RCCPL Kundangunj

SPECIAL GROUP TRAINING PROGRAMM ON ENERGY AUDIT AND CONSERVATION

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 Contents
• Roles and principals of energy audit
• Fuels for cement production
• Optimization of grinding systems
and bag filters
• Improving energy efficiency in
electrical system
• Energy saving opportunity in
compressors
• Energy conservation in fans
• Heat balance studies

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 Roles and principals of energy audit

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  Energy audit in India is carried by BEE(Bureau of Energy
Efficiency)
 BEE comes in existence in March,2002 by Ministry of power
 Purpose- Development of policies and strategies, with an
emphasis on self-regulation and market principles
under the Energy Conservation Act, 2001.
 Headquarters- SEWA Bhawan,New Delhi

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  As per energy conservation act, 2001,energy audit is defined
as “The verification, monitoring and analysis of use of energy
including submission of report containing recommendations
for improving energy efficiency with cost benefit analysis and
an action plan. To reduce energy consumption”.
 Energy audit classified into two categories:
i) Preliminary Audit
ii) Detailed Audit

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 AGENDA
 Energy Conservation Act, 2001 ; Every designated consumer
shall have its first energy audit conducted, by an accredited
energy auditor within 18 months of the notification issued by
the Central Government under clause (i) of section 14 of the
Act.
 The interval of time for conduct and completion of
subsequent energy audits shall be three years with effect
from the date of submission of the previous energy audit
report by the accredited energy auditor to the management of
the designated consumer.
Note: Section14,provides penalty for failure to comply with the
provisions of clause.
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 FACTORS FOR DETAILED STUDY /
ANALYSIS OF ENERGY CONSUMPTION
 QUALITY OF ENERGY INPUT.
 EXCESS ENERGY SPENT DUE TO FREQUENT
STOPPAGES.
 INHERENT NATURE OF SYSTEMS OF PLANT.
 ENERGY LOSSES FROM THE RECEIVING POINT TO
POINT OF ACTUAL USE.
 HOUSE KEEPING AND MISCELLANEOUS FACTORS.

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 ANALYSIS OF ENERGY PERFORMANCE
 EFFECT OF CAPACITY UTILISATION ON ENERGY PERFORMANCE
VARIATION IN QUALITY OF ENERGY INPUTS.
 EQUIPTMENT & SECTION WISE SPECIFIC ELECTRICAL ENERGY
CONSUMPTION
 PROCESS WISE SP. ELECTRICAL ENERGY CONSUMPTION
 PERCENTAGE ENERGY COST PROCESS & PLANT WISE
 PROCESS WISE ELECTRICAL ENERGY COST
 PROCESS WISE THERMAL ENERGY COST
 SPECIFIC ELECTRICAL ENERGY CONSUMPTION FOR DIFFERENT
VARIETIES OF CEMENT.
 PLANT WISE POWER FACTOR
 ENERGY MONITORING PLANS
 METHODOLOGY ADOPTED FOR FIXING TARGETS
 MEASURES FORENERGYCONSERVATION BY OPERATIONAL CONTROL
ANDOPTIMISATION

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 NEW ENERGY SAVING EQUIPMENT INSTALLED
 ENERGY SAVING PLAN,SHORT TERM,MEDIUM TERM &
LONG TERM
 METERING DEVICES FOR MONITORING ENERGY
CONSUMPTION
 PROCESS CONTROL INSTRUMENTATION
INSTALLEDAINING OF MANPOWER IN THE
 PROMOTIONAL EFFORTS MADE FOR CREATING
ENERGY CONSCIOUSNESS
 TRAINING OF MANPOWER IN THE AREA OF ENERGY
CONSERVATION

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 REASONS OF HIGH ENERGY CONSUMPTION IN CEMENT
PLANTS
 LOWER CAPACITY UTILIZATION
 TYPE OF GRINDING SYSTEM
 MATERIAL HARDNESS AND QUALITY
 AUTOMATION AND CONTROL
 UNSTABLE QUALITY OF COAL
 IRREGULAR SUPPLY OF POWER
 IDLE RUNNING OF EQUIPMENT
 FALSE AIR INFILTRATION IN SYSTEM
 HIGH EXIT GAS TEMPERATURE FROM SYSTEM
 OVERSIZED MOTORS/PARTIAL LOADING
 IMPROPER CONTROL OF FEED & PRODUCT SIZES
 POOR MAINTENANCE

