Welcome to my presentation

West heat recovery in messebo

cement factory
INTRODUCTION
 Cement plant is a plant which produce cement.
 3% world energy
 5 % carbon di oxide emission.
 Industrial waste heat refers to energy that is generated in industrial processes without being put
to practical use.
 Sources of waste heat include
 equipment inefficiencies
 hot combustion gases discharged to the atmosphere
 Heated products exiting industrial processes
 heat transfer from hot equipment surfaces.

What we must to do on this waste heat ?

VARIOUS ENERGY RESOURCES FOR MESSEBO CEMNT FACTORY

• Energy is a property of objects which can be transferred to other objects or converted in to different
forms and cause a change in a matter.
Type of energy 1 chemical energy released when a fuel burns.
2 the radiant energy carried by light.
3 thermal energy due to an object's temperature
Energy resource for messebo cement factory.
1 coal: south Africa and jimma coal
there are many process that consumes coal like rotary kiln ,calciner
2 Biomass: This biomass came from the residual of selth from humera and welkayte. know a time
Around 10 percent of the coal is replaced by biomass.
3 Fuel : uses to start up the rotary kiln.
4 electrical energy : that bring from elipa. needs electrical energy to operate on the company, like
rotary kiln, clinker coolers conveyers and crushers raw mill cement mill …..
PROCESS TO PRODUCE CEMENT IN MESSEBI CEMENT FACTROS

• 1 QUARRY AND CRUSTURE 2 conveyer belt

• 3 RAW MATERIAL STORAGE.
why we need this?
Stacker Reclaimer
4 PROPORTIONING UNIT is area or place where proportioning of the four raw materials.
 Have four variable speed motors one for each raw material
 have two type of conveyer
5 RAW MILL The purpose of raw mill is to produce homogeneous raw meal which can give good
burning condition in kiln by drying and grinding the raw material.
6 PYRO PROCESSING
 PRE HEATER
• is the arrangement of five cyclones on line 1 and 5 cyclones.
• Why we need preheater – to reduce emission
- to reduce energy consumption
- to remove moisture content
 CALCINER
• Used to capture carbon di oxide from limestone.
 ROTARY KILN
• Kiln is used for burning of the raw material by flow the material through the kiln.
• Kiln is the most expensive than the other components of cement plant cause 60% of energy consume at this
and the kiln does not stop without maintenance.
 CLINKER COOLER
 use to cool high temperature material which is dropped from the rotary kiln. Inside the cooler there
are 8 fun with different size and cooling capacity. The fun suck the heat of the material and helps to
reduce the temperature of the clinker.
 CEMENT MILL
• The final manufacture stage at the cement plant is the grinding of cement from
kiln, mixed with approximate 4-5%gepsum and other possible additives, in to the
final product cement. The quality of final cement is dependent on the operational
mode and parameters of the cement grinding plant.
PACKING
• It used to fill the cement in the bagel and it has weight sensor that indicates how
many kilogram of cement is fill in the bagel. After full fill the bag it passes through
the bag rejecter. if it is bellower above 50kg it rejects it but know the bagel
rejecter is removed.
THE OVERALL WORK FLOW OF MESSEBO CEMENT FACTORY
THE KILN MODEL
• With the view to obtain a useful description for the analysis of the
phenomena which take place in the kiln, a kiln model is used. Without
taking the preheater into consideration, practical experience shows
that the hot part of the kiln model can be divided into five zones. The
zones, of course, are not distinguished by sharp boundaries but
instead they are characterized by the dominant physical and chemical
processes occurring to the material in each zone.
• These zones are commonly denoted as the calcining zone (CZ),
heating Zone (HZ), liquid zone (LZ), maximum temperature zone
(MZ), and cooling zone (AZ), respectively.
•
Zones of killin
• ENERGY SAVING OPTION
• Heat recovery from the kiln system
• The overall system efficiency can be defined by Q6/Qtotal input
1758.05/3417.54= 0.5144 or 51.44%, which can be regarded as relatively
low. Some kiln systems operating at full capacity would declare an
efficiency of 55% based on the current dry process methodology. The
overall efficiency of the kiln system can be improved by recovering some of
the heat losses. The recovered heat energy can then be used for several
purposes, such as electricity generation and preparation of hot water.
There are a few major heat loss sources that would be considered for heat
recovery. These are heat losses by:
• Kiln exhaust gas (21.00%),
• Hot air from cooler stack (1.91%) and
• Radiation from kiln surfaces (4.08%). In the following section, we suggest
some possible options for recovering this heat energy
The use of Waste Heat Recovery Steam Generator
(WHRSG)
• As the name implies, (HRSGs) are boiler were heat, generated in different
processes, is recovered and used to generate steam or boil water.
• The main purpose of these boiler are to cool down flue gases produced by
metallurgical or chemical processes , so that the flue gases can be either
further processed or released with out causing harm.
• To give an example of the construction of a heat exchanger model, a heat
recovery steam generator (HRSG) IS constructed next as a heat exchanger
cascade. The HRSG is basically a boiler with out a furnace – the HRSG
extracts heat from flue gases originated from fuel combusted in an external
unit.
Waste heat recovery by using turbine
Heat recovery from kiln surface

