Energy 154 (2018) 190e200

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Energy
journal homepage: www.elsevier.com/locate/energy

Analyzing thermodynamic improvement potential of a selected

cement manufacturing process: Advanced exergy analysis
S. Fellaou a, *, T. Bounahmidi a, b
a
Laboratory for Analysis and Synthesis of Industrial Processes (LASPI), University Mohammed V, Mohammadia School of Engineers, Rabat, Morocco
b
Euromed University of Fes, Fez, Morocco

a r t i c l e i n f o a b s t r a c t

Article history: Cement industry uses very energy-intensive operations resulting in a suboptimal sustainable perfor-
Received 23 December 2017 mance. The objective of this research is to provide insight into the value of exergy analysis in sustain-
Received in revised form ability assessment of cement industry. For that purpose, a detailed exergy evaluation of a complete
18 April 2018
cement plant located in Morocco was performed using both conventional and advanced exergetic
Accepted 20 April 2018
Available online 21 April 2018
analysis. The major internal exergy losses were identified during the calcination process and the two raw
mill departments, which amounts to about 78.66%, 70.86%, and 72.12% respectively. Those irreversibil-
ities are split into avoidable/unavoidable exergy destruction in the advanced exergy analysis. Findings
Keywords:
Cement industry
show that 15%, 29.21% and 31.54% of the total exergy destruction in the calciner and the raw mills 1 and 2
Exergy analysis respectively are avoidable. However, there is a need for optimization of comminution and combustion
Exergy efficiency operating parameters in the cement production process currently in use.
Irreversibility © 2018 Elsevier Ltd. All rights reserved.

1. Introduction intensive cement production, inefficiencies and potential im-

High energy intensity puts the cement industry under pressure
from both an environmental and economic point of view. The in-
dustry operates at about 54% thermal efficiency [1,2,3]. This inevi-
tably means that huge amounts of the resources used in cement
production are used in vain, and that the greenhouse gas emissions
caused by production of cement that gets lost or wasted are also
emissions in vain. The large losses should be seen not as an insur-
mountable obstacle but as a challenge to achieve technical im-
provements [4]. Thermodynamics offers a great help in studying
sustainable development due to its wide applicability in all fields of
science and engineering. The exergy concept particularly needs to
be evaluated and eventually be confirmed through practical expe-
rience. In doing so, exergy method is used in this study to analyze a
cement processing facility, which is one of the largest energy
consumers within the cement industry in Morocco. While a con-
ventional energy analysis maps the energy flows of the system and
suggests opportunities for process integration [2], a detailed exergy
analysis pinpoints the locations, causes and magnitudes of ther-
modynamic losses [5]. By applying this methodology to the energy-
* Corresponding author.
E-mail addresses: Soukaina.fellaou@research.emi.ac.ma, fellaou.soukaina@
gmail.com (S. Fellaou).
provements are to be detected with the aim to develop towards a
more sustainable system. In this study, both exergy efficiency and
exergy destruction are analyzed and evaluated for that purpose.
Conducting research projects in this field can serve as a reference to
calculate exergy values that are not being effectively shared among
the research community yet. Such research projects also provide
useful information to the managers and decision makers for
prioritizing the potential improvements and developing strategies
for system performance enhancement [6].
Many books published over the recent years have been based on
the concept of exergy (Enrique et al. [7], Silvio [8], Dincer [9],
Bejan [10], Dincer [11]), many conference reports (Rashad et al.
[12], Bühler et al. [13], Bühler et al. [14]) as well as a significant
number of studies have been published in the exergy field. Among
them, there are very important and deductive papers. Camdali
et al. [15] indicated that the first law of thermodynamics, which is
used to increase the energy recovery and decrease losses, is not
enough to establish a detailed energy management scheme for the
cement industry. Traditionally exergy analysis has been applied
mainly to single processes or applications. Utlu et al. [16] per-
formed an energy and exergy analysis of a raw mill in a cement
production plant. According to their study, the energy and exergy
efficiencies are determined to be 84.3% and 25.2%, respectively.
Atmaca and Kanog
lu [17] also studied the raw mill in cement

