Cement Process & Energy Saving

October, 2006 The Energy Conservation Center, Japan Taichiro Kawase

Laos 2006.10 1

Bird-eye View of Japanese Cement Factory

Coal yard

Water

SP & calciner Waste tire yard Rotary kiln Raw mill crusher

Electrostatic Precipitator

Cement silo

Shipping pier

Layout of one Japanese cement factory

Laos 2006.10

Chemical Composition of Raw Materials and Cement Product

Raw Materials CaO(%) Limestone Clay Silica Iron-ore Gypsum 26-41 47-55 45-78 77-96 40-90 37-59 10-26 3-9 SiO2(%) Al2O3(%) Fe2O3(%) SO3(%) CO2(%) 37-43

Cements CaO(%) Portland cement Blended cement (BF slag) 63-65 52-58 SiO2(%) 20-23 24-27 Al2O3(%) 3.8-5.8 7.0-9.5 Fe2O3(%) 2.5-3.6 1.6-2.5 SO3(%) 1.5-2.3 1.2-2.6 others

Laos 2006.10

Temperature Profile in Wet Process Kiln

Temperature, 2000 Gas temperature 1000

Material temperature Drying Preheating Water content of raw meal : 38 40% Raw meal Kiln
Fuel

Calcining Sintering Zoning

Cooling Clinker temp : 80 100

Chain Curtain Zone: 20- 25% extension

Cooler Clinker

Figure 5 Temperature Profile in Wet Process Kiln Laos 2006.10 4

Chemistry of Cement Process

Heating () 100110 drying 110700 700750 750900 9501200 12001300 sintering 13001450 Vaporization of physically adsorbed water Vaporization of chemically bonded water Decomposition of MgCO3 Decomposition of CaCO3, Formation of 2CaOSiO2 Transition to 2CaOSiO2 Formation of 3CaOAl2O3, 4CaOAl2O3Fe2O3 Formation of 2CaOSiO2, Sintering of Al2O3, Fe2O3, Na2O, K2O, etc During a course of cooling, pebble-like black colored clinker is formed, which consists of the following components; cooling 3CaOSiO2 2CaOSiO2 150200 3CaOAl2O3 : referred to as Alite or C3S : referred to as Belite orC2S : referred to as aluminate phase or C3A

calcining

4CaOAl2O3Fe2O3 : referred to as ferrite phase or C4AF

Laos 2006.10

Raw Materials and Energy required for production of 1 ton of Cement

Energy Consumption Raw Materials (kg) Limestone Clay Silica Iron-ore Gypsum total 1,095 204 78 30 34 1,439 Coal Petroleum coke Combustible waste Heavy oil
Base : 1 ton of cement

Fuel (*1) Electric power (kWh)

105 99

(*1) : kg of coal equivalent where HHV of coal is 6,200 kcal/kg. Fuel by kind (%) 78 13 5 4

Laos 2006.10

Dry Process Kiln with Suspension Preheater (SPNSP)

Raw material Suspension preheater Kiln: Raw material is calcined and sintered by fuel burning. Calcining is CO2 removal reaction. Sintering is formation of molten clinker by heating. fuel exhaust gas cooler Pre-calciner: A part of calcining reaction is made in pre-calciner in modern NSP process. air clinker Cooler: Molten clinker is quenched by cold air.

(Suspension) preheater: Raw material (fine powder) is preheated in suspension state by hot gas coming from kiln.

(pre-calciner) exhaust gas

stack

stack

Electrostatic precipitator (EP): Dust-containing gases are dedusted in EP or bag filter.

