Review on Thermal Energy Audit of Pyro-Processing Unit of a Cement Plant

Abstract

Energy consumption in cement factories is an important issue for the government as well as private organizations. The cement manufacturing industrial sector has become the worldwide energy consumer accounting for over 40% of overall energy consumption by the industrial sub-sector. Most of the thermal energy consumption by a cement manufacturing plant occurs in the Pyro-processing unit. Thus, the energy audit of the cement plant is an essential exercise to promote energy retrofitting measures. The aim of the energy audit is to reduce energy consumption in the plant, reduce energy costs and identify possible Energy Conservation and Management Opportunities (ECMOs). The aim of this study was to review the techniques of energy auditing which include Mass (Material) balance and Energy balance by considering energy conservation in the form of thermal energy that helps to fill the gap in energy efficiency improvement, policy development, and environmental analysis. Using the operational data of Kiln system of Messobo Cement obtained from the literature, the heat losses were quantified for major energy consuming components of the system using both the mass and thermal energy balance approach. The production line's capacity for clinker was 145.4 tons per hour, and both burners received a combined 25 tons of coal per hour. Energy balance tests were conducted in all areas of the pyro processing systems, and the findings revealed significant energy losses from the surface of the kiln systems, kiln exhaust, and cooler exhaust.