Screening of Energy-Saving Technologies for Cement Production Based on Boston Consulting Group Matrix

2021 ◽  
Vol 1035 ◽  
pp. 988-998
Author(s):  
Yu Chen Zhang ◽  
Xian Zheng Gong ◽  
Yu Liu ◽  
Li Wei Zhou
Keyword(s):  
Energy Saving ◽  
Frequency Conversion ◽  
Waste Heat ◽  
Cement Industry ◽  
Cement Clinker ◽  
Cement Kiln ◽  
Cement Production ◽  
Group Matrix ◽  
Saving Rates ◽  
High Technologies

Based on the analysis of the development situation of China’s cement industry and the BCG Matrix method, this paper classifies and screens 31 energy-saving technologies in China's cement production, and puts forward guiding suggestions for the application of energy-saving technologies for cement enterprises. The screening results show that the “Energy-efficient powder separation technology” and “New low-calcium cement clinker and production technology” are “double-high” technologies with excellent on both screening indicators. The investment energy saving rates are 17.5 tce/10,000 yuan (tons of standard coal equivalent per 10,000 yuan) and 10 tce/10,000 yuan. The promotion ratio increments are 35% and 25%. “Cement clinker energy-saving nitrogen reduction firing technology”, “Fan drive mode adopts high voltage frequency conversion speed control technology”, “Pure low temperature waste heat power generation technology for cement kiln” are “single-high” technologies with excellent on one of screening indicators. The investment energy saving rates are 0.3tce/10,000 yuan, 4.1tce/10,000 yuan, 3.9tce/10,000 yuan respectively. The promotion ratio increments are 19%, 35%, 31.5% respectively.

Life Cycle Assessment of Comprehensive Utilization of Calcium Carbide Slag in Cement Kiln

2020 ◽  
Vol 993 ◽  
pp. 1487-1495
Author(s):  
Xin Ping Lin ◽  
Ai Wei Liu ◽  
Yun Fa Feng ◽  
Qi Ling Chen ◽  
Tao Chen ◽  
...  
Keyword(s):  
Life Cycle Assessment ◽  
Emission Reduction ◽  
Calcium Carbide ◽  
Cement Industry ◽  
Cement Clinker ◽  
Cement Kiln ◽  
Cement Production ◽  
Comprehensive Utilization ◽  
Carbide Slag ◽  
Portland Cement Clinker

The recycling utilization of solid waste is an important technical means for the sustainable development of the cement industry in China. Calcium carbide slag is a special solid waste in China, which can be used for cement production with a great advantage on CO2 emission reduction. With an view to providing methodological and data support for the development of policies in the cement industry, this paper quantitatively analyzes the environmental effects/environmental benefits of the comprehensive utilization of calcium carbide slag in cement kiln by comparing the traditional system of Portland cement clinker completely produced by natural resources with the system of cement clinker produced by calcium carbide slag based on the life cycle assessment (LCA) method given in standards and specifications of ISO 14040 series. The results show that the latter system has a better effect in material saving and carbon emission reduction, will increase the energy consumption in cement production process, and also slightly increase other pollutants (e.g. SOx, NOx, etc.) emission. The GWP, AP and EP indicators of the calcium carbide slag cement clinker system decrease compared with those of the Portland cement clinker system, while other indicators do not differ much or even slightly increase.

scholarly journals Feasibility and Carbon Footprint Analysis of Lime-Dried Sludge for Cement Production

2020 ◽  
Vol 12 (6) ◽  
pp. 2500 ◽  
Author(s):  
Li Ping ◽  
Gang Zhao ◽  
Xiaohu Lin ◽  
Yunhui Gu ◽  
Wei Liu ◽  
...  
Keyword(s):  
Carbon Footprint ◽  
Raw Material ◽  
Cement Clinker ◽  
Cement Kiln ◽  
Drying Process ◽  
Cement Production ◽  
Footprint Analysis ◽  
Cement Kilns ◽  
Cement Manufacturing ◽  
Dried Sludge

Cement manufacturing and the treatment of sludge are considered both energy-intensive industries and major greenhouse gas (GHG) emitters. However, there are still few studies on comprehensive carbon footprint analysis for adding municipal sludge in the cement production. In this study, the lime-dried sludge blended with calcium oxide at the mass mixing ratio of 10% was utilized as raw material for the preparation of Portland cement. The chemical and physical properties of sludge were analyzed. A set of carbon footprint calculation methods of lime-drying treatment of sludge and reuse in cement kilns was then established to explore the feasibility of coprocessing lime-dried sludge in cement kilns. The results showed lime-dried sludge containing CaO, SiO2, Al2O3, and Fe2O3 was ideal for cement production as raw material. However, the water content of lime-dried sludge should be strictly limited. The lime-drying process presented the biggest carbon emission (962.1 kg CO2-eq/t sludge), accounting for 89.0% of total emissions. In the clinker-production phase, the lime-dried sludge as raw material substitute and energy source gained carbon credit of 578.8 and 214.2 kg CO2-eq/t sludge, respectively. The sludge used for producing cement clinker could reduce carbon emissions by 38.5% to 51.7%. The addition ratio of lime and stacking time in the sludge lime-drying process could greatly affect the carbon footprint of coprocessing lime-dried sludge in cement kiln.

