT) is the
predictor of product quality. If the BZT is low,
it is expected that the clinker will be
insufficiently burnt and if the BZT is high it is
expected the clinker will be over burnt
• So that BZT should be modrete.to maintain
BZT expert optimizer is used.

21. Expert Optimizer
• It combines rule based control with modern tools
like
• Neural Networks, Fuzzy Control and Model
Predictive Control (MPC).
• EO improves on conventional control by
constantly interpreting kiln conditions and
initiating appropriate actions.
• Proper and stable kiln operation can reduce
energy consumption and maintenance costs,
increase kiln output, and improve overall product
quality.

22. Now queries ????

23. Thank you…