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 ENERGY AUDIT FLOW CHART
Plant performance Measurement Data
Plant &
data [ V.I.T.P.Q.]
machinery

Data processing &

Analysis

Identification of Potentials
Implementation of
Modified target and
conservation
norms
scheme

Performance Monitor

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 ENERGY SAVING POTENTIAL AND COST
OF SOME EQUIPMENT
NAME & COST SAVINGS
 HIGH EFFICIENCY FANS( Rs.40 Lakhs) 3-5 %
 FLUID COUPLING(FIXED SPEED) (Upto Rs 2 Lakh) Upto 3%
 FLUID COUPLING(VARİABLE SPEED) (Its 2.6-10 Lakh) Upto 40 %
 BUCKET ELEVATOR (Rs 40-125 Lakh) 60-65%
 VARIABLE SPEED AC DRIVE (Rs 10-50 Lakh) Upto 30 %

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 Optimization of Grinding System and Energy
Saving Measures and Bag filters

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 TYPES OF GRINDING SYSTEMS IN CEMENT INDUSTRY

 Conventional tube mill/ball mill - Open and Close circuit

 Tube mill/Ball mill with pre-crushing unit i.e. vertical shaft
impactor (VSI) or horizontal impact crusher (HIC)
 Vertical roller mill (VRM)
 Roller press in semi finish and finish grinding mode
 Ring roller mill or Horo mill

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 TYPE OF GRINDING FORCES IN DIFF GRINDING PATTERN

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 GRINDING SYSTEMS COMPARISON
SL Parameters Closed Ball mill HPG finish VRM
No circuit ball and HPGR mode
mill pre grinder
1 Impact ant Compressio Compressio Compressio
attrition with n in RP & n in RP n and shear
the grinding attrition in
balls ball mill
2 Feed size 90% passing Up to 2 Up to 2 Upto75mm
25mm sieve times of gap times of gap
width width

3 Air Flow Low Low Low High

4 Nos of auxiliary More More Less Less

equipments
5 Maintenance Low High High Medium

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 COST ESTIMATION OF DIFFERENT GRINDING SYSTEM

 Ball mill with closed circuit : X INR (X given as an example

unit).
 Vertical roller mill (VRM) : 2.3-2.5 X (that is to say, 2.3-2.5
times more than ball mill)
 Roller press in finish mode : 1.8-2 X (that is to say, 1.8-2
times more than ball mill)
 Roller press with ball mill : 2-2.2 X (that is to say, 2-2.2 times
more than ball mill)

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 Ball Mill

Confidential Slide 18
 Ball Mill Internals

Confidential Slide 19
 Roller Press

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 Roller Press / ROLCOX Parameter List

Regulation gate in
minimum position 0 – 10 %
to open the slide gate
and feed material

minimum torque minimum torque

min. Motorpower min. Motorpower

minimum Gap
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Confidential Slide
 VRM

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 Cement Grinding with horomill

Confidential Slide 23
 Horomill

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 SPECIAL FEATURES OF VRMS
 Ability to handle a wide range of feed size & characteristics.
 Good operation stability even at high moisture level.
 Greater flexibility in control at product chemistry and
particle size.
 Low retention time
 Any desired corrections or changes in product size or
chemistry can be quickly achieved resulting in a better
quality.
 Combination of compressive and shear forces for highly
efficient grinding process.

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 ADVANTAGES OF VRM
 Lower electrical energy consumption
 High drying capacity, ability to utilize low grade waste gas
heat
 Functions of secondary /tertiary crushing , drying ,
classifying
 one compact machine
 Processing of abrasive materials possible
 Low noise level
 Short retention time of material - easy automation
 Small space requirement
 Availability / dependability /maintenance costs comparable to
other alternatives

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 Why Energy Saving Measures Required In
Grinding Process
Grinding section (Raw material and coal and clinker) sections
consume the major share about 50-60 % of total electrical
energy consumption in a cement manufacturing process.
Experience has shown that the potential for optimization is
greatest in the cement grinding process in a cement plant
The benefits that can be achieved through optimizations are-
 Reduction in specific power consumption
 Increase in production
 Stable and sustained operation

