International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249-6890; ISSN (E): 2249-8001
Vol. 7, Issue 6, Dec 2017, 203-212
© TJPRC Pvt. Ltd.

A REVIEW ON THERMODYNAMICS ANALYSIS AND WASTE ENERGY

UTILIZATION IN CEMENT INDUSTRY

SACHIN VERMA1 &. SUDHIR Y KUMAR2

1
Research Scholar, College of Engineering and Technology Mody University Rajasthan, India
2
Associate Professor College of Engineering and Technology Mody University Rajasthan, India
ABSTRACT

In India, cement manufacturing process consumes about 15-20% energy among all the energy consuming
industries. Reduction in energy consumption in cement production process is the prime concern. Therefore, detailed review
on the energy use and reserves is essential to find out energy wastage so that essential actions could be applied to decrease
energy consumption. In this paper energy use at different sections of cement industries based on the thermodynamic
analysis specially Exergy analysis, alternative fuel used for cement kilns, various energy savings measures were reviewed
and presented.

KEY WORDS: Exergy Analysis, Cement Industries, Optimization Techniques For Energy Savings Etc

Original Article
Received: Sep 08, 2017; Accepted: Sep 28, 2017; Published: Nov 08, 2017; Paper Id.: IJMPERDDEC201722

INTRODUCTION

India’s cement industry accounted for over six percent of the world’s annual cement production.
Throughout the years innovation in the cement manufacturing technology, has created with a developing spotlight
on manageable and furthermore cost and vitality effective generation. While huge strides may not appear to be
noticeable on a year to year premise in Indian cement industry. Industrial sector energy consumption varies from
30% to 70% of total energy used in India. A generous amount of energy consumed in manufacturing of cement.
[1]Thermal energy consider around 20–25% of the total cement production cost. The typical electrical energy
consumption of a modern cement plant is about 110–120kWh per tonne of cement. Thus concentrate ought to be
given on the diminishment of vitality and vitality related ecological discharges. It is important to discover the
vitality misfortunes and limit it to bring down the vitality utilization. The Thermodynamic examination is the best
instrument for streamlining. [3, 5, 6]

Thermodynamic Analysis and Optimization

Energy consumption represents the largest part of the production cost for cement factories and has a
significant influence on product prices (Stanislav Boldyryev, 2016); the major part of the CO2 emissions from the
production of cement is released from the calcinations of limestone (50%) and from the combustion of fuels (40%).
[7]Waste heat recovery systems are already in operation in various industries with success. In Canada, the Gold
Creek Power Plant [17] has a heat recovery system that produces 6.5MWpower using ORC technology. In India, the
A. P. Cement Works with 4 MW and ORC technology is Heidelberger Zement AG Plant, in Lengfurt (Germany)
[17] with 1.5 MW power and ORC technology. Another cement industry that uses waste heat recovery (S. Karellas,

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204 Sachin Verma &. Sudhir Y Kumar

2013)

Keeping in mind the end goal to decrease energy utilization in concrete creation process, the cogeneration control
plant can recuperate the waste warms to create electrical energy with no extra fuel utilization and along these lines
diminish the high cost of electrical energy and CO2 emanations for bond generation. Since the waste heats in cement plant
are classified as middle and low temperature waste heat, several power plants are particularly well suited for these waste
heats available, [9] such as single flash steam cycle, dual-pressure steam cycle, ORC and the Kalina cycle. (Jiangfeng
Wang, 2009)

To carry out a thermo economic analysis, the first step is to define the configuration of the system, which is also
known as process flow diagram. The second step is the exergy analysis of the system, in order to calculate the exergy of
each flow. The last step is the thermo economic analysis of the system, in which unit exergy costs of each process are
calculated among other parameters. Processes which are characterised by having high unit exergy costs will be the less
efficient [11, 12, 13]

Exergy examination is a present day investigation device, which is utilized for building forms. Exergy
investigation is identified with both the primary law and second law of thermodynamics. [14] The primary reason for
exergy investigation is, to distinguish the reasons for the defect of a vitality transformation process. Exergy investigation
prompts a superior comprehension of the impact of thermodynamic procedures, on the procedure adequacy, correlation of
the significance of various thermodynamic elements, and the assurance of the best methods for enhancing the procedure
under thought [8]. A superior comprehension of locales of exergy decimations can help enhance the framework operation
and help in better plan and advancement. A higher exergetic execution of a framework converts into vitality funds and
ecological advantages. [15-20]

There have been many investigations about the cement part. Among them, there are vital and deductive papers,
demonstrating both vitality way to deal with the cement industry and the possibilities and methods for development in
vitality utilization of cement industry.

