Thermal Energy Audit in Pyro-Processing System of Messebo Cement Factory (Line-2)

Abstract

Cement factory is energy intensive industry that needs a great attention to optimize its energy usage. Messebo Cement Factory utilizes imported raw coal and domestic electric energy. Therefore, reducing energy dissipation enables the factory as well as the country saving of foreign currency and keeps the environment from damage. The aim of this thesis work is to identify the major energy loss areas in Messebo Cement Factory for the second cement line and to present suitable modification to enhance energy utilization performance of the factory. This thesis first systematically identifies the energy losses areas. This is achieved by conducting thermal energy bill analysis and determining thermal energy consumption of corresponding units. In the second stage, quantified thermal energy loss of the units is undertaken and finally to look for the energy conservation opportunities. The result of assessment shows that the Factory has an enormous opportunity for improvement without jeopardizing its product quality and reputation. Thermal energy losses take the lion share for poor energy performance of the factory. The preheater, pre-calciner, kiln and grate cooler are among extremely inefficient devices that needs immediate modification. A thorough investigation of MCF’s energy audit reveals that there is an opportunity of saving of around 67 million birr per annum by replacement of the raw coal by sesame husk partially, adapting heat recovery mechanism and process control and optimization.