Cement Energy and Environment

Table 6. Findings of a Sample Energy Review Study Energy Review Objectives Energy Review Targets Areas of Improvement ---------------------------------- -~--· ---- - 1- To reduce energy consumption 2- Waste Heat Recovery 3- Using advanced technology 4- C02 Reduction 5- Creating Awareness on Energy Efficiency for all Employees 6- Using alternative Fuels (Waste) 7- 1.1 3kWh/t product decrease in Raw Mill energy consumption 1.2 4kWh/t clinker and 15kCal/kg clinker decrease in kiln energy consumption 1.3 ... 1.4 ... 2.1 40 Milyon kWh/y electricity saving 1.2 ... 1.3 ... 3.1 kWh/t cement decrease in cement mill energy consumption 3.2 kWh/t coal decrease in coal mill energy consumption 3.3 4.1 80.000 t C02/y decrease for Plant 4.2 ... 4.3 .. . 5.1 4 h/y training per employee 5.2 6.1 1.000 Uy petcoke saving by using 10.000 Uy waste. 6.2 1- 2- 3- 4- 5- 6- Making out of service 2 pes bag filter To reduce the moisture of raw material Solving the wear problem to the mill table of Raw Mill #1 Removal of fresh air suction at intel gas pipe of Raw Mill #2 Removal of fresh air suction from the body of Bag Filter Renewal of low-precision old weigher for Rotary Kiln #1 coal supply 7- Using expert system for process control of R. Kilns and Mills 8- Waste Heat Recovery 9- Changing static separator of Cement Mills #3 with dynamic separator which is high efficiency 10- Changing 100 pes Electronic with high efficient ones. 11- Reactive power compensation and solving harmonic distortion (Legal Obligation) 12- Increase amount of secondary fuel (waste) 13- Increase cyclone efficiency for R. Kiln #1 14- Increase Clinker cooler efficiency for R. Kiln #2 15- To detect air leakage on compressed air lines 16- Using LED type lighting fixtures for outdoor lighting 17- ... NOTE It is important to survey Energy Usage Areas in detail and to find tens of improvement points during the energy review study which will be made by Energy Management Team 15