Table 1: Review Based on Thermal Analysis of Cement Manufacturing Process

Author Objective Methodology Conclusion
Jiangfeng Exergy analyses and Single flash steam cycle, dual- The exergy losses in turbine,
Wang, parametric pressure steam cycle, organic condenser, and heat recovery vapor
2009 optimizations for Rankine cycle (ORC) and the generator are relatively large, and
different cogeneration Kalina cycle are used for reducing the exergy losses of these
power plants in cogeneration in cement plant. components could improve the
cement industry The exergy investigation for performance of the cogeneration
every cogeneration framework is system.
inspected, and a parameter Contrasted and different frameworks,
enhancement for every the Kalina cycle could accomplish the
cogeneration framework is best execution in bond plant.
accomplished by methods for
hereditary calculation (GA) to
achieve the greatest exergy
productivity.

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A Review on Thermodynamics Analysis and Waste Energy Utilization in Cement Industry 205

Stanislav The improved heat The authors analyzed the energy The energy consumption of the cement
Boldyryev, integration of cement consumption of a particular factory can be reduced by 30%, with an
2016 production under cement factory accomplish the estimated recovery period of 3.4
limited process best execution in bond plant. months. The execution of this retrofit
conditions: A case venture helps the plant's productivity
study for Croatia and enhances the natural effect of the
concrete assembling process.
S. Karellas, Energetic and Examine and compare A parametric study proved that the
2013 exergetic analysis of energetically and exergetically, water steam technology is more
waste heat recovery two different WHR (waste heat efficient than ORC in exhaust gases
systems in the recovery) techniques: a water- temperature higher than 310˚C. Finally
cement industry steam Rankine cycle, and an a brief economic assessment of the
Organic Rankine Cycle (ORC). most efficient solution was
implemented. WHR establishments in
concrete industry can contribute
fundamentally in the lessening of the
electrical utilizations working cost
along these lines being an extremely
alluring venture with a payback period
up to 5 years
Vedat Ari, Energetic and Energetic and exergetic analyses The energy and exergy efficiencies of
2011 exergetic assessments of an existing rotary kiln system the existing system are 54.9 and 28.1%,
of a cement are presented, and first and respectively. With the cogeneration,
rotary kiln system second law efficiencies are these exergy efficiencies have been
calculated. obtained to be 70.6% for the use of
waste heat recovery steam generator
(WHRSG) and 81.5% for the use of
heat to pre-heat the raw material,
respectively, which dictates a
remarkable improvement over the
existing system
Ahmet Energy and exergy A mathematical model related to The first and second law efficiencies
Kolip and analyses of a parallel energy and exergy balance for were 51 and 28%, respectively. Total
Ahmet flow, four stage four-stage cyclone precalciner exergy loss of the system was found to
Fevzi cyclone precalciner type cement plant is developed. be about 72%.
Savas, type cement plant The energy and exergy balances
2010 for the whole system and each
unit are calculated and presented.
Adem Reducing energy The first and second law analysis The specific energy consumption for
Atmaca consumption of a raw of a raw mill is performed and farine production is determined to be
Mehmet mill in cement certain measures are actualized in 24.75 kWh/ton farine. The use of an
Kanoglu, industry a current crude plant in a bond external hot gas supply provides 6.7%
2012 production line keeping in mind reduction in energy consumption
the end goal to decrease the corresponding to a saving of 1.66 kWh
measure of vitality utilization in per ton of farine production
crushing procedure.

