HEAT BALANCE OF UNIT I

Date- 05.07.2006 Time- 12 pm Basis- 1 kg clinker Reference temperature- 0 C Ambient temperature- 40 C Atmospheric Pressure- 9772 mmWg
0 0

HEAT OUTPUTS 1) Heat of Formation Q = 2.2A + 6.48M + 7.646C 5.1165S 0.59F Considering loss free clinker as loss free meal feedstock under equilibrium conditions Q = 2.2*5.4 + 6.48*2.52 + 7.646*63.33 5.1165*21.3 0.59*3.71 = 401.26 kcal/kg clinker 2) Heat in preheater exit dust Gross dust loss = 13.2 TPH Clinker output rate = 132 TPH Dust in preheater exit dust = 13.2 * 1000 132 * 1000 = 0.1 kg/kg clinker Mean Specific heat of dust CPD = 0.206 + 101*427*10-6 + (-37*4272 *10-9) = 0.242 kcal/kg/0C Heat Lost in dust = Qd = md* Cpd* (Td Tr) = 0.1 * 0.242 * (427- 0) = 10.33 kcal/kg clinker 3) Heat in preheater exit gas Pitot tube measurement 65.47 kg/sec Clinker production 3171 TPD

= 36.7 kg/sec Therefore, mp = 65.47/36.7 = 1.784 kg/kg clinker Exit gas composition CO2 = 29 % O2 = 5.2 % CO = 0.01 % N2 = 65.8 % Converting to weight fraction Gas O2 CO2 CO N2 Total Volume fraction 0.052 0.290 0.0001 0.0.658 100 Weight fraction 0.052 *32/22.4 = 0.074 0.567 0.000125 0.822 1.463 Weight percentage 5.05 38.75 0.0085 56.18 100

The specific heat of exit gas is the sum of specific heats of individual gas components. Therefore, Cpp = 5.05 (0.218 + 30*427*10-6) +38.75 (0.196 +118*427*10-6 - 43*427210-9 ) 100 100 + 56.18 (0.244 + 22*427*10-6 ) 100 = 0.0116 + 0.238 +0.142 = 0.391 kcal/kg0C Therefore Qp = 1.784*0.391*(427-0) = 297.85 kcal/kg clinker. 4) Heat in clinker from cooling discharge Qc = m*Cpc*( Tc- Tr ) Cpc = 0.186 + 54*122*10-6 = 0.192 kcal/kg0C Therefore, Qc = 1*0.193*( 122 0) = 23.49 kcal/kg clinker. 5) Heat in cooler exhaust air-

Qce = mce*Cpe*(Tce Tr) Pitot tube measurement = 58.17 kg/sec Clinker output rate = 36.7 kg/sec Therefore, mce= 1.58 kg air/kg clinker Cpce= 0.237 + (23*225*10-6) = 0.242 kcal/kg0 C Therefore, Qce= 1.58*0.242*(225-0) = 86.01 kcal/kg clinker 6) Heat from cooler to coal millQcm = mcm*Cpm*(Tcm - Tr) mcm= 0.056 kg/kg clinker Cpcm = 0.247 Therefore, Qcm = 0.056*0.247*(435-0) = 6 kcal/kg clinker 7) Heat of evaporation of Raw Meal MoistureRaw meal feed rate = 220 TPH Moisture in raw meal = 0.5 % Therefore, weight of moisture = 1.623*0.5/100 = 0.008 kg water/kg clinker Heat of evaporation of moisture = 597 kcal/kg Therefore, heat of evaporation of raw meal moisture = 0.008*597 = 4.776 kcal/kg clinker 8) Heat of evaporation of coal moisture = Let coal consumption be = x kg/kg clinker Moisture in coal = 0.8 % Moisture in coal in terms of kg/kg clinker = x*0.8/100 = 0.0008x Heat of evaporation of coal moisture = .0008x*597 = 4.776x kcal/kg clinker 9) Heat loss due to incomplete combustion The heat lost in burning carbon to carbon monoxide instead of CO2 is 2417 kcal/kg of Carbon Monoxide.

