Ethiopian Institute of Technology - Mekelle

Department of Mechanical

Engineering

Energy auditing in raw mill

By

Micheale mekonen
FST/UR043/99
Supervisor

Mesele hayelom (Ir)

Hosting Company: Messebo

Building Materials Production plc.

Department of Mechanical Engineering
Mekelle
October 2011

Acknowledgment
First and foremost I would like to express my heart felt gratitude to ir mesele for his dedicated
collaboration with valuable, continuous suggestions and ideas during the energy audit process.
I would like also to express my sincere appreciation to engineers tekle, aksumawi and raw mill
attendants, those who helped me in Messebo cement factory during the internship.
My deep appreciation and thanks goes to engineer kasahun who was always gives me courage
for a very challenge I had passed.
Finally, I am very glad to say thanks for my colleagues and all those people who contribute their
own hand in my internship.

Micheale Mekonen
2011

Executive summary
Based on, the new five years curriculum of the Mekelle University, one semester is allotted for
Industrial linkage. Because of this, we have spent the fourth year second semester at Messebo building
materials production plc.
In our stay at Messebo building materials production plc, we have worked in different sections of the
company under different leaders. Working under these leaders, we have tried to observe different tasks
that are performed in the company and find problems that the workers encounter during their job
operation.
After identifying the problems, we have tried to solve some of the problems by ourselves and proposed
ways of solving the problems for those that we couldnt solve by our selves.
While doing this, we have been able to upgrade our practical and theoretical skills and improve our team
working abilities.
We have also been able to identify the opportunities present.

Table of Contents
Acknowledgment..............................................................................................i
Executive summary..........................................................................................ii
CHAPTER ONE..................................................................................................1
1. Brief History Of The Company....................................................................1
1.1 Background of the company..............................................................................................................1
1.2The main products and the suppliers..................................................................................................1
1.3 Vision, Mission, Objectives and Targets............................................................................................2
1.4 Organizational Structure of the factory..............................................................................................3
1.5 structure of messebo building maaterials production p.l.c.................................................................4
1.6 The over all process of the factory....................................................................................................5

CHAPTER TWO...............................................................................................12
2. Proposal on energy auditing in raw mill.....................................................12
2.1. Introduction....................................................................................................................................12
2.2 Problem statement...........................................................................................................................12
2.3. Research topic................................................................................................................................12
2.4. Research output..............................................................................................................................13
2.5. Methodology..................................................................................................................................13

CHAPTER THREE............................................................................................14
3. Energy auditing on raw mill.......................................................................14
3.1 Mass and energy analysis................................................................................................................14
3.2 Mass balance on sepax separator.....................................................................................................16
3.3 Energy balance................................................................................................................................17
3.4 Energy balance in sepax separator...................................................................................................19

Chapter Four..................................................................................................20
Conclusion.....................................................................................................20
Recommendation...........................................................................................21
References.....................................................................................................22

CHAPTER ONE
1. Brief History Of The Company

1.1 Background of the company

Messebo cement factory is located in Mekelle town in the Tigray regional administrative 790km.
Far from A.A (capital city) of Ethiopia.
The factory is located 11 km for from Mekelle town near to Messebo hills with the number
employees about 600 employees established with 1.2 billion Ethiopian birr. The factors taken in
the consideration to build the factory are the fulfillment raw materials availability, cement
market, energy supply, and infrastructure requirement and investment incentives.
The feasibility study fro Messebo cement factory was conducted by Austro plan, Austrian
Engineering Company and was sponsored by Tigray development association. The company was
established around Mekelle with high raw material potentials.
With the expanding construction business through out the country w/c demands cement as one of
its indispensable inputs with out the construction activity would hardly be possible to make it
sustainable. Meeting this demand at a fair price with highest quality is the objective of MCF

