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STUDY AND ANALYSIS FOR THE EFFECTS OF POWER FACTOR CORRECTION IN

AL-NAJAF CEMENT PLANT

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 Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

STUDY AND ANALYSIS FOR THE EFFECTS OF POWER

FACTOR CORRECTION IN AL-NAJAF CEMENT PLANT
M.Sc. Haider Muhamed Umran
University of Karbala
College of Engineering - Electrical and Electronic Engineering Department
[email protected]
Received 27 October 2014 Accepted 24 December 2014

ABSTRACT
The quality of an electrical power plays an important factor in any industrial process, these factors
relate to the economic and technical benefits. The cement industry used many of the miscellaneous
equipment's, which are classifying as non-linear loads such as induction motors, transformers and
etc. The electrical equipment's are absorbing additional currents called "inductive reactive currents";
the effects of additional currents making electrical network inefficient, result of reducing the power
factor. However, the low power factor will affect the increase the loads on the power station on the
one hand and on the efficiency of the equipment's, capacity of transformer's, sizes of cables and
capacity of switchgears on the other hand this in relation to the cement plant.
In this paper, the effects of low power factor on main motors which use in AL-Najaf cement plant
analyzed, such as raw material mill, cement mill and the clinker cooler. The necessary reactive
power for the capacitor bank calculated according to practical readings for equipment's information
that printed on the name-plates, by using two methods for calculation (the mathematical equations
and table of factor K). The influence of power factor correction on the motors, transformers and
sizes and losses of electrical cables calculated. The advantages of power factor correction are
analyzed for economic and technical sides.

Keywords: Reactive power, Cement plant, Maine equipment’s, Power factor correction,
Motors.

.‫دراسة وتحليل تأثيرات تصحيح عامل القدرة في معمل سمنت النجف‬

‫حيدر محمد عمران‬
‫كلية الهندسة‬/ ‫جامعة كربالء‬
‫قسم الهندسة الكهربائية و االلكترونية‬
:‫الخالصة‬
‫ تستخدم‬.‫ تتعلق هذه العوامل بالمنافع االقتصادية و التقنية‬،‫ي عملية صناعية‬ ّ ‫تلعب نوعية الطاقة الكهربائية عوامل مهمة في أ‬
‫ تعمل‬.‫ الخ‬..‫صناعة السمنت العديد من معدات المختلفة و التي تصنف كأحمال غير خطية مثل المحرّكات الحثية و المحوالت‬
‫ ان تأثيرات هذه التيارات االضافية هو‬،"‫المعدات الكهربائية على امتصاص تيارات اضافية تدعى " التيارات الحثية غير الفعالة‬
‫ ان معامل القدرة المنخفض سيؤثر على زيادة‬،‫ على أي حال‬.‫جعل الشبكة كهربائية غير كفوءة نتيجة النخفاض معامل القدرة‬
‫الحمال على محطة الطاقة الكهربائية من ناحية وعلى كفاءة األجهزة و على سعة المحوالت و حجوم القابلوات و سعات قواطع‬
‫ تم تحليل تأثيرات انخفاض معامل القدرة على‬،‫ في هذا البحث‬.‫الدورة الكهربائية من ناحية اخرى هذا فيما يتعلق بمعمل السمنت‬
‫االمحركات الرئيسية المستخدمة في معمل سمنت النجف مثل محرّك طاحونة المواد االولية و محرّك طاحونة السمنت و محرّك‬
‫ لقد تم احتساب القدرة غير الفعالة الضرورية لمصرف المكثّفات اعتماداً على القراءات العملية للمعلومات المطبوعة‬.‫مبردة الكلنكر‬
‫ تم احتساب تأثير تصحيح معامل القدرة‬.)K ‫على لوحات التسمية لألجهزة بطريقتين (المعادالت الرياضية وإستخدام جدول العامل‬
‫ تم تحليل فوائد تصحيح معامل القدرة من الناحية االقتصادية و‬.‫على المحركات و المحوالت و حجوم و خسائر القابوات الكهربائية‬
.‫التقنية‬

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 Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

Nomenclature:

IR: Active Component of Current.

S1, S2: Apparent Power Before and After Power factor Correction.

P1, P2: Active Power Before and After Power factor Correction.

Q C (Actual): Actual Reactive Power.

