best practices & technologies for energy efficiency in indian cement industry
TRANSCRIPT
BEST PRACTICES & TECHNOLOGIES FOR ENERGY EFFICIENCY ININDIAN CEMENT INDUSTRY
Indian Cement Industry –An Overview
GROWTH OF INDIAN CEMENT INDUSTRY
23 20
6145
130
98
219
181
0
50
100
150
200
Mn.
TO
NN
ES
1980 1990 2001 2009
YEAR
CAPACITY PRODUCTION
1980
DRY33%
WET61%
SD6%
2008
DRY97%
WET2%
SD1%
CHANGING PROCESS PROFILE OF INDIAN CEMENT INDUSTRY
1990
DRY76%
WET21%
SD3%
1960DRY1%
WET94%
SD5%
39
6268
8091
0102030405060708090
100
NO
. OF
PL
AN
TS
1995-96 2001-02 2003-04 2007-08 2008-09
YEAR
PLANTS WITH CAPACITY OF ONE MILLION TONNES AND ABOVE
Total : 146 Large Cement Plants
ENERGY INPUTS TO INDIAN CEMENT INDUSTRY
ITEM % OF COST OF PACKED CEMENT
RAW MATERIAL 10-15
COAL 20-25
POWER 17-20
MANPOWER 5-8
COAL CONSUMPTION : 22 Mn TONNES/YEAR
POWER CONSUMPTION : 14 BILLION UNITS/YEAR
TOTAL ENERGY BILL : RS 95 BILLION/YEAR
120122117
111112110
104105102
9791
8984 83 82
78 77 79 79
67 65
60
80
100
120
91 93 95 97 99 '01 '03 '05 '07 '09
ENERGY CONSUMPTION PROFILE(DRY PROCESS PLANTS - WTD. AVG.)
876857 846
816 815801
780 779 771763 750
742 734 729723 726 730 721 726
687
650
600
650
700
750
800
850
900
91 93 95 97 99 '01 '03 '05 '07 '09
TH
ER
MA
L
EN
ER
GY
KC
AL
/KG
CL
.
EL
EC
TR
ICA
LE
NE
RG
YK
WH
/T C
EM
EN
T
BEST IN INDIA
BEST IN WORLD
DATA OF 40 DRY PLANTS
Indian Cement Industry - Production & Energy Consumption
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
Year (1988-2009)
Va
lue
s a
s In
dic
ate
d
Production (Mn.T) Thermal Energy (kcal/kg Cl.)
Electrical Energy (kWh/t Cem)
128
726
79910
181
42
TOOLS OF ENERGY EFFICIENCY IMPROVEMENT
EXISTING PLANTS TECHNOLOGY UPGRADATION RETROFITTING OF ENERGY EFFICIENT EQUIPMENT
NEW PLANTS IDENTIFICATION AND SELECTION OF STATE-OF-THE-ART
TECHNOLOGIES
FUEL QUALITY BLENDING WITH IMPORTED COAL FOR IMPROVING
AVERAGE QUALITY USE OF PET-COKE & OTHER COMBUSTIBLE WASTES
BLENDED CEMENT GREATER USE OF INDUSTRIAL WASTES LIKE FLYASH
AND SLAG FOR MAKING BLENDED CEMENTS
Contd.
