This paper was presented at ISA Automation Week 2011 in Mobile, Ala. It was selected to represent the Energy track for 2011.

Figure 1. Pyro-processing section at the plant

Abstract: Optimization of energy use in the pyro-processing of clinker is the most important step in the modern cement industry. Since the process of clinkerization consumes the largest share of the purchased energy, engineers and managers at the cement plants are constantly trying to monitor the specific energy consumption in order to keep it under control.
This paper highlights the efforts taken by the author in developing an Energy Model for the pyro-processing of Clinker production in a dry-process rotary cement kiln. In this paper this Energy Model is applied to a state of the art cement plant in a Far East Asian country. However this Energy Model is also applicable to all the modern dry process cement kilns. This model is based on actual field input data and site observations.
The optimization study was conducted at this site during Jul 2009 – May 2010, to identify opportunities to reduce the specific energy consumption in the pyro-processing of clinkerization and to improve the productivity of the rotary kiln system in the cement plant. The energy model was utilized to evaluate 4 energy cost optimization opportunities that would result in a total cost savings of $811,000 annually. The initial estimates indicate that all the 4 projects recommended by the study have simple payback periods less than 15 months. This Energy Model is a good example & motivation for all the engineers and managers who are responsible for maintaining the efficiency and reliability of modern dry process cement plants.






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