1.2The main products and the suppliers

The factory has developed appropriate sales out lets to ensure that its customers are
actually beneficiaries.
The factorys main product is ordinary Portland cement (opc) with its distinctive features,
remains being competitive in the market. More over, its product is over standard.
Besides, the factory has already provide to customers with different cement type such as,
Portland pozzolana cement (PPC) with EN 197 standard.
The product of the factory entered to the market at country level latterly, but according to
the data collected, it gains vigorous witnesses in satisfying its users in all market and
additionally the factory product has received a certification of the cement quality
1

immediately after the commencement of production from the Ethiopian quality and
standard authority and working now for TOM certification. ISO 9001-2000.
Messebo cement factory has already developed its strategies that would enable it work with
every segment of the market when it commences distribution of its product in February 1992 E.C
particularly. Wholesalers retailers of cement, constructors, dry cargo transporters, government
and noon government organizations undertaking construction activities and the society at large,
are the ones which Messebo cement factory is looking for ward to establishing a storing tie with.
The factory technology is the leading technology of 21 st century, which was supplied and erected
by the best manufacture of cement machinery in the world FLSmith CO. of Denmark.
The annual production capacity of the factory is 600000 tones of ordinary Portland cement.
The factorys distribution centers are located at the factory compound, Addis Ababa, baherdar
and Dessei stores, besides it has a direct distribution channels to Gonder, Combolcha and Woldia
etc, (Feasibility study, 1993).

1.3 Vision, Mission, Objectives and Targets

According to the factorys business plan, Messebo Cement factory has the following mission
statement.
1.3.1 The factorys vision
The vision id designed to be, as to become fully competitive by building its internal capacity,
enhance creation fulfill national demands and to examples of modern systems and high standards
of work culture.
1.3.2 The factorys Mission
The mission of the factory is to shortly assume its existence and support the continuously
growing construction industry with supply to construction materials of acceptable quality and
reasonable price while also broadening its property ownership.
1.3.3 Objective of Messebo Cement Factory
The overwhelming expanding construction business via out the country demands cement as one
of its indispensable inputs with which the construction activity would hardly be possible.
Meeting this demand at fair with higher quality, this remains to be our objective. In line with, the
factory has the following objectives:

 To create sustainable market by supplying competitive products that fulfill

Customers requirements
Enhance property ownership
To continuously develop modern and scientific methodology, work, culture and systems
Develop human resources and crate job opportunity
Create conductive work environment
Enhance regional development
Control or remove causes for environment pollution
1.3.4 Strategies of Messebo Cement Factory
The factory established the following strategies in fulfilling its activities. By creating broad an
sustainable market by supplying competitive products that fulfils customers requirements.
To continuously develop modern and scientific work method, work culture and system.
Create conductive work environment.
Enhancing property ownership
Control or remove causes for environment pollution

1.4 Organizational Structure of the factory

The factory (Messebo Cement Factory) consists for top to bottom, the board of directors, the
general manger, department, and branch offices.
As it is clearly seen on the chart the departments are

Production

Maintenance

Quality control

Management representative and human resource

Finance

Procurement and supply

Marketing

Human resources:- Messebo Cement Factory has highly professional committed and innovative workforce
that works to its best, to deliver products with high quality standards on time to its customers. At the current

moment of time the factory has exactly 850 employees. Among which 90.2% are permanent and 9.2% are
contract employees there are seven departments to fulfill it s objectives..

1.5 structure of messebo building maaterials production p.l.c.

GENERAL MANAGER

AUDIT SERVICE

LEGAL SERVICE
IT SERVICE

EXCUTIVE
SECRETARY

Division general
manager
administration and
control

Division general manager

process and quality control

MARKETING

Division general
manager mechanical and
maintenance

PROCESS

Division general
manager
electrical and
maintenance

MECHANIAL MAINTENANCE

ELECTRICAL
FINANCE

QUARY AND CRASHER

HUMANE RESOURS

QUALITY CONTROL

PROCESS AND SUPPLY

DEPARTMENT

MAINTENANCE
DEPARTMENT

1.6 The overall process of the factory

1.6.1 Quarrying and crushing
The quarry (where the mining processes performed) is located .. km away from the plant has
the main raw materials to such as, limestone and shale that is estimated to last for years, the other
raw materials (ironore, silica sand, gypsum and pozzolanna (pumice)) are brought from near by
places .limestone provides calcium oxide and some of the other oxides, while shale and the other
materials (silicasand,iron ore)provide most of silicon,aluminium and iron oxide required for the
manufacture of Portland cement.
A few materials away from the quarry there is one fls hammer crusher which can crush 550
ton /hr

