Detailed assessment of specific exergetic costing, energy consumption, and environmental impacts of a rotary kiln in cement industry.

Abstract

Türkiyeis one of the biggest developing countries and the second biggest cement exporter in the world. In 2021, the country exported around $1billion of cement, which is responsible for over 8% of emissions globally. In order to fulfill the EU norms, energy, emissions, and cost reduction investments continue in the country. The aim of this paper is to perform a detailed exergoeconomic assessment of a rotary burner to increase the energy and exergy performance and decrease energy consumption, exergy costs and environmental impacts of a real scale cement factory in Türkiye. During the 2-year period, detailed data has been obtained from the factory by real time detection of clinker manufacturing process. By applying the specific exergy costing (SPECO) method, energy and exergy destructions, and exergetic cost distributions for the rotary burner are calculated in detail. The 1st and 2nd law efficiencies of the overall factory, specific energy (SEC) and exergy (SExC) consumption, and SPECO for clinker production are calculated to be 59.84%, 39.04%, 4786.75MJ/ton, 5230.38MJ/ton, and 10.11 $/MJ, respectively. The use of magnesia-spinel composite refractory bricks and the anzast layer formation decreased the SPECO by 2.71% corresponding to a saving of $2,280,000 preventing 13.74 MtCO2 emissions yearly.