A comprehensive study on energy and exergy analyses for an industrial-scale pyro-processing system in cement plant

• Published in: Cleaner Energy Systems 2022-12, Vol.3, p.100030, Article 100030
• Main Author: Ghalandari, Vahab
• Format: Article
• Language: English
• Subjects: Cement plant; Energy and exergy analyses; Grate cooler; Kiln; Pyro-processing system; Thermodynamic assessment
• ISSN: 2772-7831; 2772-7831
• DOI: 10.1016/j.cles.2022.100030

•The energy analysis indicated the energy efficiency of the pyro-processing system is 82.5%.•The exergy analysis showed the exergy efficiency of the pyro-processing system is 64%.•Results reveal that the fuel accounts for the majority of the input energy and exergy.•By increasing the feed rate, the energy and exergy efficiencies decrease.•When the cooling air temperature increases, the energy and exergy efficiencies improve. The Pyro-processing system is the most important part of a cement plant, which is used to produce clinker. The energy and exergy evaluations for an industrial-scale Pyro-processing system (PS) were carried out in this study. The first and second law efficiencies of the PS were calculated to be 82.5% and 64%. The electrical energy and thermal energy consumption of the PS was calculated to be 0.0308 kWh/kg and 3,127.1 kJ/kg of clinker. Experimentally, the impacts of operating factors such as feed rate, cooling air flow rate, air temperature, and grate speed on the performance of the PS were also investigated. The effects of these parameters on the first and second law efficiencies of the PS were investigated. Finally, the electrical and thermal energy consumption of the PS compared with some domestic pyro-processing systems as well as the international best available technology (IBAT). According to the findings, the PS uses about 37% and 26.8% more electrical energy, as well as around 10% and 1.8% more thermal energy, to generate clinker than the IBAT system and the domestic best PS (DBPS). [Display omitted]