https://doi.org/10.1016/j.energy.2018.04.121
0360-5442/© 2018 Elsevier Ltd. All rights reserved.
 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200
industry. They evaluated the specific energy consumption for farine
production to be 24.75 kWh/ton farine. By using an external hot gas
supply, the energy consumption of the unit has been reduced by
6.7% corresponding to a saving of 1.66 kWh/ton of farine produc-
tion. The trass mill in a cement production plant has been inves-
tigated in relation to exergy analysis. The objective of So€g
üt et al.
[18] was to perform an energetic and exergetic assessment of a trass
mill process in a cement plant, the overall exergy efficiencies are
found to be slightly less than the corresponding energy efficiencies
74% and 10.68% for energy and exergy efficiency, respectively. So €g
üt
et al. [19] investigated the energy and exergy analyses of a coal-
preparation unit in a cement plant. The mean values of energy
and exergy efficiencies of the unit are found to be 74.03% and
21.36%, respectively while the average potential improvement of
the unit is calculated as 78.24%. In Madlool et al.’s [20] work a
review of the exergy analysis was presented to demonstrate that
the implementation of exergy analysis on the cement production
line is a very efficient way to improve the performance of the
system. Although Savaş et al. [21] presented comparative energy
and exergy analyses for specific dry clinker production by three
different methods, they concluded that the lowest irreversibility
rate occurs in the serial flow pre-calcination cement production
method. The work of Bühler et al. [22] consists of analyzing the
energy and exergy efficiency, as well as the destroyed and lost
exergy of 22 industrial sectors in Denmark for the years 2006 and
2012. They concluded that industries with high temperature pro-
cesses such as cement production achieve the highest efficiencies.
Koroneos et al. [23] examined the efforts to improve energy effi-
ciency in cement production in Greece using exergy analysis. The
analysis includes calculation of energy and exergy contribution at
each stage of the cement manufacturing procedure. They found
that about 50% of the exergy is being lost while substantial amount
of waste heat is being recovered. In a study led by Ahamed et al.
[24] and Atmaca and Yumrutaş [25] the first and second law ef-
ficiencies of a clinker cooler were calculated. The study of [24]
showed that about 38% and 30% of energy cost can be saved by
changing mass flow rate of clinker and mass flow rate of cooling air,
respectively. Atmaca et al. [1] and Atmaca and Yumrutaş [26]
revealed interesting results in exergy analysis of the kiln system. In
Ref. [1] they reduced the rate of heat loss from 22.7 MW to 17.3 MW
by the application of insulation to the pyroprocessing unit of Gaz-
iantep cement plant in Turkey. They calculated that 1056.7 kW of
electricity can be generated by using the waste heat and reduced
the annual emission rates by 8.2%.
Inefficiencies in an energy system can be quantitatively deter-
mined through conventional exergy analysis; while sources of the
irreversibilities and real improvement potential can be deducted
using a relatively new method named as advanced exergy analysis
[27]. This later is applied to determine real potential for thermo-
dynamic improvements of energy systems by splitting exergy
destruction into unavoidable and avoidable portions. According to
the current knowledge of the authors, until now no cement plant
has been analyzed and evaluated using this method. However, its
applications in other sectors are relatively low in numbers: Tsat-
saronis and Moung-Ho [28] discussed how to estimate the
avoidable-unavoidable exergy destruction. They evaluated parts of
exergy destructions of compressors, turbines, heat exchangers and
combustion chambers, which were used to determine the
improvement potentials of a thermal system. Morosuk et al. [29]
presented the theory of the conventional and advanced exergetic
analyses. They concluded that the information resulted from the
advanced exergy based method was very useful in developing ap-
proaches for improving the energy conversion systems. Gungor
et al. [30] investigated the advanced exergy analysis to a gas engine
191
heat pump dryer for medicinal and aromatic plants, evaluating its
performance in parts and discussed possible structural improve-
ments of the whole system and the remaining system components.
Results found in the open literature are not typically combined
to give an overall representation of the cement industrial process
from an exergy perspective. Almost no comminution exergy model
has been proposed nor applied to a cement process in which
comminution is carried out to produce material of controlled par-
ticle size [31]. The present work contributes to the current litera-
ture from several perspectives. A detailed exergy evaluation of a
complete cement plant with all main units is performed using both
conventional and advanced exergetic analysis. In one hand, with
conventional exergy-based analysis, thermodynamic inefficiencies
were assessed; the critical points were localized and information
about improvements of the studied cement plant is revealed.
Furthermore, exergetic ternary diagram as a new graphical repre-
sentation of the exergy balances allows the immediate visualization
of the results of exergy analysis and the comparison between the
exergetic indicators (exergetic efficiency, irreversibility and exergy
losses) of each operation unit making up the whole system. In the
other hand, the advanced exergy analysis reveals the real potential
for improvement of the unit with the highest exergy destruction
ratio by calculating the amount of its avoidable part. Based on the
findings, insights for improvement can be extracted.
Before detailing the advanced exergy analysis methodology and
explaining the graphical representation used to illustrate efficiency,
irreversibilities and external losses in section 3, a brief description
of the cement-making process and data used is given. Section 4
discusses the main findings and provides guidance on the key
considerations for the assessment of the system performance.
Finally, section 5 concludes our analysis.
2. Process description of the plant production line
Cement production is a complex process which includes oper-
ations such as preparation of raw materials, clinker formation and
cooling to achieve a crystallographic structure that meets the
required cement specifications, and finish milling. For raw material
preparation and cement grinding, the main energy carrier is elec-
tricity whilst the thermal energy is consumed in the calcination
process of clinker manufacturing. In the present study, a Moroccan
cement plant with 1.2 million tons as an annual production ca-
pacity is considered as a case study for the exergy analysis assess-
ment. The plant required thermal energy inputs of 2.17 GJ/ton
clinker and 0.36 GJ electricity/ton cement. The main flows entering
or leaving the cement system boundary are summarized in Fig. 1.
Furthermore, each department is defined and delimited by a
boundary that cuts across all the streams and encloses each specific
process, but not their sub-system.
The dry production process is used in the typical plant and it
consists of grinding the mixture of raw materials (streams 8 and 24)
which are manufactured through a closely controlled chemical
combination of calcium, silicon, aluminum, iron and other in-
gredients to make a fine powder. The prepared raw meal (stream
37) is thus preheated in a four stage cyclone-type suspension pre-
heater using the waste heat of the kiln (stream 47). The preheated
raw mix powder and gases are separated in the cyclone by the
centrifugal motion induced by the geometry of the cyclone, with
the exhaust gases passing out of the top of the cyclone and the
preheated raw mix passing out of the bottom of the cyclone to the
next lower stage of the preheater. The plant owns an additional
calcining vessel, in which the raw-mix undergoes calcination to a
level of 90e95% [32]. This way, the preheated raw-mix (stream 44)
enters the calciner together with the fuel and the hot tertiary air
(stream 51). Calcining takes place at 800e900
C and breaks the
192 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200

12 28
19 35 Solid
14 15
D2 D3
26’ Gas
F1 F2 30
19 31
10’ 17 33 Air
14’ 18 30’
34 Pet coke
9 M3 29
13
H2O/CO2 leakage
36 M2
M1 25
11 16 27
32
24
8 26
22 Mill
Mill 7
2
3
1 Air/Gas flow rate measurement
23 60
Dust
4 F 61 56’
10 D1 Flow rate showed on the control panel in the
1 20 60’
39 F3 57 control room

38 58
C1A C1B 62 59
39’ 56
42’
37 40
Mill 54
C2 55
48 D4 3 M7 74
41
37’ 40’
38’ 44’ 53
C3 41’ 63 64 F4
49 50
42 43
Classifier 52
C4 44 Calciner
51 71 72

Cement
Storage silo 43’ 46
88 90
89
70

Additions
Trémies
65

Gypsum
Cyclone

Clinker
47 73 82
88’ F5
Baghouse Kiln 66
Filter 45 67 Cooler 75 76 77
83 86
M Mixer M8
68
45’ 87 M9
69
D 78
81

M10
Mill 85
80 4 84

78’
79

Fig. 1. Flow sheet of an actual cement manufacturing plant in Morocco [2].

calcium carbonate down into calcium oxide and carbon dioxide with the aid of the exergy balance is calculated. The exergetic ef-
throughout the process. Clinkering completes the calcination stage ficiency and exergetic improvement potential for each system
and fuses the calcined raw mixture into hard nodules resembling component and for the overall system were investigated then the
small grey pebbles. Molten clinker (stream 73) is quenched by cold exergetic tenary diagram is plotted to visualize clearly wasted,
air (stream 69) and finally grinded with gypsum and other additives useful and destructive exergy out of unit. The most favorable
in a ball mill to make the grey powder known as cement (stream operating conditions listed in Table 5 (unavoidable conditions) are
89). assumed and the avoidable/unavoidable exergy destruction for the
components with the highest exergy destruction ratios is calcu-
3. Exergy and advanced exergy analysis lated. The energy and exergy calculations are done using MS Excel
Professional Plus. The software makes it possible to analyze the
3.1. Exergy concept whole system by considering their interactions with each other.