 Increase in availability of the equipment - Less down time

 Improved and consistent product quality

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 GRINDING METHODOLOGY
 Grinding is performed by pressure and shear generated between
the rollers and the rotating table.
 The rotation of the grinding table accelerates the material towards
the grinding track and passes it under the rollers.
 Partially ground material passes over the dam ring encircling the
grinding table and into the hot gas stream coming from the nozzle
ring.
 The moisture in the materials is evaporated almost immediately
while the finer portion of material is carried by the gas stream to
the separator.
 Separator rejects oversized material and sends it back to the table
for further grinding. The coarsest faction of the material that spills
over the dam ring may fall through the nozzle ring and be
conveyed back to the feed material inject by a mechanical
recirculation system.
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 ADVANCEMENT OVER BALL MILLS
 40 % less sp. Energy consumption when compared to Ball Mills More
compact and occupies less space as well Separator integral part of mill.
 Most suited for drying-up to 20 % moisture More easy to control.
 More compact and occupies less space as well.
 Separator integral part of mill.
DISADVANTAGES OF VRM
 High pr. drop across the mill -Why ?
 75 % in louvre ring & 25 % in mill housing + classifier
 Pr. Drop high in louvre ring due to high gas velocity in the range of 45-55
m/sec
 High louvre velocity need to lift higher size material particle from table to
separator.
 Lower louvre velócity results in lower mill DP with higher rejects at mill
bottom

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 Factors Influencing Mill System Performance
 Grinding performance depends over material grindiability,
product fineness,mill operating parameters,roller
pressure,grinding table speed & gas flow rate
 Product output is found to increase with roller grinding
pressure & table speed. After a certain limit ,it may lead to
rougher running and increase mill vibrations
 Higher gas velocity causes higher pressure drop and high
wear rate.

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 False Air : As the roller mills operate under high negative
pressure, entry of false air in circuit is easy as well as
difficult to detect
 Major false air entry point includes dust collector, mill feed inlet, roller
bearings, sealings, pull rods, fan casing, mill outlet sealings etc.
 Air leaks into the mill in straight line & disturbs the gas helical flow,
reducing the gas flow effectiveness
 Starvation of air flow inside the mill leads to affecting mill capacity or
wastage of fan power.

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 Feed characteristics & bed stability :
 •i Soft material : These material reduces the friction force
between material and rollers . Addition of hard components is
likely to improve the mill performance
 ui set E e ed : This results in reduced frictional force between
rollers and table. By supplying higher thermal energy, this
 .situation can be corrected. VRM's can di’y up to 20 % of feed
moisture.
 th & fine material: This affects the bed stability. With higher fineness,
bed becomes fluid and can’t support the roller, It offer begins to slip
and discharges the material from table rather lisan roll over &
grinding it.
 t‹) To overcome the problem. Either dam ring height should be
increased or table speed should be reduced. Feed rate should d1so
be lowered and water spray should be used to stiffen the bed.
 t‹9 Hard components in feed: This results in an unstable grinding
bed and consequently unsteady running of the mill.
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 PROCESS AND NUISANCE DEDUSTING
FILTERS

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 WHY DUST CONTROL ?
 Reducing health hazard possibilities
 Assuring compliance with existing regulations
 Reducing cleanup and maintenance cost
 Reducing equipment wear and downtime
 IncreaJing visibility and reducing probability of accidents
 Reducing troubles in community relation
 More pleasant working condition thus improving employee
morale and productivity
 Possible product savings

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 FALSE AIR AND PRESSURE DROP
 Rule of thumb for false air in leakage:
V=0.90 * ( P )1/2 * A
V: actual false air flow (Nm3/s dry)
Dp: differential pressure over opening (Pa)
A: surface where false air enters (m2)

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 DESIGNE PROBLEM IN DUST CONTROL SYSTEM

 Vent hood: numbers/ design/location

 Dampers
 Ductwork (Diameter/ Branches/Insulation)
 Baghouse Inlet
 Deflection Plates inside the baghouse
 Fan Inlet
 Air velocity in hood must be 1.5-2.0 m/sec

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 MAIN DESIGN CONSIDERATIONS NUISANCE
FILTER
 Number of vent points: 8
 Ductwork inclination:
 min 60° for limestone, slag and cement min 50° for clinker
 min 70° for coal
 Conveying velocity in ductwork:
 › 16 m/s for slag and clinker (abrasive !)
 › 18 -20 m/s for other bulk solids
 Air to cloth (a/ c) ratio:
 1.5 m3/(m2*min) for raw material, cement
 1.2 m3/(m2*min) for slag, bypass dust, fly ash and clinker (1.0 for process filter)
 Can velocity:
 (1.0 for process filter, 0.8 for coal mill process filters)
 Number of bags per blow pipe: *=16

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