Analysis of Cement Kiln Waste Heat Power Generation System Using the Exergy Analysis Method

2013 ◽  
Vol 860-863 ◽  
pp. 639-644
Author(s):  
Jian Gang Wang ◽  
Pu Yan Zheng ◽  
Zhi Yun Zhou ◽  
Yan Zhou Yuan
Keyword(s):  
Power Generation ◽  
Energy Saving ◽  
Energy Use ◽  
Waste Heat ◽  
Scientific Basis ◽  
Economic Benefits ◽  
Cement Kiln ◽  
Heat Power ◽  
Generation System ◽  
Power Generation System

Power generation using waste heat from cement kiln can not only bring economic benefits to the enterprise, but also play an important role in environment protection. Constantly researches have proved that there is still large energy saving potential in its operation. In this paper, the waste heat power generation system was divided into several subsystems, and the exergy calculation model of each subsystem unit was established. Finally, the weakest part in energy use was found according to the results. It provides a scientific basis for performance improvement and energy saving transformation of waste heat power generation.

Use of waste derived fuels in cement industry: a review

2016 ◽  
Vol 27 (2) ◽  
pp. 178-193 ◽  
Author(s):  
Nickolaos Chatziaras ◽  
Constantinos S. Psomopoulos ◽  
Nickolas J. Themelis
Keyword(s):  
Alternative Fuels ◽  
Fossil Fuels ◽  
Fossil Fuel ◽  
Cement Industry ◽  
Wastewater Sludge ◽  
Cement Clinker ◽  
Firing Process ◽  
Cement Production ◽  
Content Type ◽  
Recycled Plastics

Purpose – Cement production has advanced greatly in the last few decades. The traditional fuels used in traditional kilns include coal, oil, petroleum coke, and natural gas. Energy costs and environmental concerns have encouraged cement companies worldwide to evaluate to what extent conventional fuels can be replaced by waste materials, such as waste oils, mixtures of non-recycled plastics and paper, used tires, biomass wastes, and even wastewater sludge. The paper aims to discuss these issues. Design/methodology/approach – The work is based on literature review. Findings – The clinker firing process is well suited for various alternative fuels (AF); the goal is to optimize process control and alternative fuel consumption while maintaining clinker product quality. The potential is enormous since the global cement industry produces about 3.5 billion tons that consume nearly 350 million tons of coal-equivalent fossil and AF. This study has shown that several cement plants have replaced part of the fossil fuel used by AF, such waste recovered fuels. Many years of industrial experience have shown that the use of wastes as AF by cement plants is both ecologically and economically justified. Originality/value – The substitution of fossil fuels by AF in the production of cement clinker is of great importance both for cement producers and for society because it conserves fossil fuel reserves and, in the case of biogenic wastes, reduces greenhouse gas emissions. In addition, the use of AF can help to reduce the costs of cement production.

scholarly journals Physico-Mechanical Properties of Bricks Manufactured using Cement Kiln Dust

2020 ◽  
Vol 9 (3) ◽  
pp. 1804-1808
Keyword(s):  
Mechanical Properties ◽  
Compressive Strength ◽  
Waste Management ◽  
Industrial Waste ◽  
Cement Content ◽  
Cement Industry ◽  
Cement Clinker ◽  
Cement Kiln Dust ◽  
Cement Kiln ◽  
Kiln Dust