C: Capacitor.

ESP: Electrostatic Precipitator.

P1Losess, P2 Losses: Power Losses Before and After Power factor Correction.

P.F.: Power Factor.

IQ: Reactive Component of Current.

QC: Reactive Power.

Q1, Q2: Reactive Power Before and After Power factor Correction.

QC Total: Total Reactive Power.

θ: Displacement Angle.

η%: Efficiency of Motor.

∆P Losses: Reduction in Power Losses.

1. INTRODUCTION
In recent years, increasing attention has been paid to minimize the cost of energy and inefficiency in
electricity generation, transmission and distribution especially in industrial applications. The
machineries and equipment which using in cement industry are electrical motors, pumps,
compressor, transformers, fans, blowers, conveyors, kilns, transportation, lightings and others.
These machines consume different forms of energy according to the cement manufacture processes.
The electrical power received from the high voltage or medium voltage grid has to be distributed to
the medium and low voltage loads. This power has to be transformed to the medium voltage level
for supplying a large drives; and then by distribution transformers to the low voltage level for
smaller drives. The large numbers of electric drives makes the operation of these drives and their
power consumption a significant cost factor.
The active and reactive power consumption and harmonics influence on operating costs and
efficiency of drive systems, transformer and the cable losses. Therefore, the power factor and
harmonics play major role, in improving of the machineries and equipment performance and reduce
the cost of power consumption. In all electrical equipment the active power only be useful, whereas
the reactive power does not make any useful contribution but it causes additional voltage drops and
power losses which appear in the form of heat [5].
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There are many researches have been done in the power factor improvement in cement factory.
However, JBV, et al. [6] proposed thyristor switched capacitor to improve power factor in windmill
power plant and used MATLAB software tool to obtain on results. Ahrens, et al. [8] designed of
harmonic filter and power factor compensation installations by several approaches in cement plants.
Gonzalez, et al. [3] designed the shunt filters to minimizing voltage distortion caused by nonlinear
loads in industrial power systems. Jain, et al. [5] use the switches bank to correct the power factor
through generating the locally necessary reactive energy for the transfer of electrical useful power.
Nikolic, et al. [2] designed and implemented of measuring and information system for analysis of
power quality in compliance with EN 50160 in different points of power supply network.
Osafehinti, et al. [16] highlighted the methods of power factor correction in improving electricity
supply and generated a table to determine a multiplying factor for all range of the power factor
correction in the industrial environment. Khalid, et al. [12] presented the power quality problems,
issues, related international standard, and effect of power quality problem in different apparatuses in
Industry and methods for its correction. Onohaebi, et al. [15] studied the power factor correction in
improving the efficiency of energy consumption in industries using a medium scale industry in
Nigeria as a case study and an overview for power factor correction method and collection of
various data relevant.
In this paper, the electrical energy flow, effect of harmonics and the main parts of the for Al-Najaf
cement plant are illustrated. The calculations of reactive power is focusing on the big from electrical
motors, transformers, electrical cables and power losses in these cables, because they most effective
on the power factor. These calculations are based on the practical readings for the equipment's. The
controller on the power factor correction discussed and the necessary reactive power is calculated.

2. ELECTRICAL ENERGY FLOW AND MAIN EQUIPMENTS FOR FACTORY

The process of operation of Al-Najef cement plant is called wet process. The main equipment's of
cement plant are classified according to the production stages. Therefore, the electrical energy flow
in a process of cement production as shown in Fig.1.
The electrical energy is not uniform and in some situations require to convert from AC to DC
according to the equipment's use in process of cement production. The rated powers of the main
equipment's for the factory set out in the table 1.
The electrical power supplies to the factory through one feeder line to the distribution main station
by 33 kV. The main power station consists of power transformer with 5 MVA rated power 33/11kV
and three main switch with rated 11kV - 630A. The electrical substation includes a number of step-
down transformers to supply the loads by 3.3kV and 400V.
In this research, the calculations were achieved only on the main equipment's, such as: motors of
the raw mill, the cement mill, the cooler and on some transformer's. Because they much effective in
draw of reactive power if compared with other equipment's.

