Energy Efficiency with IKN Pendulum Cooler BEE, WORKSHOP on 08.11.2016 R. Madhusudan (Country Head, IKN India)
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, 08.11.2016 Potential of Power savings
Savings of Thermal = 20 kcal/kg cl 28200 Wagons of coal/year Potential of Heat savings _ cooler
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 3.66 6.06 6.55 6.32 8.5 5.5 Actual cooler losses (0 C ref) kcal/kg 109.4 137 144 130.5 145 141.7 STD cooler losses kcal/kg 87 106 125 104 119 117 Maintenance cost Rs/t 1 2.8 Not Avl 3 8.3 8 IKN Vs Others (Power)
How IKN has lowest power?
Parameters IKN OEM Plant A OEM Plant B Total Specific Total Specific Total Specific Cooler fans sp. Power as installed [kwh/t] 1076 6.46 1627 11.5 1288 7.73 Cooler drive sp. Power as installed [kwh/t] 180 1.12 227 1.6 297.32 1.78 Clinker crusher sp.power as installed [kw/t] 44 0.21 99 0.7 49 0.29 Total sp.power as installed [kwh/t] 1300 7.79 1953 13.8 1453 9.80 IKN is lower by [%] - 44% 21% lowest Installed power
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
Higher Grate Resistance
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
Fines on Top, Coarse on Bottom
Fan pressures are lower in IKN cooler IKN cooler screen shot (UTCL-Rawan#2)
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 3.66 6.06 6.55 6.32 8.5 5.5 Actual cooler losses (0 C ref) kcal/kg 109.4 137 144 130.5 145 141.7 STD cooler losses kcal/kg 87 106 125 104 119 117 Maintenance cost Rs/t 1 2.8 Not Avl 3 8.3 8 IKN Vs Others (Thermal)
IKN approach: Grate Resistance
Different Type of Gaps Plate Gap Side Gap Thrust Gap
Simple enough: Every 3 rd row movable
Ideal Heat Exchange Heat Exchange Surface Clinker Particle Cooling Air
The COANDA- Effect Section through a grate plate Row of Coanda Nozzles Grate surface with Coanda Nozzles
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?
Cooler Thermal Energy
IKN cooler screen shot (UTCL-Rawan#2)
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 3.66 6.06 6.55 6.32 8.5 5.5 Actual cooler losses (0 C ref) kcal/kg 109.4 137 144 130.5 145 141.7 STD cooler losses kcal/kg 87 106 125 104 119 117 Maintenance cost Rs/t 1 2.8 Not Avl 3 8.3 8 IKN Vs Others (Maintenance)
Grate Repairs IKN Scrap generated by other coolers
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
J.K. Lakhsmi Cement Case study 1
Hot air recirculation tapping from stack Case study: J.K. Lakshmi Cement
S. No. Parameters No recirculation After Recirculation Remarks 1 Production 4619 t/d 4619 t/d 2 Cooler loading 46.7 t/d/m 2 46.7 t/d/m 2 3 Heat in mid air 4 5 6 7 WHRS generation @ 20% boiler efficiency Recuperation efficiency normalized at 1.15 kg/kg (SA+TA) Clinker temperature Cooler fans and vent fan power 99,38 @ 390 C 110,6 kcal/kg @ 415 C 4.12 MW 4.54 MW 74.6% 74.6% 122 C 133 C 4.09 4.58 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
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