the actual increase in global industrial production and manufacturing, produces a continuous increase in amount of industrial waste and continues to emit an all-time high amount of air pollutants and greenhouse gas emissions. To fight and mitigate these phenomena, proper Waste Management became the pillar of most environmental strategies worldwide. By reduction of consumption, re-use of goods and recycling of products, waste management aims to preserve the resources and to protect the environment. The Cement industry is one of the most important industrial sectors for society development; however it also has significant negative environmental impacts due to its emissions and production of waste. Cement kiln dust (CKD) is an industrial waste or by product which results from cement manufacturing. CKD is fine grained, solid, highly alkaline particulate material chiefly composed of oxidized, anhydrous, micron-sized particles collected from electrostatic precipitators during the production of cement clinker. This research examines the effects of using large amounts of CKD to replace the cement content in the fabrication of solid cement bricks. It is triggered by the quadruple objectives of reducing the amount of cement consumption, disposing efficiently of its industrial waste and producing economic bricks with safe strength. The purpose of this paper is to assess the properties of solid cement bricks containing different amounts of CKD. Cement bricks produced using different amounts of CKD were tested to find their properties and final comparison has been made to identify the effect of using different CKD/Cement ratio on the performance of bricks compared to the reference specimen produced using cement only with no CKD. For the brick mixes, Ordinary Portland cement (OPC), with two cement content of 200kg/m3 and 250kg/m3 were used throughout this investigation. The physical properties; unit weight, water absorption and mechanical properties; compressive strength, flexural strength, of the produced bricks were determined. Results showed that partial replacement of OPC with CKD reduces the brick compressive strength by 18% to 23% for CKD/OPC ratio of 30% and by 36% for CKD/OPC ratio of 50% and in all cases the strength remains largely higher than the standard limit for load bearing bricks.

scholarly journals Utilization of lime-dried sludge for eco-cement clinker production: effects of different feeding points

2017 ◽  
Vol 77 (4) ◽  
pp. 960-970 ◽  
Author(s):  
Haihua Cao ◽  
Wei Liu ◽  
Jingcheng Xu ◽  
Jia Liu ◽  
Juwen Huang ◽  
...  
Keyword(s):  
Heterocyclic Compounds ◽  
Cement Industry ◽  
Cement Clinker ◽  
Cement Kiln ◽  
The Sustainable Development ◽  
Alternative Materials ◽  
Cement Manufacturing ◽  
Dried Sludge ◽  
Production Effects ◽  
Clinker Production

Abstract Co-processing lime-dried sludge (LDS) in cement kilns is an appropriate technique to solve the problem of LDS disposal and promote the sustainable development for cement industry. However, there were limited studies that investigated the effects of feeding points on product quality and cement kiln emissions. In this study, simulated experiments were conducted by dividing the feeding points into high-temperature zones (HTZs) and raw mill (RM). Cement quality and major cement kiln emission characteristics were comprehensively investigated. The results showed that in terms of burnability, compressive strength and microstructure, the optimum co-processing amount of LDS were 9 wt% when feeding at RM, while 6% when feeding at HTZs. Meanwhile, the organic emissions of RM samples were mainly low environmental risk compounds of amides and nitrogenous heterocyclic compounds. Inorganic gaseous pollutions of NOX and SO2, respectively, were 8.11 mg/g DS and 12.89 mg/g DS, compared with 7.61 mg/g DS and 4.44 mg/g DS for HTZs. However, all the cement kiln emissions concentration were still much lower than standard requirements. Overall, RM had a bigger LDS co-processing capacity and higher, but acceptable, cement kiln emissions. Feeding LDS via RM could dispose larger amounts of sludge and provide more alternative materials for cement manufacturing.

scholarly journals Parametric Studies of Cement Production Processes

2020 ◽  
Vol 2020 ◽  
pp. 1-17 ◽  
Author(s):  
John P. John
Keyword(s):  
Energy Consumption ◽  
Alternative Fuels ◽  
Cement Industry ◽  
Production Costs ◽  
Cement Clinker ◽  
Cement Production ◽  
Exhaust Gases ◽  
Industrial Sectors ◽  
Study Results ◽  
Parametric Studies

The cement industry is one of the most intensive energy consumers in the industrial sectors. The energy consumption represents 40% to 60% of production cost. Additionally, the cement industry contributes around 5% to 8% of all man-made CO2 emissions. Physiochemical and thermochemical reactions involved in cement kilns are still not well understood because of their complexity. The reactions have a decisive influence on energy consumption, environmental degradation, and the cost of cement production. There are technical difficulties in achieving direct measurements of critical process variables in kiln systems. Furthermore, process simulation is used for design, development, analysis, and optimization of processes, when experimental tests are difficult to conduct. Moreover, there are several models for the purpose of studying the use of alternative fuels, cement clinker burning process, phase chemistry, and physical parameters. Nonetheless, most of them do not address real inefficiency taking place in the processes, equipment, and the overall system. This paper presents parametric study results of the four-stage preheater dry Rotary Kiln System (RKS) with a planetary cooler. The RKS at the Mbeya Cement Company (MCC) in Tanzania is used as a case study. The study investigated the effects of varying the RKS parameters against system behaviour, process operation, environment, and energy consumptions. Necessary data for the modelling of the RKS at the MCC plant were obtained either by daily operational measurements or laboratory analyses. The steady-state simulation model of the RKS was carried out through the Aspen Plus software. The simulation results were successfully validated using real operating data. Predictions from parametric studies suggest that monitoring and regulating exhaust gases could improve combustion efficiency, which, in turn, leads to conserving fuels and lowering production costs. Composition of exhaust gases also depends both on the type of fuel used and the amount of combustion air. The volume of exit flue gases depends on the amount of combustion air and infiltrating air in the RKS. The results obtained from the study suggest a potential of coal saving at a minimum of about ṁcoal=1263 kg·h−1, which approximates to 76,126 tons per year at the current kiln feed of 58,000 kg·h-1. Thus, this translates to a specific energy saving of about 1849.12 kJ·kgcl-1, with relatively higher clinker throughput. In this vein, process modelling provides effective, safe, and economical ways for assessing the performance of the RKS.