.the crusher reduces 85% of the rock lumps from a 2meter size down to lessthan 25

mm.
1.6.2. Raw material preparation
In messebo cement factory there is closed longitudinal material storage hall with 342 35 m
area used to store all the raw materials mentioned above.
There are about 7 piles (previously and 9 piles now (limestone additive and pozzollana piles
adds). One common stacker is used for stacking nine raw materials which have been crushed in
the crusher. Limestone and shale which need homogenizing effect are stacked chevron method of
stacking and the other piles which need no homogenization effect are stacked after cone shell
method. The separate reclaimers one for limestone and the other for shell are installed to
homogenize the particulate materials and to convey the homogenized material from the piles to
the out going conveyor. Silica sand and iron ore and loaded by loader on the hopper which
beneath it has a conveyor that discharges them to the out going belt conveyor.
Gypsum, limestone additive and pumice are brought to the cement by the loader
1.6.3. Proportioning
In the department four intermediates bins for limestone, shale, and silica sand and iron ore
storage are placed. Beneath each bin there are dosimat feeders which adjust their speed
according to the signal given from the QCX software from the laboratory in this way the raw
materials are proportioned in order to satisfy the final chemistry requirement.
That is the chemistry of each raw materials analyzed by x-ray analysis is fed to the software,
based on this soft ware will calculate the proportioning in percent of mass of the raw materials,
5

this will be sent to plc type system and this system will give the proportioning signal to each
dosimat, each dosimat will then vary their speed based on the load sensed by the load cell
poisoned there. Every hour, samples (accumulated at sampler for continuous one hour) from raw
mill product will be analyzed and fed to the software to correct any deviation (from the set point
inserted in the computer) that may occur due to different reasons. Therefore the system does not
allow uniform chemistry that may have a negative effect in burning the raw meal at kiln.
1.6.4 Raw material grinding
The raw material grinding systems equipped with a ball mill (diameter = 5, drying chamber
length=2.2. and grinding chamber length =8.22m). The nominal capacity of the mill is 180t/h,
the finesse of the product is 15% residual on 90m sieve and moisture content in the raw meal is
less than 1%. In Messebo cement factory the exhaust gas from pre-heater is used to dry the raw
materials from average moisture content of 4% to less than 1% in the raw meal.
As mentioned above there are four feeding bins in raw material proportioning station (limestone
bin, shale bin, sand stone bin and iron ore bin).
The four kinds of raw materials are fed to a common belt conveyor according to the pre-set
proportioning rations by corresponding weighing feeder (dosimat feeder). Then the raw material
on the conveyor is fed to the ball mill. In the raw mill drying and grinding take place and the
very fine materials will go with the air as separation air and the Coarse ones go to the air slide at
the out let of the mill then to bucket elevator and then finally to the separator through an air slide.
The ground material is then classified by a sepax separator. The coarse parties returned to the
mill for further grinding and the fine part as product is carried out with the gas and collected
(separated) by two cyclone separators. The pre-dedusted gas is vented out and sent to some
recirculated as separation air and some to the Electrostatic precipitator for further clean u and
sent to the environment then after.
The raw meal collected by the two cyclones is transported to then raw meal homogenization silo
(CF silo, or controlled flow silo) by air slide and elevator
1.6.5. Raw meal homogenizing and kiln feeding system
Kiln feeding system is mainly comprised of cf-silo and LOW (loss of weight) unit,cf silo is for
raw meal storage and homogenizing. Kiln feed measuring is mainly accomplished by LOW
system. There are 7 extraction holes at the bottom of cf silo,3 rotary blowers are selected. And
6

the blowers controlled by the programmable logic control, will alternatively aerate 3 segments
(place at 3 different extraction holes), and simultaneously material is extracted from these out let
holes.
Three load cells are provided at the bottom of LOW hopper, which are used to measure materials
weight in the hopper.
Kiln feed control is fulfilled by measuring the reduced material quantity in the hopper with in
certain period of time (during emptying period).and mathematical model during filling period.
The adjustable motorized gate is controlled by signal from the programmable control unit, the
load cells in the tank, and set values for the feed rate from the operator at CCR.
Metered kiln feed is conveyed to the top of the preheated by an air slide and then by two air lift
blowers.
1.6.6. The waste gas treatment system
Whenever the kiln is in normal operation and the raw mill is stopped, the exhaust gases induced
by ID fan are treated by gas conditioning tower to around 150-160

