Energy and cost analysis of cement production using the. An unstable kiln and cooler leads to inefficient production and inconsistent clinker quality. When the added complexity of on and off peak power costs, interruption clauses, supply charges versus energy charges, etc, are added, the evaluation of the benefits of energy saving investment can become very complex. The cement industry has long recognized that the cost of energy can be significant, varying between 25 percent and 35 percent of total direct costs. Drivers and obstacles within the cement value chain merit attention, but so to do cross sectoral dynamics that shape the incentive environment. The electrical, manual and combustion energy consumption together with the material mass flow are allotted to each unit operations with the dry cement operation. Pdf analysis of material flow and consumption in cement. Energy demand in clinker production has been significantly reduced over the last few decades. Comparison of technologies for co2 capture from cement. The excess clinker produced in the plant will be sold outside or shall be.
The process generates hot and co2 rich exhaust streams. Low carbon technology roadmap for the indian cement. Clinker production costs eurt clinker, 2020 assumption. It is produced by sintering fusing together without melting to the point of liquefaction limestone and aluminosilicate materials such as clay during the cement kiln stage. Traditional clinker grinding station adopts ball mill to grind clinker, and has much dust, loud noise and high energy consumption in the process of production, it will be replaced gradually by vertical roller mill. Energy and cost analysis of cement production using the wet and. The cement clinker grinding plant or cement grinding station acts as an individual production line while in the final period from the cement production course of action. Even after considering heat for dryingoff nominal moisture content, around 30 kwh t clinker of power can still be generated by whrpp, i. Energy efficiency improvement and cost saving opportunities. Capex target excluding capitalized merger implementation costs. Sncr no x reduction efficiency for various utility boiler sizes 2 figure 1. Pdf cement production output and prices trends in mozambique.
Environmental protection agency program helping organizations and individuals fight climate change through superior energy efficiency. Portland cement clinker is a dark grey nodular material made by heating ground limestone and clay at a temperature of about 1400 c 1500 c. The production line presently with large area occupying and complex production. Ecsprocessexpert stabilizes the kiln and cooler using advanced process control, resulting in.
The united states has 118 cement manufacturing facilities operating 192 kilns. It is used after the raw meal has been burnt in rotary kilns at temperatures of over 1,000 c to produce clinker. Cement production is a thermal energy intensive process, which requires heating solid particles up to 1450c and cooling it down. The project is cement plant with present clinker production of 0. The remaining plants suggest the existence of a considerable potential. For the producer, these factors have a significant influence on cost competitiveness, usually accounting for over 50 per cent of total production costs, so that accurately and continuously monitoring energy usage must be a way of life for any producers technical team. Pre feasibility report for expansion of cement plant with. Buyer power cement producers are highly concentrated in the different. Clinker production schenck processs multicor k massflow feeding system plays the main role in the second cement production stage. The equipment presently with high energy consumption and low production efficiency, and its not meet the requirements of national policy. The slight increase in consumption will be probably offset by new. Within the finished product time period, the cement clinker is ground by including reasonable mixing products and after that forms the completed cement. The particle size will have only a small effect on reactivity in clinker production or the generation of supplementary materials since the raw materials. This department has a preheater tower with heating capacity of 3,500 tonnes clinker per day.
Typical cement plant power costs can range from eur39 to eur170mwh. Pdf energy savings measures for clinker production in cement. Pdf energy and cost analysis of cement production using the. Energy and cost analysis of cement production using the wet. Energy efficiency and co2 emissions jrc publications repository.
Dp 216 final regional markets, politics and value chains the. Clinker and cement everyting for clinker and cement in. In addition, when the cement clinker grinding machine is running, always check the working status of the cement clinker grinding machine, and pay attention to whether the numbers of the instruments are normal. The second case is a collaboration project between concrete and cement supply chain in cemex colombia resulting in an increase in concrete mixers availability to 93% and a reduction in maintenance cost by 25%. The proposal is for increase of clinker production to 3. Within the finished product time period, the cement clinker is ground by including reasonable mixing. Additives are fed in during the clinker grinding process to achieve the required type and grade of cement. If an abnormality occurs, stop working immediately, check what is the problem, and solve it before using it. However, there are technical reasons why this will. Great wall machinery is the professional manufacturer of cement equipment, can offer complete solution for grinding station, and improves production efficiency, reduces power. Cement production has undergone tremendous developments since its beginnings some 2,000 years ago. Limestone and other raw material the second major component in the production of cement is. The production of cement is an energyintensive process.
The cost of energy as part of the total production costs in the cement industry is. Cement clinker is a solid material produced in the manufacture of portland cement as an intermediary product. From a cement performance viewpoint, faster cooling of the clinker enhances silicate reactivity. The kiln and cooler can be further optimized using a multifuel addon application see page 6 for more information. The clinker store is the source of supply for the cement grinding process.
Total energy use 19901998 the next table shows total energy use, total clinker production and energy use per tonne of clinker. Supply chain management in the cement industry isabel agudelo advisor. Most of the heat given off during clinker cooling is recovered for use in the production process. The international energy agency iea 2 estimated that in 2005, there were around 1,215 million tonnes of material suitable for clinker substitution globally excluding pozzolan and.
