New Cement Plants including Grinding Units

Introduction of New Technologies in Cement Industry

Dry, semi-dry, semi-wet and wet processes are the four main process routes that are used for the production of cement. Dry processes are considerably more energy efficient but the choice of technology mainly depends on the state of raw materials.

Due to the availability of dry materials, a great share of cement production is done through dry processes. Dry processes are also the choice for new plants or for those looking for expansions or upgrades.

Clinker is the main component of cement and produced by sintering limestone and few additives like clay etc. Good amount of Electricity is needed for crushing and grinding raw materials and the finished products. Good amount of Heat Energy is required for converting Lime stone to Clinker.

With the new cement technologies, considerable amount of Electrical & Heat Energy is saved today.

Waste Heat from Cement Kilns is usually used for drying of raw materials such as Limestone, Coal, Fly ash, Slag. Depending upon the, Preheater configuration, humidity of Raw material and the Cooler technology, additional Waste heat is available from the Preheater exit gases and Cooler exhaust gases. This Waste Heat can be used for electricity generation. Power can be produced by using Steam Rankine cycle, ORC, etc. About 30% of the Electricity requirement of the cement plant can be met through power produced from the Waste Heat Recovery Plant.

With the continued contraction of Fossil fuels like Oil/Coal availability to the Cement Industry over the last couple of years and no signs of its improvement in the near future, the Cement Industry has been moving towards enhanced usage of alternate fuels in the cement manufacturing and in the process bringing down further the emissions level from the Plants. Conventional fuels like Coal & Lignite are commonly used fuels in cement making that have high specific CO2 emissions. They are expensive also and have limited availability (exhaustible source). Substituting with other fuels like Agro waste, Tyres, Plastics etc. and with their proper combustion technique, these alternate fuels can meet the energy demands and is an effective way of reducing CO2 emissions and cost of production of Clinker.