HANDY MANUAL

CEMENT INDUSTRY

Output of a Seminar on Energy Conservation in Cement Industry

Sponsored by

United Nations Industrial Development Organization (UNIDO)

and

Ministry of International Trade and Industry (MITI), Japan

Hosted by

Ministry of Energy and Mineral Resources, Bangladesh

Organized by

Ministry of Power and Energy, Sri Lanka

The Energy Conservation Center (ECC), Japan 1994 Bangladesh Sri Lanka

PREFACE
The conservation of energy is an essential step we can all take towards overcoming the mounting problems of the worldwide energy crisis and environmental degradation. In particular, developing countries are interested to increase their awareness on the inefficient power generation and energy usage in their countries. However, usually only limited information sources on the rational use of energy are available. The know-how on modern energy saving and conservation technologies should, therefore, be disseminated to government and industrial managers, as well as to engineers and operators at the plant level in developing countries. It is particularly important that they acquire practical knowledge of the currently available energy conservation technologies and techniques. In December 1983, UNIDO organized a Regional Meeting on Energy Consumption as well as an Expert Group Meeting on Energy Conservation in small- and medium-scale industries for Asian countries. During these meetings, it was brought out that, for some energy intensive industries, savings up to 10% could be achieved through basic housekeeping activities, such as auditing and energy management. All these experiences brought UNIDO to prepare a regional programme on the promotion and application of energy saving technologies in selected subsectors, since the rational use of energy calls for a broad application of energy conservation technologies in the various industrial sectors where energy is wasted. One of these energy intensive industrial sectors to be considered to improve efficiency through the introduction of modern energy conservation technologies is the cement industry. The cement industry consumes much energy. The cement industry is also noted for great percentage of the energy cost in the total production cost. In the cement industry, appreciable amounts of energy could be saved or conserved by preventing of leakage in the kilns, modifying the equipment to recover heat from the preheater and cooler in the process of cement-making and effective use of industrial waste materials. Currently, UNIDO is implementing this programme with the financial support of the Japanese Government, in selected Asian developing countries. This programme aims at adapting these innovative energy conservation technologies, developed in Japan, to the conditions of developing countries.

In this programme, we are considering that the transfer of these technologies could be achieved through: (i) (ii) (iii) (iv) Conducting surveys of energy usage and efficiency at the plant level; Preparing handy manuals on energy management and energy conservation/saving technologies, based on the findings of the above survey; Presenting and discussing the handy manuals at seminars held for government officials, representatives of industries, plant managers and engineers; Disseminating the handy manuals to other developing countries for their proper utilization and application by the industrial sector. The experience obtained through this programme will be applied to other programmes/projects which involve other industrial sectors as well as other developing countries and regions. UNIDO has started this programme with the project US/RAS/90/075 - Rational Use of Energy Resources in Steel and Textile Industry in Malaysia and Indonesia and the project US/RAS/92/035 - Rational Use of Energy Saving Technologies in Pulp/Paper and Glass Industry in Philippines and Thailand. These were followed by project US/RAS/93/039 Program for the Use of Energy Saving Technologies in the Ceramic and Cement Industries in Sri Lanka and Bangladesh. The present Handy Manual on Cement Industry was prepared by UNIDO, with the cooperation of experts from the Energy Conservation Center (ECC) of Japan, on energy saving technologies in the framework of the above-mentioned UNIDO project. It is based on the results of the surveys carried out, the plant observations and the recommendations and suggestions emanating from the Seminars on Energy Conservation in the Cement Industry, held under the same project in May 1994 in Dhaka, Bangladesh and Colombo, Sri Lanka respectively. The handy manual will not only be interesting for government and representatives from industry, but it is, in particular, designed for plant-level engineers and operators in developing countries as a tool to improve energy efficiency in the production process. Appreciation is expressed for the valuable contribution made by the following institutions to the successful preparation and publication of the manual mentioned above: Ministry of Energy and Mineral Resources, Bangladesh Ministry of Power and Energy, Sri Lanka Ministry of International Trade and Industry (MITI), Japan The Energy Conservation Center (ECC), Japan June 1994

CONTENTS
PREFACE 1. Production process of cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Characteristics of energy consumption in cement production .............................................. 3 2.1 Energy consumption ........................................................................................................3 2.2 Raw material process .......................................................................................................4 2.2.1 Wet process ...............................................................................................................4 2.2.2 2.3 2.3.1 Dry process................................................................................................................4 Clinker burning process ...................................................................................................6

Wet process ...............................................................................................................6 2.3.2 Semi-dry process .......................................................................................................8 10 Dry process................................................................................................................ 12 2.4 Finish grinding process ................................................................................................... 2.3.3 3. Promotion of energy conservation technique ........................................................................13 15 3.1 Energy management ........................................................................................................ 3.1.1 1.5 Energy consumption rate ........................................................................................... 1 3.1.2 Analysis of operation condition ................................................................................ 7 2 3.1.3 Establishment of operation manual ........................................................................... 4 2 3.1.4 Choice of raw material and fuel ................................................................................ 5 3.1.5

