REDUCE FUEL CONSUMPTION IN ALBURGE CEMENT PLANT

Abstract

Cement production has been one of the most energy intensive industries in Libya In order to produce clinker, rotary kilns are widely used in cement plants. This research deals with the energy audit analysis of a dry type rotary kiln system working in Alburge Cement Plant (ACP) in Arab Union Cement Company AUCC).The kiln has a capacity of 4272 ton-clinker per day. In this research the main aim of energy audits is to provide an accurate account of energy consumption and energy use analysis of different components and to reveal the detailed information needed for determining the possible opportunities for energy conservation. waste heat recovery from hot gases and hot kin surfaces in a kiln system are known as potential ways to improve overall kiln efficiency. However ,it is still fairly difficult to find a detailed thermal analysis of rotary kiln systems in the open literature. It was found that the simulation done on the process (software program MATLAB) showed that, the optimum fuel consumption (14917-15000 Kg/hr.) with maximum product (178 t hr) and the minimum carbon dioxide emissions(787.2431-792.0879 KgCO2/tclinker) These results leads to reduce fuel consumption and protection of kiln bricks from damage. Also It was found that about (27.52 %) of the total input energy is being lost through hot flue gas ( 21.13 %),Cooler stack(5.16 %) and kiln shell(1.23 %) convection plus radiation.