Exergetic and environmental performance improvement in cement production process by driving force distribution

Seyed Ali Ashrafizadeh; Majid Amidpour; Ali Allahverdi

Korean Journal of Chemical Engineering, Vol.29, No.5, 606-613, May, 2012

DOI10.1007/s11814-011-0226-y Export Citation

Exergetic and environmental performance improvement in cement production process by driving force distribution

Seyed Ali Ashrafizadeh, Majid Amidpour^†, and Ali Allahverdi¹

Department of Environment and Energy, Science and Research Branch, Islamic Azad University, Tehran, Iran
¹Cement Research Center, School of Chemical Engineering, Iran University of Science and Technology, Narmak 1684613114, Tehran, Iran

E-mail:

This paper presents an investigation of the effects of temperature gradient distribution by the aid of a secondary burner on exergetic and environmental functions of the cement production process. For this reason, the burning system of the cement production (kiln & preheater) process was simulated in four thermal areas. Three lines of cement production with 2,000, 2,300 and 2,600 ton/day were investigated. Fuel injection ratio into the secondary burner, from 10 to 40 percent was studied for each line. The obtained results show that, for cyclone preheaters, fuel injection into the secondary burner up to a proportion resulting in the minimum temperature required for alite formation (2,200 ℃) in the kiln burning zone is suitable. For shaft preheaters, however, according to percent calcinations, there exists an optimum proportion for 15 to 20 percent injection fuel into secondary burner. Finally, it was shown that the secondary burner application can reduce the exergy losses about 25 percent, which leads to a reduction of the green house gases of about 35000 cubic meters per year for each ton per day of clinker production.

Keywords:Exergy Analysis;Green House Gases;Secondary Burner;Cement Production;Driving Force

[References]

Rant Z, Forsch. Ing. Wes., 22, 36 (1956)
Bosnjakovic F, Technical Thermodynamics, Holt, Rinehart & Winston, New York (1965)
Szargut J, Morris DR, Steward FR, Exergy Analysis of Thermal, Chemical and Metallurgical Processes, Hemisphere Publishing Corporation, New York, London (1988)
Kotas TJ, the Exergy Method of Thermal Plant Analysis. Krieger Publishing Company, Malabar, Florida (1995)
Bejan A, Entropy Generation through Heat & Fluid Flow, Wiley, New York (1982)
Bejan A, Advanced Engineering Thermodynamics, Wiley, New York (2006)
Bejan A, Tsatsaronis G, Moran M, Thermal Design & Optimization, Wiley, New York (1996)
Kaantee U, Zevenhoven R, Backman R, Hupa M, Cement manufacturing using alternative fuels and the advantages of process modeling, Recovery, Recycling, Re-integration, Feb. 12-15, Geneva, Switzerland (2002)
Choate WT, Energy and Emission Reduction Opportunities for the Cement Industry, U.S. Department of Energy, Energy Efficiency and Renewable Energy (2003)
Koroneos C, Roumbas G, Moussiopoulos N, Int. J. Exergy., 2(1), 55 (2005)
Kawaes T, Cement Process and Energy Saving, the Energy Conservation Center, Japan (2006)
Sogut Z, Oktay Z, Int. J. Exergy., 5(5), 218 (2008)
Zeman F, Lakcner K, The Reduced Emission Oxygen Kiln, A White Paper Report for the Cement Sustainability Initiative of the World Business Council on Sustainable Development, Lenfest Center for Sustainable Energy Columbia University in New York Report No. 2008.01. (2008)
Worrell E, Galitsky C, Price L, Energy efficiency improvement opportunities for the cement industry, Environmental Energy Technologies Division Lawrence Berkeley National Laboratory (2008)
Sogut Z, Oktay Z, Karakoc H, Appl. Therm. Eng., 30(8-9), 817 (2010)
Sogut Z, Oktay Z, Hepbasli A, Int. J. Exergy (IJEX)., Issue 5, 6 (2009)
Park SS, Kang HY, Korean J. Chem. Eng., 23(3), 367 (2006)
Ahn YC, Cho JM, Kim GT, Cha SR, Lee JK, Park YO, Kim SD, Lee SH, Korean J. Chem. Eng., 21(1), 182 (2004)
Kurt EP, Cement Manufacturers’ Handbook, Chemical Publishing Co. Inc. New York (1979)
Kohlhaas B, Labahn O, Cement Engineers’ Handbook, 4th Ed. Int. Public Service (1982)
Duda WH, Cement Data Book (1), Bauverlag GmbH (1985)
Boateng AA, Rotary Kilns: Transport Phenomena and Transport Processes, Elsevier (2008)
Alsop PA, The Cement Plant Operation Hand Book, International Cement Review (2010)
Ashrafizadeh SA, Sanat Siman., 90, 8 (2007)
Sato N, Chemical energy and exergy an introduction to chemical thermodynamics for engineering, Elsevier, First Ed., 112 (2004)
Ashrafizadeh SA, Designing of a clinker burning pilot plant, M.Sc. thesis, Adviser: Dr. Taeb A, Cement Research Center, Chemical Eng. Group, Iran University of Science and Technology, Sep. (1997)

