Академический Документы
Профессиональный Документы
Культура Документы
Key Laboratory of Networked Control Systems, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, China
University of Chinese Academy of Sciences, Beijing 100049, China
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 15 October 2013
Accepted 11 March 2014
Available online 26 April 2014
The cement clinker manufacturing process is a complex process which involves energy conversion and
consumption. The objective of this study is to establish the thermal efciency analytic model of this
process. Energy ow models of the whole process and its three process units of raw material preheating
& decomposition, clinker calcination, clinker cooling are established in this paper. The thermal efciency
of the whole process is quantitatively described based on the energy consumption fraction of each
process unit. Energy consumption fractions of the three process units in a cement plant are 1.15, 0.43 and
0.47 respectively. It shows that the thermal efciency of the raw material preheating & decomposition
process unit has the greatest impact on the thermal efciency of the whole process, successively followed by the clinker cooling and clinker calcination process units. Methods to improve the thermal
efciency of the whole process are discussed.
2014 Energy Institute. Published by Elsevier Ltd. All rights reserved.
Keywords:
Cement clinker
Energy ow model
Energy consumption fraction
Thermal efciency
1. Introduction
The cement industry is a typical energy intensive industry with energy accounting for 50%60% of production costs [1]. Scholars have
studied on energy models and energy conservation measures of various high energy consumption industries such as the cement industry. In
the aspect of energy consumption modelling, Jebaraj and Iniyan summarized the existing energy models, including the energy demand
supply model, the energy consumption forecasting model, the energy optimization model and the energy dissipation model [2]. In addition,
some scholars advanced the energy consumption model [3,4] and the energy ow model [5,6] which were independent of specic energy
forms and energy equipment. On the other hand, some researches advanced the energy ow models in the manufacturing processes of
cement, steel and aluminium [710]. They further analysed the impacts of relevant changes on energy consumptions. In the aspect of energy
efciency models, Giacone and Manc dened the energy efciencies in industrial processes [11]. Some scholars analysed the useful energy
for manufacturing processes [12,13] and established the energy efciency indexes of industrial processes [14]. Some researches discussed
the energy conservation measures of process units from the perspective of manufacturing technology and equipment [1518]. The abovementioned literatures analysed the high energy consumption industries such as the cement industry in the aspects of energy models, energy
efciencies and energy conservation measures. All of these results played an important role in the implementation of energy conservations
and emission reductions. However, the previous literatures did not consider the energy efciency relationships between industrial processes and their process units, and lacked corresponding theoretical guidance on the implementation of energy conservation measures. In
addition, the energy conservation measures in above literatures were based on the manufacturing techniques and the production equipment of industrial processes. For stable manufacturing processes, the optimal control of process parameters is an effective method for
improving the energy efciency of the cement clinker manufacturing process. Therefore, the establishment of energy efciency analytic
relations between the cement clinker manufacturing process and its process units has a great signicance for analysing and formulating
reasonable energy efciency improvement measures.
* Corresponding author. Key Laboratory of Networked Control Systems, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, China. Tel.: 86
024 23970248.
E-mail addresses: liuzhao@sia.cn (Z. Liu), zwang@sia.cn (Z. Wang), mzyuan@sia.cn (M.Z. Yuan), yhb@sia.cn (H.B. Yu).
http://dx.doi.org/10.1016/j.joei.2014.04.004
1743-9671/ 2014 Energy Institute. Published by Elsevier Ltd. All rights reserved.
77
The cement clinker manufacturing process consists of three process units, including the raw materials preheating & decomposition,
clinker calcination and clinker cooling. In order to analyse the energy efciency relationship between the cement clinker manufacturing
process and its three process units, the energy ow models of the whole process and each process unit are established. The thermal efciency analytic model of the whole process is quantitatively described based on the energy ow models and the energy consumption
fractions of its three process units. It is found that improving the decomposition rate of raw materials fed into kiln, stabilizing the temperature of the rotary kiln burning zone and improving the temperature of the secondary and tertiary air are effective approaches to
improve the thermal efciency of the whole process.