3. HARMONICS
Most the loads which are used in cement factory have resistive and reactive impedances therefore
they called by non-linear loads and absorb non-sinusoidal current. These currents will increase the
load on the electrical station switchgears and distribution network on the one hand and on the
consumer's equipment's on the other hand. Therefore they are causing in voltage drop of non-
sinusoidal type from the supply side of electrical network. In consequence the linear loads will
supply by distorted voltage [8], the fundamental and harmonics waveforms are shown in Fig. 2.
According to the Fourier theorem, an ideal sinusoidal waveform does not present any harmonics for
different order from the fundamental wave. Therefore the presence of harmonics in electrical
system is an indication of distortion of voltage or current waveform and this increases the value of

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total harmonic distortion THD, and may cause disabling equipment's [17], the effects of harmonics
on the equipment’s are summarized in table 2.

4. POWER FACTOR
The main effective equipment's which using in cement factories are inductive loads. Furthermore in
an AC electrical power system the value of total power (the apparent power) which drawn from the
electrical station depends on the nature of the connected loads. The apparent power (currents which
absorbed by loads) can analyze to two components: the active component (IR), which be in phase
with the supply voltage, is directly related to the output the part of electric energy converted into
different types from energy such as mechanical energy, light energy, thermal energy…etc.; and the
reactive component (IQ), in quadrature to the voltage, is used to generate the flow necessary for the
conversion of powers through the magnetic fields to produce flux necessary for the operation of
induction machines and other. In this case of loads the total current (I) lags with respect to the active
component (IR). Anyway define of a power factor cos θ, as the ratio between the active component
(IR) and the total value of the current (I) as in Eq. 1, [1].

The phase angle θ is the angle between the voltage and the current or between the apparent power
(S) and active power (P) which are shown in Fig. 3.
In cement factory, the range of power factor is between of 0.7 to 0.8. This means that a 1MVA
transformer can only supply 700 – 800 kW or the loads can draw only 70 - 80 useful Amps from a
100Amp supply. So, improving the power factor means supplying the necessary reactive power to
getting on active power or reduce the amount of wasted power (reactive power).

5. REACTIVE POWER CONTROLLER

The power factor compensation system is essential to its application in electrical systems, according
to the used machines work cycle which have different electrical characteristics. Capacitor banks are
used much to get the corrected power factor. These capacitor banks are operate and controlling it by
automatic control relay. The relay maintain the system of power factor at a set value under
fluctuating load conditions, by connecting or disconnecting capacitor banks to the 415V bus. The
automatic compensation system is formed from some of detection sensors to detecting the current
and voltage signals. The micro-controller comparing the measured power factor with the desired
value and then, connecting and disconnect the capacitor banks. The electric board contains
switches, protection devices and alarm signals. The circuit diagram of the relay as illustrated in Fig.
4. [7].

6. CALCULATION OF REACTIVE POWER

In this paper, calculations of the required capacitor to improve the power factor are achieved on the
main equipment's. There are two methods to calculate the necessary capacitor bank to obtain a
defined power factor by using mathematical analysis and table of coefficient K (KVAR/kW) [4,
10].

6.1. Calculations of Reactive Power for Motor of Raw Mill

The type of raw mill drive is slip ring with the following specifications according to name plate:
(50Hz) line frequency, (3300V) three phase voltage, (970kW) rated power, (0.84) power factor and
(212.5A) rated current. The power factor will improve up to (0.94) and will watching the effect of

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 Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

this improving on the motor efficiency. The calculation of the reactive power as first step as in the
following:

Where,

The reactive power per phase is calculate as in Eq. 3:

In a 3-phase system, the capacitor bank consisted by three capacitors having the same capacitance
value and can be connected delta or star as shown in Fig. 5. In this case, the capacitor bank
connected in delta mode, to get a small size of the capacitances of each phase [13]. Therefore, the
total value of reactive power is calculated as in Eq. 4.

The value of the capacitor can be calculated according to the accurate value for reactive power. The
practical efficiency of the motor calculates depending on the ratio between actual current (I1) to
rated current (in name-plate) for motor as in Eq. 5:

Now, the accurate (actual) value for reactive power is:

The value of capacitor is calculating as in Eq. 8:

The calculating the value of current which had drawn from the motor of the same rated power after
factor improvement as:

The saving in current about (21.46 A) and the apparent power reduce as shown in Eq. (10 & 11).

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 Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

The reactive power reduces as shown in Eq. (12 & 13).

