Conversion of Long Dry Kilns to Preheater/Precalciner Kilns

Whenever economically feasible, considerable energy savings can be achieved by uprading a long dry kiln to the current state of the art multi-stage preheater/precalciner kiln.

Indian flag In India, majority of the long kilns are already equiped with preheater/precalciner systems .  

Development Status Products
Commercial
Cement, clinker

Conversion of Long Dry Kilns to Preheater/Precalciner KilnsCosts & Benefits

Parent Process: Clinker Making
Energy Savings Potential

Up to 1.4 GJ/t-clinker can be saved.

CO2 Emission Reduction Potential

For every ton of clinker, following amounts of CO2 reductions are estimated: 

Chinese Flag

 132.4 kg in Chinese context;

Indian flag 138.5 kg in Indian context;

US flag 108.8 kg in the United States.

Costs

Upgrading costs are reported to be between US $8.6 to $29 per annual ton of clinker capacity.  

Conversion of Long Dry Kilns to Preheater/Precalciner KilnsSchematic

Conversion of Long Dry Kilns to Preheater/Precalciner Kilns 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: 

11

Development of State of the Art Techniques in Cement Manufacturing: Trying to Look Ahead

The report represents the independent research efforts of the European Cement Research Academy (ECRA) to identify, describe and evaluate technologies which may contribute to increase energy efficiency and to reduce greenhouse gas emissions from global cement production today as well as in the medium and long-term future. 

Page Number: 

25-26