Cement and Energy

-~ - ~· -- CEMENT and ENERGY , A QUARTERLY NEWS LETTER Vol. II No. 1 January 1998 EDITORIAL BOARD R. Partha Sarathy Dr. S.P. Ghosh P.K. Tikku VK.Arora S.V.Joshi CONTENTS • New Insulating Bricks for Calcination Zone 1 ~ • Cogeneration of Power Utilising 2 Waste Heat in Cement Manufacture ~ · Combustible Wastes as Source of Energy ~ · Pilot Cogeneration Plant under Installation • • Round-up ~ ~ Productivity and Energy Efficiency Awards to Cement Industry It• Clinker Cooler Replacement • • Reducing Pressure Loss and Saving Energy with a Vortex Finder Vane System • • Forthcoming Events For Private Circulation 4 5 6 7 7 9 13 U'itli tliis iss~ "Cement altlf 'Enertf.YJI' enters its secomlyear of!uo!ication.. 'l1ie !l{pusfetter lias 3een we[{received. "Cement altlf 'Enertf.YJI' wislies a[{ its reatfers a Ve'!f Jfaff!l andPros1erous 1998. (~ !Partha Sara~) Secreta'Y genera£ CMft NEW INSULATING BRICKS FOR CALCINATION ZONE T n cement rotary kilns lined with conventional insulation bricks, a good Lmount ofheat still manages to escape to the outer shell from where it is lost through radiation . This loss is estimated to be 6-12% of the total heat input to the system, and 30% of this takes place over the calcination zone. To mi tigate this problem, a new generation of insulating lining bricks has been developed for the calcination zone -by Shri- Nataraj -Ceramic and Chemical lndusuies Limited (SNCCIL), Dalmiapurain.' ·.'' •.· Thermal Energy Saving Known by the proprietary name Dalmia Clog bricks, these are claimed to reduce kiln shell temperatures by 30 to 40o C thereby cutting down radiation losses. The resultant saving in heat is 3- 7 kcal/kg clinker depending on the kiln diameter, length and its production capacity. The annual saving will work out to 1740 million kcal for a 3.80 m dia kiln ofcapacity I 800 TPD with precalciner and 1100 TPD with nom1al preheate r. The thermal efficiency and fuel saving is achieved by a special design in which the total Slllface contact area with the shell has been reduced by 70% at the cold end. The gap between the contact areas is filled with low thermal conduction insulating matetial. The lower contact area and voids leave little room for heat to be conducted to the outer shelL A cluster of air