Volume % of CO in waste gases = 0.01 Weight % of CO in waste gases = 0.0085 Amount of waste gases = 65.47 kg/sec Amount of CO in waste gases = 0.0085*65.47/100 = 0.0056 kg/sec = 0.0056/36.7 kg/kg clinker = 0.000152 kg/kg clinker Therefore, heat loss in incomplete combustion = 0.000152*2417 = 0.367 kcal/kg clinker 10) Radiation and Convection losses The surface loss consists of radiation and convection losses. RAD = 4.87*10-8**( T4 T4) kcal/hm2 = {4.87*10-8*0.95*(4804 3134)*99.22} + {4.87*10-8*0.95*(5464 3134)*533.3} + {4.87*10-8*0.95*(5034 3134)*62} = 199619.8 + 1955967 + 156087.4 = 2311674.2 kcal/h CON = {80.33*[(T +T)/2]-0.724 *(T T)1.333} kcal/hm2 = {80.33*[(480 +313)/2]-0.724 *(480 313)1.333*99.22} + {80.33*[(546 +313)/2]-0.724 *(546 313)1.333*533.3} +{80.33*[(503 +313)/2]-0.724 *(503 313)1.333*62} = 96212 + 760840 + 701663 = 1558715.2 kcal/h Total radiation and convection losses from kiln = 2311674.2 + 1558715.2 = 3870389 kcal/h Kiln Output = 3171*1000/24 = 132125 kg/hr Therefore specific radiation and Convection losses from kiln shell = 3870389/132125 = 29.29 kcal/kg clinker On the kiln shell losses, 5% can be added to compensate for heat loss occurring from kiln line rings. So the kiln shell losses = 29.29*1.05 = 30.75 kcal/kg clinker Radiation Losses from preheater (kcal/hr) Stage IA IB Roof 39325 39325 Cyclone 20181 11248 Cone 3851 7079 Riser Duct 66133 57679 Down Pipe 42433 19552

II 20618 10367 14819 III 49451 13671 16309 IV 37729 25836 31982 Total 703218 Convection Losses from preheater (kcal/hr) Stage IA IB II III IV Total Roof 22191 22191 12566 27971 21826 Cyclone 10621 5172 4646 6569 14499 Cone 1676 3581 8311 9146 19322 391690

4257 63984 -

29937 28876 48576

Riser Duct 37090 31603 1853 38766 -

Down Pipe 21344 11493 16131 16877 26245

Total radiation and convection losses from preheater = 1372747.35 kcal/h Specific Radiation and Convection losses from preheater = 1372747.5/132125 = 10.38 kcal/kg clinker Taking radiation and convection losses from cooler as 5 kcal/kg clinker, Total radiation and convection losses = 30.75 + 10.38 + 5 = 46.13 kcal/kg clinker HEAT INPUTS 1) Heat of coal consumption = 7456x kcal/kg clinker 2) Heat in kiln feed Q = mf*Cpf*(Tf Tr) Cpf = 0.206 + 101*75*10-6 = 0.213 kcal/kg0C mf = 220 TPH = 220/132.125 = 1.66 kg/kg clinker Therefore, Q = 1.66*0.213*(75 0) = 26.16 kcal/kg clinker 3) Heat in cooling air Q = mc*Cpc*(Tc- Tr) Cpc = 0.237 kcal/kg0C

Therefore, Q = 2.47*0.237*(40 0) = 23.5 kcal/kg clinker 4) Heat in primary air Q = mpcp(Tp Tr) mp = Total primary air (kiln and calciner) = 0.041 kg/kg clinker Tp = 400C Cp = 0.237 + 40*23*10-6 Therefore, Q = 0.041*0.2379(40 0) = 0.39 kcal/kg clinker 5) Sensible heat of fuel Q = mfuel*Cp*(Tfuel Tr) = x*0.289*(70 0) = 20.23x kcal/kg clinker

HEAT BALANCE Total heat inputs = 7456x + 26.16 + 23.5 + 0.39 + 20.23x = 7476.56x + 50.05 Total heat outputs= 401.26 + 10.33 + 297.85 + 23.49 + 86.01 + 6 + 4.776 + 4.776x + 0.367 + 46.13 = 876.21 + 4.776x Calculation of heat consumption Total heat inputs = Total heat outputs 7476.56x + 50.05 = 876.21 + 4.776x => 7471.78x = 826.16 => x = 0.1105