Exergy is a thermodynamic concept routed in the first two laws

of thermodynamics. While the first law describes the conservation 3.2. Calculating exergy contents
of energy principle, the second law deals with the non-
conservation of entropy principles indicating the direction of re- Data for the analysis have been gathered for each process unit
actions and their irreversibility. Exergy can be considered as the from the plant records, while other relevant data are evaluated
maximum theoretical useful work that can be obtained when the using the degree of freedom analysis. The variables associated with
system moves from a particular thermodynamic state to a state of the streams (flows and temperatures) and those associated with
equilibrium with the surroundings [33]. Therefore, the exergy is a units have been analyzed and grouped in the degree of freedom
property which is associated with the state of the system and the tabulation [2], hence, it was concluded from this analysis that the
environment [34]. process is correctly specified and the entire installation was
Since exergy is not conserved, the difference between in- and defined. Furthermore, data reconciliation was used as means of
outflows is the exergy loss, which needs to be calculated in order to obtaining accurate and consistent data in cement process plant
study where irreversibilities occur. The exergy losses can be divided [35]. In this paper, the redundant measurements were detected on
into two basic types: internal exergy losses or exergy destruction the cement mill department specifically at the mixer 10 (see Fig. 1).
caused by irreversibilities taking place inside the control volume, This unit has two inlet streams (84 and 85) and one outlet stream
and external losses discharged to the environment. (86). Initially, mass flow rate and composition of every stream are
The methodology used to employ advanced exergy analysis for assumed to be directly known. Therefore, the redundant mea-
the cement plant considered in this study is summarized in a flow surements were exploited through the Lagrange multiplier method
diagram shown in Fig. 2 while the relations used in calculations are to improve the quality of available measures so that all the mass
presented in detail in the next subsections. First of all, the exergy balance constraints are met simultaneously by the adjusted values.
values associated with each material and energy streams are per- The reconciliation problem is thus a constrained optimization
formed. Next, the exergy destruction in each system component problem with the quadratic function given by Ref. [35]:
 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200 193

are presented in Tables A.1 and A.2.

Advanced exergy Analysis The energy sources used in the exemplary plant are electricity
and petroleum coke. The feeding of the Petroleum coke in the kiln
and calciner is respectively of 5.25 ton/h and 5.33 ton/h.
The general rate form of the mass balance and the energy bal-
ance equations can be expressed as:
Calculation of exergy components
X X
m_ in ¼ m_ out (2)

X X
Calculation of exergy destruction E_ in ¼ E_ out (3)

With all energy rate terms as follows:

Where m_ is the mass flow rate,h is the enthalpy and the sub-
Definition and calculation of the scripts ‘in’ and ‘out’ stand for inlet and outlet, respectively. Q_ and
Exergetic efficiency W_ the time rates of energy transfer by heat and work.
For the purpose of exergy balance, all types of exergy associated
with material, heat and work streams involved in the process have
to be calculated. In order to analyze the units thermodynamically,
Evaluation of wasted, useful and destructive the following Assumptions are made:

exergy indicators: Exergetic ternary diagram
Selection of the components with highest ID
e The system is assumed to be in steady state.
e The temperature and pressure of dead (environmental) state are
taken as the actual ambient conditions.
e The gases inside the systems are assumed to be ideal gases.
e Electrical energy produces the shaft work in the system.

The total exergy of a system is the sum of its kinetic, potential,

physical and chemical components. In this work, kinetic and po-
Assumption of the unavoidable operating tential contributions on the flow exergies are assumed to be
conditions negligible compared to physical and chemical exergies. In this
section, generic formulations for computing exergy in the process
are discussed.
The exergy balance is the basis for exergetic evaluation. The
Calculation of the avoidable/ second law of thermodynamics or the main exergy balance could
be depicted in equation (5) [24]:
unavoidable exergy destruction
X X
_ 
Ex _ out ¼ Ex
Ex _D (5)
in
Fig. 2. Flow diagram for advanced exergy analysis method.
Clearly, another way to express the exergy balance of the system
is given by equation (6) below:

 1  X X X
_  _ _ _
Yi* ¼ I  VAT AVAT A Yi (1) Exin Ex Usefull  Ex lost ¼ ExD (6)

The pertinent equations used in evaluating the exergy in the

Where Yi the vector of measurements (flow rate and composition
variables); Yi the vector of reconciled measurement. V is the vari-
ance matrix for each of the measurements that contain information
about the correlation between them. The constraint matrix, A,
represents the incidence matrix, it‘s obtained based on the process
connectivity information.
The calculation of the quadratic function (equation (1)) is per-
formed using MATLAB code. The results of the data reconciliation
process are given in Ref. [2] in more detail. The chemical compo-
sitions of the raw materials, kiln feed, clinker, cement and petro-
leum coke were determined using standard procedures; the results
most important devices of the entire installation are expressed in
more details in Table 1 below:
Where Ex _ D is the exergy destroyed inside the control volume, m_
denotes a mass flow rate through the system. The specific physical
material flow exergy of the system which is the work obtainable by
taking the substance through reversible process from its initial
state (T ,P) to the state of the environment (T0 ,P0 ) is written as [36]:
_
Ex ph ¼ ðh  h0 Þ  T0 ðs  s0 Þ (7)
In which h0 and s0 are the values of enthalpy and entropy at T0 ,

Table 5
Assumptions and summary results of advanced exergy analysis.

Components, k Unavoidable conditions Ep;k (MW) ED;k (MW) UN (MW)

ED;k AV (MW)
ED;k

Raw Mill 1 Q_ loss ¼ 0 1.55 7.36 5.21 2.15

Raw Mill 2 Q_ loss ¼ 0 0.67 3.55 2.43 1.12
Preheater cyclone units Q_ loss ¼ 0Dp ¼ 0 5.70 23.33 0.001 23.32
Calciner Q_ loss ¼ 0mex; comb ¼ 95% 11.83 38.94 33.10 5.84
194 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200

Table 1
Exergy balance equations in each department of the studied plant.