scholarly journals Global CO<sub>2</sub> uptake of cement in 1930–2019

2020 ◽  
Author(s):  
Rui Guo ◽  
Jiaoyue Wang ◽  
Longfei Bing ◽  
Dan Tong ◽  
Philippe Ciais ◽  
...  
Keyword(s):  
Calcium Content ◽  
Cement Industry ◽  
Cement Kiln ◽  
Low Carbon ◽  
Uptake Capacity ◽  
Cement Production ◽  
Dominant Position ◽  
High Calcium ◽  
Estimation System ◽  
Kiln Dust

Abstract. Because of the alkaline nature and high calcium content of cements in general, they serve as a CO2 absorbing agent through carbonation processes, resembling silicate weathering in nature. This carbon uptake capacity of cements could abate some of the CO2 emitted during their production. Given the scale of cement production worldwide (4.10 Gt in 2019), a life-cycle assessment is necessary in determining the actual net carbon impacts of this industry. We adopted a comprehensive analytical model to estimate the amount of CO2 that had been absorbed from 1930 to 2019 in four types of cement materials including concrete, mortar, construction waste and cement kiln dust (CKD). Besides, the process CO2 emission during the same period based on the same datasets was also estimated. The results show that 21.12 Gt CO2 (18.12–24.54 Gt CO2, 95 % CI) had been absorbed in the cements produced from 1930 to 2019, with the 2019 annual figure mounting up to 0.90 Gt CO2 yr−1 (0.76–1.07 Gt CO2, 95 % CI). The cumulative uptake is equivalent to approx. 52 % of the process emission, based on our estimation. In particular, China's dominant position in cement production/consumption in recent decades also gives rise to its uptake being the greatest with a cumulative sink of 6.21 Gt CO2 (4.59–8.32 Gt CO2, 95 % CI) since 1930. Among the four types of cement materials, mortar is estimated to be the greatest contributor (approx. 58 %) to the total uptake. Potentially, our cement emission and uptake estimation system can be updated annually and modified when necessary for future low-carbon transitions in the cement industry. All the data described in this study, including the Monte Carlo uncertainty analysis results, are accessible at https://doi.org/10.5281/zenodo.4064803.

Numerical Investigation of the Effect of Waste Heat Extracting Location on Temperature Distribution

2011 ◽  
Vol 354-355 ◽  
pp. 361-364
Author(s):  
Zhan Xu Tie ◽  
Hai Xia Li ◽  
Xiao Dian Guo
Keyword(s):  
Heat Transfer ◽  
High Temperature ◽  
Gas Flow ◽  
Waste Heat ◽  
Cement Clinker ◽  
Cement Kiln ◽  
Gas Temperature ◽  
Flow And Heat Transfer ◽  
Grate Cooler ◽  
High Temperature Gas

The numerical model was established to simulate the gas flow and heat transfer in cement grate cooler. It is useful to increase the gas temperature when the extracting exit position is close to the cement kiln end. The appropriate position of the extracting high temperature gas is about 5 m far away from the cement clinker inlet.

The Design and Experimental Study on the Lance of the Cement Industry Flue Gas Denitration Technology

2014 ◽  
Vol 1015 ◽  
pp. 663-666
Author(s):  
Li Juan Zhang
Keyword(s):  
Flue Gas ◽  
Production Line ◽  
Average Diameter ◽  
Structure Design ◽  
Cement Industry ◽  
Cement Clinker ◽  
Injection System ◽  
Cement Production ◽  
Dry Process ◽  
Visual Distance

The lance is the key equipment of SNCR flue gas denitrification technology injection system on the new dry process cement production line.The atomizing effects of reducing agent will directly influence the result of flue gas denitration. In this paper, there are the structure design and experimental analysis on denitration lance.The results show that the lance can ensure the average diameter of atomized particles is from 50 to 55um,uniformly degree is above 80%, and visual distance of atomized ammonia is above 4 meters.It has been applied in a new dry process cement production line of daily 5kt SNCR flue gas denitration project, reaching above 70% of denitration efficiency. These results are valuable for similar new dry cement clinker production line of SNCR denitration Technology.

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