Heat consumption (from coal consumption) = 0.1105*7456 = 824 kcal/kg clinker

FALSE AIR MEASUREMENT IN UNIT- II

Date 30.06.06 Time 3.05 pm O2 at Preheater outlet Pyro String = 4.1 % Kiln String = 5.8 % O2 at kiln inlet 3.84 % O2 at calciner outlet 2.6 % Now, false air at the kiln-string = 5.8 -3.84 20.9 3.84 = 11.48 % False air at the pyro-string = 4.1- 2.6 20.9-2.6 = 8.19 %

CHARACTERISTICS OF ENERGY CONSUMPTION IN CEMENT PRODUCTION

ENERGY CONSUMPTION

The cement industry is said to be an energy intensive industry together with steel, paper and petrochemical industries. The percentage of energy cost in Portland cement production cost is 20 to 30 %. Compared percentage of fuel consumption by use

AREAS OF ENERGY WASTAGE

The main areas of energy wastage are- High exit flue gas temperature for preheater and cooler exhaust. - High clinker temperature from cooler. - False air infiltration in kiln, preheater and ESP circuits. - Improper combustion. - High Radiation losses from kiln and preheater.

SUGGSTIONS AND RECOMMENDATIOS FOR IMPROVEMENT OF THERMAL EFFICIENCY

1) COGENERATION OF POWER THROUGH WASTE HEAT RECOVERY The preheater exhaust gas has about 20 % of the heating value brought in by the fuel. In the Unit I of SCL the temperature of the preheater exhaust gas is about 4500C and it is about 2500C in Unit II. Upto 25-30 % of total power requirement can be met through cogeneration of power utilizing waste heat in a cement plant. A circuit diagram has been shown below for the use of preheater gas for power cogeneration

COGENERATION OF POWER BY PREHEATER WASTE GAS

The preheater gas can be used for power cogeneration as shown in the diagram above. A part of the preheater exhaust gas passes to the raw mill and the rest is sent to a separator for separating dust from the gas. The clean gas is used in the High Pressure Boiler for generation of steam which is used in the turbine for electricity generation. The cooled gas is sent to the ESP for precipitating the dust. There are also some barriers in introduction of cogeneration systems in Indian Cement Industry. They arei) High cost of imported technology and difficult access to funds. ii) High cost of capital without any fiscal incentive. iii) Reluctance of funding agencies to fund an untried technology in India. iv) Contemporary barriers in some states for putting up captive power generation units. Nevertheless, the system promises to return the capital investment within a short period.

2) COPROCESSING OF WASTES
There is a huge potential for waste coprocessing in the Indian Cement Industry. There is a need for waste management strategy in India. GENERATION OF WASTES Almost all industries- petroleum/automobile/power/steel/chemical/mineral and many more generate wastes which can be classified as (a) Liquids hazardous/non-hazardous with fuel value (b) Solids hazardous/non-hazardous with fuel value (c) Sludges without fuel value SOURCES OF WASTES - Metallurgical, steelmaking industries. - Industrial and port/dock cleaning. - Mechanical and automobile industries. TYPES OF HAZARDOUS WASTES 10

Waste oil. Oil containing residues. Oil emulsions. Paints, adhesives and varnishes

USE OF WASTE IN CEMENT INDUSTRY AS FUEL To satisfy the total and safe destruction of the wastes, the system has to reach the following conditions 8500C at 6% O2 if the waste contains less than 1 % chloride. By contrast, coprocessing achieves a more beneficial environmental impact by reclaiming waste materials. The very high retention time, high temperatures and high turbulence in kiln ensure complete combustion of the wastes. Coprocessing facilitates use of 10-50 % of wastes as fuel. The cement kiln has the capacity to burn wastes due to High temperature profile. High turbulence. Long residence time. Sufficient oxygen in the system Capacity of the end product (cement) to absorb the metals without affecting its quality. Cement production is an energy intensive process. It has potential to accept wastes which are otherwise not accepted by incinerator.

Shree Cement has a huge scope for coprocessing wastes and thus conserve the conventional sources of energy.

