HARAMAYA UNIVERSITY

HARAMAYA INISTITUTE OF TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

PROCESS CONTROL AND DYNAMICS:- PROJECT 1

TITLE :- DUST EMMISION CONTROL IN CEMENT INDUSTRY

GROUP NAME ID NO:

1. Abdi Geremu 3512/10

2. Abebe Teshome 3559/10
3. Debela Degefa 3818/10
4. Isayas Indrias 4737/10
5. Nardos Adugna 4327/10.
6. Mohammed Shafi 4269/10

Submitted to : Mr. Gadissa T. October,7/2021 GC

Table of Contents

CHAPTER ONE..............................................................................................................................1
1.Introduction...............................................................................................................................1
1.1 Background of the study....................................................................................................2
1.2 Objectives of the study.......................................................................................................2
CHAPTER TWO.............................................................................................................................3
2. LITERATURE REVIEW........................................................................................................3
2.1 Overall procedure of emission control...............................................................................3
CHAPTER THREE.........................................................................................................................5
3.GENERAL MODELING PROCEDURE OF DUST EMMISION CONTROL......................5
3.1Material and Energy Balance of kiln System.........................................................................5
3.2.Energy balance Calculation in the Kiln System.................................................................6
CHAPTER FOUR.........................................................................................................................17
4.CONCLUSION AND RECOMMENDATION.....................................................................17
4.1 CONCLUSION................................................................................................................17
4.2 RECOMMENDATION...................................................................................................18
REFERENCES..........................................................................................................................19

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CHAPTER ONE
1.Introduction
The intermediate as well as the final product in the cement industry is in powdered/particulate
form. Particulate matter or suspended and Respirable, Nitrogen Oxide, Carbon Monoxide
,Sulphur Dioxide , Volatile Organic Compound(VOC) and Green House Gases(GHG). Particulate
air pollution is a complex of small and large particles of varying origin and chemical composition.

The healthy effects of particulates are strongly linked to particle size. Small particles, such as
those from Fossil Fuel composition are like to be most dangerous, because they can be inhaled
deeply into the lungs, settling in areas where the bods natural clearance mechanisms cannot
remove them.

The accompanying Phenomenon of handling and processing of the material components which
finally form Portland cement is in the form of dust. To prevent the emission the dust into the
environment, studying the dust emission analysis is very important. Then it helps to take
corrective measure depending on analyzed data.
1.1 Background of the study
Chimney or stack are very important industrial structures for emission of poisonous gases to a
higher elevation such that the gases do not contaminate surrounding atmosphere. This structure
are tall, slender and generally with circular cross sections. Diffe rent construction materials, such
us concrete, steel are used to build chimney.

Fig 1.1: self- supporting chimney

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1.2 Objectives of the study
• To analyze the amount of dust emitted to environment through chimney.
• To take the corrective measure on the amount of material wasted to the atmospheric air 
To Control environmental pollution.

CHAPTER TWO
2. LITERATURE REVIEW
2.1 Overall procedure of emission control
2.1.1 SOURCES OF DUST IN CEMENT PRODUCTION LINE
In a cement production plant, the effects of abrasion, crushing, unloading, handling, cooking food
on the grill and move within it and ... Dust is generated . These items are described as follows
Handling: conveyor belts for material handling equipment used is one of three areas that cause
dust is beginning to embrace cord conveyor belt, where the material is hit. To adjust the conveyor
belt can be applied to the following: Change the speed, angle of 20 degrees to 30 degrees, for
example rollers, conveyor width increases from 24 to 36 inches, for example, the method of
loading the material on the belt strap can be transported back. The end point of conveyor belt is an
important factor in production of the dust.

