scholarly journals Parametric Studies of Cement Production Processes

2020 ◽  
Vol 2020 ◽  
pp. 1-17 ◽  
Author(s):  
John P. John
Keyword(s):  
Energy Consumption ◽  
Alternative Fuels ◽  
Cement Industry ◽  
Production Costs ◽  
Cement Clinker ◽  
Cement Production ◽  
Exhaust Gases ◽  
Industrial Sectors ◽  
Study Results ◽  
Parametric Studies

The cement industry is one of the most intensive energy consumers in the industrial sectors. The energy consumption represents 40% to 60% of production cost. Additionally, the cement industry contributes around 5% to 8% of all man-made CO2 emissions. Physiochemical and thermochemical reactions involved in cement kilns are still not well understood because of their complexity. The reactions have a decisive influence on energy consumption, environmental degradation, and the cost of cement production. There are technical difficulties in achieving direct measurements of critical process variables in kiln systems. Furthermore, process simulation is used for design, development, analysis, and optimization of processes, when experimental tests are difficult to conduct. Moreover, there are several models for the purpose of studying the use of alternative fuels, cement clinker burning process, phase chemistry, and physical parameters. Nonetheless, most of them do not address real inefficiency taking place in the processes, equipment, and the overall system. This paper presents parametric study results of the four-stage preheater dry Rotary Kiln System (RKS) with a planetary cooler. The RKS at the Mbeya Cement Company (MCC) in Tanzania is used as a case study. The study investigated the effects of varying the RKS parameters against system behaviour, process operation, environment, and energy consumptions. Necessary data for the modelling of the RKS at the MCC plant were obtained either by daily operational measurements or laboratory analyses. The steady-state simulation model of the RKS was carried out through the Aspen Plus software. The simulation results were successfully validated using real operating data. Predictions from parametric studies suggest that monitoring and regulating exhaust gases could improve combustion efficiency, which, in turn, leads to conserving fuels and lowering production costs. Composition of exhaust gases also depends both on the type of fuel used and the amount of combustion air. The volume of exit flue gases depends on the amount of combustion air and infiltrating air in the RKS. The results obtained from the study suggest a potential of coal saving at a minimum of about ṁcoal=1263 kg·h−1, which approximates to 76,126 tons per year at the current kiln feed of 58,000 kg·h-1. Thus, this translates to a specific energy saving of about 1849.12 kJ·kgcl-1, with relatively higher clinker throughput. In this vein, process modelling provides effective, safe, and economical ways for assessing the performance of the RKS.

Use of waste derived fuels in cement industry: a review

2016 ◽  
Vol 27 (2) ◽  
pp. 178-193 ◽  
Author(s):  
Nickolaos Chatziaras ◽  
Constantinos S. Psomopoulos ◽  
Nickolas J. Themelis
Keyword(s):  
Alternative Fuels ◽  
Fossil Fuels ◽  
Fossil Fuel ◽  
Cement Industry ◽  
Wastewater Sludge ◽  
Cement Clinker ◽  
Firing Process ◽  
Cement Production ◽  
Content Type ◽  
Recycled Plastics

Purpose – Cement production has advanced greatly in the last few decades. The traditional fuels used in traditional kilns include coal, oil, petroleum coke, and natural gas. Energy costs and environmental concerns have encouraged cement companies worldwide to evaluate to what extent conventional fuels can be replaced by waste materials, such as waste oils, mixtures of non-recycled plastics and paper, used tires, biomass wastes, and even wastewater sludge. The paper aims to discuss these issues. Design/methodology/approach – The work is based on literature review. Findings – The clinker firing process is well suited for various alternative fuels (AF); the goal is to optimize process control and alternative fuel consumption while maintaining clinker product quality. The potential is enormous since the global cement industry produces about 3.5 billion tons that consume nearly 350 million tons of coal-equivalent fossil and AF. This study has shown that several cement plants have replaced part of the fossil fuel used by AF, such waste recovered fuels. Many years of industrial experience have shown that the use of wastes as AF by cement plants is both ecologically and economically justified. Originality/value – The substitution of fossil fuels by AF in the production of cement clinker is of great importance both for cement producers and for society because it conserves fossil fuel reserves and, in the case of biogenic wastes, reduces greenhouse gas emissions. In addition, the use of AF can help to reduce the costs of cement production.