Plant departments Exergy balance equations

P _ P _ _ _ _ _
Grinding departments ðm_ in Ex ph; in Þ ðm_ out Ex ph; out Þ þ Ex Q  ExW  Excom ¼ ExD
P _ P _ _ _ _ W  Ex_ _
Preheater/calciner ðm_ in Ex ph; in Þ  ðm_ out Ex ph; out Þ þ Ex Petcoke þ Ex Q  Ex R1 ¼ ExD
P _ P _ _ _ _ _ _
Rotary kiln ðm_ in Ex ph; in Þ  ðm_ out Ex ph; out Þ þ Ex Petcoke þ ExQ  ExW  ExR2 ¼ ExD
P _ P _ _ _ W ¼ Ex _D
Cooler ðm_ Ex
in ph; in Þ  ðm_ out Ex ph; out Þ þ ExQ  Ex

P0
_ _ CaCO3 Exch1 þ m_ MgCO3 Exch2
Note that the entropy change of an incompressible substance is Ex R1 ¼ m (13)
given by:
_ _ CaCO3 Exch1 þ m_ C3 S Exch3 þ m_ C2 S Exch4 þ m_ C3 A Exch5
Ex R2 ¼ m
T þ m_ C4 AF Exch6
s  s0 ¼ cavg ln (8)
T0
(14)
Cpavg is the average specific heat between T0 and T.
It is noteworthy to mention that the exergy consumed in re-
The exergy of comminution is equal to [37]:
actions in preheater-calciner system corresponds to dissociation of
" # clay and MgCO3 plus 90% of CaCO3 calcination [41]. The amounts of
_ com ¼ DAv *g ¼ 6Fr 1  1 *g
Ex (9)
formed clinker phases in 1 kg of clinker are given as:
r df di r 0.593 kg C3S, 0.205 kg C2S, 0.107 kg C3A and 0.101 kg C4AF

Where DAv the increase in the surface area per unit volume after
comminution, Fr is the surface roughness factor, g the surface 3.3. Exergy efficiency
energy (specific) of material, r the density anddi ; df are the initial
and final geometric mean size of the particle. The exergy efficiency aims at measuring the degree of thermo-
The exergy of work can be calculated thanks to equation (10) dynamic perfection of the process under investigation. In the
[38] while exergy of heat streams is usually given by equation exergy literature there are many definitions of exergy efficiency, in
(11) where Q represents the amount of exchanged heat, T the this study, we used equation (15) below considering only the useful
temperature of the heat source and k the boundary of the exergy output from the process which represents the desired result
component. produced in system [36e43]:
P _ _ P
Exout  Ex losses Useful Exergy from the process
_ W ¼W
Ex (10) ε¼ P _ ¼ P _
Exin Exin
(15)
X
T

_ 1 0 _
Ex Q ¼ Q k (11)
T
The chemical exergy of the petroleum coke is written in the 3.4. Exergetic improvement potential
form [39]:
Besides exergy efficiency, an important parameter is applied to


_ x x investigate the performance of the cement plant in the conven-
Ex Petcoke ¼ D hPetcoke * 1:0437 þ 0:1896* H þ 0:0617* O
tional exergy analysis. Maximum improvement in the exergy effi-
xc xc
 ciency for a process system is obviously achieved when the exergy
xN
þ 0:0428* þ 9710*xS (12) loss rate or irreversibility rate (Ex_in  Ex_out Þ is minimized [44].
xc
Consequently, it is useful to employ the concept of an exergetic
WherexH ; xC ; xO ; xN ; xS are the mass fractions of the corre- “improvement potential” when analyzing different processes. This
sponding elements of the petroleum coke. improvement potential in the rate form, denoted IP_ , is given by
The chemical exergy of calcination and clinker formation in the Ref. [44]:
kiln are based on the chemical equations and the standard chemical
exergy values listed in Table 2. IP_ ¼ ð1  εÞ$ðEx_in  Ex_out Þ (16)
The chemical exergy of the calcination and the clinker formation
are given by Ref. [41]: Where ε is the exergy efficiency.

Table 2
Chemical exergy values of the calcination and clinker formation reactions.

Reactions name Reactions Chemical exergy of reactions ExCh [40].

Calcination CaCO3/CaO þ CO2 1275.1 kJ/kg CaCO3

MgCO3 dissociation MgCO3 /MgO þ CO2 610 kJ/kg MgCO3
C3S formation 3CaO þ SiO2 / C3S 33.16 kJ/C3S
b-C2S formation 2CaO þ SiO2 / b -C2S 735.9 kJ/b -C2S
C3A formation 3CaO þ Al2O3 / C3A 18.69 kJ/C3A
C4AF formation 4CaO þ Al2O3 þ Fe2O3 / C4AF 28.57 kJ/C4AF
192 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200

12 28
19 35 Solid
14 15
D2 D3
26’ Gas
F1 F2 30
19 31
10’ 17 33 Air
14’ 18 30’
34 Pet coke
9 M3 29
13
H2O/CO2 leakage
36 M2
M1 25
11 16 27
32
24
8 26
22 Mill
Mill 7
2
3
1 Air/Gas flow rate measurement
23 60
Dust
4 F 61 56’
10 D1 Flow rate showed on the control panel in the
1 20 60’
39 F3 57 control room

38 58
C1A C1B 62 59
39’ 56
42’
37 40
Mill 54
C2 55
48 D4 3 M7 74
41
37’ 40’
38’ 44’ 53
C3 41’ 63 64 F4
49 50
42 43
Classifier 52
C4 44 Calciner
51 71 72

Cement
Storage silo 43’ 46
88 90
89
70

Additions
Trémies
65

Gypsum
Cyclone

Clinker
47 73 82
88’ F5
Baghouse Kiln 66
Filter 45 67 Cooler 75 76 77
83 86
M Mixer M8
68
45’ 87 M9
69
D 78
81

M10
Mill 85
80 4 84

78’
79

Fig. 1. Flow sheet of an actual cement manufacturing plant in Morocco [2].

calcium carbonate down into calcium oxide and carbon dioxide with the aid of the exergy balance is calculated. The exergetic ef-
throughout the process. Clinkering completes the calcination stage ficiency and exergetic improvement potential for each system
and fuses the calcined raw mixture into hard nodules resembling component and for the overall system were investigated then the
small grey pebbles. Molten clinker (stream 73) is quenched by cold exergetic tenary diagram is plotted to visualize clearly wasted,
air (stream 69) and finally grinded with gypsum and other additives useful and destructive exergy out of unit. The most favorable
in a ball mill to make the grey powder known as cement (stream operating conditions listed in Table 5 (unavoidable conditions) are
89). assumed and the avoidable/unavoidable exergy destruction for the
components with the highest exergy destruction ratios is calcu-
3. Exergy and advanced exergy analysis lated. The energy and exergy calculations are done using MS Excel
Professional Plus. The software makes it possible to analyze the
3.1. Exergy concept whole system by considering their interactions with each other.

