Eng. Demiss Alemu - Energy Efficiency Improvement and GHG Emission Reduction Strategy for Cement Industries in Ethiopia, 3rd EACCES
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The document outlines a strategy for improving energy efficiency and reducing greenhouse gas emissions in Ethiopia's cement industry, focusing on the National Cement Factory. It details an energy audit conducted to identify energy conservation measures, quantify energy use, and suggest alternatives to enhance efficiency, leading to significant cost savings and emission reductions. Recommendations include implementing biomass co-firing, optimizing equipment operation, and enhancing energy management practices.
Eng. Demiss Alemu - Energy Efficiency Improvement and GHG Emission Reduction Strategy for Cement Industries in Ethiopia, 3rd EACCES
- 1. ENERGY EFFICIENCY IMPROVEMENT AND GHG EEMISSION REDUCTION STRATEGY FOR CEMENT INDUSTERIES IN ETHIOPIA: THE CASE OF NATIONAL CEMENT FACTORY By: Demiss Alemu AAIT， Addis Ababa University 1
- 2. POINTS OF DISCUSSION Introduction Background Objective of the study Energy audit and monitoring Utility bill analysis Discussion of the result Alternatives solution of efficiency improvement Economic evaluation Environmental issues Conclusion and Recommendation 2
- 3. INTRODUCTION Energy is one of the most important inputs in the process of economic growth and industrial development. Cement industry is one of the most energy intensive sector. About 40-60% of the total production cost of cement is attributed to energy. Hence ifed energy is not utilized in efficient way it incurs high manufacturing cost. 3
- 4. CONT… Currently, there are 6 major plants with a combined production capacity of about 15 million tons per year. 4
- 5. NATIONAL CEMENT FACTORY National Cement Enterprise is one of the known cement factory in Ethiopia. It was re-established in 2013 with a single production line daily capacity 3000 tons of clinker. It is located in Dire Dawa 515 kms east of the capital, Addis Ababa, on an elevation of about 1250 mts above sea level. The annual production capacity is up to 1.2Million tons of cement. 5
- 6. OBJECTIVE OF THE STUDY The general objective of the study is to conduct energy audit of the factory with regard to fuel and electricity consumption and identify feasible energy conservation measures that will reduce specific energy use, annual operating cost and GHG emission with minimal investments. 6
- 7. METHODOLOGY The methods employed to achieve the objectives of the research are: Literature Survey Audit preparation Conduct preliminary analysis Data collection and Detail audit Identified main ECOs (Energy conservation opportunities) Performed feasibility study on energy conservation opportunities Identified the feasible ECOs Estimate the GHG emission reduction 7
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- 10. ENERGY AUDIT An Energy Audit Study helps an organization to understand and analyze its energy utilization and to identify areas where energy use can be reduced, to budget energy use, plan and implement feasible energy conservation measures that will enhance their energy efficiency, curtail energy wastage and substantially reduce energy costs. 10
- 11. TYPES ENERGY AUDIT There are two types of Energy Audit 1. Preliminary Audit 2. Detailed Audit 11
- 12. ENERGY MONITORING National cement factory has one production line. Energy audit was carried out in order to study the energy use and various losses occurring in the system and arrive at suggestions for improving the performance. Utility bill analysis o Clinker production 12
- 13. CLINKER PRODUCTION N o . Year Clinker Productio n in Tons 1 2013 from May 302304 2 2014 623895 3 2015 from Jan 15- may 15 208280 13 0 100000 200000 300000 400000 500000 600000 700000 2013 2014 2015 CLINKER PRODUCTION Series1
- 14. CEMENT PRODUCTION N o . Year Cement Production in Tons 1 2013 from May 318387 2 2014 719777 3 2015 from Jan 15- may 15 240488 14 0 100000 200000 300000 400000 500000 600000 700000 800000 2013 2014 2015 CEMENT PRODUCTION Series1
- 15. ELECTRICITY CONSUMPTION N o . Year Electricity consumptio n kWh 1 2013 from May 34996800 2 2014 114782400 3 2015 from Jan 15- may 15 38860800 15 0 20000000 40000000 60000000 80000000 100000000 120000000 140000000 1 2 3 ELECTRICITY CONSUMPTION Series1
- 16. SPECIFIC ELECTRICAL ENERGY CONSUMPTION 16 0 20 40 60 80 100 120 140 160 180 2013 2014 2015 Series1
