Master of Energy Management (MEM)

DMX9402 Thermal Energy Utilities (TEU)

Group Project Presentation

Group Members
H.A.J.N Sameera ( 620253085 )
H.K.D.S.R Kokawala ( 220253280)
G.D.T Perera ( 720253955)
G. Thamilchchelvan (720254412)
E.N.L Mirando ( 420253158)
H.N.T Wijesekara ( 520253279)
Academic Year : 2020
Date of Submission : 05.06.2020
 INTRODUCTION
 We have Selected INSEE Cement Factory at Puththalam for our group project Analysis
 The plant has 48.3 Ton /hour clinker generation two Ideal Kilns. One kiln is selected and
conduct the below calculations.
 The plant has the full cement process line from mining to cement finish grinding. It has a
production capacity of 1159.2 tons of clinker and 1600 tons of cement per day . The
current state of the preheater limits heat transfer resulting in high gases temperatures
exiting the preheater usually above (370–400) °C.
 The plant consumes of average 4,248,480 kWh of electrical energy per month and all of
which comes from the national grid. The Demand is on average 7.5 MW. The average
specific power consumption from mine to cement dispatch plant is 88.51kWh/ton of
cement.
 CEMENT MANUFACTURING PROCESS
FLOW DIAGRAM

Cooler waste air Preheater exhaust Gas 374 0C

395 0C 75.8 ×103 Nm3/hr
26.8 ×103 Nm3/hr
Energy flow of cement manufacturing process

The cement making process is highly energy intensive accounting for nearly 40 — 50 % of
the production costs
Thermal energy generation and thermal energy
utilization in the cement production process

Thermal Energy Generation System

1. Kiln system – Coal and Waste material burning

Thermal Energy Utilization Systems

1. Pre – Heating System Kiln Heat Balance
2. Clinker Cooling System
3. Clinker Production System
4. Raw Mills and Coal Mills Raw mill Heat Balance
 Heat Balance of Kiln
Input Energy = Output Energy
Heat Input
Sensible heat in kiln feed (Q1)
Sensible heat in cooling air (Q2)
Sensible heat in primary air (Q3)
Sensible heat in leaking air (Q4)
Sensible heat in fuel (Q5)
Heat from Fuel combustion(Q6)

Heat Output
Heat of formation of Clinker ( ∆HR )
Heat in dust in preheater exit gases (Q7)
Heat in preheater exit gases (Q8)
Heat in Clinker leaving cooler (Q9)
Heat in cooler exhaust air (Q10)
Heat for evaporation of moisture of kiln feed (Q11)
Heat due to partly decarbonized material(Q12)
Heat in incomplete combustion (Q13)
Radiation & convection losses (Q14)
Kiln Heat Balancing Procedure
Purpose of the heat balancing is to get a reference regarding the existing thermal performance
of a kiln and to investigate the potentials for further improvements targeting kiln thermal
energy optimization.

Kiln Heat balancing procedure mainly contained with 5 stages.

 Planning
 Preparation
 Execution
 Evaluation (with calculated values)
 Discussion for potential waste heat recoveries.
Planning Stage.

In this stage we should plan,

 Which boundaries should use to divide the system for mass balance & heat balance?
 What sample points we need to measure?
 No of people &What tools/equipment we should use?
 What duration the tests should carried out?
 At what condition kiln should operate when the measurements are taken?
Preparation Stage.
In the preparation stage required manpower & set of tools/equipment were prepared to take the
measurements at steady kiln operation.
Below equipment were used to measure the mentioned parameters.
1. Kiln Weigh Feeder – Kiln Feed.
2. Husler Apron weigh feeder – Clinker quantity.
3. Radiation Pyrometer – Clinker temperature at cooler inlet.
4. CEM system – Preheater exhaust properties.
5. Flue gas analyzer – secondary air composition.
6. Flow & DP sensors – Secondary air & cooling air details.
7. Thermocouples – Temperature readings at required measuring points.
8. Pitot tube – For specific air velocity & DP readings.
9. IR Thermometer – Kiln Shell, cooler & Cyclone temperature readings.
Execution Stage.
After completing the required preparations, the test was carried out for 12 hours as per
recommendations of Holcim process technology guidelines. Below mentioned data were
recorded from the relevant tests.

 Kiln Data
 Fuel Data. (Coal, Biomass & Alternate Fuel)
 Ambient conditions.
 Kiln Feed Properties.
 Primary Air fan Details.
 Kiln Dust loss characteristics in direct feeding.
 Clinker Properties.
 Gas Properties. (Preheater inlet, outlet, bypass duct & cooler waste air)
 Cooler fan characteristics.
 Kiln Shell, Cyclone, Cooler & downcomer duct temperatures.
Calculation & Evaluation Stage.
Applying the gained values previously mentioned, relevant heat calculations were carried out
below formulas.