Exergy is a thermodynamic concept routed in the first two laws

of thermodynamics. While the first law describes the conservation 3.2. Calculating exergy contents
of energy principle, the second law deals with the non-
conservation of entropy principles indicating the direction of re- Data for the analysis have been gathered for each process unit
actions and their irreversibility. Exergy can be considered as the from the plant records, while other relevant data are evaluated
maximum theoretical useful work that can be obtained when the using the degree of freedom analysis. The variables associated with
system moves from a particular thermodynamic state to a state of the streams (flows and temperatures) and those associated with
equilibrium with the surroundings [33]. Therefore, the exergy is a units have been analyzed and grouped in the degree of freedom
property which is associated with the state of the system and the tabulation [2], hence, it was concluded from this analysis that the
environment [34]. process is correctly specified and the entire installation was
Since exergy is not conserved, the difference between in- and defined. Furthermore, data reconciliation was used as means of
outflows is the exergy loss, which needs to be calculated in order to obtaining accurate and consistent data in cement process plant
study where irreversibilities occur. The exergy losses can be divided [35]. In this paper, the redundant measurements were detected on
into two basic types: internal exergy losses or exergy destruction the cement mill department specifically at the mixer 10 (see Fig. 1).
caused by irreversibilities taking place inside the control volume, This unit has two inlet streams (84 and 85) and one outlet stream
and external losses discharged to the environment. (86). Initially, mass flow rate and composition of every stream are
The methodology used to employ advanced exergy analysis for assumed to be directly known. Therefore, the redundant mea-
the cement plant considered in this study is summarized in a flow surements were exploited through the Lagrange multiplier method
diagram shown in Fig. 2 while the relations used in calculations are to improve the quality of available measures so that all the mass
presented in detail in the next subsections. First of all, the exergy balance constraints are met simultaneously by the adjusted values.
values associated with each material and energy streams are per- The reconciliation problem is thus a constrained optimization
formed. Next, the exergy destruction in each system component problem with the quadratic function given by Ref. [35]:
196 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200

X .X X .X
1¼ _
Ex _ þ
Ex _
Ex Ex _D
_ þ Ex
Usefull in lost in
P _ P _ P _ P _ _ P _
Where ExUsefull = Ex in ; Exlost = Ex in ; ExD = Exin repre-
sent the indicators IU, UL and ID respectively.
In this study, in order to illustrate the results found the exergetic
ternary diagram was used as a graphical tool. This latter can be read
from right to left. Unit operations that should be first analyzed are
located at the right. The purpose behind the consideration of this
diagram is to make each unit operation to get closer to the 100%
efficiency side (left side) by minimizing exergy destruction and
losses [49]. In other words, as a result, this graphic presentation
specifies the efficient unit operation as the closest point to the IU
vertex positioned inside the triangular diagram, while the closest
point to the IL tip allows to search for the right waste stream so-
lutions and waste minimization techniques. Finally, the nearest
point to the ID tip shows up the presence of weak points in the
devices and the need of optimization of operating parameters that
will improve the performance of the unit operation significantly.
Additionally, the position of each area corresponds to the three
coefficients (IU, ID and IL) and the point's size is proportional to the
amount of irreversibilities, physical and chemical losses in the unit
operations [50].
4. Results and discussion
4.1. Discussion of research findings
It is generally more advantageous to conduct a comprehensive
exergy analysis covering entire cement production process. This is
due to the fact that all the unit operations are interrelated. The
present study extends the earlier research by applying both a
conventional and an advanced exergy analysis to a typical Moroc-
can cement plant. Exergy balances are thus made not only for the
process as a whole, but for each department to evaluate and
highlight the irreversibility and the thermodynamic inefficiencies.
In this work emphasis is put on breaking down the results among
the cement unit processes to assess the source and magnitude of
exergy degradation per production step. By splitting the exergy
destruction into avoidable/unavoidable parts, the advanced exergy
analysis provided additional information to conventional exergy
analysis for improving the cement production process. The input
and output energy and exergy results of the various streams of the
cement production process calculated per kg of clinker produced
are summarized in Table B.1 according to their state numbers as
specified in Fig. 1. It is necessary to be stressed that results obtained
in present work are deeply dependent of the quality of measure-
ments which often are not good enough. Hence, data reconciliation
is mandatory to check the validity of the data collected before
exergy analysis.
From the outlet exergy indicators of Table 3 it was possible to
.X plot the exergetic ternary diagram related to the process (Fig. 3). In
_
Ex this graph, the position of each area corresponds to three factors (IL,
in
ID and IU) and size point is proportional to the sum of irrevers-
(19)
ibilities and external losses. As it can be seen in Table 3 and Fig. 3,
the raw meal grinding departments are responsible for over 72% of
the destroyed exergy in this unit, which are the irreversibilities
associated with heat transfer and friction [51,52]. In spite of the
exergy efficiency calculated for the raw mills 1&2 is about 20.97%
and 19.69%. The exergy efficiency coefficient of the raw meal
grinding systems remains lower than the literature [16,20,17].
When it comes to exergy performance, particles size helps in
increasing the exergy efficiency, which appears clearly in the Pe-
troleum coke and finish grinding departments (material feed size
are 4 mm and 10 mm respectively) with an exergy efficiency of
59.6% and 62.14% respectively. The exergy efficiency of the baking
line including the pre-heater/calciner and the rotary kiln is calcu-
lated from equation (15) to be 17.64% and 63.09% respectively. This
corresponds to an exergy loss of 3.71% and 7.06% respectively in the
line. Here most of the internal losses are due to combustion and
chemical reaction. Additionally, cooling the clinker to the lowest
possible temperature affords an exergy efficiency of about 48%
which is low compared to 60% reported in literature [1].
The baseecase process has a total irreversibility of 132.29 MW
and a total exergy loss of 15 MW. Those values should be put into
perspective, as the global exergy efficiency is 41.6% which is
considerably lower than the overall energy efficiency of the process
with a value of 55% [2]. The best way of decreasing the irrevers-
ibilities for a process or system is to decrease the difference be-
tween the total exergy output and input values [44]. Determination
of the exergetic improvement potential values to deduct the
possible improvements in each component along with the whole
system are calculated by the use of the Van Gool equation (16) and
are outlined in Table 4. The highest IP rate is calculated for the Pre-
heater/calciner as 24.33 MW, which has the lowest exergy effi-
ciency. Thus, its exergy improvement potentials are important. The
rotary kiln, the cooler and the first raw mill department follow the
pre-heater/calciner for the IP rates with 7.30 MW, 4.31 MW and
4.12 MW respectively.
The results obtained in this study prove clearly that the primary
contributors to exergy destruction are the exothermic combustion
of the fuel, the strong endothermic calcination reaction, heat
Table 4
Exergetic improvement potential for the plant studied.
Unit Inlet exergy Outlet exergy IP_ (MW)
(kJ/kgcl) (kJ/kgcl)
Raw mill department 1 220 64 4.12
Raw mill department 2 101 28 2.01
Pre-heater/calciner 2633 1750 24.33
Rotary kiln 2266 1670 7.30
Cooler 630 382 4.31
Pet-Coke mill department 53 35 0.24
Cement mill department 97 68 0.37