2 Waste heat recovery power generation ..................................................................... 8 29 3.1.6 Equipment investment ............................................................................................... 3.2 Energy conservation technique in cement production process ........................................31 31 3.2.1 Raw mill .................................................................................................................... 33 3.2.2 Kiln and preheater ..................................................................................................... 3.2.3 3.2.4 36 Air quenching cooler ................................................................................................. 36 Coal mill .................................................................................................................... 38 3.2.5 Finish grinding mill ................................................................................................... 4. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 40

1. Production process of cement

In the times of Egypt and Greece, sintered and ground lime or plaster was used as cement for civil engineering and construction. In the 19th century, portland cement was produced in England. This manual covers energy conservation in portland cement production. A cement production plant consists of the following three processes. 1. Raw material process 2. Clinker burning process 3. Finish grinding process The raw material process and the clinker burning process are each classified into the wet process and the dry process. In the wet process, raw materials other than plaster are crushed to a diameter of approximately 20 mm by a crusher and mixed in an appropriate ratio using an automatic weigher, as shown in Fig. 1. Then, with water added thereto, the mixture is further made finer by a combined tube mill with a diameter of 2 to 3.5 m and a length of 10 to 14 m into slurry with a water content of 35 to 40%. The slurry is put in a storage tank with a capacity of several hundred tons, mixed to be homogenized with the corrective materials, and is sent to a rotary kiln for clinker burning. In the wet process, the slurry can be easily mixed but a large amount of energy is consumed in clinker burning due to water evaporation. In the dry process, crushed raw materials are dried in a cylindrical rotary drier having a diameter of 2 m and a length of about 20 m for example, mixed by an automatic weigher, ground and placed in storage tanks. The resultant mixture is further mixed to make the ingredients uniform, and sent to a rotary kiln for clinker burning. These processes are selected with consideration given to properties of raw materials, costs of fuel, conditions of location and others. For the wet process, plant construction cost is rather low and high-quality products are manufactured easily. On the other hand, the dry process consumes less energy and its running cost is lower. The progress of technology is, however, eliminating the differences in quality between products from the above processes, while needs for energy conservation are getting increasingly strong. In future, the wet process will not be employed positively.

-1

Finishing Process

2. Characteristics of energy consumption in cement production

2.1 Energy consumption The cement industry is said to be an energy-intensive industry together with steel, paper and petrochemical industries. The percentage of energy cost in portland cement production cost is 20 to 30%. If the energy cost is reduced, the manufacturing cost is lowered, resulting in increasing the company profits. s Fig. 2 shows the component ratio of fuel and electric power consumption by the whole cement industry in Japan. Component ratio of fuel consumption by use
Drying of raw materials and

Component ratio of electric power consumption by department

(Note) Total is expressed in a value converted into coal (calorific value: 6,200 kcal/kg) Source: Cement in Japan 1993, Japan Cement Association (JCA)

Figure 2 Component ratio of energy consumption in 1992 Ninety percent or more of fuel is consumed for clinker burning. About 40% of electric power is consumed for finish grinding, and a little under 30% each is consumed by the raw material process and the clinker burning process. The finish grinding process mainly consumes electric power for the mill, and the clinker burning process mainly for the fan. The raw material grinding process consumes a large volume of power for the mill and fan.

-3-

The Japanese cement production process is mostly occupied by SP and NSP kilns and coal is used as fuel, so that the ratio of electric power consumption by the clinker burning process is high. In a plant mainly using a wet process kiln, the finish grinding process consumes power in a larger quantity than the aforementioned example. In such a case, energy conservation measures shall be taken by focusing on the clinker burning process for the fuel consumption and on the finish grinding process for the electric power consumption. 2.2 Raw material process 2.2.1 Wet process Since raw materials can be homogenized and the mixing ratio can be corrected after grinding, this process is relatively simple. A typical example is shown in Fig. 3.

Figure 3 Wet process raw material grinding system 2.2.2 Dry process Fig. 4 shows three processes a, b and c. Raw materials received by a plant contain a small amount of water. Limestone contains 2 to 5% of water and clay about 5 to 10%. The dry process needs to evaporate water when grinding. In Fig. 4, process a is provided with an independent dryer to evaporate water, and the dryer may be a rapid dryer or impact dryer with a disintegrating or crushing function instead of the rotary dryer as illustrated.

- 4 -

In Fig. 4, process b is a closed circuit grinding process combining an air separator and a ball mill or tube mill, which is provided with drying function. The above mill and separator are available in several types. In Fig. 4, process c is an example of vertical roller mill. For drying, exhaust gas from the kiln and preheater is used, but sometimes a hot gas generator is installed for a time of commissioning of the plant and for a time of year when water contained in raw materials increases.

