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• Energy is a property of objects which can be transferred to other objects or converted in to different
forms and cause a change in a matter.
Type of energy 1 chemical energy released when a fuel burns.
2 the radiant energy carried by light.
3 thermal energy due to an object's temperature
Energy resource for messebo cement factory.
1 coal: south Africa and jimma coal
there are many process that consumes coal like rotary kiln ,calciner
2 Biomass: This biomass came from the residual of selth from humera and welkayte. know a time
Around 10 percent of the coal is replaced by biomass.
3 Fuel : uses to start up the rotary kiln.
4 electrical energy : that bring from elipa. needs electrical energy to operate on the company, like
rotary kiln, clinker coolers conveyers and crushers raw mill cement mill …..
PROCESS TO PRODUCE CEMENT IN MESSEBI CEMENT FACTROS
• The hot kiln surface is another significant heat loss source, and the
heat loss by convection and radiation dictates a waste energy of (9.56
%) of the input energy. On the other hand, the use of a secondary
shell on the kiln surface can significantly reduce this heat loss. Since
the kiln surface needs to be frequently observed by the operator so
as to see any local burning on the surface due to loss of refractory
inside the kiln, we would not consider insulating the kiln surface. The
basic principle of the secondary shell is shown the figure below.
•
• For the current rotary kiln, R=1.902m is radius of the kiln and consider
the radius of the sell Rs=2.302m.the distance between the two
surface is relatively small (20cm), a realistic estimation for the
temperature of the secondary sell can be made. Assume shell
temperature=2900c =5630k.we will consider stainless steel for the
material of the secondary shell since it has relatively low surface
emissivity and thermal conductivity. The heat transfer rate by
radiation is then calculated using the following equation
• This heat loss is to be transferred thought the insulation on the
secondary shell. Therefore, assuming a reasonable temperature for
the outer surface of the insulation, we can determine the required
thickness of insulation. For glass wool insulation, thermal conductivity
is taken as 0.05W/mk.therfere the resistance of the insulation layer is
would be:
Rinsu 2.336m
Therefore
the thickness of insulation is (E)
E= Rinsu-Rshell =2.336-2.302
E=3.4cm~4cm
It should be noted that when the secondary shell is added on to the kiln surface,
the convective heat transfer would preassembly become insignificant. This is
because of the fact that the temperature gradient in the gap would be relatively
very low there fore the total energy saving due to the secondary shell would be:
From the radiation heat transfer:
(139.44kj/kg-clinker) x (26.54kg-clinker/s)-317.985=3382.7526kw
From the convective heat transfer:
(187.28kj/kg-clinker) x (26.54kg-clinker/s)= 4970.4kw
Therefore, we can safely conclude that the use of secondary shell on the current kiln
surface would safe at list 8.4 Mw, which is 9.85 % of the total input energy .This energy
saving would result in a considerable reduction of fuel consumption (almost 25.74 % )of
the kiln system.
• Cost analysis for fuel only
Fuel consumption of the kiln with out secondary shell =3100lr/hr
1 liter = 7.8162 birr
3100 liter = X?
Therefore X = 24230.22 birr/hr
• For a year =24230.22 birr/hr *300days/year*24hr/day
=174,457,584 Birr/Year
• The total heat input of the kiln system is calculated as mf*Hc
• Where: mf=mass flow of fuel in=2883kg/hr
• Hc = calorific value of fuel=40758.498kj/kg
• Therefore
• Qin=32.64Mw
• Heat saved from the surface of kiln by using the secondary shell is =8.4Mw
• X=44,897,427.13 Birr/year
• Therefore 44,897,427.13 Birr/year is saved.
• 4.7.3 IMPROVEMENTS FROM THE SAVING OPTIONS
• Total thermal energy consumption = 3417.546 KJ/Kg clinker
• Useful energy at current status = 2222.62KJ/Kg clinker
• Initial thermal energy efficiency = 65%
• Potential thermal energy saved = 357.95 KJ/Kg clinker
• Useful energy after saving option = 2580.57 KJ/Kg clinker
• Thermal energy efficiency improvement = 75.6%
conclusion