• The hot kiln surface is another significant heat loss source, and the
heat loss by convection and radiation dictates a waste energy of (9.56
%) of the input energy. On the other hand, the use of a secondary
shell on the kiln surface can significantly reduce this heat loss. Since
the kiln surface needs to be frequently observed by the operator so
as to see any local burning on the surface due to loss of refractory
inside the kiln, we would not consider insulating the kiln surface. The
basic principle of the secondary shell is shown the figure below.
•
• For the current rotary kiln, R=1.902m is radius of the kiln and consider
the radius of the sell Rs=2.302m.the distance between the two
surface is relatively small (20cm), a realistic estimation for the
temperature of the secondary sell can be made. Assume shell
temperature=2900c =5630k.we will consider stainless steel for the
material of the secondary shell since it has relatively low surface
emissivity and thermal conductivity. The heat transfer rate by
radiation is then calculated using the following equation
• This heat loss is to be transferred thought the insulation on the
secondary shell. Therefore, assuming a reasonable temperature for
the outer surface of the insulation, we can determine the required
thickness of insulation. For glass wool insulation, thermal conductivity
is taken as 0.05W/mk.therfere the resistance of the insulation layer is
would be:
 Rinsu  2.336m
Therefore
the thickness of insulation is (E)
E= Rinsu-Rshell =2.336-2.302
E=3.4cm~4cm
It should be noted that when the secondary shell is added on to the kiln surface,
the convective heat transfer would preassembly become insignificant. This is
because of the fact that the temperature gradient in the gap would be relatively
very low there fore the total energy saving due to the secondary shell would be:
From the radiation heat transfer:
(139.44kj/kg-clinker) x (26.54kg-clinker/s)-317.985=3382.7526kw
From the convective heat transfer:
(187.28kj/kg-clinker) x (26.54kg-clinker/s)= 4970.4kw
Therefore, we can safely conclude that the use of secondary shell on the current kiln
surface would safe at list 8.4 Mw, which is 9.85 % of the total input energy .This energy
saving would result in a considerable reduction of fuel consumption (almost 25.74 % )of
the kiln system.
• Cost analysis for fuel only
Fuel consumption of the kiln with out secondary shell =3100lr/hr
1 liter = 7.8162 birr
3100 liter = X?
Therefore X = 24230.22 birr/hr
• For a year =24230.22 birr/hr *300days/year*24hr/day
=174,457,584 Birr/Year
• The total heat input of the kiln system is calculated as mf*Hc
• Where: mf=mass flow of fuel in=2883kg/hr
• Hc = calorific value of fuel=40758.498kj/kg
• Therefore
• Qin=32.64Mw
• Heat saved from the surface of kiln by using the secondary shell is =8.4Mw
• X=44,897,427.13 Birr/year
• Therefore 44,897,427.13 Birr/year is saved.
• 4.7.3 IMPROVEMENTS FROM THE SAVING OPTIONS
• Total thermal energy consumption = 3417.546 KJ/Kg clinker
• Useful energy at current status = 2222.62KJ/Kg clinker
• Initial thermal energy efficiency = 65%
• Potential thermal energy saved = 357.95 KJ/Kg clinker
• Useful energy after saving option = 2580.57 KJ/Kg clinker
• Thermal energy efficiency improvement = 75.6%
conclusion

• For the first two losses, a conventional WHRSG system is proposed.

Calculations showed that 1.1 MW of energy could be recovered. For
the kiln surface, a secondary shell system has been proposed and
designed. It is believed that the use pf this system would lead to 8.4
MW of energy saving from the kiln surface. Hence, the total saving for
the whole system has been estimated to be nearly 9.5 MW, which
indicates an energy recovery of 11.14 % of the total input energy. The
pay back period for the two systems is expected to be less than two
years.
Recommendation

• For the desired maximum productivity and profitability of the plant,

the high consumption of fuel for generating and heating of the kiln
during failure of power and down time should be avoided or
minimized by installing the Cogeneration plant and the recovery
options made in this project..
The end
Thank you !!!