Table 3
Outlet exergy indicators results.

Unit Inlet exergy (kJ/kgcl) Irreversibility (kJ/kgcl) Useful exergy Indicator (%) Wasted exergy Indicator (%) Destroyed exergy Indicator (%)

Raw mill department 1 220 156 20.97 8.17 70.86

Raw mill department 2 101 73 19.69 8.19 72.12
Pre-heater/calciner 2633 883 17.64 3.71 78.66
Rotary kiln 2266 596 63.09 7.06 29.85
Cooler 630 249 48.17 12.38 39.44
Pet-Coke mill department 53 18 59.59 6.96 33.46
Cement mill department 97 29 62.14 7.55 30.31
 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200
transfer and friction. To deal with them effectively, the principal
sources of inefficiency not only should be understood qualitatively,
but also determined quantitatively [53]. Using the advanced exergy
analysis, splitting the exergy destructions within a component into
avoidable/unavoidable parts helps facilitate a subsequent optimi-
zation of the overall system [27]. In this paper, values of unavoid-
able and avoidable exergy destruction are also presented for
selected components (raw mill 1&2, preheater tower and the
calciner system) in the advanced exergy analysis. The results of the
advanced exergetic analysis are summarized in Table 5 and are
obtained using equations (17) and (18). The unavoidable exergy
destruction within the selected components of the plant is larger
than the avoidable one except for the preheater tower which 99%
(23.32 MW) of its total exergy destruction rate is avoidable. This
result proves that the preheater is the most important system
component according to the design standpoint. In the calciner unit,
approximately 85% of the exergy destruction is unavoidable. Table 5
also shows that the raw mill 1 & 2 follow the calciner with 71% and
68% of unavoidable exergy destruction. Therefore, much can be
made to lessen the irreversibilities for the calciner and the raw mills
system, e.g. elimination of approximately 6 MW of avoidable exergy
destruction in the calciner the greatest improvement in the effi-
ciency of the overall system can be achieved.
Since this work aims also to provide practical improvement
suggestions based on the findings, they are considered further in
the next section.
4.2. System performance enhancement
After identifying the amounts and true locations of irrevers-
ibilities within the system, here are suggestions that may reduce
exergy destruction. Based on the results presented in the exergetic
ternary diagram Fig. 2 and the advanced exergy analysis, the
improvement can start by decreasing the exergy destruction, which
is large in comminution operations and optimizing the calcination
process.
The chemical reaction of calcination is a significant source of
thermodynamic inefficiency. Advanced exergy analysis gives us
information that 15% of the exergy destruction within the calciner
unit can be avoided. Therefore, the general suggestion is to work to
reduce the destruction of exergy during combustion [54] through
the employment of systems performing combustion in better
conditions (high internal energy) can meet this challenge. Also,
there are ways to decrease the exergy destruction or entropy pro-
duction related to combustion by increasing the temperature of
reactants and increasing the temperature of combustion products
(i.e. increasing the adiabatic flame temperature), by adopting
stoichiometric ratio between oxidizer and fuel and by utilizing the
fuels having simple molecular structure [55]. This is because lesser
entropy will be generated during combustion when simple mo-
lecular fuel species transform into complex molecular species of
combustion products. The exergy destruction in the calciner unit
under consideration can also be reduced by minimizing the use of
excess air and by preheating the reactants [53e55]. Moreover, fuel
substitution can be considered as an alternative option to reduce
environmental pollution. In order to assess the exergy efficiency of
the studied baking line; waste heat can be captured from com-
bustion exhaust gases, heated products, or heat losses from sys-
tems. It can improve the energy and exergy efficiency values to 84%
and 48%, respectively [18]. Furthermore, seals are used at the kiln
inlet and outlet to reduce false air penetration, as well as heat losses
[56]. Up of 23 MW could be saved just in the preheater cyclone
units. Hence, designing the pyroprocessing tower with refractories
and insulation materials with better thermal properties will lead to
an increase in the exergetic efficiency values and decrease the
197
energy loss rates considerably [57].
The results found in this study indicate a need to improve exergy
efficiency in comminution and justify reaching the decrease of
energy input for size reduction. As electricity use for raw meal and
finish grinding depends strongly on the hardness of the material
and on the surface area required for the final product [58] and the
desired fineness of the product. Thus, for ball mills, it is advisable to
avoid feed over 8e10 mm in diameter, as larger particles will
significantly raise energy requirements [59]. Furthermore, opti-
mizing the type of comminution equipment used and the operating
parameters can provide significant energy savings, which vary
depending on the materials being comminuted [59]. The majority
of losses in any system are from mechanical components (various
frictions). All friction losses are either directly proportional to or
have a squared relationship to speed. Reducing the speed reduces
the friction; reducing the friction reduces the losses [60]. Signifi-
cant energy savings can also be obtained by the application of the
high-pressure grinding roll presses instead of tumble mills or by
combining the roller press with the ball mill [61]. The mixing
temperatures of the materials, which constitute farine and gas
coming from the preheater cyclones and being the energy source of
the raw mills, should be reevaluated [16]. Additionally, 12.38% of
the exergy is wasted to the environment in the clinker cooler. Im-
provements in the exergetic efficiency of this unit can be obtained
through a waste heat recovery steam generator. Using heat recov-
ery from the exhaust air, energy and exergy recovery efficiencies of
the cooling system found to be increased by 21.5% and 9.4%,
respectively [62]. The electricity generated would offset a portion of
the purchased electricity, thereby reducing the electricity demand
[63].
The near-term energy and emission-reduction opportunities
will mainly come from better energy management practices,
changes to greener fuels, and, to a smaller degree, changes in
product formulation. Morocco is a country where the use of solar
thermal energy should be strongly encouraged since solar radiation
is strong and reliable. Heat generated by solar concentrators could
preheat the air supply for the plant, preheat the raw mill or
generate additional heat to increase the electricity output of the
waste heat recovery during daytime. Also, in the longer term, the
introduction of innovations such as novel quarrying methods, en-
ergy efficiency improvements, environmental controls, and new
cement products not only will result in reduction in specific energy
consumption norms but also reduce the impact of environmental
degradation.
However, all the aforementioned improvement suggestions
need to be deeply analyzed from economical viewpoint.
5. Conclusions
As a conclusion, the exergy analysis contributes to providing a
quantitative structure for assessing cement industry, mapping the
irreversibility and material flows which should be valued. In this
paper, the exergy balances for the whole system and each unit are
calculated and presented. The outcomes give important data con-
cerning exergetic performance of the overall facility and its sections
through exergy destructions and second law efficiencies. The major
findings can be stated as follows:
 Based on the results presented on the ternary diagram, we
pointed out that the Preheater/Calciner and the raw meal de-
partments are highly irreversible and have lower second-law
efficiency.
 Pyroprocessing found to be representing a major share of irre-
versibility, it has been found to be about 79%. That is, those
198 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200

