Replacing Vertical Shaft Kilns

For vertical shaft kilns (VSK), which are commonly used in China, switching over to a new and more efficient suspension preheater/precalciner kiln system offers the main energy efficiency opportunity. Such replacements may only be feasible when coupled with capacity expansions. 

Indian Flag In India, VSKs have a capacity of up to 200 - 250 ton per day, whereas the new pre-heater/pre-calciner systems are of more than 600 ton per day capacity. Hence, such transformations are only valid if coupled with a significant capacity expansion. 

Development Status Products
Commercial

Replacing Vertical Shaft KilnsCosts & Benefits

Parent Process: Clinker Making
Energy Savings Potential

Savings up to 2.4 GJ/t clinker can be obtained. 

Indian flag Savings of  1.6-2.0 GJ/t clinker are reported from India depending on pre-heater/pre-calcination system configuration

CO2 Emission Reduction Potential

Chinese flag In China, CO2 emissions can be reduced by 227 kg/t clinker by converting VSKs to pre-heater/pre-calciner kilns.  

Costs

Costs of such conversions can be between US $28-41 per annual ton of clinker production. 

Replacing Vertical Shaft 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: 

17-18