A DIGNOSTIC TOOL TO ACHIEVE PAT TARGETS IN INDIAN CEMENT INDUSTRY

THERMAL ENERGY AUDIT

O P Grover, Sd. Rayees Ahmed, Prateek Sharma and Rabindra Singh National Council for Cement and Building Materials ABSTRACT Cement manufacturing is an energy-intensive process in which the cost of thermal energy accounts for about 50% of the total energy cost. Increasing cost of fuel over the years has stimulated Cement Industry for reducing heat consumption. Apart from this, energy and process related carbon dioxide (CO2) emissions from cement manufacturing are estimated to be about 7% of global CO2 emissions, nearly 40% of which are due to the combustion of fossil fuels. The 83 designated cement plants in India has an energy saving potential of 8,26,853 tonne of oil equivalent/year in the last year of PAT cycle (2012-2015). Hence, reducing fuel consumption which results in cutting down the CO2 emissions is top priority for majority of cement plants in India to achieve BEE PAT targets. Energy Audit Studies by NCB in a number of cement plants reveal the fact that cement kilns are still operated with heat consumption as high as 850 kcal/kg clinker and above indicating huge potential for thermal energy reduction. In Thermal Energy Audit (TEA) studies by NCB, various components of heat consumption / losses are estimated based on process parameters measurements and remedial measures indicating thermal energy saving potentials are suggested. The paper highlights case studies of TEA indicating excess heat loss on account of suboptimal performance of cooler and false air entry in preheater system etc. 1.0 INTRODUCTION The Indian Cement Industry has accorded highest priority to energy conservation in its efforts towards overall cost reduction in cement manufacture, essential for survival in prevailing competitive domestic and international market scenario. It is a fact that energy constitutes about 35-40% of total cost of cement production and thermal energy constitutes about 50% of the total energy cost of cement production. The 83 designated cement plants in India has an energy saving potential of 8,26,853 tonne of oil equivalent/year in the last year of Perform Achieve and Trade (PAT) cycle (2012-2015). Hence, reducing fuel consumption which results in cutting down the CO2 emissions is top priority for majority of cement plants in India to achieve Bureau of Energy Efficiency (BEE) PAT targets. The significance of Thermal Energy Audit (TEA) for energy and cost saving in cement plants is highlighted in this paper through three case studies out of the large number of studies carried out by NCB in the recent past. 2.0 NECESSITY OF THERMAL ENERGY AUDIT The Indian cement industry is quite responsive in adopting various technological developments. The significant fact is that the best operating level of thermal energy consumption in cement plants in India is 675-685 kcal/kg clinker, which compares well with world best figure of 650 kcal/kg clinker. Some of the cement plants by their pioneering efforts have reduced energy consumption by 10 20 % by retrofitting energy efficient systems during the last 10 years giving them competitive advantage over others. National Council for Cement and Building Materials (NCB)s Center for Mining and Environment Plant Engineering and Operation (CME) divulges the fact that a number of cement plants are still not operating their kilns to their full potentials. These kilns are operated with heat consumption varying widely from 680 to 850 kcal/kg clinker. The high heat consumption is mainly due to inadvertent high heat losses through the various exit points of kiln during its continuous operation. Hence, huge potential exists for reducing thermal

energy consumption in these kilns. It, therefore, becomes a necessity for the cement plants to conduct TEA of such kilns and implement corrective measures to achieve PAT target and cost savings. TEA has emerged as a potential tool for identification and analysis of excessive heat consumption areas and implementation of energy conservation measures. Energy diagnostic studies through audit have found that there is potential for reducing specific heat consumption to the tune of 40 kcal/kg clinker in some Indian cement plants. Estimates reveal that a reduction of just 5 kcal/kg clinker heat in kiln confers cost advantage of Rs 45-50 lakh per annum for a million tonne cement plant. 3.0 SCOPE OF TEA AND NCBS APPROACH TEA involving detailed process measurements and examination of operational practices in kiln system is found an effective tool to diagnose the causes for high heat losses. In these studies, various components of heat consumption / losses are estimated and remedial measures suggested to accrue potential thermal energy saving. NCB is fully equipped with latest portable instruments required for precise assessment of thermal performance of kiln, preheater, precalciner & cooler. The scope of NCBs thermal energy audit is quite comprehensive and covers the following specific activities with emphasis on process diagnostic: Assessment of kiln operation through study of prevailing performance data. Field measurements of gas/air flow rates, temperature, draught, O2 & CO levels in kiln circuit with portable instruments Study of the profile of process parameters in preheater Compartment-wise distribution of cooling air in the grate cooler Establishing gas/air balance Laboratory investigations at NCB on samples of selected in-process materials Evaluation of kiln system including heat balance on kiln Formulation of action plan for thermal energy conservation Cost benefit analysis of energy efficient measures. Based on the studies, some of the major causes of thermal energy wastages identified are: 4.0 4.1 Inefficient operation of cooler Incomplete/ delayed burning of fuel in kiln/precalciner False air infiltration through preheater circuit Inconsistent kiln operation Lack of adequate monitoring and instrumentation Inherent deficiency in design of system Poor refractory practices