Eu Ei Er Ed Ee El Er
(1)
78
Symbol
Upstream energy ow
Imposed energy ow
Internal reused energy ow
Downstream energy ow
External reused energy ow
Lost energy ow
Energy
Energy
Energy
Energy
Energy
Energy
Eu
Ei
Er
Ed
Ee
El
is
is
is
is
is
is
Ec Ec Ec00 Eu Ei Er Er Ee
(2)
where Ec is the energy consumption of a process unit (kJ), Ec is the energy inputs of a process unit (kJ),
unit (kJ).
The energy efciency of energy consumption process units is:
hc
Ed
100%
Ec
Ec00
(3)
ht
Ed Ee
100%
Ec
(4)
where ht is the energy efciency of energy conversion process units (%). [11]
3.2. The scope of energy ow modelling of the cement clinker manufacturing process
The schematic diagram of thermal balance in the cement clinker manufacturing process is shown in Fig. 3. The scope of energy ow
models is from the exhaust gas export of preheater to the clinker export of grate cooler. The functions of preheater and calciner are raw
materials preheating and decomposition, so they will be considered as a whole. Thermal energy is the main energy consumption in the
cement clinker manufacturing process, so thermal energy is the only energy category for consideration in this study. Other forms of energies
are not considered here.
79
Fig. 3. Schematic diagram of the thermal energy balance in the cement clinker manufacturing process.
Eu QsR Qs Qsk
(5)
(6)
Er Qyh
(7)
Ed Qsh
(8)
Ee Qmmf Qmmff
(9)
(10)
Table 2
Thermal energy balance of the cement clinker manufacturing process.
Thermal energy input
Item
Symbol
Item
Symbol
QrR
Qr
QsR
Qs
Qyh
Q1k
QLk
Qsk
QLOk
Qsh
QLsh
Qss
Qf
Qfh
Qpk
QLfh
Qmmf
Qmmff
QB
Qqt
80
Ec Ec Ec Eu Ei Er Er Ee
QsR Qs QLk Qsk QrR Qr Q1k QLOk Qmmf Qmmff
Qsh Qss QLsh Qf Qfh Qpk QLfh QB Qqt
11
The main energy consumptions are the formation heat of clinker and kinds of heat expenditures according to Equation (11).
The thermal efciency of the cement clinker manufacturing process is:
hc
Ed
Qsh
100%
100%
Ec
Qsh Qss QLsh Qf Qfh Qpk QLfh QB Qqt
(12)
3.4. Energy ow models of the three process units in the cement clinker manufacturing process
(1) The raw materials preheating & decomposition process unit is composed of preheater, calciner and some other equipment. In this
process unit, the raw materials go through dehydration, preheating, as well as most carbonate decomposition and then enter into rotary
kiln for burning. The raw materials preheating & decomposition process unit is a typical energy consumption process unit and its
thermal energy balance is shown in Table 3.
where:
(13)
(14)
Er;P Qyh
(15)
(16)
(17)
Table 3
Thermal energy balance of the raw materials preheating & decomposition process unit.
Thermal energy input
Item
Symbol
Item
Symbol
QrR,P
Qr,P
QsR
Qs
Qyh
Qyq
Q3k
Qsk
QLOk,P
Qss
Qfh
Qf
Qtf
Qry
QB,P
81
Ec;P Ec;P
Ec;P
Eu;P Ei;P Er;P Er;P Ee;P
QsR Qs Qyq Q3k Qsk QrR;P Qr;P QLok;P
Qry Qtf Qss Qf Qfh QB;P
18
The thermal efciency of the preheating & decomposition process unit is:
hc;P
Ed;P
Ed;P
100%
100%
Ec;P
Eu;P Ei;P Er;P Er;P Ee;P
(19)
Qtf Qry
100%
Qry Qtf Qss Qf Qfh QB:P
where hc,P is the thermal efciency of the preheating & decomposition process unit (%).
According to Equations (18) and (19), the main energy consumptions of the preheating & decomposition process unit are the carbonate
decomposition and all forms of heat expenditures. So increasing the carbonate decomposition rate and the temperature of materials into
kiln is an effective way to improve the thermal efciency of this process unit.