Figure 4 Dry process raw material grinding system -5-

2.3 Clinker burning process 2.3.1 Wet process A typical example of the wet process is a straight cylindrical type kiln having a length of about 40 times of the shell inner diameter, which is generally known as a long economical kiln, installed s with an inclination of 2.5 to 4% and slowly rotated at 0.5 to 1.5 rpm. Raw material is slurry containing 38 to 40% of water and fed from the upper end of the kiln, while fuel is blown in from the lower end of the kiln. At the raw material inlet, a chain curtain zone is installed extending to 20 to 25% of the overall length to help dry the slurry. The hot clinker, which has been sintered in the kiln, is sent to the cooler and cooled down to 80 to 100C. Hot air from the cooler is effectively used as the secondary air for combustion in the kiln. Fig. 5 shows the temperature distribution in the kiln.

Figure 5 Temperature profile in wet process kiln -6-

As obvious from the above figure, the wet process kiln has remarkable characteristics which allow four processes of drying the slurry, and preheating, calcining and sintering raw material collectively. Since the system is simple and easily operated, once the optimum operating condition is found, this condition can be easily retained stable. On the other hand, evaporation of about 40% of water of the slurry needs an extra heat value of about 400 kcal per kg of clinker. As a result, the largest consumption of fuel among all types of kilns is the disadvantage of the wet process kiln. As a countermeasure, a process of using a filter to dehydrate physically the raw material to a water content of 18 to 20% may be applied. In this case, however, since it is difficult to lower the kiln exhaust gas temperature to 500C or below, another countermeasure such as using the remaining heat value for generation of electricity is needed. Therefore, the system becomes inevitably complex.

-7-

2.3.2 Semi-dry process The semi-dry process is a special example of the dry process and uses a Lepol kiln or shaft kiln. In either kiln, the raw material ground in the dry process is shaped into pellets with diameter of 10 to 15 mm, so that about 13% of water is added. In the case of the Lepol kiln, the pellets are dried and preheated once by the movable grate preheater shown in Fig. 6 and fed into the kiln. This system applies for the first time in the cement plant a concept of separating the raw material preheating process which used to be effected in the kiln and preheating by a separate device with high thermal efficiency. Then, the Lepol kiln has lost its position when a kiln with suspension preheater (SP kiln) was introduced but deserves special mention since it motivated energy conservation activity in the cement plants. Fresh Air

Raw Material Pellet

Kiln

Figure 6 Grate preheater

-8-

In the shaft kiln, fuel (coke, oil coke or anthracite) is added in the pelletizing process. All processes of drying, sintering and cooling are effected in the vertical movable bed. This concept had been conducted before the rotary kiln was spread and, recently, as shown in Fig. 7, the shaft kiln with a continuous discharging function installed at the furnace bottom is mainly used in India and China. This kiln advantage is heat economy but it also has disadvantages since the poking work in the s furnace has to be repeated to retain a stable combustion state and nonuniformity of quality cannot be avoided.

Figure 7 Shaft kiln

-9-

2.3.3 Dry process In the dry process, there are the dry long kiln, the short kiln with boiler, the SP kiln and the NSP kiln. The dry long kiln is mainly used in the Near and Middle East where rain falls less and alkaline components in raw material are large; its characteristics are similar to the wet process long kiln. In Southeast Asia, Central and South America, and North America, the wet process long kiln is mainly used. Fig. 8 shows a transition of production systems in Japan. It can be seen that the wet process is rapidly replaced by the dry process. It reflects increasing needs for energy conservation and suggests what the true cement plant of the future should be.

Year

Figure 8 Transition of clinker manufacturing capacity by type A recent large NSP process has a heat consumption rate of about 750 kcal/kgcl and is superior to all the conventional sintering processes. In this connection, the wet process long kiln may have a heat consumption rate of 1,500 to 1,700 kcal/kgcl except in some special cases, and the semi-dry process kiln may have 1,000 to 1,200 kcal/kgcl.

-l0-

Fig. 9 shows an SP kiln with 4-stage cyclone (dry process kiln with 4-stage cyclone preheater). Addition of a calciner in this figure will result in an example of NSP kiln. Generally, exhaust gas (350 to 380C) from SP and NSP kilns is used to dry raw material (and to generate electricity) as shown in Fig. 10.

