Energy Efficiency with IKN Pendulum Cooler
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- Britney Newman
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1 Energy Efficiency with IKN Pendulum Cooler BEE, WORKSHOP on R. Madhusudan (Country Head, IKN India)
2 Savings of power consumption = 1.5 kwh/t Savings in power of India if all clinker is cooled by IKN = 66 MW (equivalent to 5*66 = 330 MW Generation at Grid) IKN savings can supply 8 months of power to Agra BEE, Delhi, Potential of Power savings
3 Savings of Thermal = 20 kcal/kg cl Wagons of coal/year Potential of Heat savings _ cooler
4 Description Units IKN OEM-A OEM-B OEM-C Plant name - UTCL- Rawan#2 Plant A Plant B Plant C Plant D Plant E- Old cooler Power kwh/t Actual cooler losses (0 C ref) kcal/kg STD cooler losses kcal/kg Maintenance cost Rs/t Not Avl IKN Vs Others (Power)
5 How IKN has lowest power?
6 Parameters IKN OEM Plant A OEM Plant B Total Specific Total Specific Total Specific Cooler fans sp. Power as installed [kwh/t] Cooler drive sp. Power as installed [kwh/t] Clinker crusher sp.power as installed [kw/t] Total sp.power as installed [kwh/t] IKN is lower by [%] - 44% 21% lowest Installed power
7 Clinker bed transport Hardface wear protection Stroke kw 2 Cooler with dead layer IKN Cooler Effective Layer kw IKN 850 mm 600 mm kw 1 Dead Layer Fan capacity kw1 + kw2 = 7 kw (Installed) Fan cap. kw IKN = 5 kw (NB: kw 2 = kw IKN) Bed aeration kw requirement
8 Higher Grate Resistance
9 Segregated layer of clinker will have easy passage of air and hence low pressure. Low pressure drop for the similar cooling air volume Even Aeration Lifts up Fines
10 Fines on Top, Coarse on Bottom
11 Fan pressures are lower in IKN cooler IKN cooler screen shot (UTCL-Rawan#2)
12 Description Units IKN Group-A Group-B Group-C Plant name - UTCL- Rawan#2 Damoh UTCL- NCJW(Nar mada) Wonder Kotputli UTCL-Old RC#3 cooler Power kwh/t Actual cooler losses (0 C ref) kcal/kg STD cooler losses kcal/kg Maintenance cost Rs/t Not Avl IKN Vs Others (Thermal)
13 IKN approach: Grate Resistance
14 Different Type of Gaps Plate Gap Side Gap Thrust Gap
15 Simple enough: Every 3 rd row movable
16 Ideal Heat Exchange Heat Exchange Surface Clinker Particle Cooling Air
17 The COANDA- Effect Section through a grate plate Row of Coanda Nozzles Grate surface with Coanda Nozzles
18 Precision Grate technology Superior metallurgy for the clinker contact surface Liner pendulum support (LPS)-avoid sinking of mobile frame Reasons for Low cooler heat losses?
19 Cooler Thermal Energy
20 IKN cooler screen shot (UTCL-Rawan#2)
21 Description Units IKN Group-A Group-B Group-C Plant name - UTCL- Rawan#2 Plant A Plant B Plant C Plant D Plant E- Old cooler Power kwh/t Actual cooler losses (0 C ref) kcal/kg STD cooler losses kcal/kg Maintenance cost Rs/t Not Avl IKN Vs Others (Maintenance)
22 Grate Repairs IKN Scrap generated by other coolers
23 Fresh air to kiln hood Fresh air to mid air Fresh air to vent air Fresh air Fresh air To stack Dedusting WHRS No Mid air Filter Dedusting 1400 C X Vent air 1400 C 65 C 78 C a) Standard cooler b) Recirculation cooler Hot air recirculation concept
24 J.K. Lakhsmi Cement Case study 1
25 Hot air recirculation tapping from stack Case study: J.K. Lakshmi Cement
26 S. No. Parameters No recirculation After Recirculation Remarks 1 Production 4619 t/d 4619 t/d 2 Cooler loading 46.7 t/d/m t/d/m 2 3 Heat in mid air WHRS 20% boiler efficiency Recuperation efficiency normalized at 1.15 kg/kg (SA+TA) Clinker temperature Cooler fans and vent fan power 390 C 110,6 415 C 4.12 MW 4.54 MW 74.6% 74.6% 122 C 133 C Benefits of Recirculation No change in production ~10% more heat for boiler ~10% more power generated No reduction in the efficiency 11 C increase due to increased cooling air temperature Increased by 0.49 kwh/t due to increased cooling air temperature and a longer duct from the stack
27 Make Indian cement plant world class Green Let US make Indian cement plant green Let US save our resource for our children
28 cool down Thanks for your attention!
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