John Kline
[email protected]
1
Composition
4.1%
4.9%
5.0%
86.0%
Clinker
Gypsum
Limestone
Other
2
Operating Power of Main Components
7000
6000
3000
Operating Power
5000
4000
y = 0.9048x
R² = 0.9646
On Average
90.5% of Mill
Motor Power
Consumed
2000
1000
R² = 0.1141
R² = 0.2118
R² = 0.2437
0
0
1000
2000
3000
4000
5000
6000
7000
8000
Installed Power Mill Motor
Mill Operating kW
Fan Operating kW
Separator Operating kW
Auxilaries Operating kW
Linear (Mill Operating kW)
Linear (Fan Operating kW)
Linear (Separator Operating kW)
Linear (Auxilaries Operating kW)
3
Total Shop Power Compared with Mill Motor Power
Red Dots are
Vertical Mills
Total Shop Power =
~110% of Mill Power
4
Mill Throughput Compared with Mill Motor Power
Mill Throughput TPH =
Mill Motor kW * 0.0245
5
Reasonable Correlations






Mill motor consumed power = 90% of mill
motor installed power (r2 = 0.9646)
Mill shop power = 110% of mill motor
installed power (r2 = 0.8957)
Mill throughput = 0.0245 * mill motor
installed power (r2 = 0.7781)
Indicating a mean power consumption of
36.7 kWh/t for the mill and 44.7 kWh/t for
the shop
Larger mills are seen to be approximately
5.8% more productive (r2 = 0.8452) TPH2
The above were all with forced intercepts of zero
TPH1
=
kW2*1.058
kW1
6
Equipment Impacts
7
Motor Power Comparison
Motor Power (kW)
Motor Power
5000
4000
3000
2000
1000
0
Ball Mill
Rated
Vertical Mill
Operating
8
Power Consumption Auxiliares
Chart Title
2500
Highest
Power Consumption (kWh/t)
2000
1500
Top 10%
1000
500
Average
Bottom 10%
Lowest
0
Fan
Separator
Consumed Power kWh/t
Auxiliaries
9
Blaine impact on power consumption
180
160
Power Consumption (kWh/t)
140
120
100
R² = 0.3317
80
60
40
20
0
0
1000
2000
3000
4000
5000
6000
7000
Surface Area as Measured by Blaine (cm2/gram)
8000
9000
10
Power Consumption Relationships
8000
200
y = 3134e0.005x
R² = 0.3263
7000
180
6000
140
5000
Production Rate (TPH)
Mill Installed Power and Blaine Fineness
160
4000
3000
120
100
80
60
2000
y = 3262.7e-0.008x
R² = 0.0549
1000
40
20
y = 150.3e-0.021x
R² = 0.2526
Mill Power Consumption (kWh/t)
0
0
20
Mill Rated kW
40
AVG Blaine
60
TPH
80
100
Expon. (Mill Rated kW)
0
120
140
Expon. (AVG Blaine)
160
180
Expon. (TPH)
11
No apparent relationship to grinding aid
12
13
IEEE West Coast Conference
San Antonio, TX
October 30, 2015
Steve Coppinger, P.E. (VP, Engineering Services)
CalPortland Company
14
ENERGY STAR Plant
Energy Performance Indicator (EPI)
• Benchmarking tool
that compares plant
energy efficiency to
comparable plants in
the industry.
• Based on PCA
Energy & Labor Survey
• Certification requires
plant efficiency to be in
top quartile.
• 27 Cement Plants are
certified
The Cement Industry Curve Has Shifted
Energy Performance Score (Percentile Ranking)
100
The distribution of energy
performance has shifted
75
1) Low performers improved the most
2) 61 trillion Btu saved
3) 13% reduction
4) Based on 2011 Duke Study - 1997
baseline to 2008
50
25
4.000
5.000
6.000
7.000
8.000
Million Btu per ton of Clinker
9.000
10.000
• Industry wanted to drill down to plant area energy efficiency
• Finish mills were identified as large energy consumers
• Survey developed by PCA Energy Subcommittee and ENERGY STAR
Cement Focus group
• Intended to measure finish mill process energy efficiencies
• Surveys collected from 19 companies, 61 plants, and 170 mills
Mill Type
Vertical
(5.9%)
Ball
93.5%
Type of Separator
Static
(15.2%)
Dynamic
84.8%
Circuit Type
Open
(2.5%)
Closed
97.5%
Number of Compartments
Three
(2.3%)
One
(17.4%)
Two
80.3%
Average Blaine of Cement Produced
Average Blaine
Type I Blaine
Type II/V Blaine
Block Blaine
Range
Min.
Max.
4257
4228
4251
4558
3262
7640
Percent of Plants Primarily Producing Cement Types
Additive Composition of Cement Produced
Mill Motor
Fan
Separator
Auxiliaries
Roll Press
Average Operating kWh per Ton
180
Average kWh per Ton
160
140
120
100
80
R² = 0.2182
60
40
20
0
0
50
100
Average Tons per Hour
150
200
180
160
Average kWh per Ton
140
120
R² = 0.279
100
80
60
40
20
0
3000
4000
5000
6000
Average Blaine
7000
8000
140
120
Average kWh per Ton
100
R² = 0.1601
80
60
40
20
0
3000
3500
4000
Average Blaine
4500
5000
180
160
Average kWh per Ton
140
120
100
R² = 0.0002
80
60
40
20
0
5000
5500
6000
6500
Average Blaine
7000
7500
8000
• ENERGY STAR will review data and provide further analysis
• Final report will be issued
• Possibility of evaluating other plant areas if requested