THERMAL ENERGY AUDIT A FEW CASE STUDIES Methodology The methodology for carrying out TEA studies involves collection of relevant data through data collection format, field measurements of process parameters with the help of portable instruments and analysis of data for identifying the areas of thermal energy saving. 4.2 Case Studies Thermal energy audit study was carried out by NCB in three cement plants during 201213. Plant A having Fuller Inline Calciner (ILC) kiln equipped with 4 stage preheater and grate cooler, Plant B having FLS ILC kiln with 6 stage PH and grate cooler and Plant C having

KHD ILC kiln with 4 stage preheater and grate cooler with IKN stationary grate at cooler inlet. These three kilns having rated capacity of 3000 tpd, 5250 tpd and 3000 tpd were producing 4390 tpd, 5182 tpd and 3024 tpd clinker respectively during the period of the thermal energy audit study. Plant data and some of the performance indicators of these kilns are given at Annexure I. 4.2.1 Heat Balance The flow diagrams of kiln circuits of all the three plants are shown in Figs. 1-3.

Fig 1: Measurements in kiln circuit (Plant A)

Fig 2: Measurements in kiln circuit (Plant B)

Fig 3: Measurements in kiln circuit (Plant C) The heat balance on these kilns was prepared indicating heat consumption for clinkerisation and heat losses through various exit points across kiln system as shown in Tables 1-3. Table 1 : Heat Balance of Kiln (Plant A) 4390 TPD Item Item kcal/kg Heat Input Sensible heat in coal Sensible heat in air Sensible heat in kiln feed kcal/kg cl 413.7 164.9 11.1 112.4 21.2 10.0 51.7 785.0

cl

1.4 3.9 16.9

Combustion difference)

heat

through

coal

(by

762.8

Heat Output Theoretical heat of reaction Heat in preheater exit gases Heat in preheater return dust Heat in cooler vent air Heat in clinker leaving cooler Heat for moisture removal Radiation losses & Total convection

Total

785.0

Table 2 : Heat Balance of Kiln (Plant B) 5182 TPD Item kcal/kg Item cl Heat Input Heat Output Sensible heat in coal 1.4 Theoretical heat of reaction Sensible heat in air 7.5 Heat in preheater exit gases Sensible heat in kiln feed 16.8 Heat in preheater return dust Heat from combustibles in raw meal 8.0 Heat in cooler vent air Heat in clinker leaving cooler

kcal/kg cl 417.6 141.4 3.4 120.1 35

Combustion difference)

heat

through

coal

(by

747.8

Heat for moisture removal Radiation losses & Total convection

11.6 52.4 781.5 kcal/kg cl 407.5 184.7 13.9 31.3 98.1 25.2 13.7 53.8 828.2

Total

781.5

Table 3 : Heat Balance of Kiln (Plant C) 3024 TPD Item kcal/kg Item cl Heat Input Heat Output Sensible heat in coal 2.0 Theoretical heat of reaction Sensible heat in air 6.2 Heat in preheater exit gases Sensible heat in kiln feed 14.0 Heat in preheater return dust Heat in cooler vent air Heat in hot air to 2 CVRMs Heat in clinker leaving cooler 806 Heat for moisture removal Combustion heat through coal (by difference) Radiation & convection losses Total 828.2 Total 4.2.2