processes represent a big potential for increasing the exergy support to undertake the above work.
efficiency.
 The examination of exergy efficiency of the overall system
shows that 1429.75 kJ/kg clinker of the exergy is a useful exergy Appendix A. Chemical composition
to the kiln system with the remaining 676.46 kJ/kg clinker being
exergy destroyed.
 Among the different sections, raw meal grinding is responsible
Table A.1
for over 72% of the destroyed exergy, which are the irrevers- Chemical composition of principal streams
ibilities associated with heat transfer and friction. The exergy
efficiency values for the raw mill 1 & 2 respectively are obtained Composition (%) Stream 8 Stream 24 Stream 37 Stream 73 Stream 89

to be 20.97% and 19.69% which are even worse than energy LOI 34.34 34.40 35.01 0.13 1.35
utilization. SiO2 13.4 13.52 13.65 20.55 21.57
Al2O3 3.15 3.18 3.30 5.04 5.74
 It has been identified that sizeable amounts of exergy are wasted
Fe2O3 2.06 2.11 2.45 3.24 3.58
and destroyed from the clinker cooler system 12.38% and 39.44% CaO 43.05 42.86 43.14 65.40 59.41
respectively. Thus, capturing the waste heat from the hot exit MgO 0.76 0.86 1.19 1.30 2.07
gases in the system can be considered as a potential option to SO3 0.25 0.28 0.35 1.53 2.46
improve exergy efficiency in the unit. K2O 0.43 0.48 0.57 0.90 0.90
TiO2 0.18 0.20 0.25 0.10 0.002
 Values for IP ratio indicate that the Preheater/Calciner unit has MnO 0.05 0.05 0.07 0.00 0.06
most impact on exergy improvement potential of the overall P2O5 0.12 0.18 0.15 0.21 0.32
system. Na2O 0.00 0.00 0.17 0.15 0.02
 A significant part (33.10 MW) of the exergy destruction within Cl- e e 0.01 0.01 0.001
CaOl e e e 1.7 1.58
the calciner unit is unavoidable. The irreversibility due to
Total 100 100 100 100 100
combustion cannot be avoided completely. However, irrevers- H2O 2.21 2.30 0.13 e e
ibility due to combustion can be reduced to a minimum value,
working with the suitable excess air coefficient (near stoichio-
metric condition) and using the better fuel.
Table A.2
 The raw grinding process has an unavoidable exergy destruction
Chemical composition and lower heating value of Petroleum coke.
of about 7.64 MW. Therefore, improvements can be made in this
section such as optimizing the type of comminution equipment Composition Petroleum coke (%)
used, the operating parameters, particle size distribution of the C 83.7
feed and ore hardness could result in the saving of considerable S 4.61
N 1.40
amounts of energy.
H 3.60
O 3.13
The calciner system presenting the large share of the unavoid- Aches 0.20
able exergy destruction. Owing to this reason, the future work in- H2O 3.40
volves the improvement of the unit exergy efficiency which will be Total 100%
(LHV) (Kcal/Kg) 8096
performed using statistical modeling.

Acknowledgements
Appendix B. Exergetic analysis results
The authors gratefully acknowledge the support of engineers of
the selected cement factory for providing the necessary facilities

Table B.1
Exergy balance analysis over the total production system. T0 ¼ 298.15K

Equipment Input streams M (kg/ Cp (kJ/ T (K) DH (kJ/ DS (kJ/ E x (kJ/ Output streams M (kg/ Cp (kJ/ T (K) DH (kJ/ DS (kJ/ Ex (kJ/
kgcl) kg K) kgcl) kgcl) kgcl) kgcl) kg K) kgcl) kgcl) kgcl)

