12.00 Thomas Marx, ABB

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© ABB Group March 14, 2011 | Slide 1

Comprehensive Energy Optimizationfor Cement Plants

Thomas Marx, CPM @ Minerals, 07-March-2011


Comprehensive Energy OptimizationDefine the Target

Cement industry contributes for apprx. 8% of the worlds CO2 emission

50% are related to the Calcination process

40% are related to Fuel used in the process

10% are related to Electrical energy usage

50% of the used energy can be optimized and reduced by utilizing modern techniques

Picture by ElectroPhysics

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Comprehensive Energy OptimizationObvious Areas of Saving

Thermal Energy

Electrical EnergyRaw Mill Coal Mill Cement Mill

Pre-Calciner, Kiln, Cooler


Comprehensive Energy Optimization Expert Optimizer – Advanced Process Optimization

Expert Optimizer helps in all processes which are dependent on a number of various control parameters

Expert Optimizer supports the operators like an autopilot to improve the process in terms of

Minimizing process variations

Reduction of energy consumption

Increasing production

Expert Optimizer helps the process to run in a more stable condition independent of the human interface

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Comprehensive Energy Optimization Expert Optimizer – Model Predictive Control in Action

Evaluate position (=measurement) and estimate system state

Predict the future moves (mathematical algorithm, optimization)

Implement the first move (new actuator set-point)

Restart after the opponents move (process reaction)

Constraints are considered (allowed moves)

A cost function is considered (e.g. minimize losses of figures)


Comprehensive Energy Optimization Expert Optimizer – Advanced Process Optimization

Process Control and Sensors

MeasurementsActuators Setpoints

Expert Optimizer Engine

Kilns

Blending

Calciners

Grinding

Economic Process Optimization

Thermal Energy

Plant StatusPlant Schedule

Electrical Energy

Scheduling

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SecondaryPrimary CommissioningAudit

Comprehensive Energy Optimization Expert Optimizer – Stabilize then Optimize

Prod

uctio

n R

ate

Manual Operator Setpoint

Optimized Setpoint

Benefitdue to

Optimization

Time

Process Capability

Optimize

Stabilize


Comprehensive Energy Optimization Expert Optimizer – Thermal Energy

Pre-Calciner / Kiln / Cooler

Reduced energy consumption 2% to 3%

Increased Output 2% to 5%

Return on investment 3 to 4 Month

Side effects:

Better and more constant Clinker quality

Maximum usage of alternative Fuels Global Fuels Conference Award for “most innovative technology for energy savings”

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Comprehensive Energy Optimization Expert Optimizer – Electrical Energy

Material Grinding

Reduced Specific Power by 3 to 5%

Increased Output by 3 to 5%

Return on Investment 5 to 8 Month

Side effects:

Reduced Quality Variability

Reduced Number of Mill Stops

Less wear due to more constant operation


Comprehensive Energy OptimizationNon Obvious Areas of Saving

Thermal Energy



HeatRecovery

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Thermal Energy



HeatRecovery


Comprehensive Energy OptimizationTypical waste heat sources in a cement plant

Heat source 1clinker cooler

air (CC)

Heat source 2Pre-heater

gas flow (PH)

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The ABB Heat Recovery System operates with the Organic Rankine Cycle (ORC) to use low temperature (from 170°C) waste heat sources for a profitable power generation

Comprehensive Energy OptimizationABB Heat Recovery System


Comprehensive Energy Optimization Advantages of the ORC technology

Constant high turbine efficiency

Constant turbine power due to variable turbine geometry

No water cooling cycle: air condenser

Fast start up times, also from cold

Automatic operation without personal

Low operation and maintenance cost

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Comprehensive Energy OptimizationElectric power generation out of waste heat

Electricity neededfor 1t cement

Cement productionmedium plant

Electricity con-sumption yearly

Electricity costyearly

~ 105 kWh/t 2’200 t/day~ 690’000 t/year

72’000 MWh/year 124 US$/MWh =9 MUS$/year

Heat Recovery & Power generation module

Electricity production

Electricity production yearly

Electricity earnings yearly

1.8 MWel 7’200 MWh/year 124 US$/MWh =0.9 MUS$/year

Potential electricity cost saving yearly = ~ 10%


Comprehensive Energy Optimization Heat Recovery – Economical Justification

Cost approx. 3 to 6 Million US$ per Mega Watt

Variable with process conditions

Bigger installations tend to get more cost efficient

Return on investment 6 to 10 years

Dependent on size of the project

Dependent on heat sources available

Dependent on local market electricity cost

No CO2 credits included

No governmental subventions considered

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Thermal Energy



HeatRecovery

StockpileBlending


Thermal Energy

Electrical Energy

Coal Mill Cement Mill


StockpileBlending

HeatRecovery

Raw Mill

Comprehensive Energy OptimizationQuarry & Stockpile Management reduces Energy Usage

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What is needed?

Good overview of material available in the quarry / quarries

On-line Analysis of all material after crusher

Controled material pick up in the quarry / quarries

Comprehensive Energy OptimizationQuarry & Stockpile Management reduces Energy Usage

Limestone Stockpile or Blended Stockpile

Build Stockpile to a given LSF Set-point


Comprehensive Energy Optimization1st Step – Quarry Management


Define quarry sections

Make your daily blow

Get one truck of material from each section after the blow

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Use fast on-line analysis to classify the materials



Update the material data of the sections in a blending software

Section CaO SiO2 Al2O3 Fe2O3

47.05 10.59 1.42 0.88A

46.28 10.55 1.15 0.92B

51.00 5.00 0.86 0.51C



Quarry Zones

Material analysis per zone

Detail of Material analysis per selected zone

Zone activation Optional fixed set-point

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Update the material data of the sections in a blending software


No running average, real time one minute analysis's are reported

Capable of analyzing single truck deliveries

No radioactive material used

Light based System

Using ABB‘s Near Infra Red SolbasTM Technology

Comprehensive Energy Optimization1st Step – Quarry Management – SpectraFlow


SpectraFlow analyzers have a fast data acquisition of 100 ms

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Comprehensive Energy Optimization2nd Step – Stockpile Building

Based on the Targets given material demands from the different quarry sections are calculated

Targets

Active Quarry Zones


Comprehensive Energy Optimization2nd Step – Stockpile Building – Truck Management

Trucks are routed to the different sections

Truck Routing

Tonnage delivered for each truck is reported

Quarry Zones

Trucks available per Quarry zone

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Comprehensive Energy Optimization2nd Step – Stockpile Building – Blending Result

Total material is analysed, Results reported on a minute basis

Stockpile composition is updated and new demand calculated

SpectraFlow Analyzer


Comprehensive Energy Optimization2nd Step – Stockpile Building – Analysis Comparison

LSF standard deviation less than 2.5 on pile reclaiming

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Comprehensive Energy OptimizationQuarry & Stockpile Management – Energy Saving

Customers are reporting

Up to 3% less electrical energy consumption due to smoother Raw-Mill operation and less time in the homogenization silos

Minimum 5% thermal energy saving due to smoother kiln operation

3 to 5% savings on Truck Fuel due to better routing and less waiting times

Side effects:

3% increase in production

Less additives used


Comprehensive Energy OptimizationAnalyzing Your Demands

Thermal Energy



HeatRecovery

StockpileBlending

ABB‘s Offer

Analyze each area of your production process

Analyze your assets and utilization

Find the bottlenecks

Deliver solutions for

Process optimization

Energy optimization

Asset modernization and optimization

We call it FingerPrint

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Thank you for your attention

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12.00 Thomas Marx, ABB

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