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Retrofitting and adoption of energy efficient equipment
Better operational control and Optimization
Up gradation of process control and instrumentation facilities
Better monitoring and Management Information System
Active participation of employees and their continued exposure to energy conservation efforts etc.
The improvements in energy performance of cement plants in the recent past have been possible largely due to
Slip Power Recovery System
Variable Voltage & Frequency Drive
Grid Rotor Resistance
Soft Starter for Motors
High Efficiency Fans
High Efficiency Separators
Vertical Roller Mill
Pre-Grinder/Roller Press
Low Pressure Preheater Cyclones
Multi-channel Burner
Bucket Elevator in place of pneumatic conveying
Fuzzy Logic/Expert Kiln Control System
Improved Ball Mill Internals
High Efficiency Grate Cooler
Plugging of leakages in kiln and preheater circuit, raw mill and coal mill circuits Reducing idle running of equipment Installation of Improved insulating bricks/blocks in kilns and preheaters Effective utilization of hot exit gases Optimisation of cooler operation Optimum loading of grinding media/grinding mill optimisation Rationalization of compressed air utilization Redesigning of raw mix Installation of capacitor banks for power factor improvement Replacement of over-rated motors with optimally rated motors Optimisation of kiln operation Changing from V-belt to flat belt
Operational Control and Optimisation
Energy Conservation Measures in Cement Industry
SHORT TERM MEASURES
Roughly about 2 – 5% reduction is possible by adopting the following simple short term measures.
Increase capacity utilization of primary & secondary crusher
Reduce idle run of crushers and belts
Reduce idle operation of dust collection equipment
MINES
Control raw mill feed size by regular monitoring
Avoid idle running of raw mill conveyor system (auxiliaries) by suitable interlocking
Stop idle running of raw mill lubrication system
Install ‘Isolation’ type dampers in the preheater – raw mill inlet duct and raw mill vent fan – ESP ducts. This reduces air infiltration into ESP fan system when raw mill is stopped
RAW MILL GRINDING & STORAGE
Minimize false air entry in raw mill system
Optimize compressed air consumption for raw meal silo blending
Stop one raw meal silo – vent blower during non – blending period ( batch blending systems)
Optimize air slide blowers air requirement by damper throttling
RAW MILL GRINDING & STORAGE
Improve kiln combustion efficiency
Eliminate leakages in suspension preheater by regular monitoring
Optimize primary air to kiln
Optimize kiln feed conveying air if any
Optimize kiln solid fuel conveying air if any
Optimize kiln shell cooling fans operation by interlocking with kiln shell scanner
KILN & COOLER
Initiate secondary firing in SP kilns
Ensure good compartment sealing
Reduce material leakages to avoid rehandling and loss
Install soft starters for clinker breaker
Improve solid fuel yard stacking to avoid carpet loss
KILN & COOLER
Increase coal mill output by
Optimizing fineness
Optimizing grinding media load
Installation of pre – crusher
Connect grate cooler vent to coal mill for drying
Avoid idle running of coal conveyer & crusher
Maintain higher residue for precalciner firing
KILN & COOLER
Water spraying on the clinker at cooler outlet (temperature > 90C, consumes more grinding energy)
Optimize cement grinding fineness
Avoid idle running of clinker conveyer & dust collector fan
Avoid idle running of cement silo exhaust fans
Optimize water spray compressor capacity
Optimize packing compressor capacity
CEMENT GRIDING, STORAGE & PACKING
Eliminate compressed air leakage by a vigorous maintenance programme
Install compressed air traps for receivers
Minimize compressor discharge pressure
Regularize frequency of cleaning of filters by measuring filter pressure drop. Maximum pressure drop across < 25mm WG.