.if both kiln and raw

mill are in opration,hot gas is supplied to raw mill for drying purpose.
Gases not used in raw mill are passing the GCT and joining the gases from raw mill, where after
the entire gas flow is dedusted in raw mill/kiln ESP.
The dust precipitated in the raw mill/kiln filter is returned to either cf silo or preheater.
The cooler excess air is de-dusted in a separate ESP specially designed or clinker dust. The
recuperated dust is returned to the clinker transport system.
1.6.7. Clinker burning and clinker transportation
The kiln burning system is composed of a

3.75 57m with inline calciner and a single

five stage preheater. The average specific heat consumption of the system is 710-750 kcal/kg
clinker. after the raw meal is pre heated in pre heater stage cyclone 1 to 5 are precalcined in
precalciner,the caco3 calcining rate in the kiln inlet can reach 95%.th remaining 5% of the
calcinations and clinkerazation process will be taken place inside kiln. the ratio of firing oil
burned in the kiln for clinkerization and the precalcined is 4:6.
A grate cooler is applied to clinker cooling by cooler fans. The clinker getting out of the cooler
is commuted by the built in hammer crusher and then carried to clinker storage by means of

bucket conveyor. The exit gas from the cooler pertly goes to kiln as secondary air and partly to
calciner as tertiary air. The surplus part is emitted to the atmosphere after cleaned by a cooler EP.
1.6.8. Clinker storage
A clinker storage silo with capacity of 15000tons and an open yard with a capacity of 20000 tons
are built in the plant. Under the clinker silo, the rod gate and the motorized discharging gate are
installed. The clinker discharged by the equipment is fed to different belt conveyor
correspondingly, then carried to the clinker feed bin in cement grinding plant by means of belt
conveyor.
1.6.9. Cement grinding
A closed circuit grinding is applied. The main equipment consists of a 4.6 12m double
compartment tube mill and sepax separator. This mill at this time produces two types of cement
namely ordinary Portland cement (opc) and pozzolana Portland cement (ppc).
OPC compromises 90% clinker, 5%additives (limestone) and 5% (gypsum).PPC compromises
70% of clinker,25% pozzolana and 5% gypsum.
The capacity of the mill is 105-120t/h for OPC cement and 135-140t/h for PPC cement when the
specific surface of the product is 2800cm2/g to 3000 cm2/g.
The clinker, additive (limestone, pozzolana) and gypsum are fed by the corresponding belt
weighting feeder (dosimat feeder) to a common belt conveyor then the belt conveyor feed them
to the tube mill.
The ground material is carried to the sepax rotor via air slides and bucket elevator. The separator
will classify the ground material in to two parts the course and the fine. The coarse material is
fed back to the tube mill via air slides. The product from the separator is carried to a cyclone by
means of gas stream and is collected by it. Most of the air leaving the cyclones is recycled to the
sepax separator; the remaining air is cleaned in bag filter before released to the atmosphere via
the chimney. Product as cement is conveyed to cement silos via air slides, belt conveyors, screw
conveyor and bucket conveyor
1.6.10. Cement storage
Two

16m concrete silos are setup as cement storage facilities; each of them has a storage

capacity of 10,000ton.
Air ducts are erected on the bottom of the silo for aeration of the cement fluidization. The air is
supplied to these ducts by root blowers.
8

On the bottom of each cement silo a discharging unit of manual gate and a pneumatic flow
control gate is installed. The discharge from these gates is transported to the cement packing
system via air slides and bucket elevator. Connecting with the discharging units, there is bulk
loader for both silos installed for loading the bulk cement to the Lorries.
The cement flow rate to the loader can be controlled by a flow control gate, which is mounted
beside the discharging unit,
1.6.11. Cement packing
The packing line of products in powder form is equipped with different elements/machines.
The principal elements of the packing line are;
1.
2.
3.
4.
5.

