B1 POWER B1.1 Specific Power Consumption Power consumption rose significantly with the introduction of dry process kilns and has continued to rise with conversion to coal, increased fineness of cement, and with the demands of environmental protection. Typically, power consumption is presently 110-120kWh/t cement which may be broken down: Quarrying & preblend ekwhit 5% Raw milling 28 24 Blending 7 6 Burning & cooling 25 22 Finish milling 44 38 Conveying, packing & loading G 5 Total 116kWhit (Ellerbrock & Mathiak; 2KG; 11/1994, pg E296) B1.2 Power Conservation Conservation of electrical power should first address such areas as: Blending (if turbulent) ~ convert to CF Pneumatic conveying = convert to mechanical Milling install pregrinding ID fans - eliminate air inleakage, use high efficiency impellers. Cooler fans (with outlet dampers) ~ convert to inlet vane or variable speed Plant air compressors (if central) minimise system loss and convert to distributed system Plant lighting ~ basic lighting can be augmented by additional lighting as required with timed shut-off. For most large fan applications, frequency controlled variable speed dri- ves offer significant power savings over damper or inlet vane controlled fixed speed ac drives albeit at higher capital cost. A technical and cost comparison is made by Bosche (WC; 6/1993, pg 2). Cement Plant Operations Handbook * 217Energy efficiency should obviously be built in to original plant design. For existing plants, most remedies involve significant capital cost which must be justified by anticipated power savings. (Shenoy & Chacko; ICR; 10/1997, pg 60) B1.3 Three-Phase Power kVA = ¥3xAxV/ 1000 kW = V3xAxVx0/ 1000 Power factor (a) is a measure of inefficiency and is defined as the cosine of the phase angle between current (A) and voltage (V). Actual voltages vary with country and with plant age and design. Typically, incoming power may be at 60-115kV transformed to 4160- 6300V for large motors (>1000kW), then to 380-460V (3-phase) for inter- mediate equipment (3-1000kW), and 110-220V (1-phase) for small equipment and lighting. B1.4 Motor Power Output Shaft kW = V3xAxVxoxE/1000 where E = motor efficiency B1.5 Peak Power Tariffs These tariffs allow significant cost savings in exchange for shutting down all or some equipment during designated peak demand periods, This requires the availability of excess capacity (eg to allow cement mills to catch up), production and maintenance scheduling and the assiduous attention of operators. Similarly, there may be a penalty for operating at a power factor below the utility’s stated minimum (0.8-0.95). A low power factor can be corrected using large synchronous (mill) motors or automatic capacitor control supplying reactive power to each individual load. Load management is discussed by Foster (ICR; 1/1996, pg 44). 218 © Cement Plant Operations HandbookB1.6 Power Generation Major fossil-fueled power generators typically operate at 35% efficien- cy. Thus 1 tonne of coal with 6000kcal/kg net heat value will produce approximately 2.5MW of power. Note that coal burning produces on average 70% fly ash and 30% bottom ash. B1.7 Co-generation The generation of electric power from kiln waste heat is not usually considered viable. Heat not required for drying raw materials is better conserved using 5- or 6-stage preheaters and high efficiency clinker coolers. Certain exceptions may apply, however, when power tariffs are particularly high or where co-generation is subsidised or mandatory (Huckauf & Sankol; ZKG; 3/2000, pg 146: ICR; 9/2000, pg 92). eee Cement Plant Operations Handbook * 219