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Thermodynamic Performance Improvement of Cement Production Processes: The Case of Mbeya Cement Rotary Kiln System
MUST JOURNAL OF RESEARCH AND DEVELOPMENT,
Vol. 1 No. 6 (2021): Thermodynamic Performance Improvement of Cement Production Processes: The Case of Mbeya Cement Rotary Kiln System
Abstract
Physio-chemical and thermo-chemical reactions involved in cement kilns are still not well understood because of their complexity. The reactions are the source of the internal irreversibility and have a decisive influence on energy consumption, environmental degradation and the cost of cement production. The energy cost represents 40 % to 60% of production costs. Additionally, it contributes to around 5% to 8% of all man-made CO2 emissions. The study investigated thermodynamic performance of Mbeya Cement Company Rotary Kiln System relative to sustainable energy use. The study employed Computer-Aided exergy-based method for performance evaluation of the components and processes. The steady state model in Aspen Plus was successfully developed, validated using real plant data and used to predict the performance of individual components, sub-systems including processes. The method simplified the work of analyses, giving detailed insight of real processes, source and type of real imperfections, its magnitudes and how imperfections can be minimized. Major findings indicated that the Rotary Kiln Sub-systems and the overall kiln system have poor exegetic performance, suggesting that potential for process and equipment performance improvement exists. The highest source of irreversibility encompassed chemical reactions, especially combustion, calcination and clinker burning processes. The proposed improvement measures were implemented and results suggest that the RKS thermal and environmental performance could be significantly improved.
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