Factors for Excess Thermal Energy Consumption The factors contributing to excess Thermal Energy Consumption with their actual levels and normative values are shown in Table 4. Table 4: Factors contributing to High Heat Consumption Item Actual Recommended Plant A Plant B Plant C Cooler vent air temperature (0C) Clinker discharge temperature (0C) Cooler recuperation efficiency (%) Preheater exit gas temperature (0C) Radiation losses (kcal/kgcl) 4.2.3 430 130 63 355 51.7 330 198 57 280 52.4 380 150 54 365 53.8 <275 <120 >70-80 for Latest generation cooler >65-75 for Retrofit cooler <340-360 for 4-stage <270-290 for 6-stage <45 for 4500tpd <60 for 3000tpd

Measures for Improving the Thermal Energy Performance The remedial action plan for improving the Thermal Energy performance of the three plants and potential energy saving are highlighted in Table 5.

Table 5: Recommendations for Reduction of Heat Consumption

Recommendations Reducing false air entry in PH system Replacement of worn out bricks Optimization of cooling air distribution and periodic inspection & maintenance of cooler to achieve heat recuperation efficiency of 70% for A & B 65% for C Total

Energy saving (kcal/kg cl) Plant Plant Plant A B C 11.3 20 7.4 36.4 36.4 31.1 49.8 28 48

The acceptable levels of specific heat consumption should be in the range of 725-750 kcal/kg clinker for the kilns operating with 4-stage preheater cyclones (plants A and C) and 670690 kcal/kg clinker for the kiln operating with 6-stage preheater cyclones (plant B). By implementing the recommendations of the studies as above, the expected specific heat consumption of kilns and annual cost savings to the plants at their present production levels and landed cost of coal are compiled in Table 6. Table 6: Expected Specific Heat Consumption and Cost Saving Item Plant A Plant B Present specific heat consumption (kcal/kg cl) 762.8 747.8 Expected specific heat consumption (kcal/kg cl) 726.4 698 Cost saving due to reduction in heat consumption (Rs Lakh/yr) 476 944 Plant C 806 758 438

Landed cost of coal per tonne is Rs 7000/- for Plant A, Rs 6000/- for Plant B and Rs 5000/- for Plant C. 5.0 CONCLUSION

The studies on three kilns with different systems reveal that excess heat loss is mainly from cooler, false air infiltration in PH system and worn out bricks. It has also been observed that cooler recuperation efficiency is lower and needs to be increased to the expected level 70-80% for latest generation cooler and 65-75% for retrofitted grate cooler with stationary grate at cooler inlet. Further, cooler needs to be optimized and this can be achieved by: Re-adjusting the cooling air distribution in compartments and undergrate pressures Inspection and rectification of any mechanical damage to cooler internals through periodical maintenance. Indian Cement Industry is striving hard for thermal energy conservation over the past several years. The increased consciousness for energy conservation and the steps taken towards effective monitoring, better operational control & process optimization and retrofitting of energy efficient systems have contributed greatly in energy conservation efforts. NCBs TEA serves as a diagnostic tool to identify the areas of excess heat looses, which would help the cement manufacturers to take corrective action on those specific areas of high heat loss and achieve significant thermal energy reduction, resulting in substantial financial savings and achieving PAT targets. Acknowledgement The authors have freely drawn upon completed R&D work/status reports of NCB and some of the unpublished work in NCB. This paper is being published with the permission of Director General, NCB.

Technical Data of the Plants and Performance Indicators Technical Data SI Description No. 1. Rated capacity, tpd 2. 3. kiln size Preheater Precalciner Grate Cooler Plant A 3000 4.57 m x 67 m L / 4 stage ILC Fuller make with conventional cyclones SF cross bar Plant B 5250

Annexure I

Plant C 3000

4.35 m x 67 m L 3.85 m x 56 m L 6 stage ILC FLS 4 stage ILC KHD make make with LP with conventional cyclones cyclones SF cross bar 1KN stationary grate & CFG Plant A 4390 46 762 4.79 3.39 42.21 Plant B 5182 -1 747 6.31 3.33 44.3 Plant C 3024 0.8 806 5.78 3.08 58

4.

Performance Indicators SI No. Description 1. Actual production (tpd) 2. 3. 4. 5. 6. Percentage higher than rated output (%) Specific heat consumption (Kcal/kg clinker) Volumetric loading (tpd/m3) Thermal loading (Gcal/hr/m2) Cooler loading (tpd/m2)