MANAGEMENT SYSTEMS ENERGY MANAGEMENT TOTAL PRODUCTIVE MAINTENANCE (TPM),
COMPUTERIZED MAINTENANCE SYSTEM AND INVENTORY CONTROL
TOTAL QUALITY MANAGEMENT (TQM) REFRACTORY MANAGEMENT SYSTEM
POWER SUPPLY IMPROVING QUALITY OF POWER THROUGH CAPTIVE
GENERATION (DIESEL, THERMAL AND WIND POWER) PERFORMANCE MONITORING
INTER-FIRM COMPARISON AND BENCHMARKING TARGET SETTING AND MONITORING
Energy Efficient Cement Manufacturing Technologies
HIGH EFFICIENCY SIZE REDUCTION TECHNIQUES
VERTICAL ROLLER MILL BALL MILL OPERATION IN CLOSED CIRCUIT BOLTLESS & CLASSIFYING LINERS IN BALL
MILLS ROLLER PRESS V - SEPARATOR SEPARATOR
HIGH EFFICIENCY TWO-STAGE MODULAR SEPARATOR SYSTEM
15
19
0
5
10
15
20
25
30
KW
H/T
MA
TE
RIA
L
VRM BALL MILL
TYPE OF MILL
ELECTRICAL ENERGY CONSUMPTIONVRM Vs BALL MILL (RAW MILL)
27 26
32
0
5
10
15
20
25
30
35
40
KW
H/T
CE
ME
NT
VRM RP + BM BALL MILL
TYPE OF MILL
ELECTRICAL ENERGY CONSUMPTIONVRM Vs ROLLER PRESS Vs BALL MILL (CEMENT MILL)
HIGH EFFICIENCY PYRO-PROCESSING SYSTEMS
LATEST GENERATION PRECALCINER 5/6 STAGE PREHEATER WITH LOW PRESSURE
CYCLONES HIGH EFFICIENCY GRATE COOLER MULTI-CHANNEL BURNER
702 718
300
450
600
750
KC
AL
/KG
CL
INK
ER
PC (6-ST) PC (5-ST)
TYPE OF KILN CIRCUIT
THERMAL ENERGY CONSUMPTION6-ST PC Vs 5-ST PC
OTHER EFFICIENT EQUIPMENT/SYSTEMS
HIGH EFFICIENCY POLLUTION CONTROL EQUIPMENT (LESS THAN 50 mg/NM3 EMISSION)
ELECTRO-STATIC PRECIPITATOR (ESP) FIBRE GLASS BAG FILTER
HIGH EFFICIENCY FAN (75-82% EFFICIENCY) ENERGY EFFICIENT MOTOR (93-95% EFFICIENCY) VARIABLE SPEED AC DRIVES EFFICIENT ILLUMINATION SYSTEMS MECHANICAL MATERIAL CONVEYORS (IN PLACE OF
PNEUMATIC CONVEYING SYSTEMS) HIGH SPEED HIGH CAPACITY BUCKET ELEVATOR PIPE CONVEYOR
PRESENT STATUS OF TECHNOLOGY
PRESENT STATUS OF TECHNOLOGY
Low Technology Plants
Modern Plants Global Technology
Mining and Material Handling
Conventional Computer aided Computer aided
Crushing Two stage Single stage In-pit crushing & conveying
Conveying of Limestone
Dumpers/Ropeway/ Tippers
Belt conveyors Pipe conveyors, Belt conveyors
Grinding Ball Mills with / without conventional classifier
VRM’s, Roller Presses with dynamic classifier
VRM’s, Roller Presses with dynamic classifier
Contd…..4
Low Technology Plants Modern Plants Global Technology
Pyro Processing
WetSemi Dry Dry - 4 stage preheater- Conventional cooler- Single channel burner
Dry- 5/6 stage preheater- High Efficiency
Cooler - Multi Channel
Burner
Dry- 6 stage preheater- High Efficiency
Cooler - Multi Channel
Burner- Co-processing of
WDF- Co-generation of
power- Low NOX/SO2
emission technologies
Blending & Storage
Batch-Blending Silos Continuous Blending silos
- Continuous Blending
- Multi-chamber Silos
- Dome silosContd…..
5
Low Technology Plants
Modern Plants Global Technology
Packing & Dispatch
Bag - Bag- Bulk
- Bulk- Palletizing &
Shrink Wrapping
Process Control Relay Logic / Hard Wired / PLC
- DDC-Fuzzy Logic expert system
- DDC- Neurofuzzy expert
system
Energy consumption level
90-100 kWh/t cem.900-1000 kcal/kg cl.
75-85 kWh/t cem.700-800 kcal/kg cl.
70-80 kWh/t cem.675-740 kcal/kg cl.