[Referenced By]

[1] Rant Z, Forsch. Ing. Wes., 22, 36 (1956)

[2] Bosnjakovic F, Technical Thermodynamics, Holt, Rinehart & Winston, New York (1965)

[3] Szargut J, Morris DR, Steward FR, Exergy Analysis of Thermal, Chemical and Metallurgical Processes, Hemisphere Publishing Corporation, New York, London (1988)

[4] Kotas TJ, the Exergy Method of Thermal Plant Analysis. Krieger Publishing Company, Malabar, Florida (1995)

[5] Bejan A, Entropy Generation through Heat & Fluid Flow, Wiley, New York (1982)

[6] Bejan A, Advanced Engineering Thermodynamics, Wiley, New York (2006)

[7] Bejan A, Tsatsaronis G, Moran M, Thermal Design & Optimization, Wiley, New York (1996)

[8] Kaantee U, Zevenhoven R, Backman R, Hupa M, Cement manufacturing using alternative fuels and the advantages of process modeling, Recovery, Recycling, Re-integration, Feb. 12-15, Geneva, Switzerland (2002)

[9] Choate WT, Energy and Emission Reduction Opportunities for the Cement Industry, U.S. Department of Energy, Energy Efficiency and Renewable Energy (2003)

[10] Koroneos C, Roumbas G, Moussiopoulos N, Int. J. Exergy., 2(1), 55 (2005)

[11] Kawaes T, Cement Process and Energy Saving, the Energy Conservation Center, Japan (2006)

[12] Sogut Z, Oktay Z, Int. J. Exergy., 5(5), 218 (2008)

[13] Zeman F, Lakcner K, The Reduced Emission Oxygen Kiln, A White Paper Report for the Cement Sustainability Initiative of the World Business Council on Sustainable Development, Lenfest Center for Sustainable Energy Columbia University in New York Report No. 2008.01. (2008)

[14] Worrell E, Galitsky C, Price L, Energy efficiency improvement opportunities for the cement industry, Environmental Energy Technologies Division Lawrence Berkeley National Laboratory (2008)

[15] Sogut Z, Oktay Z, Karakoc H, Appl. Therm. Eng., 30(8-9), 817 (2010)

[16] Sogut Z, Oktay Z, Hepbasli A, Int. J. Exergy (IJEX)., Issue 5, 6 (2009)

[17] Park SS, Kang HY, Korean J. Chem. Eng., 23(3), 367 (2006)

[18] Ahn YC, Cho JM, Kim GT, Cha SR, Lee JK, Park YO, Kim SD, Lee SH, Korean J. Chem. Eng., 21(1), 182 (2004)

[19] Kurt EP, Cement Manufacturers’ Handbook, Chemical Publishing Co. Inc. New York (1979)

[20] Kohlhaas B, Labahn O, Cement Engineers’ Handbook, 4th Ed. Int. Public Service (1982)

[21] Duda WH, Cement Data Book (1), Bauverlag GmbH (1985)

[22] Boateng AA, Rotary Kilns: Transport Phenomena and Transport Processes, Elsevier (2008)

[23] Alsop PA, The Cement Plant Operation Hand Book, International Cement Review (2010)

[24] Ashrafizadeh SA, Sanat Siman., 90, 8 (2007)

[25] Sato N, Chemical energy and exergy an introduction to chemical thermodynamics for engineering, Elsevier, First Ed., 112 (2004)

[26] Ashrafizadeh SA, Designing of a clinker burning pilot plant, M.Sc. thesis, Adviser: Dr. Taeb A, Cement Research Center, Chemical Eng. Group, Iran University of Science and Technology, Sep. (1997)