Get documents about "BEE AS axena 27 Jan 2010
Shared by: HC121106071019
-
Stats
- views:
- 0
- posted:
- 11/5/2012
- language:
- Unknown
- pages:
- 34
Document Sample
BEST PRACTICES & TECHNOLOGIES
FOR ENERGY EFFICIENCY IN
INDIAN CEMENT INDUSTRY
By
Ashutosh Saxena
General Manager
National Council for Cement and Building Materials
Indian Cement Industry –
An Overview
GROWTH OF INDIAN CEMENT INDUSTRY
219
200 181
Mn. TONNES
150 130
98
100
61
45
50 23 20
0
1980 1990 2001 2009
YEAR
CAPACITY PRODUCTION
CHANGING PROCESS PROFILE OF
INDIAN CEMENT INDUSTRY
1960 1980
SD DRY SD
5% 1% 6% DRY
33%
WET
WET 61%
94%
1990 2008
SD WET SD
WET 3% 2% 1%
21%
DRY
DRY
76%
97%
PLANTS WITH CAPACITY OF ONE
MILLION TONNES AND ABOVE
100 91
90 80
80
NO. OF PLANTS
68
70 62
60
50 39
40
30
20
10
0
1995-96 2001-02 2003-04 2007-08 2008-09
YEAR
Total : 146 Large Cement Plants
ENERGY INPUTS TO INDIAN CEMENT
INDUSTRY
ITEM % OF COST OF PACKED
CEMENT
RAW MATERIAL 10-15
COAL 20-25
POWER 17-20
MANPOWER 5-8
COAL CONSUMPTION : 22 Mn TONNES/YEAR
POWER CONSUMPTION : 14 BILLION UNITS/YEAR
TOTAL ENERGY BILL : RS 95 BILLION/YEAR
ENERGY CONSUMPTION PROFILE
(DRY PROCESS PLANTS - WTD. AVG.)
900 876
857 846
850
816 815
801
800 780 779
KCAL/KG CL.
771
763 750
THERMAL
ENERGY
750 742 734
729 723 726 730 721 726
700 687
650
650
600
91 93 95 97 99 '01 '03 '05 '07 '09
120122
117 BEST IN INDIA
120
111112110
104105
102
KWH/T CEMENT
ELECTRICAL
100 97 BEST IN WORLD
91
ENERGY
89
84 83 82
80 78 79 79
77
67 65
60
91 93 95 97 99 '01 '03 '05 '07 '09
DATA OF 40 DRY PLANTS
Indian Cement Industry - Production & Energy
Consumption
181
Values as Indicated
128
910
79
726
42
88
89
90
91
92
93
94
95
96
97
98
99
00
01
02
03
04
05
06
07
08
09
19
19
19
19
19
19
19
19
19
19
19
19
20
20
20
20
20
20
20
20
20
20
Year (1988-2009)
Production (Mn.T) Thermal Energy (kcal/kg Cl.)
Electrical Energy (kWh/t Cem)
TOOLS OF ENERGY EFFICIENCY
IMPROVEMENT
EXISTING PLANTS
TECHNOLOGY UPGRADATION
RETROFITTING OF ENERGY EFFICIENT EQUIPMENT
NEW PLANTS
IDENTIFICATION AND SELECTION OF STATE-OF-THE-ART
TECHNOLOGIES
FUEL QUALITY
BLENDING WITH IMPORTED COAL FOR IMPROVING
AVERAGE QUALITY
USE OF PET-COKE & OTHER COMBUSTIBLE WASTES
BLENDED CEMENT
GREATER USE OF INDUSTRIAL WASTES LIKE FLYASH
AND SLAG FOR MAKING BLENDED CEMENTS
Contd.