Vibrating screen
Feed hopper
Rotary feeder
Packing machine
Discharge belt

Flow of material in the packing plant;

The flow of material rises from the bucket elevator to reach the vibrating screen, where is
screened, to be settled in the storage hopper. The former is equipped with control systems (called
sensors) placed inside the hopper. These sensors control the extraction system and keep the level
as the steady as possible.
Then the flow of materials passes through the rotary vane feeder equipped with alternate gear to
adjust the level of materials in the packet hopper. The sensor, by which the bag packer is
equipped, serves the purpose of the checking the rotary vane feeder in order to keep the level as
steady as possible. The flow of materials is in then directed to the spouts; most part of it is
packed in the bag, whereas a very small of scraps, in the form of dust, over flows.
The dust is sucked up and collected, by means of a sucking chute, in the lower hopper. The reject
is then separated: the dust is gathered by screw conveyors and led back into the conveying cycle.
The packing bag cement is sent out and guided to the bag cleaner and bag cutter (for those less
than 50kg) by means of belt conveyor. The cleaned bags are carried by a roller conveyor and a
belt conveyor to truck loaders conveyor, and then loader or trucks.
The weight tolerance of bagged cement is guaranteed by the automatic control system

Internship
The challenges that I had faced
During, the internship time I had to expose to a lot of challenges that eventually support me to
know what and how I had to do.
This starts which seems as ease as like asking where to find the office of human resource
department (HRD) up to talking with our supervisor about the internship.
I really remember it while I was arriving the first day in Messebo cement factory .we didnt have
any idea about the over all process and these huge machineries as well.
Besides, to this the working environment is too dusty and noisy especially when you are become
close to these machines.
Even though, such working environment were strange for me I had to adopt them as fast as
possible in order to accomplish for what I had been there.
The second problem that I had to face was to interact with workers who are already engaged.
After a time I introduce a lot of workers in every division, I start to feel like I was there for many
years.
There for, this enables me to extract information in a well defined manner in almost all sections.
Finally, the most problems were about the datas and manuals that put in practice and the
working principles of some part of machines which is necessary for the analysis of identified
problems.
Benefits that I gained form this internship
Unfortunately, our predecessors didnt get such an interesting chance. So, feel my self like
lucky man.
When we come to the main aim of internship, I think I achieved all of them what are expected
from me.
During the internship time I got a lot of experience which will be valuable and useful in my
future career. In terms of practical skill, I have been improving my practical skill through
participation when there were maintenances of machines
I was take parting when there had been a break down of machines so, I used to see and gain
significant skill. For instance, a maintenances of bucket elevators, belt conveyors and rotary kilns
10

and one of the main benefits that, I gained was up grading my theoretical knowledge which, I
was familiar in thermodynamics, heat transfer and strength of materials..etc
Besides of, improving my practical skills and upgrading theoretical knowledge, I also used to
improve my communication skill with my advisor and some operators who were willing to told
me the operating principles of these machines ,the way how they maintains. And with every one
who has been working on the cement factory.
Most of times we were working with operators in a brotherhood manner so, I think I became
familiar with team and leadership skills.
Consequently, I also became aware of what it has to be my duty and responsibility.
Finally, I have been inspired to do my own work without any expectation of hiring.

11

CHAPTER TWO
2. Proposal on energy auditing in raw mill
2.1. Introduction
The raw mill are a horizontal clinkers with a powerful internal metal shielding that contains tons
of balls mills inside used to crush the raw materials.
As the raw mill rotates these ball mills fall dawn, hit the material particles and the impact force
will divided it in two and more pieces granules which form what is called raw meal.
Currently, the raw mills have a capacity of 180tons/hour for crushing raw materials to the
required size and quality.
Finally, the raw meal is conveyed to special silos where the homogenization process is
completed.