3) USE OF MINERALIZER
By using mineralizer along with feed the fuel consumption can be brought down as the mineralizer helps in reducing the clinkerisation temperature. The results of an experiment in a kiln where 0.72 % of baryte is used as mineralizer are shown below TPD of kiln 3700 Addition of barite 0.72 % Kiln feed per day 5730 MT. Baryte required per day 42 MT Additional cost of baryte Rs. 62000 per day COAL AND RAW MATERIAL SAVING POTENTIAL Reduction in kiln feed required per day- 42 MT Reduction in clinkerisation temperature 550C

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Coal consumption without baryte per day 725 MT Coal consumption with baryte per day 678 MT Coal saving per day 47 MT SCOPE FOR INCREASE IN PRODUCTION Total air required per day without baryte 5430 kg Total air required per day with baryte 5070 kg Reduction in combustion air 6.6 % Scope for increase in production 6.6 % If the use of mineralizer is implemented in Shree Cement a lot of raw material and fuel can be saved and production can also be increased.

4) INSTALLATION OF ONLINE ANALYSER To produce a good quality product and to maintain optimal and efficient condition in the kiln, it is crucial that the raw meal is completely homogenized. Quality control starts in the quarry and continues to the blending silo. Online analyzers for raw mix control are an integral part of the quality control system. If online analyzers are installed then the raw mix can be optimized and thus the thermal energy can be used to the optimum. CSIRO worked in collaboration with Fuel and Combustion Technology (FCT) to develop two key online analyzer systems- an on-conveyor belt bulk elemental analyzer for the raw materials and an on-line analyzer for determining the composition and phases in the cement. These analyzers were designed to improve cement processing in the Australian Cement Industry. The CSIRO X-belt analyzer (XENA) can be used to control the raw mix composition of cement. It can be positioned directly on the conveyor belt transporting the raw material to the mill. XENA can accurately measure the concentrations of calcium, silicon, aluminium, iron and minor elements independent of both horizontal and vertical segregation and independent of changes in belt loading. XENA is based on a newly-developed fast neutron and gamma ray technique that uses highly penetrating radiation so that measurements can be averaged over a large volume of material on a conveyor belt.

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5) INSTALLATION OF DEFLECTOR PLATES IN PREHEATER CYCLONES

If the III Stage and IV Stage Cyclones are provided with Deflector Plates the hot gases along with the kiln feed material would be guided by the Deflector Plates to obtain better cyclonic effect (Whirling Motion). The turbulence would be more which would result into better heat transfer as well as reduction in pressure drop in both the cyclones. Thus the radiation losses and preheater exhaust gas temperature would come down ant the load on ID fan would also decrease.

6) IMPROVEMENT OF BURNING CONDITIONS IN CALCINER

An analysis of GCT inlet sample of Unit-I has shown the following results % CaCO3 in Preheater exhaust % Free Lime in the exhaust gas % CaCO3 in kiln feed % Fuel in exhaust 77.27 3.52 75.43 1.3

The analysis above shows that calcined material is getting carried away with the gas. Also as the calcination is almost negligible in cyclone I, the calcined material is

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coming from bottom. This puts a question on the efficiency of C-II, C-III and C-IV. Fuel is also coming out from the top. This means fuel is also getting carried away with the gases from the calciner and it is very much possible that this fuel is getting burnt in C-III, C-II or C-I. This will certainly increase the exhaust gases temperature. As the highly calcined material resides in calciner, C-IV & C-III, this material is getting carried away from these sections. Further more in the course of traveling it is getting carbonized as the gas which carries the calcined material is also having CO2. The reaction between calcined material and CO2 is exothermic so it leads to high temperature in the exhaust of preheater. Calcined material from these sections is going upwards with air and this CaO is not getting separated. Even though a part of calcined material is getting carbonized we get nearly 4 % CaO at the exhaust. So separation efficiency of C-III and C-II needs to be improved. It is found that 1.3 % fuel is there at the exhaust. This suggests calciner burning conditions should be improved. For improving the calciner burning conditions we should use finer fuel. For proper mixing of fuel and air we can have a swirl vane installed in the burner. Even increasing calciner length can serve the purpose to certain extent.