Carbon Management in an Emissions-Intensive Industry in a Developing Economy: Cement Manufacturing in Indonesia

2018 ◽  
Vol 2 (1) ◽  
pp. 1-9 ◽  
Author(s):  
Togar W. S. Panjaitan ◽  
Paul Dargusch ◽  
Ammar A. Aziz ◽  
David Wadley
Keyword(s):  
Alternative Fuels ◽  
Cement Industry ◽  
Cement Production ◽  
Carbon Management ◽  
Production And Consumption ◽  
Carbon Dioxide Equivalents ◽  
Strategic Position ◽  
Reduce Emissions ◽  
Cement Manufacturing ◽  
Capital Intensive

Around 600 Mt carbon dioxide equivalents (CO2e) of anthropogenic greenhouse gases (GHG) emission originates from energy production and consumption in Indonesia annually. Of this output, 40 Mt CO2e comes from cement production. This makes the cement industry a key sector to target in Indonesia’s quest to reduce its emissions by 26% by 2020. Substantial opportunities exist for the industry to reduce emissions, mainly through clinker substitution, alternative fuels, and the modernization of kiln technologies. However, most of these abatement options are capital intensive and considered as noncore business. Due to this, the private sector is unlikely to voluntarily invest in emission reduction unless it saves money, improves revenue, enhances the strategic position of the firm, or unless governments provide incentives or force adoption through regulatory and policy controls. In this study, we review the profile of the Indonesian cement industry and assess the carbon management and climate policy actions available to reduce emissions. The case highlights opportunities for improved carbon management in emission-intensive industries in developing countries.

Co-Processing Hazardous Waste in the Chinese Cement Industry - Status 2014

2015 ◽  
Vol 768 ◽  
pp. 679-686 ◽  
Author(s):  
Juan Xu ◽  
Shao Feng Sun ◽  
Kårehelge Karstensen ◽  
Da Hai Yan ◽  
Zheng Peng
Keyword(s):  
Waste Management ◽  
Hazardous Waste ◽  
Alternative Fuels ◽  
Raw Materials ◽  
Cement Industry ◽  
Waste Generation ◽  
Cement Production ◽  
Management Capacity ◽  
The World

As China develops its economy, hazardous waste generation is expected to increase rapidly. Recovery and recycling, i.e. co-processing of Alternative Fuels and Raw materials (AFRs) and treatment of hazardous waste in energy-and resource-intensive industries such as the cement industry seems to be an supplementary option to conventional technologies which can increase the overall waste management capacity in China significantly. With the largest cement production in the world, the industry can save significant amounts of non-renewable coal and raw materials by substitution with wastes which needs treatment. However, co-processing requires appropriate regulations and policies to support its development and safe and sound implementation.

scholarly journals Metode Menentukan Klor dalam Sludge Oil: Perbandingan Metode Wet dan Metode Jena

2021 ◽  
Vol 10 (1) ◽  
pp. 1-7
Author(s):  
Herliati Rahman ◽  
Akhirudin Salasa
Keyword(s):  
Environmental Sustainability ◽  
Alternative Fuels ◽  
Negative Impact ◽  
Raw Materials ◽  
Cement Industry ◽  
Raw Material ◽  
Chlorine Content ◽  
Cement Production ◽  
Average Accuracy ◽  
The Difference