2.2 Problem statement

The production of raw materials using grinding of materials is the most energy intensive
production process is one cement industry consuming an approximately 45-80kwh/t
corresponding to approximately 50-75% of the total consumption of electrical energy of 90130kwh/t clinker.
As a result of this, optimal raw material operation in terms of material balance (mass and energy)
is therefore essential.

2.3. Research topic

The raw mil units have three (3) main features;
i.
ii.
iii.

Raw mill unit

Separator
Cyclones

2.3.1 Research topic units

The raw mill is the where the grinding of raw material is takes places in order to produce the
required amount of raw meals.
The sepax separator is used in a closed circuit grinding plant for separation of the fine from the
coarse material which is received from the mill.
12

Subsequently, the fine fraction is separated in to 4(four) cyclones arranged in planetary system
and at this stage the fines are referred to as a finished product.
The coarse fraction is recycled to the mill inlet for further grinding.
Consequently, there is a heat loss in the mills due to conduction through and insignificant
radiation from the shell mill.
Besides the moisture content of the raw material is and because of the 85-95% efficiency of the
four (4) separator cyclones there exists mass and energy un balance.

2.4. Research output

Since, the main aim of the raw mill is to produce sufficient raw feed for keeping the kiln in
continuous operation. As a result of the optimum mass and energy balance (material balance) on
raw mill is going to enable us in order to secure the desired output of clinker at lowest possible
energy consumption.
A uniform clinker output at a high level ensures a lower consumption of energy on the pyro
process as well.
It improves thermal efficiency of the energy intensive process on cement industry which is
grinding (raw mill).
It also improves the pyro processes and related material (mass) operations and environmental
benefits to the overall kiln operation.

2.5. Methodology
The previous data that has been collected and the quantification of the numerical specification
for the mass and energy analysis that is going to carried out.
The inputs (raw materials), energy consumption and output like emissions, loss and the main
product (raw meals) will also illustrate.

13

CHAPTER THREE
3. Energy auditing on raw mill
The raw material grinding systems equipped with a ball mill (diameter = 5, drying chamber
length=2.2. and grinding chamber length =8.22m). The nominal capacity of the mill is 180t/h,
the finesse of the product is 15% residual on 90m sieve and moisture content in the raw meal is
less than 1%. In Messebo cement factory the exhaust gas from pre-heater is used to dry the raw
materials from average moisture content of 4% to less than 1% in the raw meal.
As mentioned above there are four feeding bins in raw material proportioning station (limestone
bin, shale bin, sand stone bin and iron ore bin).
The four kinds of raw materials are fed to a common belt conveyor according to the pre-set
proportioning rations by corresponding weighing feeder (dosimat feeder). Then the raw material
on the conveyor is fed to the ball mill. In the raw mill drying and grinding take place and the
very fine materials will go with the air as separation air and the Coarse ones go to the air slide at
the out let of the mill then to bucket elevator and then finally to the separator through an air slide.
The ground material is then classified by a sepax separator. The coarse parties returned to the
mill for further grinding and the fine part as product is carried out with the gas and collected
(separated) by two cyclone separators. The pre-dedusted gas is vented out and sent to some
recirculated as separation air and some to the Electrostatic precipitator for further clean u and
sent to the environment then after.
The raw meal collected by the two cyclones is transported to then raw meal homogenization silo
(CF silo, or controlled flow silo) by air slide and elevator.

3.1 Mass and energy analysis

On raw mill inlet we have three mass inputs;
I.
Mass of materials
II.
Mass of coarse return
III.
Mass of hot flue gas from kiln

14

Mass of materils1

Mass of matrials2

Mass of return coarse

Hot flue gas

mass of gas leaving

mill
T= 324

T= 99.63

Pressure= 2mbar

pressure= 32 mbar

Fig.1. Control volume, various streams and components for raw mill.

