Efficient Mechanical Transport Systems

Transport systems are required to convey powdered materials such as kiln feed, kiln dust, and finished cement throughout the plant. These materials are usually transported by means of either pneumatic or mechanical conveyors. Mechanical conveyors use less power than pneumatic systems. Conversion to mechanical conveyors is cost-effective when replacement of conveyor systems is needed to increase reliability and reduce downtime.

In India, conversion to mechanical transport systems are more effectively realized in cases where transportation of limestone over longer distances is necessary.

Development Status Products
Commercial

Efficient Mechanical Transport SystemsCosts & Benefits

Parent Process: Raw Material Preparation
Energy Savings Potential

2.0 kWh/t-raw material can be saved.

Japanese flag In a Japanese plant (of 300 tpd capacit) energy used for raw material transport was reduced by up to 80% - depending on the distance. (APP, 2010. p. 75)

Indian flag In Indian context this technology is reported to provide savings in the range of 0.6-0.8 kWh/t material/100m (with typical energy consumption of around 0.41 kWh/t-100m). 

CO2 Emission Reduction Potential

Chinese flag For Chinese context, reductions are estimated to be 1.58 kg-CO2/t-raw material (assuming 0.79 kg CO2/kWh electricity)
Indian flag For Indian context, reductions are estimated to be 1.62 kg-CO2/t-raw material (assuming 0.81 kg CO2/kWh electricity)

Costs

Costs are estimated to be around $2.2 per annual ton of raw material processed. 

Indian flag In India, implementation costs are reported to be around  0.5-0.7 million, or around $20 000 per t/h capacity, depending upon the capacity. 

Efficient Mechanical Transport Systems 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: 

2

Energy Efficiency and Resource Saving Technologies in Cement Industry

 

This Cement technologies booklet was compiled by the APP Cement Task Force (CTF) through one of its activities to help its member countries share information on all available energy efficient technologies generally used in the world’s cement industry. The document offers a comprehensive compilation of commercially-available energy efficient technologies used in the cement industry.

Page Number: 

75