Cement Energy Environment

55 Process fans are one of the major energy consumers in cement plant. At MCW, the power consumption of unit-1 preheater fan is about 9.8 kWh/ton. During the measurements carried out at the preheater fan, it was observed that the preheater fan inlet box velocity was about 30.38 m/s. The high velocity was attributed to the high pressure drop across the inlet box and the damper. An energy saving proposal was made by in-house Enlargement of all major process fans inlet box to reduce the power consumption energy team to increase the inlet box area and to reduce the pressure drop to the extent of about 25 to 30 mmwc. Based on the suggestion and the proposal the preheater fan inlet box and the damper were modified and achieved 21 kW/hr power reductions. After achieving the power reduction, we have implemented the similar modification in four other major fans. As a result of the interventions, annual saving of INR 42 Lakhs from electrical energy savings (0.30 kWh / MT Clinker) and (0.1 kWh/MT Cement) was achieved in this fan inlet box modification. Fan inlet pressure drop reduction Fan power reduction Annual savings Investment Description mmwg kW/hr Rs Lakhs/Annum Rs Lakhs Units 25 21 7.48 1.0 PH fan-1 15 8 2.37 0.9 VRM-1 40 45 16.03 1.0 PH fan-2 30 40 14.25 1.1 PH fan-3 14 10 2.25 0.8 CM-2CA fan