LIMESTONE CRUSHING PLANT LOAD MANAGEMENT
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LIMESTONE CRUSHING PLANT LOAD MANAGEMENT Jaco Snyman 2012-08-15. CEMENT MANUFACTURING. ENERGY USAGE OF THE CEMENT MANUFACTURING INDUSTRY. Industry consume 30 – 70% of total energy Malaysia & Iran: 12 – 15% of industrial energy used for cement manufacturing

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Energy usage of the cement manufacturing industry
ENERGY USAGE OF THE CEMENT MANUFACTURING INDUSTRY

  • Industry consume 30 – 70% of total energy

  • Malaysia & Iran: 12 – 15% of industrial energy used for cement manufacturing

  • Energy source: 75% Fossil fuel, 25% Electrical


Electrical energy usage of cement plants
ELECTRICAL ENERGY USAGE OF CEMENT PLANTS

  • Typical 110 – 120 kWh per ton of cement produced


Energy savings previous studies
ENERGY SAVINGS – PREVIOUS STUDIES

  • No comprehensive review on energy usage & savings up to 2012

  • Recent studies estimate:

    • Grinding energy can be reduced with 10 – 20% by increasing mill efficiency & schedules.

    • Waste heat from pyro processing can be used to increase efficiency with 2 - 10%.


Energy savings crushing plants
ENERGY SAVINGS – CRUSHING PLANTS

  • Why?

    • Global cement production of 3.5 Gtons (2011) translates to estimated global crusher energy consumption of 12 282 GWh.

    • 10% saving = 102 MW Daily energy efficiency

    • Very limited studies on crushing plants


Case study overview of the crushing plant
CASE STUDY - OVERVIEW OF THE CRUSHING PLANT

  • Operate according to production requirements

  • 2x 50kton Stock piles, one loaded and one reclaimed


Reducing energy cost of the crushing plant
REDUCING ENERGY COST OF THE CRUSHING PLANT

  • Determine required stock-pile levels using:

    • Present stock levels (raw meal, clinker & cement)

    • Sales forecast

  • Optimise crusher running schedule to:

    • Avoid running during Eskom peak periods

    • Maintain minimum required stock

    • Accommodate optimised maintenance schedules

  • Update proposed daily, weekly and monthly schedules on a daily basis


Results energy
RESULTS - ENERGY

  • Proposed and actual baseline for April 2012



Conclusion
CONCLUSION

  • Savings not realised due to:

    • Unexpected equipment failure

    • Unexpected sales & lack of confidence in proposed schedules

    • Negative attitude from personnel

  • Average peak time saving of 1.2 MW possible in this study

  • Global saving of 102MW possible, 50% in China

  • Address challenges to realise potential savings