Analysis of waste heat and its recovery in a cement factory

Doheim, M.A.; Sayed, S.A.; Hamed, Osman A.

doi:10.1016/0890-4332(87)90006-8

Cited by 13 publications

(6 citation statements)

References 1 publication

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“…For large-capacity plants, the specific heat losses by radiation are smaller, and thus the fuel requirements are lower, which in turn results in smaller heat losses through lower exit gas volumes. Figure 4 also reveals that the kiln's heat consumption, as exhibited by the cement production lines under investigation, is generally higher than has been reported in the literature (Duda, 1985). It also shows that, if production capacities are reduced to ranges below lo00 tons per day, the specific energy consumption is greatly increased.…”

Section: Kiln Energy Analysismentioning

confidence: 58%

“…Technically, also, natural gas burns easily, and also there is no need for preheating and pressurizing. But, on the other hand, the heat consumption when firing with natural gas is higher than that of a rotary kiln operating with liquid fuel (Duda, 1985). This is because the combustion of natural gas generates more combustion gases than liquid fuels, and hence the heat losses via the exit gases are higher.…”

Section: Energy Conservation Opportunitiesmentioning

confidence: 99%

“…The conservation measures which are normally employed in the cement industry consist of those that can be implemented in the short term which do not require major capital outlays and where the economic return can be realized relatively quickly. These include such measures as heat transfer improvements (Fog and Nadkarni, 1983;Lekatompess, 1980), reduction of the moisture content in wet process plants (Fog and Nadkami, 1983;Lekatompess, 1980), improvements in burnability of the raw mix (Chiogioji, 1979 (Beood, 1984) and avoiding air leakage and improving insulation (Doheim et al, 1987;Weinder et al, 1984). The conversion from a wet to a dry process (Fog and Nadkarni, 1983;Gartner and Tresouthich, 1982;Weber, 1982) and power generation from waste heat (Gartner and Tresouthich, 1982;Haltenhof, 1980;Long and Mosimann, 1983), can be considered as long-term options.…”

Section: Introductionmentioning

confidence: 99%

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Energy analysis and conservation prospects in the UAE cement industry

Hamed

Abdalla²

1992

Int. J. Energy Res.

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An energy audit was performed to determine the energy patterns of the cement industry in United Arab Emirates (UAE). A macro‐energy analysis revealed that the cement industry consumes annually 467,000 tons of oil equivalent (TOE). The thermal energy consumption represents 81–91% of the total utilized energy. The breakdown of the overall energy requirements among the most important unit processes was determined covering the cement production lines in the UAE and was compared with published values in the literature. A micro‐energy analysis was also carried out for one of the cement production lines to determine the thermal energy disposition by type. The study revealed that the thermal losses via the exit gases and the radiation losses account for 25 and 13%, respectively, of the total input thermal energy. Opportunities for energy conservation such as a change from expensive liquid fuels to relatively cheap natural gas and the modification of existing energy consuming systems are discussed.

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Section: Kiln Energy Analysismentioning

confidence: 58%

Section: Energy Conservation Opportunitiesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Energy analysis and conservation prospects in the UAE cement industry

Hamed

Abdalla²

1992

Int. J. Energy Res.

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“…Most cement plants focus on waste with high-heating value. This includes the burning of automobile tires, plastics, carpets and refuse oil from power generation plants, auto repair centres and restaurants (Kaantee et al 2002;Kumar 2005;Ewall and Nicholson 2003;Utlu et al 2006;Doheim and Sayed 1987). Municipal waste requires extensive preprocessing.…”

Section: Waste Utilizationmentioning

confidence: 99%

Energy conservation and waste utilization in the cement industry serve the green technology and environment

Najjar

Waite

2014

International Journal of Sustainable Engineering

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The cement industry is one of the most energy-intensive industries consuming 4 GJ/ton of cement, i.e. 12 -15% of the energy use in total industry. Energy cost accounts for 30% of the total cost of cement production. Seventy-five per cent of this energy is due to the thermal energy for clinker production. It is also found that 35% of this supplied thermal energy is lost in flue gas streams. Most modern kilns use pet coke or coal as their primary fuel. Instead, the municipal waste in landfills offer a cheap source of energy and reduce the environmental effects of dumping solid waste. The calcination and drying processes and the kiln need large quantities of thermal energy. About 40% of the total energy input is lost in the hot flue gases and cooling the stack plus the kiln shell. Hence, it is suitable to use an organic Rankine cycle (ORC) to recover the exhaust energy from the kiln. Alternatively, a 15 MW gas turbine engine combined with a steam turbine could be utilized. It was found that ORC produces 5 MW with a capital cost recovery period of 1.26 years. However, the gas turbine combined system produces 21.45 MW with a maximum recovery period of 2.66 years.

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“…Madlool et al [3] reviewed the energy use in cement industry. Doheim et al [4] examined the thermal energy consumption, losses and the heat saving potentials. For dry process in cement industry, Engin et al [5] and Kabir et al [6] applied an analysis of energy audit.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Waste Heat Recovery in Cement Industry: A Case Study

Madlool¹,

Saidur²,

Rahim³

2012

IJET

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In recent years, there has been an increasing interest in waste heat recovery in the cement industry. The aim of this work is to determine the waste heat recovery by utilizing the waste exit gases from the pre-heater and grate cooler to generate electricity, furthermore estimation of cost saving. The results based on the operational data which is collected from Al-Muthanna Cement Plant. The net power output of 834.12 kJ/kg was estimated. A 6.673 ×103 MWh/yr electricity generation were achieved. The cost saving was estimated of 467,110.00 USD/yr in addition to 20 months was expected as the simple payback period.

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Analysis of waste heat and its recovery in a cement factory

Cited by 13 publications

References 1 publication

Energy analysis and conservation prospects in the UAE cement industry

Energy analysis and conservation prospects in the UAE cement industry

Energy conservation and waste utilization in the cement industry serve the green technology and environment

Investigation of Waste Heat Recovery in Cement Industry: A Case Study

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