Figure 9 Dry process kiln with suspension preheater

Kiln

SP EP : F S AQC

: Suspension Preheater Electrostatic Precipitater : Fan : Stabilizer : Air Quenching Cooler

Figure 10 Gas flow diagram of SP kiln

-ll-

2.4 Finish grinding process The finish grinding process is roughly divided into an open circuit grinding system and a closed circuit grinding system. The mill used is a tube mill or ball mill. In Fig. 11, a shows a closed circuit and b shows an open circuit. In the open circuit mill, the mill shell has a length of about 4 to 5 times of its diameter to obtain a prescribed fineness, and the shell outer wall is sprayed with water to prevent the temperature of the product in the mill from rising. It is also possible to spray water into the mill interior but the closest attention has to be paid so as not to deteriorate the product quality. In the closed circuit mill, the mill has a length of 3 times or below of its diameter so as to accelerate the passage of the product. The separator works as a cooler for the product in addition to its function as classifier for the product.

Product

a. Closed Circuit

Product b. Open Circuit Figure 11 Clinker grinding system -12-

3. Promotion of energy conservation technique

Energy conservation in industrial sectors starts from the software including operation control and process control, then extends into the field of hardware including equipment improvement and process improvement. Generally, energy conservation efforts can be classified into the following three steps:

Step 1 - Good housekeeping Energy conservation efforts are made without much equipment investment, including elimination of the minor waste, review of the operation standards in the production line, more effective management, improvement of employees cost consciousness, group activities, and improvement of operation technique. For example, such efforts include management to prevent unnecessary lighting of the electric lamps and idle operation of the motors, repair of steam leakage, as well as reinforcement of heat insulations.

Step 2 - Equipment improvement This is the phase of improving the energy efficiency of the equipment by minor modification of the existing production line to provide a waste heat recovery equipment and a gas pressure recovery equipment or by introduction of efficient energy conservation equipment, including replacement by advanced equipment. For example, energy conservation efforts in this step include an effective use of the waste heat recovery in combustion furnaces and introduction of the gas pressure recovery generator in the iron and steel works and waste heat recovery generator in cement plant.

Step 3 - Process improvement This is intended to reduce energy consumption by substantial modification of the production process itself by technological development. Needless to say, this is accompanied by a large equipment investment. However, this is linked to modernization of the process aimed at energy conservation, high quality, higher added value, improved product yield and man power saving.

-13-

The energy conservation technique in the cement industry is classified as follows:

Raw material process First step Clinker burning process Finish process 1) Management of fineness 1) Management of optimum grinding media I) Installation of closed circuit (dynamic separator) 2) Installation of feed control system

1) Selection of raw material 1) Prevention of stop due 2) Management of fineness to failure 3) Management of optimum 2) Selection of fuel grinding media 3) Prevention of leak 1) Use of industrial waste material (fly ash) 2) Replacement of fan rotor 3) Improvement of temperature and pressure control system 4) Improvement of mixing & homogenizing system 1) Use of industrial waste material (waste tires) 2) Recovery of preheater exhaust gas 3) Recovery of cooler exhaust gas (drying of raw material and generation of electricity) 4) Replacement of cooler dust collector from multiclone to E.P. 1) From wet process to dry process 2) Conversion of fuel (from petroleum to coal) 3) From SP to NSP 4) Use of industrial waste (slag and pozzolan) 5) From planetary and under coolers to grate cooler

Second step

Third step

1) From wet process to dry process 2) From ball and tube mills to roller mill

-14-

3.1 Energy management 3.1.1 Energy consumption rate Fig. 12, Fig. 13 and Fig. 14 show a change of energy consumption and energy consumption rate in all cement plants in Japan. Comparing the period when the fuel consumption rate lowers sharply in Fig. 12 with Fig. 8, it coincides with the period when the NSP system was introduced. In the same period, the electric power consumption rate increases once and then continues to decrease, remaining stable for some period from 1978. In this period, fuel was changed from petroleum to coal. The improvement after that period may result from the active adoption of a roller mill as the raw material mill.
Unit kg/t

(Note) Consumption rate = Fuel consumption (excluding for generation of electricity)/ Cement production Source: Cement in Japan 1993, JCA

Figure 12 Change of fuel consumption rate (Coal (6,200 kcal/kg) conversion)

-15-

(Note) Consumption rate = Electric power consumption/ Cement production Source: Cement in Japan 1993, JCA

Figure 13 Change of electric power consumption rate

2. Total energy consumption rate= Total energy consumption/Cement production Source: Cement in Japan 1993, JCA

Figure 14 Change of total energy consumption and consumption rate (Calorie conversion)

-16-

3.1.2

Analysis of operation condition

Improvements start with correct recognition of the present situation. The daily operation of the plant should be recorded in log sheets, which are routinely reviewed by the executives and compared with past data; if there is any abnormality, it should be immediately referred to the job site. Since part of the data which seems to be important is stored in the recorder, any problems concerning daily operation will mostly be solved by analyzing the data. But, to further improve the present situation, such data are not sufficient and, therefore, more detailed measurement is made and the obtained results are collected in the form of a material balance and a heat balance. What is important is to review the results. Problems are highlighted by merely referring to the original design of the plant and the past measured results, and comparing with other similar plants. By simulating a little, the improvement effects can be predicted, and it can be judged whether the implementation should be made or not for the first time. Table 3.1 shows the heat balance of 43 SP kilns and 8 NSP kilns. Measurement does not require special techniques or equipment. But, since the temperature, pressure and flow rate are always variable during operation, a little skill and patience are required to keep the error up a minimum. Since it becomes necessary to set up a measuring point at a place different from the usual working place, consultation shall be held with a relevant party in advance taking the safety of work into consideration, and the measurement shall be made in cooperation with that party. Readings of the instrument for operation shall not be adopted as the measured data as they are. Data for operation are sufficient as long as relative changes can be read but they do not always show absolute values correctly.