SP EP F S

Suspension Preheater Electrostatic Precipitator Fan Stabilizer (conditioner) (Air Quenching) Cooler 7

Laos 2006.10

AQC

Cement Production Process

Dry Process
Silica Limestone Clay Slag

Finishing section Raw Material section

Water

Clinker Burning section Ordinary Kiln

Pelletizer

Clinker BF slag Heavy oil Coal Gypsum

Fly ash

Silica

Burner

Dryer Weigher

Cooler Burner

Crusher Raw Mill

Lepol Grate

Lepol Kiln
Cooler

Cement mill

Admix mill

Dryer

Blending Silo Weigher

Elec Generator Dust Collector WHB Cement Silo Weigher Mixer

Dry Powder Suspension preheater Water Slurry tank Mixer Burner

SP/NSP Kiln
Cooler

Cement Silos

Wet Process

Raw Mill Weigher

Filter

Shipping Burner Cooler tanker Bulk loader Packer Packer truckFreight ship car

Long Kiln

Packing center

Figure 1 Cement Production Process Laos 2006.10

Marketing

Factory 1

Heat Requirement in Burning Section

Kiln Shaft kiln Dry long kiln Wet kiln Lepol kiln SP kiln NSP kiln kcal/kg-cl 940 1,487 1,357 954 797 773 Source(1) Yogyo Kogaku H/B JCTA(1961) JCTA(1981) Nm3/kg-cl(2) 1.65 2.62 2.38 1.68 1.40 1.35

Note 1: JCA means Japan Cement Technology Association 2: Estimated based on 1.40 Nm3/kg-cl in SP kiln Factory 2

Laos 2006.10

Dry Process Raw Material Grinding System

a

a. Open Circuit Dryer and raw mill are installed separately. Dust made in milling is not recovered. b. Closed Circuit Separator is added. Coarse dust made in milling is separated and recycled to mill. Drying is done within mill.

EP Dryer Storage Dryer Heat generator b EP Collector Storage EP F : fan Collector BT & ST Raw mill Pre-heater Storage Separator BT : Blending tank ST : Storage tank EP : Electrostatic precipitator BT & ST Raw mill Pre-heater c Raw mill BT ST Pre-heater & kiln

Factory 1 ? Factory 2

c. Closed Circuit Energy-efficient vertical roller mill (VRM) is employed. VRM is also space-saving.

Figure 4 Dry Process Raw Material Section Laos 2006.10 10

Vertical Roller Mill

Lower part : Classifier

Upper part : roller mill

Vertical roller mill (VRM) is energy-efficient and also space-saving.

Laos 2006.10

11

Energy Management System (Cement Factory)

Aspect Organization Accountability Organization Monitoring Monitoring Targeting Technology Operation & maintenance (O&M) House keeping Major Activity Employee education (awareness) EE&C promotion committee Energy manager Data recording & reporting to employee Specific energy consumption (SEC) Key efficiency parameters Technical review (energy audit) Product yield (avoid off-spec product) Preventive maintenance (avoid unscheduled shutdown)

Laos 2006.10

12

Energy Saving Measures in Cement Factory

Raw material section First step 1)Selection of raw materials 2)Management of particle fineness 3)Management of grinding media 1)Replacement of fan rotor 2)Improvement of temperature and pressure control system 3)Improvement of mixing & homogenization system 4)Installation of closed circuit mill (separator) Clinker burning section 1)Prevention of unscheduled shutdown 2)Selection of fuel 3)Prevention of leakage 1)Use of industrial waste (waste tire, etc) 2)Heat recovery of pre-heater exhaust gas and cooler exhaust gas (drying of raw material and generation of electricity) 3)Replacement of cooler dust collection from multiclone to EP 1)Conversion of fuel from petroleum to coal 2)Conversion of SP to NSP 3)Conversion of planetary cooler to grate cooler Finishing section 1) Management of particle fineness 2) Management of grinding media 1)Installation of closed circuit mill (separator) 2)Installation of feed control system

Second step

Third step

1)Conversion from wet process to dry process 2)Replacement of ball or tube mill by vertical roller mill 3)Pneumatic transfer of raw material to mechanical transfer

1)Use of industrial waste (slag, pozzolan)

Laos 2006.10

13

Boundary of Heat Balance (Measurement)

Exhaust gas
F

Raw material
T T F O2 T

gas flow material flow Air leak

Pre-heater Section

T O2

Kiln Section
O2 F

1ry air Fuel oil

Cooler exhaust vent

Air leak
T

Cooler Section
T

Trial & Error Method

T T F

measured or assumed calculated

2ry air Clinker exhaust gas rate

Laos 2006.10

14

Prediction of Maximum Attainable Production Capacity (Tool : Heat Balance Method)