COMPRESSOR & COMPRESSED AIR SYSTEM
Avoid unnecessary lighting during day time
Install photocell for automatic switching off
Avoid idle running of motors
Convert delta to star connection for motors loaded below 50% of full load (for occasional peak load provide automatic star / delta convertor)
ELECTRICAL SYSTEM
Use of polyester insulated copper chokes in place of conventional chokes
Operate lighting system at lower voltage ( say 360V in 3 phase)
Provide interlock for electric motor to avoid idle running
ELECTRICAL SYSTEM
Increase engine jacket temperature (max 85C) or as per engine specification
Stop cooling tower fans & cooling water circulation when not necessary
DG SETS
medium TERM MEASURES
Reduction up to 10% of energy bill by involve medium investment.
Energy Conservation Measures in Cement Industry
Install adjustable lifters in case of double chamber ball mill
Install variable louvre system for roller mill
RAW MILL GRINDING & STORAGE
Install CO & O2 analyser in kiln for monitoring
Maintain proper kiln seal to avoid false air infiltration
Install of coal weigh feeder at kiln firing and calciner firing
Use of lignite in place of coal
KILN & COOLER
Minimize kiln radiation losses by better refractory lining
Utilize cooler / cooler vent air as primary air
Install multichannel burners
Install water spray in cooler to minimize fan power consumption
KILN & COOLER
Minimize coal mill vent by
Reducing & regulating air vent
Installation of bag filter / ESP in the vent line
Use coal fired furnace instead of oil fired furnace for coal drying
COAL YARD & COAL MILL
Install belt conveyor / screw conveyor / bucket elevator system instead of pneumatic conveying
Storing of clinker for 7 – 10 days for seasoning of clinker
Install adjustable lifters
Utilize grinding aids
CEMENT GRINDING, STORAGE & PACKING
Cool compressed inlet air
Take compressor suction from outside the compressor house
Automatic loading / unloading of compressors and installation of auto start / stop sequence
Replace multiple small units with single large units
COMPRESSORS & COMPRESSED AIR SYSTEM
Use energy efficient lighting
Distribute load on transformer network
Improve power factor
Individual compensation
Group compensation
Centralized compensation
ELECTRICAL SYSTEM
Improve load factor
Install demand controller for maximum utilization of demand
Replace oversized motors
Replace old in-efficient motors with energy efficient motors
Use variable frequency drives for low / partial loads
ELECTRICAL SYSTEM
Install energy saver in fluorescent lighting circuit
Optimize height of lighting fixtures
Use servo stabilizer in lighting circuits
Replace conventional fluorescent tubes (40W) with slim tubes (36W)
ELECTRICAL SYSTEM
Increase loading on DG sets (max 90%)
Install turbocharger
Take turbocharger air inlet from outside engine room
Install oil flow meter & monitor
Install waste heat recovery system in DG set
DG SETS
LONG TERM MEASURES
Another 10% saving potential (average) is available by Implementing some of the long term measures
Energy Conservation Measures in Cement Industry
Install vertical roller mill in place of ball mill
Install belt & bucket elevator in place of pneumatic conveying
Install pre-crusher before raw mill
Install on-line X-ray analyser for raw meal
Install slip power recovery system / VFD for raw mill vent fan / ESP fan
Install high efficiency separators
Install continuous blending silo
RAW MILL GRINDING, STORAGE
Utilize waste tyre, rice husk, groundnut shell & urban waste in precalciner
Install electrostatic precipitator/bag filter for maximum dust recovery and minimum energy consumption
Conversion from pneumatic conveying of kiln feed to mechanical mode
Insulate preheater ducts internally by installing calcium silicate blocks followed by insulating bricks and refractory
KILN & COOLER
Install waste heat recovery system for preheater exhaust
Install waste heat boiler in cooler vent & run steam turbine
Modify internal drag chain system to external drag chain system to reduce break down hours
Install high efficiency coolers
KILN & COOLER
Install pre-crusher / roll press before ball mill
Install vertical roller mills for cement grinding
CEMENT GRINDING, STORAGE & PACKING
Install slip power recovery system for controlling speed for larger size slip ring motor
Install multi-speed motor
Optimize operating voltage level of motor for lightly loaded motors
Increase cable size / run additional cable to reduce distribution losses
ELECTRICAL SYSTEM
Use cheaper fuel for high capacity DG sets
Replace multiple small size DG sets with bigger DG sets
DG SETS