Active power is calculating before and after power factor improving as:

The apparent and reactive power reduced, while the value of active power still constant. However,
the saving in current is (21.6A). The connection diagram for the power factor correction with the
motors is shown in Fig. 6.

6.2. The Raw Material Mill Feeding Cable Size Calculations

The benefits of improving power factor are not only limited in improving of the motor performance
and the exploitation of active power fully, but also it exceeding to optimal use of the electrical lines
[1]. The feeding cable to the raw mill is calculated according to the rated power of the load (motor).
Where, the effect of improving of power factor on current carrying capacity for cable is clarified
through the calculations below. If is take into account the impact of starting current and effects of
other factors on cable capacity, the cable is designed for carrying current the limits of (344.4A) with
(0.84) power factor. Under standard conditions, the cross sectional area for XLPE/EPR cable which
chosen is (120 mm2), depending on the current carrying capacity (I) of copper cables as in table 3.
Now, the new value of current with (P.F = 0.94) and for the same consideration's, is (307.8 A).
With this value of current, the cross - sectional area becomes (95 mm2).

6.3. The Raw Material Mill Feeding Cable Losses Calculations

The effect of improving power factor on the losses, with the same value of transmitted active power
calculated. Where, the power losses of an electric cable are depending on the resistance of the
conductor and on the square of the current [9]. In this case, the length of cable used is (240m), the
cross sectional area (120mm2) with (0.84) power factor, therefore the resistance of the cable is
(0.0204Ω). In a three-phase system the losses are calculated as follows:

Now, the reduction in the losses after power factor correction is calculated as in Eq. 18:

Where, (P Losses1 and I1) are respectively the power losses and current before the power factor
improving, (P Losses2 and I2) are respectively the power losses and current after the power factor
improving and (∆P Losses) the reduction in the power losses.

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6.4. Calculations of Electrical Transformer for Raw Material Mill

The size of the transformer specifies according to the apparent power (S). By improving the power
factor, the value of reactive power (Q) and the apparent power (S) would be reduced but still deliver
the same active power (P) [7]. The variation of the power for MV/LV of three-phase transformers as
a function of the P.F is defined by the table 4. However, the rated power of the transformer which
feed raw mill 1500 kVA and the necessary compensation power is (40.5 kvar). The transformer will
supply 1050 kW as a total power to the load with (P.F. = 0.7). If the loads absorbed the same power
with (P.F = 0.9), it would be sufficient to use a transformer with power (1250 kVA). The necessary
reactive power to correct the power factor for (0.94) is calculated as:

When taking the necessary reactive power to operate the transformer in account, the total reactive
power which delivers from the power factor correction unit becomes:

7. CALCULATIONS OF REACTIVE POWER FOR CEMENT MILL

The type of cement mill drive is slip ring with the following specifications according to name plate
of motor: (50 Hz) line frequency, (3300 V) three phase voltage, (1900 kW) rated power, (0.84)
power factor and (422 A) rated current. The method of calculations in this section will depend on
using table of coefficient K (KVAR/kW) to extract the value of required reactive power per/phase
as shown in the table 5.

The power factor of motor is 0.84 and the power factor to be obtained is 0.94. The power of the
capacitor bank QC is:

The value of K is extracted from intersect the row "initial cos θ1" 0.84 with the column "final cos
θ2" 0.94, that equals 0.283.
So,

Where,

Referring to Eq. (5-15) the results of calculations are illustrated in the table 6.

7.1. The Cement Mill Feeding Cable size Calculations

As illustrated in (6.2), the impact of starting current on cable capacity taken into account. Therefore,
the cable is designed for carrying current the limits of (674.7A) with (0.84) power factor. Referring
to table 3, the cross sectional area for cable chosen is (300 mm2). The current with (0.94) power
factor become (602.8A), according to table 3; the cross-sectional area for the cable becomes
(240mm2), with increasing a safety factor.

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7.2. The Cement Mill Feeding Cable Losses Calculations

The length of cable used is (180m), the cross sectional area (300mm2) with (0.84) power factor,
therefore the resistance of the cable is (0.0252Ω). Referring to Eq. (16-18), the results of power
losses and reduction in the power losses are illustrated in table 7.

