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Best Practices in Energy Efficiency
J.K. Cement Works,
Nimbahera
From:-Team J.K. Nimbahera
CFD Study and Implementation in Preheater cyclone ducting
Computational fluid
dynamics (CFD) modelling
To reduce pressure drop
across cyclones & inlet ducting
Analysing the results and
locating the problematic areas
in the existing design
Iteratively modify the design so
as to remove the problematic
areas
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CFD Study and Implementation in Preheater cyclone ducting
Conclusion for PH-III system
By small modification in 4th stage cyclone inlet duct, the reduction in
pressure drop by 45mm WC in the system
To get the exact flow in the 4th cyclone to capture the centre core (vortex)
there is need to increase the dip tube height to 2500 mm.
Conclusion for PH-IV system For the trail modification by increasing the width of the inlet of 4th stage
cyclone at the riser duct, pressure drop reduction by 20 mmWC , which is
optimum without affecting the efficiency of the cyclones
KILN-3: Total Annual Saving is 30.6 Lakh kWh (Approx..)
KILN-2: Total Annual Saving is 6.4 Lakh kWh (Approx..)
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PC 4th Cyclone inlet Before Modification
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4th cyclone inlet after modification
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Kiln-3 String, 4th cyclone inlet After Modification
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PH-2, 3rd cyclone inlet duct after modification.
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PH-2 4th cyclone inlet duct
PREHEATER NO.-3
PRESSURE DROP (BEFORE)
PRESSURE DROP (AFTER)
CYCLONE (mmWG) (mmWG)
I 78 60
II 80 145
III 175 155
IV 225 215
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PREHEATER NO.-4
PRESSURE DROP (BEFORE)
PRESSURE DROP (AFTER)
CYCLONE (mmWG) (mmWG)
I 20 70
II 115 90
III 118 110
IV 102 120
V 215 125
STATUS OF PRESSURE DROP BEFORE AND AFTER MODIFICATIONS
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PREHEATER NO.-2
PRESSURE DROP (BEFORE)
PRESSURE DROP (AFTER)
CYCLONE (mmWG) (mmWG)
I 55 79
II 185 85
III 70 98
IV 205 179
STATUS OF PRESSURE DROP BEFORE AND AFTER MODIFICATIONS
Cost reduction By using Carbon black 2014-15
11
Quantity of Carbon
Black/Charcoal Dust
GCV Indian
Coal Avg. GCV
Equivalent Quantity of Indian
Coal
Quantity of Indian Coal Saved
MT kcal/kg kcal/kg MT MT
430.98 5898.76 4948.17 513.7 82.80
We are planning to consume 30-40 MT/Day carbon black in 2015-16:-
Power reduction in compressors
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S.No. Section Existing compressor Compressor Replaced
1. CM 2 in silo 2 & 4.
Compressor Z2X11 (52
M3/min, 340 kw)
Compressor Z1X04 (41
M3/min, 225 Kw )
2. CM 2 in Silo 6
Compressor Z2X17 (70
M3/min, 615 Kw)
Compressor Z2X11 (52
M3/min, 340 kw )
3. Packing dust filter Compressor P1X06 (19
M3/min, 160 kw )
Compressor Z5X09 (10
M3/min, 55 Kw)
4. When CM-3,CM-4
and packer-1,2& 3
is only running
2 compressors (10
M3/min,55 kw)
1 compressor (10 M3/min, 55
kw) for dust filters in both
cement mill and packing
plant
Power reduction in Return water tank due to installation of level sensor & automation
• Total saving per year ( assume 300 days)
= 318.52 X 300
=95556 kWh (Approx.)
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S.No. Section Running KW
Before KWH( Unit)/ day
After automation KWH( Unit)/ day
1. V3KO1 (25 HP) 16 225.6 304
2. V3KO2 (25 HP) 15 276.5 292.5
3. V3KO3 ( 30 HP) 19.91 421.67 384.263
4. V2K01 (25 HP) 15.8 79 37.92
5. V2K03 (25 HP) 16 376 41.6
Total KWH( Unit)/ day 1378.80 1060.80
Modification of cooler fan
Modification of cooler fan K17 inlet (Narrow cylindrical to bell mouth)
Total Saving is 1.6 Lakh kWh (Reduction in Fan Load by 20 kW)
Replacement of (50 No's & 250 W each ) HPSV lights with 90 watt LED lights Total
Saving is 0.31 Lakh kWh
Replacement of (25 Nos & 125 W each ) HPMV lights with 70 watt Metal Helide
lights Total Saving is 0.054 Lakh kWh
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Saving with replacement of lights
15 Other Savings in 2014-15
Project/Program Investment Electricity Saving,
Lakh, kWh)
Coal Saving, in
MT
Implementation of CFD suggestion in Preheater No-2 8 6.4 220
Use of Alternative fuel (Carbon Black & Char Dust) in Kiln 0 82.8
Modification in CF Silo for bin and Silo aeration 1.93
Modification of cooler fan K17 inlet (Narrow cylindrical to bell mouth)
0.25 1.6
Installation of VFD in GCT-1 water pump 2.5 1 Installation of VFD in GCT-2 water pump 2.6 0.96 Installation of VFD in GCT-3 water pump 3.9 1.2 Installation of PID in Booster fan-1 0.25 0.96 Installation of PID in Booster fan-2 0.25 1.2 Installation of PID in Booster fan-4 0.25 3.6 Insttalled of SPRS in Raw Mill-4 fan 100 12.68 Insttalled of SPRS in SG FAN-4 60 15.84 Replacement of (50 Nos & 250 W each ) HPSV lights with 90 watt LED lights
0.32
Replacement of (25 Nos & 125 W each ) HPMV lights with 70 watt Metal Helide lights
0.05
Thanks For further information, please contact:
Mr. Narpat Anjana, Astt Manager (Process), J K Cement, Nimbahera Plant
narpat.anjana@jkcement.com
Mr. M P Malav , Astt Manager (Process), J K Cement, Nimbahera Plant mp.malav@jkcement.com
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