7) MODIFICATION OF PREHEATER CYCLONE

The following are the advances in preheater designs which can be implemented in the Unit I of Shree Cement for better heat transfer - Low pressure drop Cyclones - Enlarged inlets and outlets - Sloped shelves - Favorable inflow geometry - Gas velocity in preheater cyclone duct in the range of 10-15 m/sec Here is the diagram of FLS Low Pressure drop Cyclone-

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8) USE OF BOILER ASH IN FEED

Mr. Bhatty and others in year 2000 & 2001 demonstrated the use of a fly ash that contained approximately 20 % unburned carbon at a preheater kiln. The composition of the fly ash used in the trial run is shown in the table below OXIDE COMPOSITION OF THE HIGH CARBON FLY ASH Oxide SiO2 Al2O3 15.46 Fe2O3 7.1 CaO MgO SO3 4.47 1.3 0.49 Na2O K2O 1.88 2.5 TiO2 LOI 1.08 20.8

Percentage 42.9 5

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The high carbon fly ash was blended with the raw materials (crushed limestone and a small amount of shale) and ground into raw feed. The composition of the raw feed was targeted to the normal raw feed. The fly ash composition and that of other raw materials (limestone and shale) limited the fly ash substitution to 6 %. The total heat content (calorific value) of the ash was estimated to be greater than 740 KJ/kg, which translated to an anticipated energy contribution from the fly ash of 16 kcal/kg of clinker. During the demonstration, the operation ran in a more efficient, stable and predictable manner. Consequently, the cement plant incurred a fuel savings of nearly 4 %, and the clinker production increased by almost 10 %. Characteristics of clinker produced during the demonstration as determined by XRF, XRD and free lime tests are shown below. The XRF analysis indicates lower sulphate in the fly ash clinker than in the normal one. OXIDE COMPOSITION OF CLINKER Oxide SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O K2O LOI Alkalies as Na2O Free Lime Before Using fly ash 20.07 5.45 2.49 64.09 2.44 2.43 0.40 1.28 0.10 1.24 2.98 After using fly ash 21.57 5.98 2.59 64.60 2.47 0.59 0.39 0.56 0.09 0.76 0.44

The results and ASTM C150 standard physical requirements for cements presented in table indicate that the fly ash used cement is comparable to the commercially produced cements. ASTM C150 DATA FOR CEMENTS PRODUCED BEFORE AND DURING THE DEMONSTRATION Compressive Strength, MPa Cement Before After 3-Day 25.9 25.2 7-day 31.0 28.9 28-Day 40.5 41.9 Air Content, % Initial 7.8 85 8.1 105 Setting Time (mins) Final 180 210 Autoclave Expansion, % 0.12 0.07

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A similar study for Electric Power Research Institute (EPRI) was carried out by Bhatty and others (1998) on several high-carbon fly ashes (carbon ranging from 6 % to 16 %) that produced similar results. The ashes were used as a component for raw feed collected from different cement plants across the US. Clinkers and cement were produced from these mixes and tested. The data indicated that clinkers had normal formation and distribution of the major clinker phases, and the cement had strength and setting properties comparable to that produced at the actual cement plants. A cement plant in Canada has also used upto 10 % high carbon fly ash as a raw kiln feed component. The primary motivation for the plant was fuel savings. USE OF BOILER ASH IN SHREE CEMENT Shree Cement produces around 150 MT of boiler ash from its captive power plant. The analyses of the boiler ash are as follows Proximate analysis (in %) Total Moisture 12.7 Volatile Matter 7.6 Ash 35.59 Fixed carbon 56.81 GCV 5253 NCV 5147

Ultimate Analysis (%) Carbon 26.08 Hydrogen 1.91 Nitrogen 0.35 Sulphur 4.85 Mineral Matter 52.44

Chemical analysis SiO2 51.1 9 Fe2O

3

Al2O
3

CaO 11.0 8

MgO SO3 Na2O K2O P2O

5

Cl 0.01 3

TiO2 Mn2O3 0.64 0.16

3.87

20.24

1.64

5.0 7

0.25

0.39

0.04

Comparing the composition with the previous fly ash there is not much difference between the two. SO3 content is little higher but it will get absorbed in the clinker and get reduced. The calorific value is 5147 Kcal/kg and its carbon content is 26 % compared to 20 % in the previous fly ash. Therefore if 6 % of boiler ash is used in

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the feed then fuel savings of about 6 % can be made and clinker production would increase by 10 %. Thus it would be a huge benefit from the energy efficiency point of view.

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