Cement Energy and Environment

"E .. E .. " 0 ~ ~ 8. "' "E :> ·"----------------------, The yearly average consumption is 115.38 units up to Dec. 1998; the plant was stopped about 7 months due to recession in the cement market. But in December 1998, a figure of 103 kWh/tonne was achieved. 17 0 160 150 140 130 120 11 0 100 90 "' "! 0 "' F "' "' ~ "' No. I. 2. 3. 4. 5. 6. g .,; ... ,;;;, "' "' "' "' ·- 0 <D ..; 0 "' ... ..; ,;,. "' ;. 1- 0 0 "' ~ "! "' "' .,; ... ... ... ;;;. F ;;, ~-N ~ 1- "' ..; "' !:? ! F ;;; ... ... "' ..; F 1- 1- - "' "' ~ M .,; F - - - "' "' "' "' r!. a:, "' "' i I I I I i I J Modifications Carried Out Fig11re 1 Yearwise Power Consumption The modifications carried out and the respective saving in power achieved are summarised chronologically in Table 2. Table 2 Modifications carried out and power saving accrued Plant Section Modification Power Saving Year of kWh/tonne of Commissioning Cement Raw mill Installation of bucket elevator in place of PS 2.49 1996-97 pump Kiln Replacement 6 cooler fans with higher 2.00 1996-97 efficiency fans Kiln Installation of bucket elevator in place of PS 3.07 1996-97 pump for kiln feed transportation Cement mill Installation of belt conveyor in place of PT 3.72 1996-97 pump for cement transportation Kiln Installation of new cooler ESP for clinker 2.00 1997-98 dust recovery. Replaced 6.6 KV 425 HP ID fan with 415 volts 150 HP motor Kiln Replacement of preheater fan with higher Improved 1998-99 efficiency fan preheater inlet draught from 560mmWG to660 mm WG. In addition to the major modifications carried out, various changes in the operation system and several minor modifications are being incorporated on a continuing basis to bring down the overall power consumption and improve the productivity. The measures so introduced are as follows : ii) Minimised false air entry into preheater section and gas conditioning tower; this could considerably reduce specific heat consumption and also decrease the power consumption per tonne of clinker besides optimising production level. i) Incorporated secondary firing system with the efforts of our in-house dedicated team of engineers; as a result, the production could increase to 5-7 TPH of clinker. iii) In lighting circuit, extra fittings were removed wherever not required and greater use of natural light favoured in offices. Halogen fittings, incandescent lamps, HPMV lamps were replaced with higher efficiency HPSV lamps on a continuous basis. 2