7.3. Calculations of Electrical Transformer for Cement Mill

The rated power of the transformer which feed cement mill (2000kVA) and the necessary
compensation power is 54kvar, the transformer will supplying (1200kW) as a total power to the
load with (P.F.= 0.6). According to the table 2, if the loads absorbed the same power with
(P.F. = 0.9), it would be sufficient to use a transformer with power (1500kVA). The results of
calculations for necessary reactive power to correct the power factor for (0.94) as it illustrated in
(6.3) are: QC is 1163.23 kvar and QC Total is 1217.23 kvar.

8. CALCULATIONS OF REACTIVE POWER FOR MOTOR OF COOLER

The specifications of motor which use in the cooler according to name plate are: induction motor,
(50 Hz) line frequency, (200kW) rated power, (380V) three phase voltage with (0.84) power factor
and (355A) rated current. The calculations of necessary actual value for reactive power to correct
the power factor to (0.94), are achieved as illustrated in (6.1). The results of calculations for
necessary actual reactive power capacitor, the current (before and after) power factor improvement
and the other values are illustrated in table 8.

8.1. The Cooler Feeding Cable Losses Calculations

The actual length of cable used is (60 m). According to the rated current of motor, the cross-
sectional area for cable is (120mm2); therefore the resistance of the cable becomes (0.0084Ω). Where,
the calculations achieved according to Eq. (16-18). The results of Cable losses calculations are
illustrated in table 9.

9. CONCLUSION
In this research, the effects of power factor on performance of the main motors, the electrical cables
and transformers which are used in an Al- Najaf cement plant are discussed. The calculations of
reactive power for power factor correction has demonstrated several benefits such as: The total
value of current which is drawn from the network is reduced with limits of (96.23A) to the
equipment’s which has been calculated, reduce the power rating of transformers, the reduction in
the cross-sectional area of cables and decrease the losses of cables which is about (8.682 kW). The
technical benefits of power factor correction are increasing the operational life for equipment's
which are host in the factory and utilizing the complete active power. Regarding the economic
benefits of analyzing the mentioned equipment’s are the reduction of the cross sectional area of the
used cables and the rated capacity of transformers and switchgears, this will have a great impact in
cost reduction of these equipment's.

References:
[1] A. Baggini, “Handbook of Power Quality”, John Wiley & Sons Ltd., 4th Edition, ISBN 978-0-
470-06561-7, UK, Sep., 2008.

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 Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

[2] A. Nikolic, D. Naumovic -Vukovic, S. Skundric, D. Kovacevic, “Methods for Power Quality
Analysis According to EN 50160”, IEEE, 9th International Conference Electrical Power Quality
and Utilization EPQU, Vol. 10, No. 9, P. 1-6, Barcelona, Spain, Oct. 2007.

[3] D. Gonzales, A. Damian, J. McCall, “Design of Harmonic Filters to Reduce Harmonic

Distortion in Industrial Power Systems” IEEE Trans, on Industry App., Vol. IA-23, No. 3, P. 504 –
511, Issue 3, May, 1987.

[4] Eaton Electrical Inc., “Power Factor Correction: A Guide for the Plant Engineer”, Manual,
SA02607001E, USA, 2004.

[5] J. Sandesh, Thakur Shivendra S., Phulambrikar S.P. “Improve Power Factor and Reduce the
Harmonics Distortion of the System”, Research Journal of Engineering Sciences, Vol. 1, No. 5,
P.31-36, ISSN 2278 – 9472, Nov. 2012.

[6] J. Subrahmanyam, S. Radha K. R., P. K. Sahoo, C. Sashidhar, N. Madhukar reddy, “A Novel

Method for Improvement of Power Factor using Thyristor Switched Capacitor in Windmill Power
Station” International Journal of Emerging Technology and Advanced Engineering, Vol. 2, , P. 71-
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[7] K. Ravi Kumar, “Impact of APFC Panel at LT Side of Transformer” Bhogadi. Havya Int.
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[8] M. Ahrens, Z. Konstantinovic, “Harmonic Filters and Power Factor Compensation for Cement
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[9] M. OKE & O.M. Bamigbola, “Minimization of Losses on Electric Power Transmission Lines”,
Mathematical Theory and Modeling, Vol.3, No.7, P. 28-31, ISSN 2224-5804, 2013.
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Capacitor Bank”, Proceedings of World Academy of Science, Engineering and Technology, Vol.
32, P. 695 -701, ISSN 2070-3740, Aug. 2008.