- 17. COAL CONSUMPTION N o . Year Coal consumptio n in tons 1 2013 from May 48605.65 2 2014 102411.18 3 2015 from Jan 15-may 15 35008.82 17 0 20000 40000 60000 80000 100000 120000 2013 2014 2015 COAL CONSUMPTION Series1
- 18. SPECFIC FUEL ENERGY CONSUMPTION The average specific energy consumption of three years is 4323.8kJ/kg clinker. 18 4100 4150 4200 4250 4300 4350 4400 4450 2013 2014 2015 KJ/KG CLINKER
- 19. BENCHMARK The actual fuel energy use for different kiln systems is in the following ranges MJ/ton clinker. 3 stages: 2800 to 3300 MJ/tonne clinker 4 stages: 2700 to 3000 MJ/tonne clinker 5 stages: 2600 to 2900 MJ/tonne clinker 6 stages: 2500 to 2800MJ/tonne clinker The average five stage energy consumption is 2750MJ/ton clinker. 19
- 20. CONT… o In NCF the amount of thermal energy needed to produce a ton of clinker on average has been 4323.8 MJ/ton clinker o The world average of this technology is 2750 kJ/kg clinker which is 1573.8 kJ/kg clinkers lower than from NCF. 20
- 21. DATA COLLECTION Instruments used 1. Gas Analyzer 2. Infrared Thermometer 3. power clamp and 4. The factory control panel 21
- 22. USING THE MEASUREMENT Typical Components needed to be determined are: Energy in dry flue gas Energy from burning of hydrogen Radiation and convection loss from the system Heat loss from discharged clinker Heat loss from dust Heat loss from moisture content of RM and fuel The Load factor and the efficiency of motors 22
- 23. DISCUSSION OF RESULTS The performances of forty five motors are measured by determining the power factor, load factor and efficiency. Some of the motors performed either under or over load conditions. 23
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- 25. SANKY DIAGRAM OF THE KILN 25
- 26. ALTERNATIVE SOLUTION FOR EFFICIENCY IMPROVEMENT The proposed measure that could be taken to improve the efficiency of the system are: 1. Improving the efficiency of motors 2. Replacing the seal 3. Improving the Refractories 4. Reduction of kiln shell loss 5.Installing waste heat recovery steam generator 26
- 27. ESTIMATED ENERGY SAVING FROM ENERGY EFFICIENCY MEASURES 27
- 28. CONT… 28
- 29. ECONOMIC EVALUATION A comparison of the costs and benefits of an alternative is often required to be made a judge the absolute or relative profitability of the investment made towards efficiency improvement alternatives. 29
- 30. PROFITABILITY ANALYSIS FOR POWER GENERATION FROM WASTE HEAT RECOVERY 30
- 31. FUEL SAVING 31
- 34. GHG REDUCTION DUE TO ENERGY EFFICIENCY IMPLEMENTATION 34
- 35. CONCLUSION The kiln efficiency was 47.64%. The major heat loss sources are the exhaust gas, cooler hot air and kiln surface, which are 21.53%, 10.8% and 4.27% of the total heat input respectively. The selected steam cycle showed an energy saving potential of 7.9 MW from the waste heat streams. From this potential we can generate 1.7MW The secondary shell system would lead to saving 4.1% of the input energy; hence the overall efficiency would be increased by approximately 1.5 to 2.5%. 35
- 36. CONT… From reduction of excess air and improving refractories would save 5.06% of the input energy and it enhance the system efficiency by approximately 3 to 4%. Some of the motors performed either under or over load conditions. By adjusting the load to 75% which is a condition most motors operating at maximum efficiency. From this the factory would save 1988312.8kWh annually. From the measures 19.9 thousand ton of CO2 per year preserved. 36
- 37. RECOMMENDATION As an alternative fuel that company would save an enormous amount of energy and emission of GHGby by they use Prosopis juliflora plant that can be collected from Afar region was on implementation . Cofiring Biomass and biomass wastes shall be implemented in all cement Fcatories Excess energy needed for restarting the process can be sved by minimize downtime of machinery and plant and Power interruption By using a better control system (variable speed drive) and preventive maintenance (burners, motors, compressed air sytem, iln shell, fans) will save considerable amount of energy Usee oxygen enrichment, mid Kiln Firing can be considered for better energy effciency Waste heat recovery for Generation of power Use of vertical roller mill also reduces energy consumption. 37
- 38. CONT… Introduce and develop training and knowledge of energy saving practices to the workers. Support the existing and new energy research. The factory should introduce Energy Management Guidelines. 38
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