The impacts of surrounding air

temperature and dampness
substance of crude materials on
the performance of the raw mill
are investigated
DAN Extended Exergy Exergetic efficiency and CO2 Some preliminary results are presented
SONG Accounting For emission targeted at a typical
BIN Energy Consumption cement production line are
CHENA and CO2 Emissions of examined in detail with key
2016 Cement Industry—A factors of mitigation being
Basic Framework identified.

www.tjprc.org [email protected]
206 Sachin Verma &. Sudhir Y Kumar

the future emission trends are

simulated based on dynamic
prediction with different
optimization scenarios in view of
current mitigation targets
Tahsin Energy auditing and The energy audit analysis of a dry About 40% of the total input energy
Engin, recovery for dry type type rotary kiln system working was being lost through hot flue gas
Vedat Ari, cement rotary kiln in a cement plant in Turkey. The (19.15%), cooler stack (5.61%) and
2005 systems––A case kiln has a capacity of 600 ton- kiln shell (15.11% convection plus
study clinker per day radiation). Some possible ways to
recover the heat losses are also
introduced and discussed. Findings
showed that approximately 15.6% of
the total input energy (4 MW) could be
recovered.
C. Exergy analysis of involves assessment of energy It is found that 50% of the exergy is
Koroneos, cement production and exergy input at each stage of being lost even though a big amount of
2005 the cement production process waste heat is being recovered.

Laila M. Energy and exergy Exergy Analysis Energetic efficiencies of the plants
sFarag, analyses of Egyptian were found to vary between 41.6 % and
Anter G. cement kiln plants 55.5% and their exergetic efficiencies
Taghian, between 26.8% and 35.6%
2015 respectively. Energy lost with bypass
gas and dust ranges from 724.3kJ/kg
clinker for the least efficient process to
200.2 kJ/kg clinker for the highest
efficient one corresponding to 16.6% to
6.1% of the total heat input
respectively.
G. Kabir, Energy audit and Thermal energy audit analysis Thermal efficiency of the unit stands at
A. I. conservation was employed, on the pyro 41%, below 50–54% achieved in
Abubakar, opportunities, for pyro processing unit of the cement modern plants. The exhaust gases and
U. A. El- processing unit of a plant kiln shell heat energy losses are in
Nafaty, typical significant quantity, amounting to
2010 dry process cement 27.9% and 11.97% of the total heat
plant input respectively.
Power and thermal energy savings of
42.88 MWh/year and 5.30 MW can be
achieved respectively. Financial
benefits for use of the conservation
methods are substantial. Environmental
benefit of 14.10% reduction in
Greenhouse gases (GHG) emissions
could be achieve
M. G. Assessment of the model is developed on the basis The thermal energy conservation
Rasul, thermal performance of mass, energy and exergy opportunities are identifiedThis
2005 and energy balance and is applied to an investigation demonstrate that by
conservation existing Portland cement industry supplanting industrial diesel oil (IDO)
opportunities of a in Indonesia with squander warm recuperation from
cement industry in oven and cooler fumes for drying of
Indonesia crude feast and fuel, and preheating of
burning air, a security industry in
Indonesia can save around 1.264 ×105
US dollars for each year.

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A Review on Thermodynamics Analysis and Waste Energy Utilization in Cement Industry 207