Plant Size (TPD)
300 – 1800 3000 – 6000 6000 – 12000
6
BLENDED CEMENTS
CEMENT VARIETIES – CEMENT VARIETIES – PRODUCTION IN 2008PRODUCTION IN 2008
Ordinary Portland Cement (OPC) : 25 %
Portland Pozzolana Cement (PPC) : 66.50 %
Portland Slag Cement (PSC) : 8 %
Other Cements : 0.50 %
SHIFT IN TYPE OF CEMENT YEAR OPC
(%)
PPC+PSC(%)
1999 67 32
2004 45 54
2008 25 74
CO2 EMISSION FROM CEMENT MANUFACTURE
SOURCES OF CO2 EMISSION
OPC PPC
Tonne /t % Tonne /t %
CALCINATION 0.50 60 0.37 58
COMBUSTION OF FUEL 0.24 29 0.176 28
USE OF POWER 0.09 11 0.09 14
TOTAL 0.83 100 0.636 100
ALTERNATE FUELS AND ENVIRONMENT
Benefits of Utilization of Alternate Fuels in Cement Kiln
• Prevents resource depletion of non-renewable fossil fuels
• Lowers the emissions of gases such as GHG’s by replacing the use of fossil fuels
• Maximises energy recovery. All the available energy is used directly in the kiln for clinker production
• Eliminates the need for disposal of inorganic ashes
and slags as they act as substitute raw material in the cement
Alternate Fuels : Problems and Prospects
Deciding Factors for utilization of Alternate Fuels are :-
Proximity of the cement plant to the source Extent of availability on sustainable basisCompositional compatibility of raw materials and the
Alternate Fuels.Type of cement manufacturing process employed and
production capacity. Infrastructural facilities for handling and storage.
COGENERATION OF POWER UTILISING WASTE HEAT IN CEMENT MANUFACTURE
WHR SYSTEM FOR POWER GENERATION
ITEM UNIT PH AQC
1 VOLUMETRIC FLOW RATE NM3/H 360750 191600
2 BOILER INLET TEMPERATURE DEG. C 340 360
3 BOILER OUTLET TEMPERATURE DEG. C 230 90
4 GROSS POWER GENERATION KW 7700 (30%)
5 ANNUAL REDUCTION IN POWER PURCHASED
MILLION KWH
56.07
6 ANNUAL SAVING OF POWER COST RS MILLION 232.70
7 ANNUAL REDUCTION IN FOSSIL FUEL EQUIVALENT
TONNES
(OIL BASIS)
14517
8 ANNUAL REDUCTION IN CO2 TONNES 45000
(5% of Total)
CONCLUSION
MAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY
MAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY
TECHNOLOGY UPGRADATION & USE OF ENERGY EFFICIENT TECHNOLOGY FOR PRE-1990 PLANTS
WASTE HEAT RECOVERY FOR COGENERATION OF POWER
AUTOMATION, ON-LINE QUALITY CONTROL & EXPERT CONTROL SYSTEM
USE OF ALTERNATE FUELS INCLUDING RUBBER TYRES, AGRICULTURAL, INDUSTRIAL & MUNICIPAL WASTES
EFFICIENT COLLECTION, PROCESSING & TRANSPORTATION SYSTEMS FOR ALTERNATE FUELS
USE OF RENEWABLE ENERGY SOURCES USE OF NATURAL GAS AS FUEL IN CEMENT PLANT
CLUSTERSContd./-
ADOPTION OF TECHNOLOGIES FOR REDUCING EMISSION OF SO2 & NOX
BULK TRANSPORTATION OF CEMENT FUTURE R & D EFFORTS:
MAXIMISING UTILIZATION OF ALTERNATE FUELS, FLY ASH, SLAG AND OTHER RAW MATERIALS
ALGAL FARMS FOR CO2 ABSORPTION
NANO TECHNOLOGY IN CEMENT MANUFACTURE AND USE
BETTER COMBUSTION EFFICIENCY TECHNOLOGIES
MAJOR AREAS FOR ENERGY EFFICIENCY IN INDIAN CEMENT INDUSTRY