Total Heat Input = Total Heat Output

Heat Inputs
 Heat from fuel combustion
h = m. NCV

 Sensible Heat through Fuel, Kiln feed, Primary air & Cooling air
h = m. Cp. (t - 20 0C)
Heat Outputs

 Heat of formation of Clinker

h = (CaO% · 3200 + MgO% · 2710 - SiO2% · 2140 - Fe2O3% · 250 + hRes)/100
 Heat of Evaporation
h = m. 2450
 Heat gained by clinker, preheater exit air, cooler waste air bypass air etc.
h = m.Cp.(t - 20 C)
 Heat losses due to incomplete combustion
h = m. (CO. 12640 + H2. 10800 +CH4. 35840)
 Heat loss due to partly decarbonized material
CaOnc = CaO - 56 [(CO2/44) - (MgO/40)]
h = m · CaOnc · 3150
 Convection
  & Radiation Heat losses.

∝rad = CR. ε x 0.04 [Tavg/100]^3 x [1+0.25 (dT/Tavg}^2]

∝con-free = 1.4 (ρ0 · ρ · [(Tamb+273.16)/ΔT. Tavg]^(1/3)

∝con-forced = 0.00672 x λ x [ρ. v]^0.905 x D^(-095)

∝conv = + )

∝tot = ∝rad + ∝conv

Qf = ∝ tot.A.(t - t)

Convection & radiation heat losses are calculated in kiln shell, cyclones, cooler, bypass duct &
down-comer duct. Set of surface temperature readings were taken in uniform distances to improve
the accuracy of the values.
Summary of the Heat Balance Inputs.
Summary of the Heat Balance outputs
Discussion for potential waste heat Recoveries

Total heat energy input for Clinker Production process = 3757 kJ/kg-Clinker
Total heat required for Clinker heat of formation = 1755.3 kJ/kg-Clinker

Kiln Thermal Efficiency = 46.7%

 Investigation

Waste heat which can be recovered for a co-generation process,

 Preheater exhaust Gas Heat (916.6 kJ/kg-Clinker)

 Cooler waste air heat (277.5 kJ/kg-Clinker)
Preheater exhaust gas heat recovery through
Raw mills & Coal mills
 Raw Mill Heat output
 Step:1 Heat to raw material
 Step:2 Heat to de-dusting gases
 Step:3 Heat loss due to radiation
 Step:4 Heat loss to evaporate moisture
 Step:-5 Heat loss due to false air
 Raw Mill Heat input
 Step: -1 Heat from fresh feed
 Step:-2 Heat from grinding power
 Step:-3 Heat from false air
 Heat input (Hi) + (Heat from hot gases) = Heat output (Ho)
 Since Required quantity of hot gases for raw mill drying from total exhausted gases
 = (34343.94 / 75,803) * 100
 = 45 % From Total Exhausted Gases
Since we have consider 50 % exhaust gas use for raw mills and coal mills for their operation and rest 50 % we can
use for co-generation process.
Total Waste Gas Thermal Energy Content for
Power Generation
 Cooler Exhaust
 26,810 Nm3/h at 395 0C
 277.5 kJ/kg of clinker production
 Pre-Heater
 75,803 Nm3/h at 374 0C
 916.6 kJ/kg of clinker production (gas out)
Total Available Thermal Energy for Power Generation
Cooler Exhaust thermal Energy + 50 % from Pre-Heater exhaust thermal energy

= 735.8kJ/kg clinker
Clinker production
 48,300 kg/h Total Available Waste energy for
power Generation (50% of pre
heater + cooler exhaust )
35,539,140 kJ/hr
 Potential Electric Energy Generation
   
Thermal energy of preheater waste gases 916.6 kJ/kg clinker
   
% Heat requirement for drying 50%
   
Heat requirement for drying 458.3 kJ/kg clinker
   
Remainder for Power generation 458.3 kJ/kg clinker
   
Thermal energy in Cooler waste gases 277.5 kJ/kg clinker
   
Total thermal energy available for electrical heat generation 735.8kJ/kg clinker
   
Recovery Efficiency 0.2
   
Power generated 147.16 kJ/kg clinker
   
Plant clinker capacity 48.3 tons/h
   
Total Gross potential power generated 1.9744 MW
   
Auxiliary power consumption (by WHR system @15%) 296.16 kW
   
Net Potential Power Generation 1.678 MW
Rankine cycle-detailed and sample schematic
sketch of proposed power plant
Potential Electric Energy Generation Cont.

 Steam Generation Required for Steam Turbine Steam Inlet

 From preheater - 14.3727 TPH, Parameters
 From Cooler Exhaust - 8.7026 TPH 0
6 bar @ 275 C
Plant Thermal Efficiency after Implement the Co –generation
Power Plant
 
 Plant Thermal efficiency = (Use full thermal Energy Usage / Total heat input)
 = (Clinker Formation Energy + Power Generation
Energy + Coal Mill & Raw mills Use Full Energy) / Total Heat Input
 = 1755.3 kJ/kg Clinker + 147.16 kJ/kg clinker + 458.3
kJ/kg clinker *0.8) / 3757 KJ/Kg Clinker
 = 60.4 % Thermal Efficiency
Potential Saving through Co – Generation

 4 -5 % Plant thermal efficiency can be increase through power generation

 Net potential to generate 1.974 MW of electrical power from waste heat
gas recovery which was sufficient to meet 30 -40 % of the plant’s electric
power demand.
 LKR 22Milion monthly cost saving can be achieve through power
generation.
 Power Plant capital cost simple payback period of 5 years which was
considered quite attractive
 Thank You
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