MANAGEMENT SYSTEMS
ENERGY MANAGEMENT
TOTAL PRODUCTIVE MAINTENANCE (TPM),
COMPUTERIZED MAINTENANCE SYSTEM AND INVENTORY
CONTROL
TOTAL QUALITY MANAGEMENT (TQM)
REFRACTORY MANAGEMENT SYSTEM
POWER SUPPLY
IMPROVING QUALITY OF POWER THROUGH CAPTIVE
GENERATION (DIESEL, THERMAL AND WIND POWER)
PERFORMANCE MONITORING
INTER-FIRM COMPARISON AND BENCHMARKING
TARGET SETTING AND MONITORING
Energy Efficient Cement Manufacturing
Technologies
HIGH EFFICIENCY SIZE REDUCTION
TECHNIQUES
VERTICAL ROLLER MILL
BALL MILL OPERATION IN CLOSED CIRCUIT
BOLTLESS & CLASSIFYING LINERS IN BALL
MILLS
ROLLER PRESS
V - SEPARATOR
SEPARATOR
HIGH EFFICIENCY
TWO-STAGE MODULAR SEPARATOR SYSTEM
ELECTRICAL ENERGY CONSUMPTION
VRM Vs BALL MILL (RAW MILL)
30
KWH/T MATERIAL
25
19
20 15
15
10
5
0
VRM BALL MILL
TYPE OF MILL
ELECTRICAL ENERGY CONSUMPTION
VRM Vs ROLLER PRESS Vs BALL MILL (CEMENT MILL)
40
35 32
KWH/T CEMENT
30 27 26
25
20
15
10
5
0
VRM RP + BM BALL MILL
TYPE OF MILL
HIGH EFFICIENCY PYRO-PROCESSING
SYSTEMS
LATEST GENERATION PRECALCINER
5/6 STAGE PREHEATER WITH LOW PRESSURE
CYCLONES
HIGH EFFICIENCY GRATE COOLER
MULTI-CHANNEL BURNER
THERMAL ENERGY CONSUMPTION
6-ST PC Vs 5-ST PC
702 718
KCAL/KG CLINKER
750
600
450
300
PC (6-ST) PC (5-ST)
TYPE OF KILN CIRCUIT
OTHER EFFICIENT EQUIPMENT/SYSTEMS
HIGH EFFICIENCY POLLUTION CONTROL EQUIPMENT
(LESS THAN 50 mg/NM3 EMISSION)
ELECTRO-STATIC PRECIPITATOR (ESP)
FIBRE GLASS BAG FILTER
HIGH EFFICIENCY FAN (75-82% EFFICIENCY)
ENERGY EFFICIENT MOTOR (93-95% EFFICIENCY)
VARIABLE SPEED AC DRIVES
EFFICIENT ILLUMINATION SYSTEMS
MECHANICAL MATERIAL CONVEYORS (IN PLACE OF
PNEUMATIC CONVEYING SYSTEMS)
HIGH SPEED HIGH CAPACITY BUCKET ELEVATOR
PIPE CONVEYOR
PRESENT STATUS OF TECHNOLOGY
PRESENT STATUS OF TECHNOLOGY
Low Technology Modern Plants Global Technology
Plants
Mining and Conventional Computer aided Computer aided
Material
Handling
Crushing Two stage Single stage In-pit crushing &
conveying
Conveying of Dumpers/Ropeway/ Belt conveyors Pipe conveyors, Belt
Limestone Tippers conveyors
Grinding Ball Mills with / VRM’s, Roller VRM’s, Roller Presses
without conventional Presses with with dynamic
classifier dynamic classifier classifier
Contd…..
4
Low Technology Plants Modern Plants Global Technology
Pyro Wet Dry Dry
Processing Semi Dry - 5/6 stage - 6 stage preheater
Dry preheater - High Efficiency
- 4 stage preheater - High Efficiency Cooler
- Conventional cooler Cooler - Multi Channel
- Single channel burner - Multi Channel Burner
Burner - Co-processing of
WDF
- Co-generation of
power
- Low NOX/SO2
emission
technologies
Blending & Batch-Blending Silos Continuous - Continuous
Storage Blending silos Blending
- Multi-chamber
Silos
- Dome silos
Contd…..