Currently, the use of alternative fuels and raw materials (AFR) in the cement industry is very attractive. This is driven by demands for environmental sustainability and the efficiency of fuel and raw material costs. One of the materials that can be used as AFR is sludge oil. However, it needs to be ensured that the chlorine content in the sludge oil does not exceed the threshold so that it does not have a negative impact during the cement production process. It is known that if the chlorine content is more than the threshold, it can cause blocking or clogging of the separator and the kiln. This study aims to determine the performance of the Jena Multi EA 4000 instrument in determining the chlorine content in sludge oil quickly and accurately. Analytic Jena Multi EA 4000 is an Atomic Absorption Spectrometers (AAS) instrument that can be used for analysis of samples in the form of solids or slurries containing chlorine. As validation of the resulting analysis, the wet method is used, which as usual, to determine chlorine levels. From the statistic analysis, namely the F-test and T-test, We found that F-count equal to 0.0080 and F-table equal to 4.2839. it shows that F-count < F-table, indicating the difference in the variance of the two methods H0: s12 = s22 is accepted because there is no difference to the variability of these two tests and the value of T-count = -3.9717 and T-table = 2.1788 so that T-count <T-table is accepted because there is no difference in the average accuracy of the two methods H0: M1 = M2.  

scholarly journals Renewable Energy and Other Strategies for Mitigating the Energy Crisis in Nepal

2021 ◽  
Author(s):  
◽  
Ramhari Poudyal
Keyword(s):  
Renewable Energy ◽  
Energy Supply ◽  
Supply And Demand ◽  
Cement Industry ◽  
Production Costs ◽  
Solar Irradiation ◽  
Energy Crisis ◽  
Cement Production ◽  
The Government

The overarching aim of this research is to carefully review Nepal’s energy scenario from the technical and socio-economic perspective in order to determine the optimal near-term as well as long-term strategies to overcome the energy crisis. Renewable energy sources are pivotal to this research due to the abundant availability of these resources in Nepal. The long-term energy supply and demand forecast for Nepal overthe next 30 years was obtained in Long-Range Energy Planning (LEAP) software.Other quantitative results were obtained using software packages, including PVsyst,Meteo, and HOMER. In many other cases, energy data collected from open literature,government and regulator reports were analysed. There are also several case studies considered in the thesis.The PV rooftop energy systems for Nepalese town and rural households can minimise the energy trade deficit with neighbouring India, enhance energy security,and improve local employment opportunities as well as improve utilisation of the local resources. In particular, a 3kW PV rooftop system was designed and simulated inMATLAB/Simulink, and the corresponding PV and IV curves were obtained,including analysing the effects of environmental temperature and solar irradiation. The design was followed by techno-economic feasibility, assuming typical households in the Kathmandu valley. The study outcome is that the PV system for a residential building in Kathmandu is economically feasible, and it can provide nearly 6,000kWh/year of energy.The potential energy efficiency improvements in the cement industry were studied using data collected directly at one of the major cement plants in Nepal. The cement production processes are very energy-intensive, and they have not changed for years.Since the energy costs in Nepal are abnormally high, they represent over half of the cement production costs. It creates substantial pressure to conserve energy and materials while reducing the carbon footprint. Other important factors that must be considered apart from energy issues are production efficiency and sustainability, and how to exploit innovations and encourage investments.The chaotic energy situation in Nepal is exacerbated by rather significant electricity distribution losses and frequent cases of electricity theft. These two issues are significant contributors to a widening gap between energy supply and demand. iv Other such issues include overpriced and delayed hydropower projects, insufficient and outdated infrastructure, lack of energy conservation, deficient energy management, inadequately low efficiency of equipment, unsustainable energy pricing strategies, indecisive energy market regulations, reliance on energy imports, and especially inadequate exploitation of vast amounts of renewable energy resources. All these factors are also adversely affecting the geopolitical, environmental, and socioeconomic situation in Nepal. The developments in the energy sector in Nepal are also discussed in light of the relevant energy policies which have been adopted by the government over the past two decades.The results presented in the thesis can be used by the government regulators and energy policy planners, and possibly also by the public and private energy companies.It should be noted that the findings and observations in the thesis are also applicable to other countries with a similar development status and geography as Nepal.

