Cement, Energy & Environment Jan-Mar 2002

kcal/ ton of clinker for its energy needs. NCL appointed M.K. Raju Consultants Private Limited, a reputed energy auditor, to identify energy savings areas in the plant. The energy saving measures that M.K. Raju recommended for the company to implement are given ill the box below. Equipment/System/Measures Proposed In sta lla tion of low-pressure -drop high-efficiency cyclones Installations of air-canons to avoid januning of pre- heater cyclones Replacement of kiln inlet seals and double flap valves to arrest air infiltration Installation of automation system for Pyro processing system Installation of gear box to increase speed of the rotary kiln to increase capacity Insta lla tion of Bucket Eleva tor for raw material transport to blending silo Installa tion of Bucket Elevator for kiln feed Installation of Bucket Elevator for cement conveying silo Increas ing efficiency of cooler by insta lling high- efficiency grate plates Improvement in performance of raw mills and lime stone crushing system - · Providing insulation and refractory for al cyclones and riser ducts Increasing length of existing riser duct of pre-calciner to facilitate additional heat recovery from pre-heater gases Providing energy efficient high-chrome-alloy line for cement mills Total IREDA sanctioned a tern loan of Rs 320 lakh to par t finance the project. Once adopted, these measures will achieve the following: 34 Cost Electrical Thermal (Rs Lakh) Energy Saving Energy Saving (Lakh kWh/year (MTCR/year) • 50.0(). 6.81 914.87 10.00 0.13 195.92 8.00 0.00 894.28 52.00 2.60 882.51 11.00 1.74 CI.OO 34.50 2.78 0.00 36.50 3.84 0.00 24.50 1.97 0.00 65.4o" 1.56 547.16 43.30 7.01 0.00 20.00 0.00 329.47 14.80 0.00 1023.72 90.00 8.99 0.00 460.00 37.43 4787.93 Lower energy consumption to 105.6 kWh / ton of cement and 863.6 kcal/ton of clinker.