-17-

3.1.3

Establishment of operation manual

It is needless to say that the attainment of a stable operation at a high level is an essential condition to obtain a profit for a cement plant which consumes a large volume of energy. A system of calculating loss resulting from the shutdown due to a failure is different depending on the situation of a plant and the market environment. For example, the following calculation can be made. When the rated capacity of plant: 500 [t/day] the time required for one recovery: 12 [hrs] the idle time and output reduction rate in the above time: 50 [%], then, 1. Energy loss (energy cost 15.5$/t) 15.5 [$/t] x (12/24) x 500 [t] x 50 [%] = 1,938 $ 2. Lost profits due to output reduction (supposing a marginal profit is 29.5 $/t) 29.5 [$/t] x (12/24) x 500 [t] x 50 [%] = 3,687 $ hence total of 1 and 2 above is 5,625 $. If recovery is made appropriately, the loss may be less but, if a secondary accident such as the breaking of bricks is caused, the loss may be higher. Recovery takes a longer time as the facilities become larger. For thorough preventive maintenance and improvement of morale of employees to prevent the shutdown due to a failure, expenses needed therefor shall not be spared. As material for technical training of employees, the operation manual and maintenance manual provided by the equipment supplier can be used. But, such manuals are generally limited to describe the operation procedure of a process and the disassembling and assembling procedures of equipment. A method for optimum operation or preventive maintenance has to be found by the user. Ideally, such manuals are drawn up through a group activity (TQC) of engineers or foremen in a company. It is not necessary to stick to the style of manuals and the quality of the contents. What is important is that the persons concerned have an interest in such an activity. It is certain that the will to conserve energy does not occur when a stable operation cannot be continued. For the time being, if an appropriate leader is not available, a well-experienced cement expert or consultant shall be asked for cooperation to draw up such a manual urgently. Costs for that purpose will be recovered easily.

-24-

3.1.4 Choice of raw material and fuel

After the commissioning time of the plant and the removal of various uncertain factors, the supply source of raw material can be reviewed. By expansion of the stock yard or the adoption of a preblending system, there are a number of possibilities that inexpensive raw material with low purity or substitute raw material excelling in grindability and/or bumability will be found. When a computer is used to control the process for blending or mixing raw materials, it displays its great power in stabilizing the process and conserving energy beyond its role for foolproof. Table 3 shows the state of using industrial wastes orby-products in the cement industry in Japan.

Table 3 Used amount of industrial wastes and by-products in the cement industry
(Unit: t,%)

Source: Japan Cement Association Mixing of blast furnace slag, pozzolan and fly ash contributes largely to energy conservation in view of the cement base. Japanese Industrial Standard (JIS) provides quality standards to three different mixing ratios as shown in Table 4. To meet such standards, both mixtures and host cement have to be strictly controlled for quality. In this sense, quality control is a first step for energy conservation. -25-

Generally, natural gas, heavy oil and coal are used as fuel. In Japan, the fuel was changed from heavy oil to coal around 1980 with the occurrence of the second oil crisis as seen in Fig. 18. Currently, consumption of heavy oil is only about 1% of coal. The change from heavy oil to coal is being carried out not only in Japan but also in petropowers such as Indonesia and Malaysia. From the waste tires (840,000 tons) produced in 1992 in Japan, 20.1% was used for sintering of cement. Various substitute fuels may be found, depending on regions.

-27-

3.1.5 Waste heat recovery power generation Table 1 shows that the preheater exhaust gas has about 20% of the heating value brought in by the fuel and the cooler exhaust gas has about 14%. These residual heating values can be used to dry raw materials and to generate electricity. In Japanese cement plants, 19 power plants utilizing waste heat are operating and, including independent power plants, 41.8% of all electric power consumed in the cement plants is provided by private power plants as shown in Fig. 2. Fig. 15 shows a flow diagram of such plants. The private power generating system is adopted on the assumption that the running cost is lower than the purchased power unit price. If the finish mill has surplus capacity, however, it can lower a load in a daytime power demand time zone and raise a nighttime load factor and, in addition, brings about advantages such as to avoid shutdown due to extrinsic factors and to improve the kiln s operation rate.