(2) The clinker calcination is an important energy consumption process unit in the cement clinker manufacturing process, including rotary
kiln, kiln hood and some auxiliary equipment. In this process unit, the materials, coming from the preheating & decomposition process
unit, complete the heat exchange with high temperature reverse airow. Finally, the materials are sintered to clinker. Thermal energy
balance in this process unit is shown in Table 4.
where:
(20)
(21)
(22)
Ee;K Qyq
(23)
El;K QB;K
(24)
00
Ec;K Ec;K
Ec;K
Eu;K Ei;K Er;K Er;K Ee;K Qxs QYsh QB;K
(25)
hc;K
Ed;K
Ep;K
Qxs QYsh
100%
100%
100%
Ec;K
Qxs QYsh QB;K
Eu;K Ei;K Er;K Er;K Ee;K
(26)
where hc,K is the energy efciency of the clinker calcination process unit (%).
According to Equations (25) and (26), the main energy consumptions of the clinker calcination process unit are the sensible heat of
clinker out of rotary kiln and the heat dissipation of kiln surface. Increasing the temperature of clinker out of kiln and reducing the heat
dissipation of kiln surface are effective methods to improve the thermal efciency of this process unit.
(3) The function of the clinker cooling process unit is to quench the clinker out of kiln and recover the heat of hot clinker. It involves grate
cooler, cooling fan and some other equipment. The clinker cooling process unit is a typical energy conversion process unit and its
thermal energy balance is shown in Table 5.
Table 4
Thermal energy balance of the clinker calcination process unit.
Thermal energy input
Item
Symbol
Item
Symbol
QrR,K
Qr,K
Qry
Q2k
Q1k
QLOk,K
Qxs
Qyq
QYsh
QB,K
82
Table 5
Thermal energy balance of the clinker cooling process unit.
Thermal energy input
Item
Symbol
Item
Symbol
QYsh
QLk
QLOk,C
Qmmf
Qmmff
Q2k
Q3k
Qpk
QLfh
QLsh
QB,C
where:
Eu;C QYsh
(27)
(28)
(29)
(30)
00
Ec;C Ec;C
Ec;C
Eu;C Ei;C Er;C Er;C Ee;C QLsh Qpk QLfh QB;C
(31)
ht;C
Ed;C Ee;C
Ec;C
100%
(32)
where hc,C is the energy efciency of the clinker cooling process unit (%).
According to Equations (31) and (32), the main energy consumptions of the clinker cooling process unit are the sensible heat of clinker
out of grate cooler and the sensible heat of exhaust air and y ashes. Increasing the temperature of secondary air and tertiary air is the
effective method to increase the thermal exchange efciency of this process unit.
3.5. Energy ow diagram of the cement clinker manufacturing process
According to the thermo technical calibration data of the real cement plant mentioned in Fig. 4, the energy ow diagram of the real
cement clinker manufacturing process is shown in Fig. 5. The thermal energy unit is kJ kg1.
83
4.1. Thermal efciency analytic model of the cement clinker manufacturing process
4.1.1. Assumptions of the thermal efciency analytic model
(1)
(2)
(3)
(4)
Qsh
100%
Qsh Qss QLsh Qf Qfh Qpk QLfh QB
Qss QLsh Qf Qfh Qpk QLfh QB
1
100%
Ec
Qss Qf Qfh QB;P QB;K QLsh Qpk QLfh QB;C
100%
1
Ec
Ec
Ec
hc
33
where Qss Qf Qfh QB,P is the thermal energy loss in the raw materials preheating & decomposition process unit, QB,K is the thermal
energy loss in the clinker calcination process unit, QLsh Qpk QLfh QB,C is the thermal energy loss in the clinker cooling process unit. The
relationships between the thermal energy loss of each process unit and the thermal efciency of the relevant process unit are as follows:
Qss Qf Qfh QB;P Ec;P 1 hc;P
(34)
QB;K Ec;K 1 hc;K
(35)
1 ht;C
QLsh Qpk QLfh QB;C Ec;C
(36)
Combining Equations (34)(36) with Equation (33), we can obtain Equation (37).
