Kiln Shell Heat Loss Reduction

The use of better insulating refractories can reduce heat losses. Refractory choice is the function of insulating qualities of the brick and the ability to develop and maintain a coating. The coating helps to reduce heat losses and to protect the burning zone refractory bricks.  The use of improved kiln-refractories may also lead to improved reliability of the kiln and reduced downtime, reducing production costs considerably, and reducing energy needs during start-ups. Structural considerations may limit the use of new insulation materials.

Development Status Products
Commercial

Kiln Shell Heat Loss ReductionCosts & Benefits

Parent Process: Clinker Making
Energy Savings Potential

Fuel consumption is estimated be reduced by around 0.12 to 0.4 GJ/t of clinker. 

CO2 Emission Reduction Potential

 in China, switching to better refractories may reduce CO2 emissions by 11 to 38 kg per ton of clinker. 

Costs

Switching to higher quality refractories may cost around US $0.25/annual tonne clinker capacity. Estimated payback period is approximately 1 years.

Kiln Shell Heat Loss Reduction 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.

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