At certain time we have a feed rate of materials in %

Table.1 feed rate of in put materials
Type of materials
Limestone
Shale
Silica sand
Iron ore
From design capacity of raw mill for materials = 180t/h

Feed rate in %
75.2%
19.7%
3.8%
1.3%

III.1.1 Input materials from proportioning unit

Table.2 analysis of input materials
Limestone
m

Shale

= 180 t /h

=180 t /h

=135.36 t / h

Iron ore

=180 t / h 0.

038

0.197

0.752

Silica sand

=6840 kg /hr

= 35460 kg/hr

=135360 kg /hr
3.1.2 Hot gas (flue) from kiln
This gas is a dust laden gas
Based on, dust balance
ass ( ) =mass

m
( out)

15

=180

t /h 0.013

= 2340 kg /hr

hr
m3 /

m3
10 g/
So, inlet dust quantity
)

kg /g
1000
237.875
2.378 kg/hr
3.1.3 Return course from separator
Here, we have a return factor (0-20%)
m
return=015
m
materials
0.15 180 t /hr

27000 kg/hr
3.1.4 Mass balance on raw mill exit
m
materials2 = 0.96 mmaterials
0.96 180 t /hr
172800 kg/hr

total = m
materials2 + m
return
So, m
172800 kg/hr +27000 kg /hr
199800 kg/hr

m
gas 2=
gas leaving mill system is a sum of total incoming gas + vapour from water

evaporated
gas 2= m
gas 1
materials
+ 0.04 m
m

2.378 kg/hr + 0.04 180 t /hr

7202.378

16

3.2 Mass balance on sepax separator

Sepax separator unit
Gas which goes to ESP and fine materials

Return course to mill

mass of materials2

Mass of gas (by-passed)

dust laden gas

Fig.2 control volume of sepax separator.

3.2.1 Mass balance on sepax separator

ass ( ) =mass

m
( out )

m
solid + m
gas by passed

dust laden gas = m

return + m
product
+ m

m
product = m
solid + m
gas by passed

dust laden gas _ m

return
+ m

(199,800+0.9025+7202.37827000) kg/hr
1800003.18 kg/hr

180 ton/hr

3.2.2 Mass of gas (by passed)

This gas is by passed from the cyclones in order to use for further separation in separators
3
Volumetric flow rate = (9000-10000) m /hr
3
Density = 95( mg/m )

17

mg

3
m

mg
So,
kg /

( 3 hr ) 95

by passed gas= 9500

m

0.9025 kg /hr

After this, the product mass separated to dust mass which goes to ESP for dedusting and
fine material which goes CF-SILO
gas goes
m
product =m
fine +
ESP
m
gas goes
3
3
m
ESP=240000 m /hr 10 g /m 1/ 1000
= 2400 kg /hr
gas goes
m
fine goes c f silo = m
product _
ESP
m
180000 kg/hr 2400 kg/hr

177600 kg/hr

3.3 Energy balance

First, drying in mills takes place on drying chamber;
3.3.1 Drying in mills
A sensible heat supplied from the hot gas (flue) to input materials;
Qsupplied = m
gas cp t

18

2 t ambient
t
)

Qsupplied = mgas cp
2.378 kg/hr 1. 005 kj/ kg . k (597.75298 ) k
=716 kj/hr
A heat required to evaporate vapor from water (moisture content)
QH = m
materials

( h)

QH =m
materials

2 h 1
h
)

180 ton/hr (2684.9104.5) kj/kg

=464472kcal/kg
3.3.2 Heat in leakage
Here, we have heat in leakage due to heat transfer (conduction type) from the system to the
surrounding through the shell of raw mill.
Qx =k A

( T )
L
Where, T =(t ambient t surface )
= (298 597.75 k

= -299.75k

L
Area =
D=5 m L=10.4 m

Area = 5 m 10.4 m
2

163.67 m

k =thermal conductivityof steel

15.1

19

Therefore,
Qx =k A

( T )
L
m. k
w/

15.1
71. 097kj

Qtotal = Qsupplied +Q H + Qx
716 kj/ hr + 464472kcal/kg + 71. 097kj
= 465259.09 kj/hr
We have a mill motor with 3000 kw power
w 1=3000 kw
We have also power consumption 18 kwh/t
w 2=

