Addition of Pre-Calcination to Kilns with Preheaters

An existing preheater kiln may be converted to a multi-stage preheater/precalciner kiln by adding a precalciner and, when possible an extra preheater stage. The addition of a precalciner will generally increase the capacity of the plant, while lowering the specific fuel consumption and reducing thermal NOx emissions (due to lower combustion temperatures in the precalciner). Fuel savings will depend strongly on the efficiency of the existing kiln and on the new process parameters (e.g. degree of precalcination, cooler efficiency). Major technology providers commonly provide offers that enable upgrades by using as much of the existing infrastructure as possible.

Development Status Products
Commercial
clinker, Cement

Addition of Pre-Calcination to Kilns with PreheatersCosts & Benefits

Parent Process: Clinker Making
Energy Savings Potential

In an Italian plant, the conversion reduced specific fuel consumption from 3.6 to 3.1-3.2 GJ/t clinker, resulting in savings of 11 to 14%, and enabled a capacity increase of 80 to 100% (from 1100 tpd to 2000 to 2200 tpd). 

CO2 Emission Reduction Potential

Chinese flag For Chinese context, this option holds the potential to reduce CO2 emissions by 38 to 47 kg for every ton of clinker produced. 

Costs

Investments in the range of US $9.4-28 per annual ton clinker may be required. Payback times are usually less than 5 years.  

Indian flag In India, the payback times are reported to be less than 3 years. 

Parent Process:
Energy Savings Potential
CO2 Emission Reduction Potential

N/A

Costs

Addition of Pre-Calcination to Kilns with Preheaters Publications

Energy Efficiency Improvement Opportunities for the Cement Industry

The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for Cement Making, discusses energy efficiency practices and technologies that can be implemented in cement manufacturing plants. This ENERGY STAR guide provides current real world examples of cement plants saving energy and reducing cost and carbon dioxide emissions.

Page Number: 

9-10