Thermal Energy Optimization For Cement Process Using Pinch Point Analysis

Cement factory require large amounts of energy that needs a good attention to optimize itsrnenergy usage. This project analyses the thermal energy optimization of the cement manufacturingrnprocesses for a selected cement plant called Ethio Cement PLC (ECPLC) which is found tornnearby Chancho city, Ethiopia. The cement industry is one of the biggest consumers of carboncontainingrnprimaryrnenergyrnsourcesrnand onernamongrnthernfirst pollutersrnofrnthernenvironment,rnemittingrnrnapproximatelyrnrn5% of world pollution. Energy consumption in ECPLC represents the mostrnimportant part of the assembly cost for cement factories and contains a significant influence onrnproduct prices. Given that it's realized in modern society that infrastructural projects result in thernnext level of economy and sustainability for countries, reducing the assembly cost withinrnthe cement industry could be a vital problem. I analysed the energy consumption of ECPLC tornsee the minimum energy targets of production and proposed pathways to boost energy efficiency.rnCement production is an energy user process that requires heat to be supplied at extremerntemperature levels under the constraints of gas-solid heat exchange phenomena and alsornthe kinetics of chemical reactions. In this project, the use of Pinch Analysis Technologyrntechniques to optimize the thermal energy recovery of the cement production was explored. Inrnaddition to the energy recovery, heat exchanger network was designed for the targeted industry.rnFinally, from the investigation, ∆Tmin = 10℃ was selected as minimum temperature differencernbetween hot and cold streams. Hint software is use for the analysis. The targets for hot and coldrnutility were 1,481.6 kW and 17,330.5 kW respectively and the maximum heat recovery obtainedrnwas 43,208.5 kW. The minimum number of heat exchanger that required in this project was 17rnand the type of heat exchanger used for design was Direct contact heat exchanger was selected.rnThis is happen on a solid particle-fluid combination inside preheater, kiln and cooler. A retrofitrnof a heat exchanger network of Pinch technology in a cement factory (ECPLC) which works 24 rnHours per day and 300 days per year can save approximately 243,052,454.3 rn��������rn����.Ethiopian rnBirr per year.

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