Ventilation of belt conveyor: ventilated areas should be designed in such a way that besides being
ventilated and adequate site to create dust, dirt deflector directs the system to the lowest dust.
Hoods of poor design, in some cases causing severe dust catcher dust too early design input to the
system is dust. Bucket elevators: consists of a series of bins, which the chain or belt is moving up
and down by the wheels, are connected. This total is placed inside a metal casing. Which in the
absence of the chamber and holes in the well casing is to contain dust? There are only two points
to lift dust emission: where the materials are fed or where the material is discharged. By
appropriate design of the transfer and holding down a fine dust emissions at low lift height of the
fall of materials can be reduced. The equipment received by the correct drain wall material and
unloading will cause dust control.

2.1.2 CONTROL AND REDUCE OF AIR POLLUTION IN CEMENT PLANTS

Dust emissions in different ways, depending on the surface condition and has the capacity and
speed of transportation. Dust emission pathways can be minimized by the following measures:

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frequent spraying of water, oil, or other materials on soil stabilization. Paving the way for paving
the way it should be cleaned periodically to remove dust collected from the surface. Reducing
road traffic transportation by replacing smaller with larger vehicles reduces the speed of vehicles.
Air pollution caused by particulate matter PM One of the major problems of environment is
mainly developed and developing countries are considered to be mixtures of silica factors known
human carcinogen in humans and a major cause lung disease job in the world is mainly through
the cement plants humans and the environment face with toxic dust containing free silica should
be given to the determination of element concentrations in the air of control and legal aspects of
health is important.

Pollutants produced from burning materials, kiln dust, dust and material loss due process and
exhaust gases from the mill is electro. Proposed strategies to control and reduce pollution, create a
fully equipped indoor dust filter holder for single packing, dust filters improve performance,
according to the retrieval and reuse and reuse of materials (especially waste), shaving mill cement
and raw materials, reduce energy consumption, eliminate storage of clinker dust is to reduce
energy consumption. Citation

… Dust is emmitteds in the following activities in the Cement production process:

mining(drilling, blasting, loading, and haulage) in Limestone, in Clay, Gypsum, and Iron mines,
primary crushing, initial mixing and storage, grinding of raw materials, preheatings, or using
rotary kiln, Silo(storage) clinker,cement mill, cement silos, or barn….(Lei et al. 2011;Edalati M et
al. 2014).

… ASpart from being a large contributer of a Green House Gas, the Cement industy is also
responsible for major air pollution through they release of particulate matter (PM), Oxides of
Nitrogen (NOx), Carbon Monoxide (CO), Sulphur Dioxide (SO2) and Volatile Organic
Compounds…(Adeyanju and Okeke, 2019)

… Cement plan units are one of the major causes of pollution in developing countries (Baby et al .
2008;Edalati et al. 2014).

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CHAPTER THREE
3.GENERAL MODELING PROCEDURE OF DUST EMMISION CONTROL
3.1Material and Energy Balance of kiln System
3.1.1 Material balance
▪ In order to analyze material balance the following assumptions are made.

1. All gas streams are ideal gases at the given temperature.

2. The System is under control volume.

3. No air enters into the system except air push coal, raw material, for calcination and
for cooling system.

4. No air exit from the system except at the preheater and cooler outlet.

MRM+MC+MCA=Mex+MD1+MCL+MD2 + MHA

Where,

MRM = Mass of raw material

MC = Mass of Coal

MCA = Mass of cooling air

M ex = Mass of preheater exhaust gas

MD1 = Mass of preheater dust

MD2 = Mass of cooler dust

MCL = Mass of Clinker

MHA = Mass of hot air

According to the data collected from CCR

MRM+MC+MCA=Mex+MD1+MCL+MD2 + MHA

Mex =( MRM+MC+MCA) – (MD1+MCL+MD2 + MHA)

=( MRM+MC + MCA) – (MD1+MCL+MD2 + MHA)

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Mex=(19.97+2.23 +6.47)kg/s-(0.00064 +12.33+0.00029 +16.3)kg/s

Mex= 39gm/sec

Therefore, this implies 39 gm/s of dust is emitted to the atmosphere

N.B: Since the the parameters are changed time to time in ethio cement factory there is no
constant dust emission.