5
Low Technology Modern Plants Global Technology
Plants
Packing & Bag - Bag - Bulk
Dispatch - Bulk - Palletizing &
Shrink Wrapping
Process Control Relay Logic / Hard - DDC - DDC
Wired / PLC - Fuzzy Logic - Neurofuzzy expert
expert system system
Energy 90-100 kWh/t cem. 75-85 kWh/t cem. 70-80 kWh/t cem.
consumption 900-1000 kcal/kg cl. 700-800 kcal/kg cl. 675-740 kcal/kg cl.
level
Plant Size 300 – 1800 3000 – 6000 6000 – 12000
(TPD)
6
BLENDED CEMENTS
CEMENT VARIETIES –
PRODUCTION IN 2008
Ordinary Portland Cement (OPC) : 25 %
Portland Pozzolana Cement (PPC) : 66.50 %
Portland Slag Cement (PSC) : 8%
Other Cements : 0.50 %
SHIFT IN TYPE OF CEMENT
YEAR OPC PPC+PSC
(%) (%)
1999 67 32
2004 45 54
2008 25 74
CO2 EMISSION FROM CEMENT
MANUFACTURE
SOURCES OF CO2 OPC PPC
EMISSION
Tonne /t % Tonne /t %
CALCINATION 0.50 60 0.37 58
COMBUSTION OF FUEL 0.24 29 0.176 28
USE OF POWER 0.09 11 0.09 14
TOTAL 0.83 100 0.636 100
ALTERNATE FUELS AND ENVIRONMENT
Benefits of Utilization of Alternate
Fuels in Cement Kiln
• Prevents resource depletion of non-renewable fossil
fuels
• Lowers the emissions of gases such as GHG’s by
replacing the use of fossil fuels
• Maximises energy recovery. All the available energy
is used directly in the kiln for clinker production
• Eliminates the need for disposal of inorganic ashes
and slags as they act as substitute raw material in the
cement
Alternate Fuels :
Problems and Prospects
Deciding Factors for utilization of Alternate Fuels are :-
Proximity of the cement plant to the source
Extent of availability on sustainable basis
Compositional compatibility of raw materials and the
Alternate Fuels.
Type of cement manufacturing process employed and
production capacity.
Infrastructural facilities for handling and storage.
COGENERATION OF POWER UTILISING
WASTE HEAT IN CEMENT MANUFACTURE
WHR SYSTEM FOR POWER GENERATION
ITEM UNIT PH AQC
1 VOLUMETRIC FLOW RATE NM3/H 360750 191600
2 BOILER INLET TEMPERATURE DEG. C 340 360
3 BOILER OUTLET TEMPERATURE DEG. C 230 90
4 GROSS POWER GENERATION KW 7700 (30%)
5 ANNUAL REDUCTION IN POWER MILLION 56.07
PURCHASED KWH
6 ANNUAL SAVING OF POWER COST RS MILLION 232.70
7 ANNUAL REDUCTION IN FOSSIL FUEL TONNES 14517
EQUIVALENT (OIL BASIS)
8 ANNUAL REDUCTION IN CO2 TONNES 45000
(5% of Total)
CONCLUSION
MAJOR AREAS FOR ENERGY EFFICIENCY
IN INDIAN CEMENT INDUSTRY
MAJOR AREAS FOR ENERGY EFFICIENCY IN
INDIAN CEMENT INDUSTRY
TECHNOLOGY UPGRADATION & USE OF ENERGY
EFFICIENT TECHNOLOGY FOR PRE-1990 PLANTS
WASTE HEAT RECOVERY FOR COGENERATION OF
POWER
AUTOMATION, ON-LINE QUALITY CONTROL & EXPERT
CONTROL SYSTEM
USE OF ALTERNATE FUELS INCLUDING RUBBER
TYRES, AGRICULTURAL, INDUSTRIAL & MUNICIPAL
WASTES
EFFICIENT COLLECTION, PROCESSING &
TRANSPORTATION SYSTEMS FOR ALTERNATE FUELS
USE OF RENEWABLE ENERGY SOURCES
USE OF NATURAL GAS AS FUEL IN CEMENT PLANT
CLUSTERS
Contd./-
MAJOR AREAS FOR ENERGY EFFICIENCY IN
INDIAN CEMENT INDUSTRY
ADOPTION OF TECHNOLOGIES FOR REDUCING
EMISSION OF SO2 & NOX
BULK TRANSPORTATION OF CEMENT
FUTURE R & D EFFORTS:
MAXIMISING UTILIZATION OF ALTERNATE FUELS,
FLY ASH, SLAG AND OTHER RAW MATERIALS
ALGAL FARMS FOR CO2 ABSORPTION
NANO TECHNOLOGY IN CEMENT MANUFACTURE
AND USE
BETTER COMBUSTION EFFICIENCY
TECHNOLOGIES
