Utilization of waste heat from rotary kiln for burning clinker in the cement plant

¹ AGH University, Faculty of Energy and Fuels, Mickiewicza Av. 30, 30-059 Krakow, Poland
² Cemex Polsk a SP.zo.o, ul. Mstowska 10, 42-240 Rudniki

^a corresponding author: sztekler@agh.edu.pl

Abstract

Cement subsector next to the glass industry is counted among one of the most energy-intensive industries, which absorbs approx. 12-15% of the total energy consumed by the industry. In the paper various methods of energy consumption reduction of in the cement industry are discussed. Cement production carries a very large emissions of greenhouse gases, where CO₂ emissions on a global scale with the industry than approx. 5%. Great opportunity in CO₂ emissions reduction in addition to the recovery of waste heat is also alternative fuels co-firing in cement kilns [1], [2]. In the cement sector interest in fitting-usable waste energy is growing in order to achieve high rates of savings and hence the financial benefits, as well as the environment ones [3]. In the process of cement production is lost irretrievably lot of energy and reduction of these losses on a global scale gives a visible saving of consumed fuel. The aim of this study is to investigate the possibility of waste heat use in Rudniki Cement Plant near to Czestochowa. After analyzing of all waste heat sources will be analyzed the heat emitted by radiation from the surface of the rotary kiln at the relevant facility. On the basis of thermal-flow calculations the most favorable radiative heat exchanger will be designed. The calculations based on available measurements provided by the cement plant, a thermal power of the heat exchanger, the heat exchange surface, the geometry of the heat exchanger, and other important parameters will be established. In addition the preliminary calculations of hydraulic losses and set directions for further work will be carried out. Direct benefits observed with the introduction of the broader heat recovery technology, is a significant increase in energy efficiency of the industrial process, which is reflected in the reduction of energy consumption and costs. Indirectly it leads to a reduction of pollution and energy consumption.