[11] R. Keith Mobley, “Plant Engineers Handbook”, Butterworth-Heinemann, 3rd Edition, UK,
ISBN 0 7506 7328 11, 2001.

[12] S. Khalid, B. Dwivedi, “Power Quality Issuer, Problems, Standards & Their Effects in Industry
with Corrective Means”, International Journal of Advances in Engineering and Technology, Vol. 1,
Issue 2, P. 1-11, ISSN: 2231-1963, May 2011.

[13] S. Khanchi, V. Kumar, “Power Factor Improvement of Induction Motor by Using Capacitors”,
International Journal of Engineering Trends and Technology (IJETT), Vol.4, Issue 7, P. 2967 –
2971, ISSN: 2967 – 2971, July 2013.

[14] S. Neelima, P. Subramanyam, “Differential Evolution Based Optimization Approach for

Power Factor Correction” ACEEE Int. J. on Electrical and Power Engineering, Vol. 4, No. 3, P. 49-
54, Nov. 2013.

[15] S. Onohaebi., Odiase, O. F., Osafehinti, S. I., “Improving the Efficiency of Electrical
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[16] S. Osafehinti, O. Arobieke, S. Amodu , M. Olusolade , “Generating a Multiplying Factor to

Determine Capacitor Value for all Range of Power Factor Correction in Industrial Environment”
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2078-0958, July 2013.

[17] Y. Kusuma Llatha, Ch. Sai Babu, Y. Obulesu, “Harmonics Mitigation of Industrial Motor
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Table 1: The rated powers of the main equipment's.

The Unit in Factory Rated Power (kW) Type of Machine

Crusher 2×130 Induction Motor
Raw Material Mill 975 Slip Ring Motor
Kiln 410 DC motor
Cooler 200 Induction Motor
Cement Mill 1900 Slip Ring Motor

Table 2: The harmonics effect of on equipment’s.

Effect of Harmonics
Equipment’s
Current Losses Overheat
1. The iron losses increase.
Motor Increased Excessive heat in motor windings
2. Copper losses increase.
Overheating due to:
1. Skin effect increased.
Cable Increased 1. High load current.
2. Copper losses increase.
2. Conductor resistance increase.
Increasing the iron and copper Excessive heat in transformer
Transformer Increased
losses due to, stray flux losses. windings.
Switchgears Causing false operations and trips, damaging components for no apparent reason.
Capacitor The capacitors absorb Excessive heat and the damage in
Increasing the losses
Bank higher current. final.

Table 3: Current carrying capacity (I) of copper cables [11].

Cu
XLPE/EPR PVC
2
Conductor cross-sectional area (mm ) I (A)
35 176 143
50 216 174
70 279 225
95 342 275
120 400 321
150 464 372
185 533 427
240 634 507
300 736 587
400 868 689
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Table 4: Power of three-phase transformers as a function of the P.F [7].

Power of the transformer (kW)

Power of the
cos θ
transformer (kVA)
0.5 0.6 0.7 0.8 0.9 1
125 63 75 88 100 113 125
160 80 96 112 128 144 160
200 100 120 140 160 180 200
250 125 150 175 200 225 250
315 158 189 221 252 284 315
400 200 240 280 320 360 400
630 315 378 441 504 567 630
800 400 480 560 640 720 800
1000 500 600 700 800 900 1000
1250 625 750 875 1000 1125 1250
1500 750 900 1050 1200 1350 1500
2000 1000 1200 1400 1600 1800 2000

Table 5: Factor K (KVAR/kW) [4].

