Cement, Energy and Environment

Operational and Optimization measures towards Energy Conservation 1. Kiln optimization 2. Ball Mill/VRM/Roller Press/Ball Mill + Roller Press optimization 3. Optimizing idle running of equipment 4. Installation of improved refractory in pyro section 5. Effective utilization of hot exit gases for drying of material 6. Optimization of cooler operation 7. Arresting leakages in Kiln/Preheater/Cooler, grinding circuits 8. Rationalization of compressed air utilization 9. Optimization of raw mix 10. Increase in the use of fly ash/slag. Utilization of Energy Efficient Equipment Use of energy efficient equipment gives very encouraging results even at the cost of some capital investment. A number of energy efficient equipment are now available to improve the energy performance of the units. Analysis revealed that more and more plants are now going for these available energy saving equipment. Various energy saving equipments available for plant operation are given below: 1. Energy efficient motors 2. Low pressure preheater cyclones/modification in cyclones 3. Variable Frequency Drives (VFD) 4. Medium voltage drives 5. High efficiency fans 6. High efficiency separators 7. Improved ball mill internals/mill upgradation 8. High efficiency cooler 9. Bucket elevators in the place of pneumatic conveying system 10. Expert kiln/mill control system 11. Water Spray System in Preheater down comer 12. Efficient fly ash feeding system 13. Cogeneration of power through waste heat recovery system 14. Harmonic filters 15. Precalciner modification. A typical flow sheet of a cement plant indicating some energy conservation measures are given in Fig below. Flow sheet of Cement plant with energy conservation measures 32