3.2.Energy balance Calculation in the Kiln System

In order to analyze the kiln system thermodynamically the following assumption are made.

1. Steady state working conditions

2. The change in the ambient temperature is neglected.

3. Cold air leakage into the system is negligible.

4. Raw materials & cold composition do not change.

5. Average kiln surface temperatures do not change.

6. The velocity of air and exhaust gas in the system is 3m/s.

7. The surface of the kiln is oxidized surface.

8. Pre heater is modeled as a vertical cylinder.

9. Cooler surface is modeled as a vertical plate.

Based on the coal composition, the net heat value of South Africa coal is 5000-6800kcal/kg.

But we take the average of the two.

Hc= (5000+6800)/2=5900kcal/kg

1kcal=4.18kJ

Hence; 5900kcal/kg=24,662kj/kg.

Therefore, the average heat value for South African coal is

Hc=24,662kj/kg

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 Heat Inputs

1. Combustion of coal

Q1= MCHC where; MC=0.18kg/kg of clinker

Q1= 0.18*24,662 HC=24662Kj/kg

Q1=4460.74Kj/kg clinker

2. Sensible heat by coal

Q2=MCHC Where; HC=CPCT

CPC=1.15kj/kg.Oc

MC=0.19kg/kg

Q2=MC*CPC*T T=50oC

Q2=0.19*1.15*50=7.42KJ/kg clink

Q2=10.92KJ/kg clinker

3. Heat by raw material

Q3=MRMHRM; HRM=CPRMT Where CPRM=0.86KJ/kg.oC

MRM=1.62kg/kg clinker

Q3=1.62*0.86*50 T=50OC

Q3=69.8KJ/kg clinker

4. Heat by primary air

Q4=MH or; where, Hor =561KJ/kg

Q4=0.03*561

Q4=16.83KJ/kg clinker

5. Heat by cooling air

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Q5=MCAHCA where; HCA=30Kj/kg, T=50oC, MCA=5.37kg/kg clinker

Q5=161.7KJ/kg clinker

6. Total inputs

QT =4719.99 KJ/kg clinker

Heat Outputs

1. Preheater exhaust gas

Q6= MexCexTex where Mex= 0.65kg/kg clinker

Q6=0.65*1.082*320 Cex=1.082KJ/kg.oC Tex=320oC

Q6=225.05KJ/kg clinker

2. Heat loss by dust

Q7=MDHD Where; MD=0.000075g/kg clinker

Q7=0.000075*440 HD=440KJ/kg

Q7=0.025KJ/kg clinker

3. Hot air from Cooler

Q8=MHAHHA

MHA=5.39kg/kg clinker

Q8=5.39*357.5

HHA=357.5 KJ/ kg at 100 oC

Q8=1926.93KJ/kg clinker

4. Clinker Discharge

Q9=MCLHCL AT 100 MCL=1.00kg/kg clinker

HCL = 73KJ/kg.oC`

Q9=1*73

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Q9=91.25kj/kg clinker

5. Clinker Formation
Items Loss SiO2 Al2O3 Fe2O CaO MgO
3
Clinker (%) 0.71 21.46 6.32 3.75 66.16 1.74
Q10= 17.196(AL2O3) +27.112(MgO) +32(CaO)-21.405(Sio2)-2.468(Feo3)

Q10=17.196(6.32) +27.112(1.74) +32(66.16)-21.405(21.46)-2.468(3.75)

Q10=1804.4kj/kg-clinker

6. Radiation from kiln surface

Mcl= 44.38 ton/s =12.33.kg/sec =5.67*10-8W/m2.k4

Where is Boltzmann constant =0.78(oxidized surface)

Ts=300 =573k

T∞ =25oC=298K

A kiln= DL= *2.84*47= 419.13m2

A Kiln= 419.13m3

Hence;

Q11= A(Ts4- T4∞)/1000MCL

Q11=34.43KJ/kg clinker

7. Convection from kiln surface

Q12=hA (TS-T ) But the convection heat transfer coefficient hcon is given by:

Ts =Temp at surface T

=Temp at surrounding

hconv. =karin/Dkiln

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The film temperature is given by:

Tf = =162oC=435k

At Tf=435k

K=0.0355W/moC

V=3.035*10-5m2/s

Pr=0.701

Where; k=Thermal conductivity of air

V=kinematic viscosity

Pr=prandtl number

Then the Reynolds Number becomes

Re=V D/v

Where; V is speed of ai

D is diameter of the kiln

Re= (3m/s*3.8m)/3.035*10-5m2/s

Re=375,617.8

Then Nusselt number (Nu) becomes:

Nu=0.027Re0.805Pr1/3

Nu=0.027*(375,617.8)0.805(0.701)1/3

Nu=738

Hence; the convection heat transfer coefficient becomes;

H conv=k air Nu/L kiln=0.0335*738/47

H conv= 0.64w/m2oC

Therefore,

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Q12=h A (Ts -T ) =0.64*680.5(300-24)

Q12=120.19KJ/kg clinker

8. Radiation from preheater surface

Q13= Aph (T2s-T4 )/1000MCL

Where; Ts=320oC=593K

T =24oC=297K

APh= DL= *4m*10m=125.6m2

=0.78(oxidized surface)

=5.67*10-8w/m2k4

MCL=12.33 kg /s

Q13=5.67*10-8*0.78*125.6(5924-2974)/ (1000*12.33)

Q13=11.82KJ/kg clinker

9. Natural Convection from pre-heater surface

Q14= hnconAPh (Ts-T )

The natural convection heat transfer coefficient (hncon) is given by;

hncon=kairNu/LPh

The film temperature becomes:

Tf= (319 Oc+24Oc)/2 =172oC=445k

At Tf=445k

Kair=0.036w/m .k

V=3.13*10-5m2

Pr=0.700

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The Rayleigh’s number is given by ;

Ra=g (Ts-T∞ )2Pr/V2

Where; g=gravity of the of earth

=The volume expansion coefficient

V=Kinematic viscosity

=characteristics length

Pr=prandtl number

The volume expansion coefficient is given by:

=1/Tf=1/445k=0.0023k-1

=10m in this case I take the length of pre-heater as a characteristics length

Then;

Ra= (9.81*0.0023*(592-297)(103)*0.7/(3.13*10-5)2

Ra=4.7*1012

Then the nusselt number becomes;

Nu=0.1*(Ra)1/3=0.1(4.7*1012)=2351

Nu=21618 Then;

hnconv=kairNu/Lph=0.036*2168/10=7.81w/m2k

hnconv =7.81w/m2k

Therefore;

Q14=7.05*125.6(592-298)

Q14=289KJ/kg

10. Radiation from cooler surface

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Q15= Ac (Ts 4-T∝4)

Where; TS=110Oc=383k

T =25oC=298K

Q15= 5.67*10-8*0.78*144*(3834-2974)

Q15=3.4KJ/kg clinker

11. Natural Convection from cooler Surface

Q16=hnconAC (TS-T∞ )

But hn con=kairNu/Lc

The film temperature is given by;

Tf =67oC=340k

At Tf=340k

Kair=0.029w/moC

Pr=0.707

V=1.96*10-5m2/s

=1/Tf=1/340k=0.00294k-1

=10m in this case the characteristrics length is length of the cooler.

Then;

Ra= (g (Ts-T∞ ) 3*Pr)/V2

Ra=(9.81*0.00294(383-297)103*0.707)/(1.96*10-5m2sec)2

Ra=4.57*1012

Then;

Nu=0.1Ra1/3

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Nu=2138

Then; hncon=KairAc (Ts-T ∞)/LC =

(0.029*1991)/10 hncon =5.64 w/moC

Therefore;

Q16=hnconAc (TS-T∞ ) =5.64*100*(110-25)

Q16=50.76kJ/kg

12. Total heat output

11
76 + 7 + …. . 15 + 16 =4697.26 KJ/kg clinker

Heat losses 4719.99 -4697.26 = 22.23 KJ/kg clinker

N.B: Since some parameters changed time to time the above losses of heat will be changed.

