BEFORE OPTIMIZATION (AFTER MAY2009 BRICK LINING WORK)

Cooler heat balance Ref.Temp.(deg.C) 35 Heat in Clinker Cooling air

Date- 12-7-2008 Flow Flow kg/kg-cl, kg/kg-cl Nm3/kg-cl 1 2.37 1 3.06

Cp

Temp.

kcal/kg OC

OC

Heat kcal/kg-cl

0.26 0.24

1350 35 Total

343.08 0.00 343

100 0 100

Heat out Cooler vent Discharged clinker Radiation loss

1.50 1

1.93 1

0.24 0.19

336 106 Total

142.49 13.61 2.44 159

90 9 2 100

NOTE:

UNDER GRATE PRESSURE IS BETWEEN 450 TO 470 MM WG.

Cooler efficiency on heat loss basis= =

((heat in by clinker + cooling air) -(heat loss by vent air+ clinker + radiation))/( total heat in) 54 %

SAVING OF THERMAL ENERGY BY COOLER OPTIMIZATION = 27.38

K Cal/kg clinke

THERMAL ENERGY COST EFFICIENCY Energy cost Clinker production Heat saving saving p.a.cooler heat

SAVING BY INCREASING COOLER Rs/m kcal 650 Tonne p.a. 900000 k cal/kg.clk 27.38 Rs.p.a. 16014510 Cr.p.a. 1.601

SAVING OF HEAT BY PREHEATER EXHAUST GAS TEMP. REDU = 10 K Cal/kg clinke

THERMAL ENERGY COST SAVING BY REDUCING PH. EXHAUST TEMP. Energy cost Rs/m kcal 650 Clinker production Tonne p.a. 900000 Heat saving k cal/kg.clk 10.00 saving p.a.PH exhaust heat Rs.p.a. 5850000 Cr.p.a. 0.585

SAVING OF HEAT BY PREHEATER EXHAUST GAS TEMP. REDU = 10 K Cal/kg clinke

THERMAL ENERGY COST SAVING BY REDUCING PH. EXHAUST TEMP. Energy cost Rs/m kcal 650 Clinker production Tonne p.a. 900000 Heat saving k cal/kg.clk 10.00 saving p.a.PH exhaust heat Rs.p.a. 5850000 Cr.p.a. 0.585

ELECTRICAL ENERGY SAVING= ELECTRICAL ENERGY COST= CLINKER PRODUCTION = POWER COST SAVING =

1.3 3.2 900000 0.3744

Unit/tonne clk Rs/unit Tonne p.a. Cr.p.a.

TOTAL SAVING BY THERMAL AND ELECTRICAL ENERGY = 2.6 Cr.p.a.

AFTER OPTIMIZATION (AFTER NOVEEMBER 2009 BRICK LINING WORK)

emp.

OC

Heat kcal/kg-cl

Cooler heat balance Ref.Temp.(deg.C) 35 Heat in Clinker Cooling air

Date- 19-12-2008 Flow Flow Cp kg/kg-cl, kg/kg-cl kcal/kg OC Nm3/kg-cl 1 2.1 1 2.72 0.26 0.24

Temp.

OC

Heat kcal/kg-cl

350 35 otal

343.08 0.00 343

100 0 100

1350 35 Total

343.08 0.00 343

100 0 100

336 106

otal

142.49 13.61 2.44 159

90 9 2 100

Heat out Cooler vent Discharged clinker Radiation loss

1.28 1

1.65 1

0.24 0.19

325 96 Total

117.06 11.66 2.44 131

89 9 2 100

WG.

NOTE:

UNDER GRATE PRESSURE IS BETWEEN 570 TO 590 MM WG.

clinker + radiation))/( total heat in)

Cooler efficiency on heat loss basis= =

((heat in by clinker + cooling air) -(heat loss by vent air+ clinker + radiation))/( total heat in) 62 %

Y BY COOLER OPTIMIZATION = 27.38 K Cal/kg clinker

ING BY INCREASING COOLER

m kcal 650 e p.a. 900000 /kg.clk 27.38 .a. 16014510 .a. 1.601

TER EXHAUST GAS TEMP. REDUCTION = 10 K Cal/kg clinker

ING BY REDUCING PH. EXHAUST GAS 650 900000 10.00 5850000 0.585

m kcal e p.a. /kg.clk .a. .a.

TER EXHAUST GAS TEMP. REDUCTION = 10 K Cal/kg clinker

ING BY REDUCING PH. EXHAUST GAS 650 900000 10.00 5850000 0.585

m kcal e p.a. /kg.clk .a. .a.

1.3 3.2 900000 0.3744

Unit/tonne clk Rs/unit Tonne p.a. Cr.p.a.

AND ELECTRICAL ENERGY 2.6 Cr.p.a.

CK LINING WORK)

Temp.

OC

Heat kcal/kg-cl

1350 35 Total

343.08 0.00 343

100 0 100

325 96 Total

117.06 11.66 2.44 131

89 9 2 100

EEN 570 TO 590 MM WG.

eat loss by vent air+ clinker +