H.P.B. L.P.M. T G C SP EP

: : : : : : :

High Pressure Boiler Low Pressure Boiler Turbine Generator Condenser Suspension Preheater Electrostatic Precipitater

Figure 15 Waste heat recovery power generation

-28-

3.1.6 Equipment investment Fig. 16, Fig. 17, Fig. 18 and Table 5 show that the energy conservation measures in Japan have been timely taken, keeping pace with measures to enhance the production capacity and to improve the labor productivity. When an investment is made not only with a view to energy conservation but in such a way as to produce combined effects including the increase of production and the stabilization of operation, advantages are large and invested capital is recovered earlier. Since an investment for renovation is indispensable for the cement industry, which is a process industry, to survive, there is always a chance to improve facilities for energy conservation and, company management should always be ready to raise funds so as not to miss the best timing. Middle management and engineers have to provide up-to-date information to support the top management making a decision. Table 5 Rationalization in cement manufacturing

Note: * Calendar year base. Source: Cement in Japan 1993, JCA

-29-

Figure 16 Change in cement production

Production Worker

Source: Cement in Japan 1993, JCA

(Billion Yen)

Figure 18 Machinery and equipment investment

3.2

Energy conservation technique in cement production process

3.2.1 Raw mill Since the wet process has a simple system, it is important to enhance the operation efficiency of the mill itself. The mill performance depends on various factors. And, among them, the basic items are given by the following empirical formulas, for example. Bond third theory: s

where, w = kwh per short ton of grinding material F = microns 80% of the feed passing P = microns 80% of the product passing wi = work index according to Bond test mill s Critical mill speed:

Mill drive power:

N = power consumption [kw] G = weight of mill charge [t] Di = internal diameter of mill [m] n = speed of mill rotation [r/m] C = power factor of Fig. 19

-3l-

Figure 19 Power factor C for determining the drive power of a tube mill The selection of appropriate ball size, ball charge amount in each chamber and many other hints are given in Cement Engineers Handbook (Labohm and others, Bauverlag Gmbh, Wiesbaden) and Cement-Data-Book (Duda, Macdonald & Evans, London), for example. Generally, mill suppliers design systems having precision which seems to be almost appropriate based on the test results of a given material sample, so that they can be appropriately adjusted at the actual location. But, as time passes, properties of raw material continue to change. Therefore, the optimum point of operation is to be finally decided by the user based on a trial at the actual location. If the capacity lowers as the operation progresses, the work index wi or feed size F in the formula (1) shall be doubted first. When the value F is larger than the planned value, one of the solutions is to increase the size of the balls in the first chamber but, a better solution is to service or adjust the preceding crusher process to decrease the feed size. If the product becomes coarse or the the value P of the formula (1) becomes large, it shall be checked first that the ball charge amount is lowered due to abrasion. The formula (1) was originally derived from the closed circuit system of the dry process but, it can also be applied to the wet process mill by adopting an appropriate conversion factor. In the wet process, since the ball surface is always washed with water, the grinding efficiency is 20 to 30% higher than in the dry process mill but the abrasion loss of the balls and lining is much larger.

-32-

The decrease of balls due to abrasion appears as a decrease of the motor load but, as it is seen from Fig. 17, the relation between them is not linear. By measuring several times at intervals of two to three months, an abrasion characteristic value of each mill can be seized. After this, depending on the operation time or the output, replenishment shall be made periodically to keep an appropriate charge. Excessive grinding should be avoided to save power consumption, regardless of the type of process, dry or wet. Recent operation experience with an SP or NSP kiln reveals that even though on the burnability in the sintering process, as far as the rough grain is composed of CaCO3. When the clay in the material has a rather grindable property, or when it is composed only of fine grains, as is sometimes seen in the wet process, it will be advisable to set the target fineness value higher. This measure may result in an about 3 to 5% electric power conservation. Mixing of fly ash or pozzolan as the substitute material for clay will attain the same result, if its grain degree is fine. In the case of the dry process mill, in addition to the efficiency of the mill, two problems of improving heat economical efficiency and lowering fan power have to be solved. As the heat source for drying raw materials, the preheater exhaust gas is generally used as shown in Fig. 23. According to Table 1, this exhaust gas has a calorific value of about 170 kcal for 1 kg of clinker, so that this gas is theoretically sufficient to dry about 10% of water in the combined raw materials. Therefore, a more significant issue is to lower the power consumption. Recently, the spread of the roller mill shown in Fig. 4, c, makes a great contribution to the reduction of power consumption in this process. To dry and grind at the same time, this process flows a large volume of gas through the system, increasing the power consumed by the fan. Therefore, the difference of the facility power of the mill itself is not related to the reduction of electric power but, as compared to the existing process with the ball mill, reduces the power consumption by 10 to 15%. More reduction can be expected by reducing of the volume of gas passing through or circulating in the process. 3.2.2 Kiln and preheater As shown in Fig. 8, the cement burning process in Japan was rapidly changed from the wet process to the NSP process and, accordingly, the heat consumption rate was remarkably improved. Fig. 20 shows typical examples of the precalciner used in Japan.

