Cement Energy Environment

73 COMPRESSED AIR SAVING DEVICE “A PORTABLE, ECONOMIC HOT SPOT COOLING SOLUTION TO PLUG AND ELIMINATE ROUTINE ENERGY WASTE IN CEMENT PLANTS” Compressed air is a very useful tool in cement manufacturing process. It is used to provide the energy to move materials and items of equipment. However, it is a very expensive form of energy. The air is almost always compressed by electrically-driven screw compressors. Unfortunately, only 10 per cent of Abstract the electrical energy input goes for producing useful mechanical work. The remaining some 90 per cent is lost as heat with compression and idling losses being the greatest. Owing to this, Compressed air is such an expensive form of energy. By K K Sharma, U K Sharma & Ketan Goel Invotech Industrial Solutions Private Limited India is reckoned as the second largest cement producer in the world, which accounted for over 12% of the global installed capacity as of 2020. India’s overall cement production capacity was nearly 545 MT in FY20. Of the total capacity, 98% lies with the private sector and the rest with public sector. The top 20 companies account for around 70% of the total cement production in India. Further, as India has high quality and quantity of limestone deposits, the cement industry promises huge potential for growth. The demand of cement industry is expected to reach 550-600 MT per annum (MTPA) by 2025 because of the expanding demand of different sectors, i.e. housing, commercial construction, and industrial construction. Introduction The above data may be enough to assume at what level cement manufacturing units must be using Compressed air in their production facilities. It is too easy for Companies to take compressed air for granted for their use and abuse to grow. Such abuses become ingrained in the way the cement factory is operated. However, in order to survive in a tough competitive environment, many companies are searching for ways to make savings in their production. Such savings can often be found in their existing compressed air systems, which have generally been in place for years. Up to 60% of energy costs can be saved through optimization at both the production facility and system level. Even small gains in efficiency and reduction in consumption