Cement production output and prices trends in mozambique article pdf available. Also, there is a kiln with the capacity of 3000 tonnes per hour. Buyer power cement producers are highly concentrated in the different regional markets. Aug 18, 2014 energy consumption hovers around 6070 kilowatt hours or kwh of power per pound of clinker produced. Clinker occurs as lumps or nodules, usually 3 millimetres 0. A comparison of organic and steam rankine cycle power systems for waste heat recovery on large ships clinker and cement energy audit and waste heat recovery system design for a cement rotary kiln in ethiopia clinker and cement safe cement silo clinker and cement. It can be observed as computed in table 1 4 that the average total energy cost of cement production by the wet process using power from national grid and manual energy during the study period has the highest in 2009 and the least in 2003. Dp 216 final regional markets, politics and value chains.
The theoretical minimum primary energy consumption heat for the chemical and mineralogical reactions is approximately 1. Aug 15, 2014 energy consumption hovers around 6070 kilowatt hours or kwh of power per pound of clinker produced. The nodules are ground up to a fine powder to produce cement, with a small amount of gypsum added to control the setting properties. The other factors to consider are the physical characteristics such as particle size distribution and some variable parameters such as moisture content. Cost effective reduction of harmonics using an active front end supply unit or at least a 12pulse line supply. It is clearly helpful, therefore, if the clinker is cool as it enters the mill. Chapter 1 selective noncatalytic reduction figure 1. Togo as key exporter of clinker, cote divoire and ghana as key importer of clinker, and cement producer, and mali as a cement importer. Driving innovation to achieve sustainability in industrial growth. Project management plan of vista cement plant project. Sncr no x reduction efficiency for boilers in various industry sectors 2 0 10 20 30 40 50 60 70 0 100 200 300 400 500 600 700 800 boiler size mw sncr reductions for utility boilers coalfired. Clinker production an overview sciencedirect topics. In modern cement plants, the burning process is performed in a chain of three systems. From an environmental and a cost viewpoint, the cooler reduces energy consumption by extracting heat from the clinker, enabling it to be used to heat the raw materials.
Initial estimates suggest that cement production returned to 4. Typically, energy consumption accounts for 2040% of production costs. Cement production an overview sciencedirect topics. Energy consumption hovers around 6070 kilowatt hours or kwh of power per pound of clinker produced. Pdf industrial development has lead to higher energy consumption, and emission of greenhouse gases. Clinker production, cement production, and materials consumption trends are quite similar. Among the constituents of the estimated total cost of energy, combustion cost records the highest average. Improvement and cost saving opportunities for cement making. Fin order to study energy efficiency of the process, authors like mujumdar et al. A global clinker tocement ratio of 78% in 2006 meant that about 550600 million tonnes of constituents other than clinker were used. Habert, in ecoefficient construction and building materials, 2014. It is produced by heating limestone and clay to the point of liquefaction at about 1400c1500c in the rotary kiln. Schenck processs multicor k massflow feeding system plays the main role in the second cement production stage. China is the largest producer of cement, accounting for close to 60% of global production, followed by india at 7%.
The international energy agency iea 2 estimated that in 2005, there were around 1,215 million tonnes of material suitable for clinker substitution globally excluding pozzolan and limestone. Rings, buildups, formation in cement kiln clinker and cement. Dec 10, 2018 a comparison of organic and steam rankine cycle power systems for waste heat recovery on large ships clinker and cement energy audit and waste heat recovery system design for a cement rotary kiln in ethiopia clinker and cement safe cement silo clinker and cement. In the multistage cyclone preheater with calciner, the raw meal is preheated to about 800 to 900 c and decarbonated by kiln exhaust gases. The lumps or nodules of clinker are usually of diameter 325 mm and dark grey in color. Energy efficiency improvement and cost saving opportunities for cement making an energy star guide for energy and plant managers august 20 energy star is a u. At present, domestic clinker grinding stations generally exist following problems. Any redistribution of this information is strictly prohibited. While the use of cement in concrete has a very long history malinowsky, 1991, the industrial production of cements started in the middle of the 19 th century, first with shaft kilns, which were later. Pdf the study evaluates the energy consumption of both wet and dry processes cement manufacturing plant in nigeria. Energy and emission reduction opportunities for the cement. He has worked with lafarge, one of the largest cement players in india for more than 6 years. A global clinkertocement ratio of 78% in 2006 meant that about 550600 million tonnes of constituents other than clinker were used. A typical process of manufacture consists of three stages.
In the sds, the thermal energy intensity of clinker production declines by 0. Process characteristics of clinker and cement production. Definition of risk clinker production in germany could be replaced with cheaper clinker imports from noneuetscountries assumptions. In this process, the steps of raw material processing, fuel preparation, clinker burning and cement grinding constitute major emission. The specific co2 emissions and the electric power consumption of the plant amount to 850.
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