1 Principle of prediction: Production capacity is approximately proportional to exhaust gas rate which flows through kiln. Calculate exhaust gas rate at pre-heater exit or kiln exit (m3N/kg-cl) by heat balance method Compare with exhaust gas rate of well-designed kiln as shown below; - SP kiln with Grate cooler : 1.4 m3N/kg-cl - SP kiln with Satellite cooler : 2.0 m3N/kg-cl - Dry kiln : 2.6 m3N/kg-cl - Wet kiln : 2.4 m3N/kg-cl

2 3

Laos 2006.10

15

Air Leakage Measurement

possible air leakage combustion air fuel cooling air stack EP raw mill
O2 O2

preheater

kiln
F

cooler

O2

O2

Air leakage may bring about an increase of both fuel consumption and fan power consumption.

Air leakage occurred in kiln and pre-heater increases fuel consumption in order for heating leaked cold air up to process temperature.

However, air leakage in EP and raw mill does not normally increase fuel consumption, but it increases required power of fan motor.

Laos 2006.10

16

Calculation of Energy Loss due to Air Leakage

Location Burner Kiln Exit Preheater Exit Raw Mill Exit EP exit Leak Amount (m3N/h) 0 5530 8690 36340 57670 48.9(*1) 76.8(*1) 18.7(*2) 29.3(*2) 28.2(*3) 33.1(*4) Fuel Increase (kg-oil/h) Elec Power Increase (kWh/h)

Calc Equation of Fuel Loss : (*1) fuel = Leak (m3N/h) x 0.31 kcal/m3NdegC x (320 30) (degC) /10170 Calc Equation of Elec Power Loss : (*2) elec (kiln fan) = Leak (m3N/h)/60 x (320+273)/273 x 400mmAq /6120 /0.7 (*3) elec (RM fan) = Leak (m3N/h)/60 x (90+273)/273 x 150mmAq /6120 /0.7 (*4) elec (EP fan) = Leak (m3N/h)/60 x (130+273)/273 x 100mmAq /6120 /0.7 Note : LHV of fuel oil = 10170 kcal/kg P mmAq Kiln fan(50) Preheater(400) Raw Mill(150) EP(100)
Laos 2006.10 17

Monitoring of SEC & Key Variables

Section Raw Mill Clinker Burning Cement Mill Monitored Item SEC = Electric Power / Raw Material Charge SEC = Fuel / Clinker production O2% of Kiln Exhaust Gas SEC = Electric Power / Cement Production Unit (kWh/kg-raw matl) (kcal/kg-cl) (%) (kWh/kg-cement)

Laos 2006.10

18

Recording of SEC on the Graph

Watch raw mill SEC daily and add grinding balls in right timing 10% energy saving expected
SEC should be monitored daily, and when SEC arrives at certain level, grinding balls is compensated. Ball diameter shrinks as time passes due to erosive effect. This leads to gradual increase of raw mill SEC.

Addition of Grinding Balls

Raw mill SEC (kWh/kg-matl)

Filling level of grinding balls is also important in grinding efficiency. Optimum level of filling should be maintained.

Oct.2

Oct.9

Oct.16

Oct.23

Oct.30

Nov.6

Laos 2006.10

19

Example of Monitoring Sheet (Wet Process)

Eng. unit Raw Material Charge Clinker Production Cement Production Elec Cons in Raw Mill Fuel Cons in Kiln Elec Cons in Cement Mill O2 in Kiln Exhaust Gas SEC of Raw Mill Sect. SEC of Kiln Sect. SEC of Finishing Mill Sect. ton/d ton/d ton/d kWh/d 103xkcal/d kWh/d vol% kWh/kg-rm kcal/kg-cl kWh/kg-ce 10/2 760 500 520 38000 750 36000 4.5 50 1500 69.2 10/3 10/4 10/5 10/6 10/7 10/8

Laos 2006.10

20