#
Ec;C
1 ht;C
Ec;P 1 hc;P
Ec;K 1 hc;K
hc 1
100%
Ec
Ec
Ec
1 VEP 1 hc;P VEK 1 hc;K VEC 1 ht;C 100%
(37)
=E are the ratios of the energy consumption of each process unit and the total consumption of
where VEP Ec,P/Ec, VEK Ec,K/Ec, VEC Ec;C
c
=E as the energy consumption
the cement clinker manufacturing process respectively. We dene VEP Ec,P/Ec, VEK Ec,K/Ec and VEC Ec;C
c
Fig. 6. Energy consumption factions of the three process units in a real cement clinker manufacturing process.
84
Fig. 7. Thermal efciencies of the three process units in a real cement clinker manufacturing process.
fraction of each process unit. The clinker cooling process unit is an energy conversion process, and can be considered as a special energy
, and the energy output is E00 . Equation (38) is obtained after the collation of
consumption process unit. The energy consumption is Ec;C
c;C
Equation (37).
hc 1 VEP hc;P VEK hc;K VEC ht;C VEP VEK VEC 100%
(38)
85
calcination process unit. Therefore, the improvement of the decomposition rate of raw materials fed into kiln can improve thermal efciency
of the raw material preheating & decomposition process unit and the clinker calcination process unit at the same time. According to the
thermal efciency equation of the clinker cooling process unit, raising secondary air temperature and tertiary air temperature is the method
to improve the thermal energy recovery efciency [21,22]. Gassolid heat exchange theory of the cement clinker cooling process unit shows
that the reasonable grading of cooling air quantity and air speed is the primary factor for raising the secondary and tertiary air temperature.
5. Conclusions
In this paper, energy ow models of the cement clinker manufacturing process and its three process units are established. The following
conclusions are obtained based on the thermal efciency analytic model of the cement clinker manufacturing process.
(1) There is a positive linear correlation between the thermal efciency of the cement clinker manufacturing process and the thermal
efciencies of its three process units in the steady state conditions. The improvement of thermal efciency of any process unit can
improve the thermal efciency of the whole process.
(2) The impact degree of each process unit to the thermal efciency of the whole process depends on the energy consumption faction of
each process unit. According to the thermo technical calibration data of a real cement plant, the energy consumption fraction of the raw
materials preheating & composition process unit is the greatest, successively followed by the ones of the clinker cooling process unit and
the clinker calcination process unit. The thermal efciency calculated by the thermal efciency analytic model can reect the reality of
the cement clinker manufacturing process.
(3) Increasing the decomposition rate of raw materials fed into kiln can improve the thermal efciency of the raw materials preheating &
decomposition process unit as well as the thermal efciency of the clinker calcination process unit. Stabilizing the temperature of rotary
kiln burning zone and improving the secondary and tertiary air temperature are also effective methods to improve the thermal efciency of the whole process.
Acknowledgements
This research is jointly supported by the National High Technology Research and Development Program of China (No. 2013AA040705),
and the Key Research Program of the Chinese Academy of Sciences (No. KGZD-EW-302).
Appendix A. The thermo technical calibration data of a real cement clinker manufacturing process in China
No. Item
kJ/kg
No. Item
1
Combustion heat of fuel
3059.67 94.38
2
Sensible heat of fuel
8.35
0.26
3
Combustion heat of the combustible materials in raw materials
41.56
1.28
4
Sensible heat of returning ashes fed into preheater
5.00
0.15
5
Sensible heat of raw materials
25.02
0.77
6
Sensible heat of primary air
3.26
0.10
7
Sensible heat of cooling air into grate cooler
93.55
2.89
8
Sensible heat of air brought with raw materials
4.78
0.15
9
Sensible heat of seeping air
3.46
0.11
10
11
12 Total thermal energy input
3241.65 100.00
Total energy efciency: 53.04%
1
2
3
4
5
6
7
8
9
10
11
12
kJ/kg
Appendix B. The thermo technical calibration data of a real clinker cooling process unit
Item
1
Sensible heat of clinker into grate cooler
2
Sensible heat of cooling air into grate cooler
3
Sensible heat of seeping air
4
5
6
7
8
9
10
Total thermal energy input
Total energy recovery efciency: 69.5%
1538.81
%
94.13
6.08
0.21
100%
No.