Raw Mill 8. Raw Material 1.15 0.86 300.15 1.97 0.007 0.007 16. Farine 1.115 0.92 348.15 51.31 0.159 3.875
1 department 3. Gaz from kiln 0.56 1 630.15 188.21 0.424 61.72 17.Gaz 1.101 1.24 434.15 185.71 0.513 32.714
7. Gaz from kiln 0.49 1 632.15 165.88 0.373 54.60 10’. Steam 0.035 1.96 354.15 3.829 0.012 0.320
4. False air 0.12 1.01 303.15 0.60 0.002 0.005 Dust 0.083 0.2097 394.15 1.669 0.005 0.222
Shaft work … … … 103.45 … 103.45 Heat losses … … … 137.03 … 17.630
Total 2.33 … … 460.14 … 219.78 Exergy of … … … 80.59 … 9.282
comminution
Irreversibility … … … … … 155.74
Total 2.33 … … 460.14 … 219.78
Raw Mill 24. Raw Material 0.573 0.876 300.15 1.004 0.003 0.003 32. Farine 0.551 0.939 350.15 26.888 0.083 2.103
2 department 22. Gaz from kiln 0.747 0.996 537.15 177.74 0.438 47.214 33. Gaz 0.808 1.18 398.15 95.345 0.276 13.125
23. False air 0.084 1.009 300.15 0.170 0.001 0.001 26’.Steam 0.022 1.89 345.15 1.992 0.006 0.142
Shaft work … … … 53.686 … 53.686 Dust 0.023 0.2088 388.15 0.429 0.001 0.054
Total 1.40 … … 232.60 … 100.90 Heat losses … … … 64.419 … 8.123
Exergy of … … … 43.533 … 4.582
comminution
Irreversibility … … … … … 72.774
Total 1.40 … … 232.60 … 100.90
37. Farine 1.666 0.861 357.15 84.637 7453.35 7.41 39. Hot Gaz 1.912 1.082 542.15 417.679 1.237 48.777
 S. Fellaou, T. Bounahmidi / Energy 154 (2018) 190e200 199

Table B.1 (continued )

Equipment Input streams M (kg/ Cp (kJ/ T (K) DH (kJ/ DS (kJ/ Ex (kJ/ Output streams M (kg/ Cp (kJ/ T (K) DH (kJ/ DS (kJ/ E x (kJ/
kgcl) kg K) kgcl) kgcl) kgcl) kgcl) kg K) kgcl) kgcl) kgcl)

Preheater- 47.Hot Gaz 0.880 1.106 1700.15 1364.93 48770.46 859.61 45.Raw meal 0.149 0.971 1123.15 119.097 0.191 62.012
Calciner 38’. False air 0.028 1.006 350.15 1.470 130.76 0.115 37’.Steam 0.003 2.047 650.15 2.041 0.005 0.693
system 39’. False air 0.058 1.006 350.15 3.011 267.91 0.236 50. Gaz 0.384 1.08 450.15 51.674 0.171 0.788
41’. False air 0.187 1.006 350.15 9.773 869.43 0.765 46.Calcined raw 0.903 0.942 1103.15 684.494 1.112 352.810
meal
43’. False air 0.033 1.006 350.15 1.867 153.26 0.279 Reaction Exergy … … … 1658.402 … 1188.115
48. Air 0.024 1.015 314.15 0.391 36.80 0.010 Heat losses … … … 481.865 … 96.890
49.Primary air 0.026 1.014 322.15 0.628 58.310 0.024 Irreversibility … … … … … 883.135
51. Tertiary air 0.404 1.0625 1168.15 373.636 16876.00 198.781 Total 3.35 … … 3415.25 … 2633.22
63.Coke 0.044 1.866 444.15 12.060 947.41 12.738
Shaft work … … … 63.246 … 63.246
Combustion … … … 1499.59 925.90 1489.999
Total 3.35 … … 3415.25 … 2633.22
Rotary 45. Calcined raw 0.149 0.971 1123.15 119.09 0.191 62.012 47.Hot Gaz 0.880 1.106 1700.15 1364.93 1.695 859.61
Kiln meal
46. Raw meal 0.903 0.942 1103.15 684.49 1.112 352.810 68.Raw meal 1.000 1.042 1280.15 1022.83 1.518 570.14
64.Coke 0.044 1.103 314.15 0.770 0.003 0.828 Leakages 0.051 1.02 610.15 16.335 0.037 5.157
Combustion … … … 1490.98 0.042 1478.340 Reaction Exergy … … … 133.90 … 80.45
65. Air 0.026 1.01 313.15 0.394 0.001 0.010 Heat losses … … … 418.57 … 154.86
66. Primary air 0.058 1.01 324.15 1.518 0.005 0.063 Irreversibility … … … … … 596.009
67.Secondary air 0.753 1.04 1020.15 566.96 0.963 279.818 Total 1.93 … … 2956.58 … 2266.24
Shaft work … … … 92.362 … 92.362
Total 1.93 … … 2956.58 … 2266.24
Cooler 68. Raw meal 1.000 1.042 1280.15 1022.834 1.518 570.143 70. Hot air from 2.062 0.9442 412.15 26.970 0.631 161.020
cooler
69. Coolant air 3.261 1.014 330.15 105.310 0.337 4.806 52. Hot air from 0.041 1.0104 807.15 21.279 0.042 8.865
cooler
Shaft work … … … 55.298 … 55.298 51. Tertiary air 0.404 1.0625 1168.15 373.636 0.586 198.781
Total 4.26 … … 1183.44 … 630.24 67. Hot air from 0.753 1.0431 1020.15 566.965 0.966 278.962
cooler
73.Clinker 1.000 0.77 330.15 1.423 0.079 21.982
Heat losses … … … 193.168 … 78.040
Irreversibility … … … … … 248.600
Total 4.26 … … 1183.44 … 630.24
Pet-coke 56. Raw coke 0.091 1.896 330.15 5.508 0.018 0.276 61.Exit Air 0.028 1.114 366.15 2.136 0.006 0.212
Mill 55. Hot air from 0.028 1.19 706.15 13.691 0.029 5.064 62.Coke 0.088 1.848 350.15 8.444 0.026 0.661
department cooler
Shaft work … … … 47.213 … 47.213 56’.Steam 0.003 1.861 345.15 0.254 0.001 0.018
Total 0.12 … … 66.41 … 52.55 Heat losses … … … 30.743 … 3.638
Exergy of … … … 24.834 … 30.442
comminution
Irreversibility … … … … … 17.582
Total 0.12 … … 66.41 … 52.55
Cement 80.Air 0.121 1.064 330.15 4.103 0.013 0.206 89.Cement 1.377 0.86 330.15 37.895 0.121 1.899
Mill 79.False air 0.168 1.014 300.15 0.341 0.001 0.001 78’.Steam 0.0001 1.88 350.15 0.008 0.000 0.001
department 78. Cement mill 1.355 0.859 378.15 93.149 0.277 10.632 90. Exit Air 0.288 0.965 360.15 17.255 0.053 1.579
feed
85.Ashes 0.022 0.795 310.15 0.205 0.001 0.004 Heat losses … … … 94.729 … 7.332
Shaft work … … … 86.322 … 86.322 Exergy of … … … 34.233 … 56.905
comminution
Total 1.66 … … 184.12 … 97.16 Irreversibility … … … … … 29.450
Total 1.66 … … 184.12 … 97.16

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