Ziya Energy and exergy Determine the actual energy Efficiencies (energy/exergetic) of the
Sogut, investigations in a losses by performing energy and processes for the raw mill, the rotary
Zuhal warm procedure of a exergy analyses and to evaluate kiln, the trass mill and the coal mill on
Oktay, creation line for a energy and exergy efficiency in the production line have been found as
2008 concrete each process for the cement 84%/25%, 61%/49%, 74%/13%,
manufacturing plant factory. In these examinations, 74%/18%, respectively.. What's more, a
and applications for each procedure energy and few proposals concerning the
exergy graphs have been diminishment of energy misfortunes
constituted on the creation line. have been proposed.
M. Z Energetic and The main objective of this study The overall exergy efficiencies are
Sogut,Z exergetic assessment is to assess the performance of a found to be slightly less than the
OKTEY,A of a trass mill process trass mill in a cement plant based corresponding energy efficiencies; e.g.
Hepbasli20 in a cement plant on the actual operational data 74% and 10.68% for energy and exergy
09 using energy and exergy analysis efficiency, respectively.
method Using energy recovery systems, waste
heat energy may be captured, while
energy and exergy efficiency values
can be improved to 84% and 48%,
respectively.
Ziya Impact assessment of An exergy analysis is carried out Annual averages of the exergy
Sogut, CO2 emissions caused for all of the thermal processes of efficiency of the kiln and its exergetic
Zuhal by exergy losses in the the cement plant. Then exergy improvement potential are found as
Oktay, cement sector losses and carbon dioxide (CO2) 48.5% and 110.58 GJ/h, respectively.
2011 emissions of the rotary kiln In this system, CO2 emissions caused
process taken exemplary by exergetic losses are calculated for
according to annual dead state the coal mixture and the natural gas as
temperature changes are an average of 38,004 kg/h and 12,668
determined. kg/h, respectively. Toward the finish
of the examination, a few proposals
concerning lessening of the
worldwide impacts for these
frameworks are made..
Ziya Mathematical In this study, heat recovery from Ss
Sogut, modeling of heat rotary kiln was examined for a
Zuhal recovery from a rotary cement plant in Turkey. At initial,
Oktay, kiln an exergy investigation was
Hikmet completed on the operational
Karakoç, information of the plant. A
2010 mathematical model was
developed for a new heat
recovery exchanger for the plant
Zafer Utlu, Energy and exergy Perform energy and exergy Proposed as a valuable instrument in
Ziya analyses of a raw mill analysis of a raw mill (RM) and the examination of vitality and exergy
Sogut, Arif in a cement production raw materials arrangement unit in use, creating vitality strategies and
Hepbasli, a bond plant in Turkey utilizing giving vitality preservation measures.
Zuhal the genuine operational
Oktay, information.
2006
G. V. Parametric analysis of A case study has been conducted The recognized key operational
Pradeep steam flashing in a at a cement factory, Telangana, parameters are steam producing weight,
Varma T. power plant using India with cogeneration plant point of confinement to high weight
Srinivas, waste heat of cement having flashing technology. blazing, breaking point to low weight
2016 factory glimmering and blaze mass proportion
Energy Recovery from Waste to Utilize in Cement Plant

The cement manufacturing process is an energy exhaustive process. It yields weighty pollution and utilizes large
amounts, on non-renewable resources. With increasing pressures to reduce greenhouse gas emissions, due to cement

www.tjprc.org [email protected]
208 Sachin Verma &. Sudhir Y Kumar

manufacture, research and development of fuel alternatives and their effect on the manufacturing process, has become an
industry focus. The cement industry is a Resource Intensive Industry (RII), with use of large quantity of natural resources
as Raw materials and Fuels. [21-22] The known fossil fuels and more importantly Coal, which is the primary fuel for
Indian cement industry is fast depleting, it is imperative to look for alternatives. The cement industry is capable to co
process wastes as alternate fuels and raw materials, to reinforce its competiveness and at the same time, contribute to
solutions to some of society’s waste problems in a way, which valorises the waste and is beneficial to the environment.[24]
The different studies done by different researchers are tabulated in Table 2 and 3, on the same era.

