Cement Energy and Environment

Table 3. Units' Current Energy Consumptions- January 2014 CONSUMPTION of SPECIFIC ELECTRICAL ENERGY kWh/ ton cement PREBELNDING 0,40 0,35 I 0,50 0,45 CRUSHERS II 0,70 0,68 Average 0,65 0,62 I 15,10 15,00 RAW MILLS II 17,50 19,00 Average 16,40 18,00 I 24,25 25,00 ROTARY KILNS II 23,65 23,00 Average 23,20 24,00 I 21,50 20,50 COAL MILLS II 18,00 18,50 Average 19,50 20,00 I 28,45 28,00 CEMENT MILLS II 30,65 30,00 Ill 30,00 31 ,00 Average 29,25 30,00 PACKAGING UNITS COMPRESSOR SOCIAL FACILITIES LIGHTING ELECTRICAL ENERGY LOSSES TOTAL In a cement plant the variables affecting the energy consumption can be listed as: raw material characteristics, fuel characteristics, power quality, design changes, demand conditions according to the change of product plans, maintenance, number of failures, shift I operator changes, differences of production processes, motivation and moods of operators, climate conditions, and etc. Besides these the staff directly affecting energy consumption in order of priority can be listed as: Operators of Central Control Room, Maintenance Employee, Technicians, Engineers, Technical Chiefs, Managers {Technical and Procurement), and Procurement Staff. The variables affecting energy consumption in 2013 were: • Rainy winter months in 2013 increased 5% moisture content of raw materials. This caused 2% increase in energy consumptions of Crusher and Raw Mills 1,60 1,50 2,50 2,50 0,20 0,22 0,50 0,40 2,20 2,00 101 ,35 100,00 • Bad grindability of export coal caused 2 kWh/ton coal increase in energy consumption of Coal Mill in April-May-June. • 5% increase in electrical and heat energy • consumptions of Kiln# 1 in March becaus& of unexpected failures. • 7% decrease in electrical and heat energy consumptions of Kiln#2 in April because of annual revision. Energy Review Study 1. Significant Energy Usage Areas Energy Usage Areas and consumption amounts in 2013 are given below. As seen in Table 4, 98,8% (136.541 TEP*IOO I 138.136 TEP) of energy consumption was realized in main production units which are defined as Significant Energy Usage Areas. These units are; "Preblending, Crushers, Raw Mills, Rotary Kilns, Coal Mills and Cement Mills". 11