Cement Process & Energy Saving

November, 2006 Hideyuki TANAKA Technical Expert International Engineering Dept., The Energy Conservation Center, Japan
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Bird-eye View of Japanese Cement Factory

Coal yard

Water

SP & calciner

Waste tire yard Rotary kiln

Electrostatic Precipitator (EP Dust collector) Raw mill crusher

Cement silo

Shipping pier

Layout of one Japanese cement factory

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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 (%) 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
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(%) SiO2 Al2O3 Fe2O3 SO3 CO2 37-43 10-26 3-9

Cements

Others

Temperature Profile in Wet Process Kiln

Temperature, 2000 Gas temperature 1000 Material temperature Drying Calcining Cooling Clinker temp : 80 100 Fuel Kiln Cooler Clinker
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Preheating Sintering Zoning Water content of raw meal : 38 40% Raw meal

Chain Curtain Zone: 20- 25% extension

Temperature Profile in Wet Process Kiln

Chemistry of Cement Process

Heating () 100110

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;

Drying

110700 700750 750900 9501200 12001300

Calcining

Sintering

13001450

Cooling

150200

3CaOSiO2 2CaOSiO2 3CaOAl2O3

: Referred to as Alite or C3S : Referred to as Belite or C2S : Referred to as aluminate phase or C3A

5 4CaOAl2O3Fe2O3: Referred to as ferrite phase or C4AF

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 Fuel by kind (%) 78 13 5 4
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Fuel (*1) Electric power (kWh)

105 99

(*1) : kg of coal equivalent, where HHV of coal is 6,200 kcal/kg (= 25,958kJ/kg)

Base : 1 ton of cement

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 JCA (1961) JCA (1981) m3N/kg-cl (2) 1.65 2.62 2.38 1.68 1.40 1.35

Note 1: JCA: Japan Cement Association 2: Estimated based on 1.40 m3N/kg-cl in SP kiln

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)
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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)

Boundary of Heat Balance

Exhaust gas Raw material
T T F O
2

gas flow material flow Air leak

Preheater Section

T O
2

Kiln Section

O
2

1ry air Fuel oil

F

T T T

Air leak

Cooler exhaust vent

Cooler Section
2ry air Clinker
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Trial & Error Method

T T

Measured or assumed calculated

Collecting Data (Wet Process)-1

Dry raw material (dry RM) Water content in wet raw material Clinker yield Clinker temp at cooler exit Specific heat of clinker (Cp) Fuel rate (kiln) Specific gravity of fuel Specific heat of fuel (Cp) Low heat value of fuel Fuel temperature Fuel rate (precalciner) O2 in exhaust gas CO2 generation in calcination Specific heat of exhaust gas t/h wt% on wet RM deg C kcal/kg-cldeg C 0.192 m3N/h kg/m3N kcal/kgdeg C kcal/m3N deg C kg/m3N Vol % m3N/kg-cl 0.27
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(40) (0.65)

Heat of clinkering (calcination & sintering) kcal/kg-cl

Exhaust gas temp at kiln or preheater exit deg C

kcal/m3Ndeg C 0.338

Collected Data (Wet Process)-2

Kiln surface temperature (average) Surface area Convection coefficient (hc) Radiation coefficient (hr) Emissivity Preheater surface temperature (average) Surface area Convection coefficient (hc) Radiation coefficient (hr) Emissivity Cooler surface temperature (average) Surface area Convection coefficient (hc) Radiation coefficient (hr) Emissivity Ambient temperature (outdoor) Deg C m2 kcal/m2hrdeg C kcal/m2hrdeg C deg C m2 kcal/m2hrdeg C kcal/m2hrdeg C deg C m2 kcal/m2hrdeg C kcal/m2hrdeg C deg C
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(10.9) (21.0) 0.95 NA NA (10.0) (19.1) 0.95

(13.0) (25.0) 0.95

Items Listed on Heat Balance Table

Heat Input Heat of combustion of fuel Sensible heat of fuel Sensible heat of wet raw material Sensible heat of combustion air I1 I2 I3 I4 Heat Output Heat for clinkering Sensible heat of clinker at cooler exit Sensible heat of cooler exhaust vent O1 O2 O3

Heat for evaporating water in raw material O4 Sensible heat of kiln or preheater exhaust gas Radiation heat on kiln surface Radiation heat on preheater surface Radiation heat on cooler surface Unaccountable heat losses O5 O6 O7 O8 O9

Base of temperature : Ambient air temperature Base of heat amount : kcal per kg of clinker (kcal/kg-cl) 13

Thank you!

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