Final P.F
Initial
0.8 0.85 0.9 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1
P.F
0.74 0.159 0.289 0.425 0.453 0.483 0.514 0.546 0.580 0.617 0.658 0.706 0.766 0.909
0.75 0.132 0.262 0.398 0.426 0.456 0.487 0.519 0.553 0.590 0.631 0.679 0.739 0.882
0.76 0.105 0.235 0.371 0.400 0.429 0.460 0.492 0.526 0.563 0.605 0.652 0.713 0.855
0.77 0.079 0.209 0.344 0.373 0.403 0.433 0.466 0.500 0.537 0.678 0.626 0.686 0.829
0.78 0.052 0.183 0.318 0.347 0.376 0.407 0.439 0.474 0.511 0.552 0.599 0.660 0.802
0.79 0.026 0.156 0.292 0.320 0.350 0.381 0.413 0.447 0.484 0.525 0.573 0.634 0.776
0.8 0.130 0.266 0.294 0.324 0.355 0.387 0.421 0.458 0.499 0.547 0.608 0.750
0.81 0.104 0.240 0.268 0.298 0.329 0.361 0.395 0.432 0.473 0.521 0.581 0.724
0.82 0.078 0.214 0.242 0.272 0.303 0.335 0.369 0.406 0.447 0.495 0.556 0.698
0.83 0.052 0.188 0.216 0.246 0.277 0.309 0.343 0.380 0.421 0.469 0.530 0.672
0.84 0.026 0.162 0.190 0.220 0.251 0.283 0.317 0.354 0.395 0.443 0.503 0.646
0.85 0.135 0.164 0.194 0.225 0.257 0.291 0.328 0.369 0.417 0.477 0.620
0.86 0.109 0.138 0.167 0.198 0.230 0.265 0.302 0.343 0.390 0.451 0.593
0.87 0.082 0.111 0.141 0.172 0.204 0.238 0.275 0.316 0.364 0.424 0.567
0.88 0.055 0.084 0.114 0.145 0.177 0.211 0.248 0.289 0.337 0.397 0.540
0.89 0.028 0.057 0.086 0.117 0.149 0.184 0.221 0.262 0.309 0.370 0.512
0.9 0.029 0.058 0.089 0.121 0.156 0.193 0.234 0.281 0.342 0.484

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Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

Table 6: Calculation results of necessary reactive power for cement mill.

Q Actual (kvar/phase) 191.2 Comments

I1 (A) 395.7
Saving current is (42.13A)
I2 (A) 353.6
C (μF) 16.77
η% 93.7
S1 (KVA) 1306
S2 (kVA) 1166.88
Q1 (kvar) 708.6
44% Reduction in Reactive Power
Q2 (kvar) 399.1
P1 (kW) 1097.04
The Active Power approximately equal
P1 (kW) 1096.87

Table 7: The calculation results of cable power losses for cement mill.

P 1(Losses 1) (kW) P 2(Losses 2) (kW) ∆P Loess (kW)

34.41 27.47 6.93

Table 8: The calculation results for motor of cooler.

QC (kvar/phase) 17.05 Comments

QC Total (kvar) 51.2
I1 (A) 339.6
Saving current is (32.5A)
I2 (A) 307.1
η% 95.7
QC Actual (kvar/phase) 17.82
C (μF) 10.64
S1 (kVA) 135.84
9.56% Reduction in Apparent Power
S2 (kVA) 122.84
Q1 (kvar) 71.56
41.3% Reduction in Reactive Power
Q2 (kvar) 42.01
P1 (kW) 114.11
The Active Power approximately equal
P2 (kW) 115.46

Table 9: The calculation results of cable power losses for cooler.

P 1(Losses 1) (kW) P 2(Losses 2) (kW) ∆P Loess (kW)

3 2.38 0.29

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Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

Electrical energy for crushers

Crushing

Electrical energy for belt conveyors Transport

Electrical energy for Mill drive

Raw Material Mill
& fans

Electrical energy for Kiln drive, fans Kiln

& ESP
Electrical energy for drive & fans Clinker Cooling

Electrical energy for drive Buckets Chain

Electrical energy for drive & fans Cement Mill

Electrical energy for machine & Packing & Dispatch

transports sets
Figure 1: Electrical energy flow in processes of cement production.

V Fundamental (50Hz)
Third harmonic (150Hz)
Fourth harmonic (250Hz)
Resulting waveform

Figure 2: Fundamental waveform and a number of harmonics waveforms.

IR V
S
θ
Q
IQ θ
P
I

Figure 3: Power factor triangle.

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 Al-Qadisiya Journal For Engineering Sciences, Vol. 8……No. 1 ….2015

Figure 4: Circuit diagram of the reactive power relay.

𝐕 C
C
V √𝟑 V

Figure 5: Three phase circuit star and delta connection.

R
S
T

Starte
r

M C

Figure 6: Connection diagram of power factor correction with the motor.

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