18 kwh /t

w total = 3018 kw
Finally, using mass and energy conservation law;
U=QW .1

m(u)=Q
+ W 2
u= q total w
total
u= 465259.09 (3018 ) kw
u=468277 kj/hr

3.4 Energy balance in sepax separator

A sensible heat load due to (from gas leaving mill and a gas by passed)
m

by passed gas ) cp gas ( t)

( gas leaving mill+ m
Q supplied =
m

by passed gas ) cp gas (t 2 t ambient )

( gas leaving mill+ m

20

 7203.2805 kj/hr 1.005 kj/ kg . k ( 372.63298 ) k

540.263 kj/hr

In sepax separator we have a motor with 300kw

w 1=300 kw
We have also an exhaust fan with 400 kw

w 2=400 kw
w total=700 k
So, from the mass and energy conservation law
U=QW 1

(u)=Q
+ W 2
u= q total w
total
u=
540 kj/hr(700 kw)

u=1240 kj/hr
Finally The Thermal Efficiency of raw mill is,

( Qout )
Thermal Efficiency 1 ( Q )

71.23

Chapter Four
Conclusion
Material quantities, as they pass through processing operations, can be described by material
balances. Such balances are statements on the conservation of mass. Similarly, energy quantities
can be described by energy balances, which are statements on the conservation of energy. If there
is no accumulation, what goes into a process must come out. This is true for batch operation. It is
equally true for continuous operation over any chosen time interval.
21

Material and energy balances are very important in an industry. Material balances are
fundamental to the control of processing, particularly in the control of yields of the
products. The first material balances are determined in the exploratory stages of a new
process, improved during pilot plant experiments when the process is being planned and
tested, checked out when the plant is commissioned and then refined and maintained as a
control instrument as production continues. When any changes occur in the process, the
material balances need to be determined again.
The increasing cost of energy has caused the industries to examine means of reducing energy
consumption in processing. Energy balances are used in the examination of the various stages of
a process, over the whole process and even extending over the total production system from the
raw material to the finished product. Therefore used in everyday process management to
maximize product yields and minimize costs.
Material and Energy balances are important, since they make it possible to identify and quantify
previously unknown losses and emissions. These balances are also useful for monitoring the
improvements made in an ongoing project, while evaluating cost benefits. Raw materials and
energy in any manufacturing activity are not only major cost components but also major sources
of environmental pollution. Inefficient use of raw materials and energy in production processes
are reflected as wastes.

Recommendation
Material and energy balances are very important in an industry. Material balances are
fundamental to the control of processing, particularly in the control of yields of the products.
When any changes occur in the process, the material balances need to be determined
again.
Material and Energy balances play a main role, since they make it possible to identify and
quantify previously unknown losses and emissions
These balances are also useful for monitoring the improvements made in an ongoing project,
while evaluating cost benefits. Raw materials and energy in any manufacturing activity are not
22

only major cost components but also major sources of environmental pollution. Inefficient use of
raw materials and energy in production processes are reflected as wastes.
There fore I proposed to have proper and continuous material and energy balances on raw mill in
order to have produced sufficient raw feed for keeping the kiln in continuous operation. As a
result of the optimum mass and energy balance (material balance) on raw mill is going to enable
us in order to secure the desired output of clinker at lowest possible energy consumption.
A uniform clinker output at a high level ensures a lower consumption of energy on the pyro
process as well.
It improves thermal efficiency of the energy intensive process on cement industry which is
grinding (raw mill).
It also the pyro processes and related material (mass) operations and environmental benefits to
the overall kiln operation.
Therefore used in everyday process management to maximize product yields and minimize costs.

References

F L S manual
Manual of maintenances of ball mills
Cengel and boles heat transfer text book
Applied thermodynamics
Moran, M.J. and Shapiro, H.N. 1995. Fundamentals of Engineering Thermodynamics,
3rd ed. John Wiley & Sons, New York.
23

 Moran, M.J. Engineering Thermodynamics

Mechanical Engineering Handbook
Ed. Frank Kreith
Boca Raton: CRC Press LLC, 1999
Hand book of cement manufacturers

24