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The cement industry is one of the most intensive energy consumers in the industrial sectors. The energy consumption represents 40% to 60% of production cost. Additionally, the cement industry contributes around 5% to 8% of all man-made CO2 emissions. Physiochemical and thermochemical reactions involved in cement kilns are still not well understood because of their complexity. The reactions have a decisive influence on energy consumption, environmental degradation, and the cost of cement production. There are technical difficulties in achieving direct measurements of critical process variables in kiln systems. Furthermore, process simulation is used for design, development, analysis, and optimization of processes, when experimental tests are difficult to conduct. Moreover, there are several models for the purpose of studying the use of alternative fuels, cement clinker burning process, phase chemistry, and physical parameters. Nonetheless, most of them do not address real inefficiency taking place in the processes, equipment, and the overall system. This paper presents parametric study results of the four-stage preheater dry Rotary Kiln System (RKS) with a planetary cooler. The RKS at the Mbeya Cement Company (MCC) in Tanzania is used as a case study. The study investigated the effects of varying the RKS parameters against system behaviour, process operation, environment, and energy consumptions. Necessary data for the modelling of the RKS at the MCC plant were obtained either by daily operational measurements or laboratory analyses. The steady-state simulation model of the RKS was carried out through the Aspen Plus software. The simulation results were successfully validated using real operating data. Predictions from parametric studies suggest that monitoring and regulating exhaust gases could improve combustion efficiency, which, in turn, leads to conserving fuels and lowering production costs. Composition of exhaust gases also depends both on the type of fuel used and the amount of combustion air. The volume of exit flue gases depends on the amount of combustion air and infiltrating air in the RKS. The results obtained from the study suggest a potential of coal saving at a minimum of about,   which approximates to 76,126 tons per year at the current kiln feed of 58,000 kg·h-1. Thus, this translates to a specific energy saving of about 1849.12 kJ·kgcl-1, with relatively higher clinker throughput. In this vein, process modelling provides effective, safe, and economical ways for assessing the performance of the RKS.

Parametric Studies of Cement Production Processes