scholarly journals Energy saving cement production by grain size optimisation of the raw meal

2009 ◽  
Vol 2 (2) ◽  
pp. 201-210
Author(s):  
B. Simons
Keyword(s):  
Grain Size ◽  
Energy Consumption ◽  
Lower Energy ◽  
Fine Fraction ◽  
Energy Resources ◽  
Cement Clinker ◽  
Cement Production ◽  
Grain Sizes ◽  
Natural Energy ◽  
Energy Consuming

The production of cement clinker is an energy consuming process. At about 50% of the energy is associated with grinding and milling of the raw meal, that normally is in the range 100% <200 μm with 90% <90 μm. Question: is it possible to use coarser components of the raw meal without reducing the clinker quality. With synthetic raw meals of various grain sizes the clinker formation was studied at static (1100 - 1450°C) and dynamic conditions (heating microscope). A routine to adjust the grain size of the components for industrial raw meals is developed. The fine fraction <90 μm should mainly contain the siliceous and argileous components, whereas the calcitic component can be milled separately to a grain size between 200-500 μm, resulting in lower energy consumption for milling. Considering the technical and economical realizability the relation fine/coarse should be roughly 1:1. The energy for milling can be reduced significantly, that in addition leads to the preservation of natural energy resources.

scholarly journals Recent Progress in Green Cement Technology Utilizing Low-Carbon Emission Fuels and Raw Materials: A Review

2019 ◽  
Vol 11 (2) ◽  
pp. 537 ◽  
Author(s):  
Ali Naqi ◽  
Jeong Jang
Keyword(s):  
Carbon Dioxide ◽  
Carbon Dioxide Emissions ◽  
Alternative Fuels ◽  
Raw Materials ◽  
Low Cost ◽  
Cement Industry ◽  
Industrial Wastes ◽  
Low Carbon ◽  
Cement Production ◽  
Cement Manufacturing

The cement industry is facing numerous challenges in the 21st century due to depleting natural fuel resources, shortage of raw materials, exponentially increasing cement demand and climate linked environmental concerns. Every tonne of ordinary Portland cement (OPC) produced releases an equivalent amount of carbon dioxide to the atmosphere. In this regard, cement manufactured from locally available minerals and industrial wastes that can be blended with OPC as substitute, or full replacement with novel clinkers to reduce the energy requirements is strongly desirable. Reduction in energy consumption and carbon emissions during cement manufacturing can be achieved by introducing alternative cements. The potential of alternative cements as a replacement of conventional OPC can only be fully realized through detailed investigation of binder properties with modern technologies. Seven prominent alternative cement types are considered in this study and their current position compared to OPC has been discussed. The study provides a comprehensive analysis of options for future cements, and an up-to-date summary of the different alternative fuels and binders that can be used in cement production to mitigate carbon dioxide emissions. In addition, the practicalities and benefits of producing the low-cost materials to meet the increasing cement demand are discussed.

Life Cycle Assessment of Comprehensive Utilization of Calcium Carbide Slag in Cement Kiln

2020 ◽  
Vol 993 ◽  
pp. 1487-1495
Author(s):  
Xin Ping Lin ◽  
Ai Wei Liu ◽  
Yun Fa Feng ◽  
Qi Ling Chen ◽  
Tao Chen ◽  
...  
Keyword(s):  
Life Cycle Assessment ◽  
Emission Reduction ◽  
Calcium Carbide ◽  
Cement Industry ◽  
Cement Clinker ◽  
Cement Kiln ◽  
Cement Production ◽  
Comprehensive Utilization ◽  
Carbide Slag ◽  
Portland Cement Clinker

