Energy Consumption of Dewan Cement

Total Cement Production=Daily x 365

= 8000 X 365
= 2920000tonnes/Annum
Annual Energy Consumption (Electrical) = Daily Energy Consumption x 365
= 31Mw x 365
= 11315Mw
Annual Energy Consumption (Fuel/Coal) = Daily Energy Consumption x 365
= 40000000Mjoule x 365
= 1.45 x 10^10Mjoule
Energy Consumption per Bag Cement = 5.5kWh

Energy Consumption of Motors:

Type of motor Annual consumption of energy

in KWh

Standards Motor 870

Energy Efficient Motor 804.59

Here we use motors of 1.1kW,4kW and 7.5Kw respectively

Energy Consumption of Kiln Area:

Electrical Energy Consumption = 22kWh/tonne

Fuel Energy Input(Coal) = 20Mjoule/tonne
Motors Energy Saving:
Here we compare standard Motor with energy efficient Motor(Using Variable Speed Drives)

Motor 1.1kw 4kw 7.5kw

Rating

% ƞ at full EEM 84 87 89.5

load
STM 76 84 87

% ƞ at EEM 84 87 89.5
half load
STM 74 83 87

P.F at full EEM 0.75 0.82 0.91

load
STM 0.70 0.78 0.84

Table shows the comparison of EEM and STM for three different ratings. Change in efficiency
over a range of 20% to 150% load for 10hp motor.

Design of EEM to Reduce the Losses:

Design criteria for EEM Involves addition of more active magnetic and conducting material,
optimum design of slots, air gaps and windings so as to achieve the maximum efficiency .Points
considered while designing the EEM are:

Core losses:

Core losses can be reduced by using high grade silicon steels, the silicon content is up to 4%.

Copper Losses:

Stator copper losses are reduced by increasing the copper section of wire which is to be wound on
the core.
Annual Energy Saving due to EEM:
Annul energy saving in Rs

100 100
= kW x P x H [ 𝐸2 − ]
𝐸1

Saving in demand charges,

100 100
=kW x [𝐸2𝑥𝑃𝑓2 − ] x Rs/kVA
𝐸1𝑥𝑃𝑓1

Where,

Pf1, Pf2=power factor of EEM and STM

E1 and E2=Efficiencies of EEM and STM

KW=Motor rating

P= Rate of energy Rs/kwh

Comparison of energy saved:

Rating STM EEM

11Kw 11kW

Opt Hours per year 3000 3000

Energy cost 12.5Rs/kWH 12.5Rs/kWH

Motor price Rs43000 Rs51000

Efficiency at full load 85.5% 89.5%

P.F 0.80 0.83

 100 100
Annual energy saving = 11 x 12.5 x 3000 [85.5 − ]
89.5

= 11x 12.5x 3000(1.169-1.1173)

= Rs 21326.25

Date Kiln kWh kWh/tone kWh/tone Difference

Production consumed Consumed Target

1/8/2016 4,248 164,716 38.8 32 28768.55796

2/8/2016 7,063 237,553 33.6 32 -11539.9746

3/8/2016 7,116 239,250 33.6 32 -11540.98304

4/8/2016 6,891 233,242 33.8 32 -12717.14596

5/8/2016 6,916 228,379 33.0 32 -7070.567166

6/8/2016 6,951 230,445 33.2 32 -8013.181096

7/8/2016 7,100 233,796 32.9 32 -6596.08213

8/8/2016 7,128 240,314 33.7 32 -12202.39771

9/8/2016 6,987 231,741 33.2 32 -8164.921333

10/8/2016 6,985 229,919 32.9 32 -6385.697548

11/8/2016 6566 29,239 33.0 32 -29238.77646

12/8/2016 6,968 230,394 33.1 32 -7432.270904

13/8/2016 7,134 238,572 33.4 32 -10270.11574

14/8/2016 7,070 and Power

Daily Production 235,964 33.4of Kiln Area
Consumption 32 (Plant Data)
-9717.200091

15/8/2016 5.848 205,518 35.1 32 -18391.84717

16/8/2016 6,094 212,036 34.8 32 -17026.47696

17/8/2016 6,094 212,036 34.8 32 -17026.47696

18/8/2016 7,126 233,540 32.2 32 -5492.65951

19/8/2016 7,152 242,258 33.9 32 -13384.03677

20/8/2016 7,115 237,593 33.4 32 -9905.563966

21/8/2016 7,134 240,906 33.8 32 -12604.34421

22/8/2016 7,152 236,972 33.1 32 -8118.520243

23/8/2016 7,133 236,701 33.2 32 -8440.898717

24/8/2016 7,103 235,660 33.2 32 -8375.263501

25/8/2016 6,094 212,036 34.8 32 -17026.47696

26/8/2016 7,148 235,308 32.9 32 -6581.900427

27/8/2016 7,146 222,841 31.2 32 5821.477173

28/8/2016 7,152 230,034 32.2 32 -1160.080789

29/8/2016 5,888 203,072 34.5 32 -14653.01906

30/8/2016 7,100 224,224 31.6 32 2975.52174

31/8/2016 7,105 230,008 32.4 32 -2659.584343

Total 204,142 6,854,264 33.5 31.2 485,021

Energy Saving in Kiln Area:

Major Reason of excessive energy consumption are due to the process and can be controlled by
minimizing the loop holes,Waste heat recovery up to 31.2Kwh/tonne i.e. 0.8kWh/tonne ,484.021
units per month Rs 2119920/- can be saved annualy.

Total Energy Saved of both Kiln and Motors:

Total = Kiln energy saved + Motors Saved Energy

2119920 + 21326.25=2141246.26
Total =2141246.26

Conclusion:

Hence by waste heat recovery of kiln and by using energy efficient motors we can save a lot of
energy approximately Rs2141246.26/Annum. There are other many sources of saving energy.