Estimation of Industrial Heat Balance Based on Actual Plant Data: A Case Study for Cement Plant

Ian Wolde; Allan Starke; Alexandre Da Silva; José Cardemil

doi:10.52825/solarpaces.v3i.2337

Authors

Ian Wolde Pontificia Universidad Católica de Chile https://orcid.org/0000-0002-1852-8626
Allan Starke Universidade Federal de Santa Catarina https://orcid.org/0000-0003-1806-2237
Alexandre Da Silva Universidade Federal de Santa Catarina
José Cardemil Pontificia Universidad Católica de Chile https://orcid.org/0000-0002-9022-8150

DOI:

https://doi.org/10.52825/solarpaces.v3i.2337

Keywords:

Process Heat, Cement Industry, Heat Balance Estimation

Abstract

The industrial sector plays a significant role in anthropogenic effect on the environment due to greenhouse gases emissions associated with energy-intensive processes. To advance in the sustainability goals, it is essential to propose new modeling methodologies to assess the yield performance of clean technologies on industrial processes. However, due to the complexity and variety of such processes it is particularly challenging to assess the non-linear performance of industrial process in terms of heat loads, temperature, and others. The present study introduces a novel methodology to configure an estimation model of the heat released by the clinkering process in the cement industry, based only on operational data. Furthermore, a methodology is proposed to evaluate the correlation between the heat of the process and the operational parameters. The result of this methodology provides a function for the heat consumed or released by the chemical reactions of the process, based on the relevant operational parameters. The approach proposes a global specific enthalpy, parameter that represents the response of the process, only through the heat consumed or released by the chemical reactions. A methodology is proposed for evaluating the correlation of operational parameters with the proposed specific enthalpy. The methodology is validated by assessing the pyro-processes in the cement industry, renowned for its high energy intensity and pollution emissions. The proposed methodology could facilitate the evaluation of clean technologies into different industrial processes. This approach can guide industries in identifying opportunities for reducing pollution emissions while optimizing energy efficiency.

Downloads

Download data is not yet available.

References

[1] K.-M. Adamson et al., “High-temperature and transcritical heat pump cycles and advancements: A review,” Renewable Sustainable Energy Rev., vol. 167, p. 112798, Oct. 2022.

[2] IEA, “Direct CO2 emissions from industry in the Net Zero Scenario, 2000-2030.” 2022.

[3] G. P. Thiel and A. K. Stark, “To decarbonize industry, we must decarbonize heat,” Joule, vol. 5, no. 3, pp. 531–550, Mar. 2021.

[4] J. M. Cardemil et al., “Assessing the Uncertainties of Simulation Approaches for Solar Thermal Systems Coupled to Industrial Processes,” Energies, vol. 15, no. 9, p. 3333, May 2022.

[5] IEA, “Direct emissions intensity of cement production in the Net Zero Scenario, 2015-2030,” Jun-2023. [Online]. Available: https://www.iea.org/data-and-statistics/charts/direct-emissions-intensity-of-cement-production-in-the-net-zero-scenario-2015-2030-2. [Accessed: 29-Jan-2024].

[6] C. Carbone, D. Ferrario, A. Lanzini, S. Stendardo, and A. Agostini, “Evaluating the Carbon Footprint of Cement Plants Integrated With the Calcium Looping CO2 Capture Process,” Frontiers in Sustainability, vol. 3, 2022.

[7] Y. K. Verma, D. Ghime, B. Mazumdar, and P. Ghosh, “Emission reduction through process integration and exploration of alternatives for sustainable clinker manufacturing,” Int. J. Environ. Sci. Technol., vol. 20, no. 12, pp. 13329–13346, Dec. 2023.

[8] J. Kline and C. Kline, “Assessing Cement Plant Thermal Performance,” IEEE Trans. Ind. Appl., vol. 53, no. 4, pp. 4097–4108, July-Aug 2017.

[9] S. Fellaou and T. Bounahmidi, “Analyzing thermodynamic improvement potential of a selected cement manufacturing process: Advanced exergy analysis,” Energy, vol. 154, pp. 190–200, Jul. 2018.

[10] Q. Liu, H. Yu, X. Wang, and S. Lu, “Research on Online Monitoring of Energy Consumption of Rotary Kiln for Cement Clinker Formation Heat,” in 2020 IEEE International Conference on Information Technology,Big Data and Artificial Intelligence (ICIBA), 2020, vol. 1, pp. 469–474.

