Emerging Technology Trends
Among the major emerging trends are:
- Use of inpit crushing through mobile crushers and belt conveyors has potential of reducing energy cost by 20-40% in transportation.
- Use of gyrator crushers (600-800 tph). May result in almost 30-50% saving in specific power consumption over jaw crusher.
- Roller mills with external recirculation system for RM grinding resulting in saving in power by 10% compare to systems without external circuit.
- Introduction of roller presses combined with ball mills form/cement grinding. 20-30% power saving may be possible compared to ball mills.
Use of roller presses alone with high efficiency separators. Upto 50% of specific power requirement compared to simple ball mills.
Use of roller mills for blast furnace slag grinding. Almost 10-15% power saving compared to grinding in ball mills. The power of move than 50% of that required by tube/ball mills could be saved.
Horizontal impact crusher for clinker grinding. Reduction of power consumption by over 35% compare to conventional system.
- Use of computerized mill control
- Enlargement of kiln size to 10000 tpd, kilns with low LD ratio less than 1:10 leading to reduction in radiation losses.
- Introduction of recirculating feed calciners which may result in fuel savings upto 7-8% compared to conventional calciners.
- Use of high performance refractory material resulting in saving of fuels upto 2-5%.
- Computerized refractory control system.
- Use of waste fuels like waste rubbers, municipal waste and sewage sludge etc. Upto 25% substitution of fuel possible.
- Use of artificial intelligence system for kilns which may result in fuel savings between 5-7%.
- Computerized chemical control system resulting in energy savings upto 20%.
- Introduction of PGNAA (Prompt Gamma Neutron Activation Analyses) technology for chemical control
- Installation of dense phase conveying system
- Low temperature clinker which has potential for saving of heat consumption upto 30% and power consumption upto 15%.
- Electron beam processing technologies for cement.
- Use of lime stone extenders.
Technology Evaluation
The viability of each of the energy conservation technology option has been discussed in the report. The import highlights are summarized in table below. The most important criteria for implementing energy conservation technologies is the pay back period. Any technology having more than 2 year pay back period does not seem to interest the plant managements.
| Measure | Actual saving potential | Viability consideration | |
| Power | Thermal | ||
| House keeping measures | 11.3% | 9.2% | Very viable For preventive & condition monitoring devises high investment needed. |
| Process Optimization | 6% | 18% | Quite Viable High investment required for raw mix proportioning equipments & material feeding system. |
| PPC/PSC Alternative Fuels | 4% | 5.5% | Saving potential may be very high but for additives/fuel availability problems. |
| Technology Upgradation | 19% . | 8.5% | Needs very high investment. Often viable only if going for expansions |
Technology Demand Potential/Outlook of Energy Saving
Based on detailed consideration of various factors it is assessed that following savings are possible in energy consumption by 1995.
EXPECTED ENERGY SAVINGS - 1995
| Measure | % penetration exptd. | Power Kwh/t |
Fuel Kcal/kg |
Exptd. Invest. Rs.cr. |
| House keeping & Operational control | 40 | 5.6 | 32.5 | 60 |
| Process Optimization | 40 | 2.96 | 63.5 | 120 |
| PPC/PSC Alternative Fuels | 32 | 1.65 | 15.35 | 500 |
| Technology Upgradation | 25 | 5.86 | 18.35 | 500 |
| Total | 137 | 16.02 | 129.90 | 780 |
A total saving of 13-15% (valued at Rs. 286 crores) is possible in power and thermal energy respectively by 1995 over the current average consumption in existing capacity. The envisaged investment is around Rs. 780 crores mostly in technology related areas. The expected investment in energy saving equipments for new projects and substantial expansions may be Rs. 1000 crores over the next 5 years. Back