Table 2: Recent Studies Based on Energy Recovery from Waste to Utilize in Cement Plant
Author Objective Methodology Conclusion
K.T. To meet the Simulation of three alternative Among the selected fuels used,
Kaddatz, requirements of fuels, namely spent carbon lining, industrial lubricant is found to be the
et al. 2013 testing and used industrial lubricants and best option regarding the CO2
implementing used tires, for identifying the emission, while the spent carbon lining
selected most effective fuel source among is the worst one. In contrast, feed
alternative fuels. these three. material requirements can be reduced
Aspen Plus software was initially by up to approximately 15% by using
selected to model the cement spent carbon lining
manufacturing process
Emad Evaluate the air This paper introduces the re- Simulation results revealed that the
Benhelal, pollution enactment of concrete process substitution of fuel oil, natural gas and
Alireza reduction through utilizing elective energizes to palm kernel shell for coal had a critical
Rafiei fuel substitution supplant coalPyro-processing commitment for emanation decrease in
2012 of coal with fuel stage of the conventional cement concrete industry.
oil, natural gas manufacturing process was
and palm kernel simulated by Aspen HYSYS
shell.
U. The goal is to In order select a suitable Dependence of process performance
Kaantee optimise process alternative fuel, a commercial on the amount of combustion air is
et al 2004 control and modelling tool (ASPEN PLUS) is clearly demonstrated
alternative fuel used to model the four-stage The vitality demand of the procedure
consumption, preheater kiln system of a full- could be anticipated for differing fuel
while maintaining scale cement plant using petcoke blends
clinker product as fuel.
quality Counts with elective fills are
finished by incompletely
supplanting the essential or
auxiliary fuel. Meat and bone
meal (MBM) and sewage slime
are considered
Azad Aspen Plus based A process model of the pre heater That maximum 3% increase of energy
Rahman simulation for tower is developed using Aspen efficiency and 2.5% reduction of CO2
et al 2014 energy recovery Plus simulation software based on can be achieved by using tyre for
from waste to the combustion mechanism. about 25% of thermal energy
utilize in cement The model is verified against requirement. Recreation comes about
plant pre heater measured data from industry and displayed in this paper offer a rule for
tower data available in the literature. actualizing chose squander inferred
powers in bond industry.
Seyed Ali Exergetic and The burning system of the cement it was shown that the secondary burner
Ashrafiza environmental production (kiln & pre heater) application can reduce the exergy
deh et al, performance process was simulated in four losses about 25 percent, which leads to
2012 improvement in thermal areas. a reduction of the greenhouse gases of
cement production about 35000 cubic meters per year for

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A Review on Thermodynamics Analysis and Waste Energy Utilization in Cement Industry 209

process by driving each ton per day of clinker production

force distribution

Table 3: Different Industrial Waste used as Alternative Fuel in Cement Production

Fuel Suitability Reference
Spent carbon • Its ability of offset a portion of the feed material
lining required
• Limited though by its sodium content
• Easiest to execute as the capacity, taking care of and
nourish necessities are fundamentally the same as that for coal
and would require negligible changes.

Used industrial • Energy content for the used lubricants analysed was the
lubricants high
K. T. Kaddatz,
• Produced the low overall carbon dioxide emissions
et al. 2013
• The co ordinations of utilizing waste ointments is
genuinely straightforward and would require insignificant
changes to the present plant Largest adjustment would be the
range required for the capacity, pumping and mixing
Used tires • The tires had a high energy content allowing them to
provide a better emissions profile than coal.
• The biggest shortcoming with utilizing this alternative is
that tires requires a convoluted taking care of setup which
regularly incorporates a lot of manual taking care of.
Fuel oil • Second largest pollution emitter after coal since
produces 31,400 kg/h CO2 and was the first SO2
producer.
Palm kernel • Reduced 46.16 % of CO2, 73% of NO2 and 68% of SO2 Emad
shell emissions as compare to burning coal. Benhelal,
Alireza Rafiei
2012
Natural gas • Mitigated 45.64 % of carbon emissions and produced
neither NO2 nor SO2.

Meat and bone • The air demand is higher with the new fuel than for the
meal (MBM) coal, it means that the kiln fans must run at higher speed U. Kaantee et
and Sewage to supply the bigger air sums. Then also the exhaust gas al 2004, Azad
sludge amounts are larger, which will affect the whole function Rahman 2014
of the pre-heating system as a whole.

CONCLUSIONS

Cement manufacturing is an energy intensive process. This review paper explains Thermodynamic analysis of
cement manufacturing plants along with use of alternative fuels or waste heat recovery was analyzed by various
researchers. Amongst the different segments, grinding consumes about 60% of total energy consumption in a cement plant.
Energy loss is maximum in grinding process. Therefore, enhancements can be made in this section to decrease heat loss or
recycle heat. Use of alternative fuels or waste heat recovery could be a good solution. However, challenges associated with
the use of alternative fuels must be overcome. This could be a potential area for future research and development.

www.tjprc.org [email protected]
210 Sachin Verma &. Sudhir Y Kumar

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