Cement, Energy and Environment

Energy Audit – A few case studies: I) Methodology The methodology for carrying out energy audit studies involves collection of relevant data through questionnaires, field measurements of process & electrical parameters with the help of portable instruments and analysis of data for identifying the areas of thermal as well as electrical energy saving. ii) Case studies Energy audit study was carried out by NCB in two different cement plants during 2018-19. Plant ‘A’ having FLSmitdh Inline Calciner (ILC) kiln equipped with 6 stage preheater and grate cooler, Vertical Roller Mill for raw material capacity of 560 TPH, coal mill capacity of 75 TPH and cement mill capacity of 260 TPH PPC. Plant A is also having two nos of CPP with rated capacity of 15 MW & 25 MW. Plant ‘B’ having FLSmitdh SLC kiln with 6 stage PH and grate cooler, Ball Mill for raw material of capacity of 145 TPH, coal mill capacity of 21 TPH and cement mill capacity of 45 TPH. Plant B is also having waste heat recovery system for generation of electricity from the waste gases from preheater and cooler. These two kilns having rated capacity of 7000 tpd and 4300 tpd were producing 7900 tpd and 4048 tpd clinker respectively during the period of the energy audit study. Design data and key performance indicators of these plants are mentioned hereunder: 33