The recycling utilization of solid waste is an important technical means for the sustainable development of the cement industry in China. Calcium carbide slag is a special solid waste in China, which can be used for cement production with a great advantage on CO2 emission reduction. With an view to providing methodological and data support for the development of policies in the cement industry, this paper quantitatively analyzes the environmental effects/environmental benefits of the comprehensive utilization of calcium carbide slag in cement kiln by comparing the traditional system of Portland cement clinker completely produced by natural resources with the system of cement clinker produced by calcium carbide slag based on the life cycle assessment (LCA) method given in standards and specifications of ISO 14040 series. The results show that the latter system has a better effect in material saving and carbon emission reduction, will increase the energy consumption in cement production process, and also slightly increase other pollutants (e.g. SOx, NOx, etc.) emission. The GWP, AP and EP indicators of the calcium carbide slag cement clinker system decrease compared with those of the Portland cement clinker system, while other indicators do not differ much or even slightly increase.

scholarly journals The effect of statistical analytical measurement variations on the plant control parameters and production costs in cement manufacturing – a case study

2010 ◽  
Vol 29 (2) ◽  
pp. 66-76
Author(s):  
A. D. Love
Keyword(s):  
Energy Consumption ◽  
Chemical Elements ◽  
Major Elements ◽  
Production Costs ◽  
Cement Clinker ◽  
Chemical Compositions ◽  
Control Parameters ◽  
Analytical Instruments ◽  
Cement Manufacturing ◽  
Plant Control

Raw materials used in cement manufacturing normally have varying chemical compositions and require regular analyses for plant control purposes. This is achieved by using several analytical instruments, such as XRF and ICP. The values obtained for the major elements Ca, Si, Fe and Al, are used to calculate the plant control parameters Lime Saturation Factor (LSF), Silica Ratio (SR) and Alumina Modulus (AM). These plant control parameters are used to regulate the mixing and blending of various raw meal components and to operate the plant optimally. Any errors and large fluctuations in these plant parameters not only influence the quality of the cement produced, but also have a major effect on the cost of production of cement clinker through their influence on the energy consumption and residence time in the kiln. This paper looks at the role that statistical variances in the analytical measurements of the major elements Ca, Si, Fe and Al can have on the ultimate LSF, SR and AM values calculated from these measurements. The influence of too high and too low values of the LSF, SR and AM on clinker quality and energy consumption is discussed, and acceptable variances in these three parameters, based on plant experiences, are established. The effect of variances in the LSF, SR and AM parameters on the production costs is then analysed, and it is shown that variations of as large as 30% and as little as 5% can potentially occur. The LSF calculation incorporates most chemical elements and therefore is prone to the largest number of variations due to statistical variances in the analytical determinations of the chemical elements. Despite all these variations in LSF values they actually produced the smallest influence on the production cost of the clinker. It is therefore concluded that the LSF value is the most practical parameter for plant control purposes.

The Design and Experimental Study on the Lance of the Cement Industry Flue Gas Denitration Technology

2014 ◽  
Vol 1015 ◽  
pp. 663-666
Author(s):  
Li Juan Zhang
Keyword(s):  
Flue Gas ◽  
Production Line ◽  
Average Diameter ◽  
Structure Design ◽  
Cement Industry ◽  
Cement Clinker ◽  
Injection System ◽  
Cement Production ◽  
Dry Process ◽  
Visual Distance

The lance is the key equipment of SNCR flue gas denitrification technology injection system on the new dry process cement production line.The atomizing effects of reducing agent will directly influence the result of flue gas denitration. In this paper, there are the structure design and experimental analysis on denitration lance.The results show that the lance can ensure the average diameter of atomized particles is from 50 to 55um,uniformly degree is above 80%, and visual distance of atomized ammonia is above 4 meters.It has been applied in a new dry process cement production line of daily 5kt SNCR flue gas denitration project, reaching above 70% of denitration efficiency. These results are valuable for similar new dry cement clinker production line of SNCR denitration Technology.

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