Item
kJ/kg
1
2
3
4
5
6
7
8
9
10
444.76
7.26
434.51
606.89
86.81
8.07
27.59
0.41
77.9
1538.81
28.90
0.47
28.24
39.44
5.64
0.52
1.79
0.03
5.07
100%
86
References
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
[22]
J.F. Wang, Y.P. Dai, L. Gao, Exergy analyses and parametric optimizations for different cogeneration power plants in cement industry, Appl. Energy 86 (2009) 941948.
S. Jebaraj, S. Iniyan, A review of energy models, Renew. Sustain. Energy Rev. 10 (2006) 281311.
K.J. Kissock, C. Eger, Measuring industrial energy savings, Appl. Energy 85 (2008) 347361.
R.B. Hiremath, S. Shikha, N.H. Ravindranath, Decentralized energy planning: modeling and application-a review, Renew. Sustain. Energy Rev. 11 (2007) 729752.
L. Andreassi, M.V. Ciminelli, M. Feola, S. Ubertini, Innovative method for energy management: modeling and optimal operation of energy systems, Energy Build. 41
(2009) 436444.
M. Geidl, G. Andersson, Optimal power ow of multiple energy carriers, IEEE Trans. Power Syst. 22 (2007) 145155.
M.G. Rasul, W. Widianto, B. Mohanty, Assessment of the thermal performance and energy conservation opportunities in a cement industry in Indonesia, Appl. Therm.
Eng. 25 (2005) 29502965.
M.Z. Sogut, Z. Oktay, A. Hepbasli, Energetic and exergetic assessment of a trass mill process in a cement plant, Energy Convers. Manag. 50 (2009) 23162323.
J.P. Andersen, J. Hyman, Energy and material ow models for the US steel industry, Energy 26 (2001) 137159.
H.Z. Wang, D.Y. Leung, M.K. Leung, Energy analysis of hydrogen and electricity production form aluminum-based processes, Appl. Energy 90 (2012) 100105.
E. Giacone, S. Manc, Energy efciency measurement in industrial processes, Energy 38 (2012) 331345.
J. Oda, K. Akimoto, T. Tomoda, M. Nagashimia, K. Wada, International comparisons of energy efciency in power, steel, and cement industries, Energy Policy 44 (2012)
118129.
N.A. Madlool, R. Saidur, N.A. Rahim, M.R. Islam, M.S. Hossian, An exergy analysis for cement industries: an overview, Renew. Sustain. Energy Rev. 16 (2012) 921932.
D. Gielen, P. Taylor, Indicators for industrial energy efciency in India, Energy 34 (2009) 962969.
N.A. Madlool, R. Saidur, M.S. Hossain, N.A. Rahim, A critical review on energy use and savings in the cement industries, Renew. Sustain. Energy Rev. 15 (2011) 20422060.
N.A. Madlool, R. Saidur, N.A. Rahim, M. Kamalisarvestani, An overview of energy savings measures for cement industries, Renew. Sustain. Energy Rev. 19 (2013) 1829.
A. Hasanbeigi, C. Menke, A. Therdyothin, The use of conservation supply curves in energy policy and economic analysis: the case study of Thai cement industry, Energy
Policy 38 (2010) 392405.
E. Worrell, C. Galitsky, L. CandPrice, Energy Efciency Improvement Opportunities for the Cement Industry, 2008. Available from: http://ies.lbl.gov/iespubs/Cement_
EEMs_English.pdf.
Z. Sogut, Z. Oktay, H. Karakoc, Mathematical modeling of heat recovery from a rotary kiln, Appl. Therm. Eng. 30 (2010) 817825.
S.Q. Li, L.B. Ma, W. Wan, Q. Yao, A mathematical model of heat transfer in a rotary kiln thermo-reactor, Chem. Eng. Technol. 28 (2005) 14801489.
E. Tahsin, A. Vedat, Energy auditing and recovery for dry type cement rotary kiln systems-a case study, Energy Convers. Manag. 46 (2005) 551562.
G. Locher, Mathematical models for the cement clinker burning process, part 4. Grate cooler, ZKG Int. 6 (2002) 4647.