Energy and exergy analysis on rotary kiln process in a cement factory equipped with preheater and calcinator

The biggest share of energy consumption belongs to the industrial sector with higher energy costs. One of the most energy-consuming industries is the cement industry. Increasing demand for cement industry in the rapidly developing world as a natural result, the energy used in this sector also increases. In addition, the effective use of energy is becoming more important. For this reason, it is important to follow the energy produced and consumed in the cement sector. The cement sector in Turkey as well as in other countries of the world uses large amounts of energy. Energy efficiency has great importance in determining how much of the energy entering the total system is being used effectively. If energy efficiency is determined, more controlled and conscious energy use will be achieved. In order to save energy effectively, the phase in which the energy losses has to be determined, so alternative proposals will be presented for the recovery of these lost energies. This study focuses on making thermodynamic analysis including energy and exergy analysis of a rotary kiln in a cement factory. For this reason mass and energy balances of the cement production process were calculated. All data evaluated for per hour basis. According to the calculations, energy yield % 62, exergy yield %36 was found. In addition, energy and exergy results are used to calculate the fuel consumption rate, efficiency loss ratio and improvement potential values.