-33-

SF

Figure 20 Calciners Fig. 21 shows the clinker burning process of the NSP system with the values of Table 1 slightly rounded up. It will be understood that most of the required heat value is consumed to decompose CaCO3 and most of the heat value is directly supplied to the precalciner. Consequently, in the NSP system, the kiln heat load is greatly reduced and the precalcining process can be freely controlled s regardless of the state of the kiln.

Figure 21 Typical heat balance model of burning process (Unit: kcal/kg clinker) Originally, the NSP system was developed for a large capacity kiln to make the kiln size small. Therefore, there are some misunderstandings but, since the aforementioned remarkable mechanism has unexpected advantages such as suppression of the generation of NOx, the NSP system should be actively adopted for a small capacity kiln.

-34-

Generally, the cyclone has a large ventilation resistance and usually accompanies a pressure loss of 100 to 150 mmAq. A preheater with this cyclone piled up in 4 or 5 stages consumes much power, which constitutes one of the disadvantages of the SP or NSP system. But, it is not preferable to lower the pressure loss at the expense of the separation efficiency of the cyclone. The lowering of the efficiency increases the circulating amount of raw material and raises the cyclone outlet temperature, resulting in merely increasing the heat loss and not leading to improvement. Preventing the leakage air from flowing into the process is important for all processes, and the preheater is not an exception. As shown in Fig. 22, when simulation is made using one section of the preheater as a model, mixing of a leakage amount of 10% results in a loss of 18 kcal/kgcl. When a loss due to the increase of the exhaust gas amount or decrease of output is added, the total losses are larger. Leakage prevention measures have to be taken from both aspects of improving facilities and training the operator.

Figure 22 Effect of leakage air The inspection and cleaning ports which are frequently opened or closed during operation should be modified to the size and structure suitable for the situation at site so as to allow a quick and appropriate operation. In addition, workers should be strictly told to close the port tightly upon completion of operation. Leaks from manholes, etc. not so frequently subjected to opening/closing are, in many cases, detected after starting of operation through air inhaling, sound or gas analysis. It

-35-

will be necessary to make it a custom to fill a sealing or coking material to provide sealing as often as required. Also it is recommendable to weld flanges and joints installed for the convenience of assembly, if a leak has occurred. In many cases, the movable sections at both edges of the kiln allow much leak due to clearances arising from deformation by heating and wear. The leaks from these sections lead directly to a reduction in the output of the kiln. After repair, comparison of operation data should be made. 3.2.3 Air quenching cooler Regardless of the type, the clinker cooler is installed to improve the product quality by quenching the clinker. But, it also functions to recover the heat retained by the clinker which was red-heated, by preheating the secondary air for combustion. From this point of view, the grate cooler is superior to the planetary cooler or under cooler because the secondary air temperature can be controlled. According to the heat balance of Table 1, the cooler exhaust gas retains a calorific value of 13 to 16% of total consumption of calorific value and, when the heat efficiency of the kiln and preheater is improved, the required amount of the secondary air used for combustion is lowered and the cooler exhaust gas amount increases, resulting in a substantial increase in loss. As a countermeasure, it is necessary to increase the layer thickness of the clinker on the grate cooler to improve the heatexchange efficiency. 3.2.4 Coal mill For drying and grinding of coal and feeding to the kiln, the following three systems are employed as shown in Fig. 23. a. Direct firing b. Semi-direct firing c. Indirect firing Among the above systems, the direct firing system is extensively used because its equipment is simple, construction cost is low and operation is simple. But, for purposes of accurately controlling the feed amount to the kiln and limiting the primary air volume to the minimum, the indirect firing system is most preferable. It is possible to remodel the system a into the system c. But, it is necessary to pay special attention to prevent spontaneous combustion and explosion of coal powder. A mill type in popular use is either a single barrel air swept mill or a roller mill.

-36-

Notation: 1 Raw Coal Silo

2 Weigh Belt Feeder 3 Air-swept Ball Mill (Tirax-mill) 4 Air Heater (Auxiliary Firing) 5 Separator 6 Cydone Collector 7 Circulating Air Fan 8 Primary Air Fan 9 Rotary Kiln 10 Satellite Coders (Unax-cooler)

a. Direct Coal Firing Mill

1 2 3 4 5 6 7 8 9 10 11

Notation: Raw Coal Silo Weigh Belt Feeder Air-swept Ball Mill (Tirax-mill) Air Heater (Auxiliary Firing) Separator Cydone Collector Circulating Air Fan Primary Air Fan Rotary Kiln Satellite Coolers (Unax-cooler) Feed Hopper (Working Bin)