[11] I. Wolde, J. M. Cardemil, and R. Escobar, “Compatibility assessment of thermal energy storage integration into industrial heat supply and recovery systems,” J. Clean. Prod., vol. 440, p. 140932, Feb. 2024.

[12] X. Liu, X. Li, and R. Yang, “High-temperature thermal storage-based cement manufacturing for decarbonization,” Carbon Neutrality, vol. 1, no. 1, p. 29, Jul. 2022.

[13] S. Verma and S. Y. Kumar, “Process Integration using pinch analysis: a cement industry case study,” International Journal of Applied Engineering Research, vol. 12, no. 24, pp. 14760–14763, 2017.

[14] S. Campanari et al., “Design and performance of CEMCAP cement plant without CO2 capture,” Politecnico di Milano., D4.1, 2016.

[15] A. Atmaca, “Detailed assessment of specific exergetic costing, energy consumption, and environmental impacts of a rotary kiln in cement industry,” Environ. Sci. Pollut. Res. Int., vol. 30, no. 14, pp. 40260–40282, Mar. 2023.

[16] X. Sui, Y. Zhang, S. Shao, and S. Zhang, “Exergetic life cycle assessment of cement production process with waste heat power generation,” Energy Convers. Manage., vol. 88, pp. 684–692, Dec. 2014.

[17] V. Ghalandari, “A comprehensive study on energy and exergy analyses for an industrial-scale pyro-processing system in cement plant,” Cleaner Energy Systems, vol. 3, p. 100030, Dec. 2022.

[18] A. Naeimi, M. Bidi, M. H. Ahmadi, R. Kumar, M. Sadeghzadeh, and M. Alhuyi Nazari, “Design and exergy analysis of waste heat recovery system and gas engine for power generation in Tehran cement factory,” Thermal Science and Engineering Progress, vol. 9, pp. 299–307, Mar. 2019.

[19] T. Engin and V. Ari, “Energy auditing and recovery for dry type cement rotary kiln sys-tems––A case study,” Energy Convers. Manage., vol. 46, no. 4, pp. 551–562, Mar. 2005.

[20] S. Khurana, R. Banerjee, and U. Gaitonde, “Energy balance and cogeneration for a ce-ment plant,” Appl. Therm. Eng., vol. 22, no. 5, pp. 485–494, Apr. 2002.

[21] L. Vasiliu, O. Gencel, I. Damian, and M. Harja, “Capitalization of tires waste as derived fuel for sustainable cement production,” Sustainable Energy Technologies and Assess-ments, vol. 56, p. 103104, Mar. 2023.

[22] M. Altinkaynak, A. Kabul, and O. Kizilkan, “Exergetic assessment of a rotary kiln for clinker production in cement industry,” Int. J. Exergy, vol. 16, no. 3, p. 263, Jan. 2015.

[23] N. Novia, M. Faizal, and S. Liana, “CFD Modeling Of Waste Heat Recovery On The Rotary Kiln System in the Cement Industry,” Jurnal Ilmu Teknik Unsri, vol. 1, no. 1, pp. 1–17, 2013.

[24] T. F. Anacleto, A. E. G. de O. e Silva, S. R. da Silva, E. F. da Costa Junior, and A. O. S. da Costa, “Chemical exergy influence in the exergetic analysis of a real clinker rotary kiln,” Brazilian Journal of Chemical Engineering, vol. 38, no. 1, pp. 197–214, Mar. 2021.

[25] S. Boldyryev, H. Mikulčić, G. Krajačić, and N. Duić, “Waste heat utilisation of Croatian cement industry accounting Total Site demands,” in Computer Aided Chemical Engineering, vol. 38, Z. Kravanja and M. Bogataj, Eds. Elsevier, 2016, pp. 2223–2228.

[26] A. Mittal and D. Rakshit, “Energy audit and waste heat recovery from kiln hot shell surface of a cement plant,” Thermal Science and Engineering Progress, vol. 19, p. 100599, Oct. 2020.

[27] A. I. Okoji, A. N. Anozie, J. A. Omoleye, A. E. Taiwo, and F. N. Osuolale, “Energetic assessment of a precalcining rotary kiln in a cement plant using process simulator and neural networks,” Alex. Eng. J., vol. 61, no. 7, pp. 5097–5109, Jul. 2022.

Estimation of Industrial Heat Balance Based on Actual Plant Data: A Case Study for Cement Plant

Authors

DOI:

Keywords:

Abstract

Downloads

References

Downloads

Published

How to Cite

Conference Proceedings Volume

Section

License

Funding data