Cement and Energy

.. Rajashree's Experience Under its Vision-2002. the plant has drawn up an action plan for Unit-II based on Unit -III experience for achieving benefits of increase in production, reduction m power and them1al consumption. The proposed modifications are given in Table 2. As shown in Table 2, all energy saving plans have already been implemented and the results are encouraging. However, the savings indicated are yet to be fully realised as the system is under stabilisation. Table 2 Energy Conservation Measures Implemented in Unit-II S.No. I 2 3 S. No. 2 Sectionwise Measure (s) Adopted Potential Ener~y Savings Power Thermal kWh/t of kcal/kg of cement clinker Raw Mill Bucket elevator in place of air lift for raw meal feeding to silo 2.00 - Kiln a) Retrofit of one grate cooler with pyrojet grate (Fig. I) 0.50 30 b) Installation of variable speed drives in all grate cooler fans (ACFC) 1.00 - c) Installation of variable speed drives like GRR in kiln ESP fans, cooler ESP fans, PH fans 1.15 - d) Pfister pump (Pyro) 0.25 3 Cement Mill Bucket elevator in place of air lift for cement feeding to silo 1.85 - Total 6.75 33 Table 3 Further Energy Conservation Measures Proposed in Unit-II Measure Proposed Installation of bucket elevator in place of air lift in kiln feed of ~reheater Installation of high efficiency/low primary air (pyrojet) burner in kil~ . Total Potential Energy Savings Status of Implementation Power Thermal kWh/t of kcal/kg of cement clinker 2 3 Feasibility under study - 6 Under installation 2 9 By adopting the measures gtven 111 Table 3, a further of 2.00 kWh/ton of cement in power and 9.00 kcallkg of clinker in thermal energy can be .anticipated. Thus the overall power consumption will ultimately reduce from 104 to 95.25 kWh/t of cement and thermal energy consumption from 742 to 700 kcal /kg of clinker. Fig 1 Stationary step grate plate, directly aerated