b. Semi-direct Coal Firing Mill

Notation: 1 Bowl Mill 2 Weigh Belt Feeder 3 Damper 4 Raw Coal Silo 5 Vent Fan 6 Dust Collector 7 Rooster Air Heater 8 DustTrap 9 Clinker Cooler 10 Rotary Kiln 11 Primary Air Fan 12 Primary Air Damper 13 Storage Silo for Ground Coal 14 Rotary Valve 15 Cydone Collector

c. In-direct Coal Firing Mill

Figure 23 Coal firing system -37-

3.2.5 Finish grinding mill Generally, in connection with the cement quality, the initial strength is enhanced by improving the finenessof the product but the long-term strength is not enhanced, so that excessive fine grinding should be avoided even to prevent waste of power. The Blaine value [cm2/g] and the residual content [%] on a sieve with 88 (or 90) micron apertures for usual operation management due to its simplicity in measurement. This unit will, however, be insufficient when some improvement is to be made. The Blaine value indicates an increment in the specific surface area of the object to be ground, that is, the amount of energy consumed for grinding, strength of the product. Although there is a correlation between these two values for the fineness of the products produced from the same system, an attempt to improve the grinding efficiency means example, specifies that ordinary portland cement should have a Blaine value of 2500 or more there may be some cases where the prescribed value 70 or more [kgf/cm 2] for 3 days, or 150 or more value of cement is within the range of 1 to 2 [%], while that for the Blaine value is within the range of 3,050 - 3,300 [cm2/g]. The particle size distribution of the product varies substantially depending on the mill types, and the product by the open circuit process has a broad particle size distribution as compared to the product by the closed circuit process. And, when half-burned raw material is mixed in the clinker, an unusually high Blaine value is sometimes obtained because such material is easily ground. In particular, when a number of mills with different sizes and systems are used, to avoid erroneous In the closed circuit process, a dynamic separator is provided to avoid excessive grinding of the product and mixing of coarse particles. Though various types of separators have been developed, mechanism to adjust a critical particle diameter by a balance of circulating ascending current and whirling current is common, so that such separators are generically called air separators. Even including the power for the separator and the attached fan, power consumption by the closed circuit process is 10 to 15% less than by ,the open circuit process. Since each separator is designed so as to allow changing of classification properties, a key point to efficiently operate this system is to control

-38-

the feed quantity to the mill so as to keep an appropriate circulation rate (generally 200 to 300%) by taking into consideration the grindability of the clinker and the desired fineness of the product. In case of trying to improve the fineness of the product with the open circuit mill whose length is about three times of its diameter, that is, relatively short, it may be successfully done by installing a separator and changing to the closed circuit process. A detailed description on the efficiency improvement of the mill itself is provided above in the paragraph on the raw mill. To avoid repetition, no further description is made here. To maintain the optimum medium filling amount is important for any kind of ball mill. It is advisable that once the optimum operation conditions have been determined, the operation sound of the mill shell at that time should be memorized or the noise level and frequency characteristics should be measured when measuring instruments are available. Thereafter, the difference from these in the sound will allow judging whether the operation conditions are appropriate or not. When the operation technique attains this level, an acoustic feed control system using a microphone can be successfully introduced. Needless to say, operating the mill under an overload condition must be avoided. To reduce the load of the finishing mill intentionally because of its higher sintering capacity compared to the kiln, however, is not recommendable except for such special cases as electric power supply being limited. Usually, it will be more profitable to operate the mill with full load and thereby reduce the operation hours for the day. Especially when power is supplied from the public power supplier, prior negotiation should be made with the supplier side so that operation can be done intensively during the nighttime zone with less power demand. This should bring about mutual merits. In the finish grinding process, grinding with blast furnace slag blended in the clinker increases electric power unit consumption rate in this process. In some cases, also fuel may be required. However, these increases in the unit consumption rate are by far smaller than the total energy unit consumption required for burning clinkers. Therefore, this will result in larger conservation of the energy unit consumption in terms of value per product cement ton. It should, however, be noted that this will make no sense if it brings about some discount in the product price because of the decline in the product quality. Closest attention should be paid to the quality control of the base clinker and the mixtures.

-39-

4. Conclusion
The cement industry in Japan has drastically changed its production process from the wet process to the dry process and promoted the NSP system as increasing production scale. Since energy cost of total cement production cost is large, energy conservation is an important matter in technical improvement activities. The cement production cost depends on the adopted production process. The wet process cannot defeat the dry process as regards energy consumption. At the technical level of quality and productivity, there is no reason why the adoption of the dry process should be impeded. The improvement of a cement plant, however, needs large investment. The timing of the investment of process improvement must be carefully determined taking into consideration the budgetary condition of enterprises and the outlook of the cement market. Before improving a process, activities of good housekeeping and equipment improvement should be applied to promote energy conservation.

-40-