Abstract
Cement subsector next to the glass industry is counted among one of the most energy-intensive industries, which absorbs approx. 12-15% of the total energy consumed by the industry. In the paper various methods of energy consumption reduction of in the cement industry are discussed. Cement production carries a very large emissions of greenhouse gases, where CO2 emissions on a global scale with the industry than approx. 5%. Great opportunity in CO2 emissions reduction in addition to the recovery of waste heat is also alternative fuels co-firing in cement kilns [1], [2]. In the cement sector interest in fitting-usable waste energy is growing in order to achieve high rates of savings and hence the financial benefits, as well as the environment ones [3]. In the process of cement production is lost irretrievably lot of energy and reduction of these losses on a global scale gives a visible saving of consumed fuel. The aim of this study is to investigate the possibility of waste heat use in Rudniki Cement Plant near to Czestochowa. After analyzing of all waste heat sources will be analyzed the heat emitted by radiation from the surface of the rotary kiln at the relevant facility. On the basis of thermal-flow calculations the most favorable radiative heat exchanger will be designed. The calculations based on available measurements provided by the cement plant, a thermal power of the heat exchanger, the heat exchange surface, the geometry of the heat exchanger, and other important parameters will be established. In addition the preliminary calculations of hydraulic losses and set directions for further work will be carried out. Direct benefits observed with the introduction of the broader heat recovery technology, is a significant increase in energy efficiency of the industrial process, which is reflected in the reduction of energy consumption and costs. Indirectly it leads to a reduction of pollution and energy consumption.
Highlights
2 Methods for waste heat utilization in cement industryThere are several main heat losses generated by the cement kiln installations, which can be efficiently used
The use of waste heat is associated with a visible improvement in thermal efficiency, which translates into reduced fuel consumption, or lower operating costs. 2.1 The use of hot air from the clinker coolers Rotary kilns are equipped with coolers into which the heated clinker falls out of the furnace to cooling to a temperature of approx. 100 °C
The use of hot air from the clinker cooler as primary air in the combustion of pulverized coal can save a certain amount of heat to warm the air and makes the process faster and there is a higher temperature of fuel combustion [7]. 2.2 The heat recovery from the rotary kiln Hot surface of the kiln, which can reach temperatures of over 400 °C is another significant source of heat loss
Summary
There are several main heat losses generated by the cement kiln installations, which can be efficiently used. These include, in particular: the flue gases from the furnace; hot air from the clinker coolers;radiationfrom the surface of the rotary kiln. 2.1 The use of hot air from the clinker coolers Rotary kilns are equipped with coolers into which the heated clinker falls out of the furnace to cooling to a temperature of approx. CR water Steam cycle is more efficient than the ORC when the flue gas temperature is greater than 310 °C. For cement plants that use old technology and flue gas temperature is high, preferred system is the use of waste heat recovery system with CR water steam cycle. This work is focused on the possibility of heat recovering from the cement shell of the rotary cement kiln which generates more than 10% of the heat losses
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