SCHEMATIC REPRESENTATION OF UNIT OPERATION

Fig.2 Stirred tank

Develop the model equations

Assumption

1: Perfect mixing process

2: The liquid hold up the volume is constant

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3: Density and specific heat capacity of the liquid are assumed to be constant

4: Heat lose are negligible

1 Total mass balance,

𝒅/𝒅=Wi-W…………………………………..eq 1

2.Total energy balance,

CpvdT/dt=Wihi-Wh+Q……………………..eq 2

For a liquid ,dU/dt≈dH/dt and at reference temperature

Eqution 2 becames CpvdH /dt=Wihi-Wh+Q…………..eq 3

Cpvd(T-Tref)/dt=WiCp(Ti-Tref)-WCp(T-Tref)………..eq 4

By differentiating and arranging eqution 4 becomes ,

CpvdT/dt=WiCp(Ti-T)+Q………………………………..eq 5

Degree of freedom analysis

No of equation=2 (eq 1 and 2)

No of variable =6

DOF=NF-NE , DOF=6-2=4 the system is under specified

Therefore we should have to control variable(temperature and volume)

 The laplace transformetion of the model is;

At steady state equation 5 becomes;

CpvdTs/dt=WiCp(Ti,s-Ts)+Qs…………………..eq 6

substracting equation 6 from 5 CpvdT’/dt=WiCp(Ti’-T’)+Q’…………………..eq 7

The laplace transform of equation 7 becomes,

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CpvsT’(s)=WiCpTi’(s)-WiCpT’(s)+Q’s ……….eq 8 By rearranging equation 8 By becomes

Wicp Ti' ( s) Q' ( s)

,T’(s)= + ……………….eq 9 let
ρCpvs+WiCp ρCpvs+Wicp

1 ρv T ' ( s ) kQ '(s)
K= andτ = then T(s)= + ……………eq 10 Transfer function the model
WiCp wi τs+1 τs+1

Ti ’ (s) 1
𝜏s + 1
T’(s)

Q’ ( s) k
𝜏s + 1

Fig. 3 Block Diagram of Transfer Function

Results and Discussion

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In all kiln systems, the exhaust gases are finally passed through an air pollution control device for
separation of the dust before being released to the atmosphere via stacks. In factory two types of
dust separators are used (i,e electrostatic precipitators and bag filters).

CHAPTER FOUR
4.CONCLUSION AND RECOMMENDATION
4.1 CONCLUSION
Cement industry is one of the industry major contribution in the amount of atmospheric
pollutants. Dust the crushing and grinding of materials, there is such a high risk of polluting the
environment and human health that comes whith dust generated in the cement industry , during
the preparation , transport and shortage. optimization of devices to supplement equipment and
modeling of the process, measures that reduce the production of dust in the kiln system have been
discussed.
4.2 RECOMMENDATION
The company is recommended to consider environmental pollution by further modification of
dedusting systems by employing modern laboratory work on cement particulate matter,
especially chimney part of stack gas.
The company management and engineering site department head should communicate with
subengineering process heads to solve the problem. I have recommended for both the hosting
company.
To withstand the material wastage it is recommended to use well skilled man power that can
communicate very closely with equipment’s specification points.
It is better to use equipment wisely; that is why because there are a lot of mishandled tools.

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REFERENCES
1 http://www.shahroudcement.com/fa/pages/content.php
2 M, Debell. “Pollution control of cement plant emission "International cement Review,
Environmental Yearbook, 1997.
3 H, Debell. Emission Pollution control of cement plant International cement review,
Environmental yearbook, 1997.
4 Gathering dust in the cement industry, University of Science and Technology, Iran, Persian
date 7 September 1373.
5 Final internship Report from Zhongshun cement Man PLC.
Manual book from Ethio Cement Factory PLC.

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