Modernization of the air system for burners in a cement plant

Supplying hot air to burners in a cement plant

In cement plants, the proper temperature of the primary air in burners determines combustion efficiency. Thanks to modernization of the air supply system and the use of hot waste air, DB Energy reduced energy consumption by 139.7 GWh per year, with savings of PLN 3.23 million.

The challenge

In cement production plants, rotary kilns with burners are a key element of the process, where flame control and combustion efficiency determine energy consumption. In the audited plant, solid fuels (alternative fuels and coal dust) were introduced into the kiln through ducts, and light fuel oil was used to ignite the burner.

The pipelines supplying primary air at a temperature of 20–25 °C were not insulated, which generated energy losses and limited combustion efficiency.

Our approach

The DB Energy team analyzed the entire primary air delivery system to the burners:

temperature and airflow measurements in the ducts,
assessment of energy losses resulting from lack of insulation,
identification of opportunities to use hot waste air to increase the temperature of the supplied air,
analysis of necessary modifications to blowers, fans, and existing equipment to safely raise air temperature.

Based on this, a modernization concept was developed, covering both improvement of thermal parameters and minimization of heat losses.

Solution

The modernization included:

increasing the temperature of the air supplied to the burners within a safe range for the fuels used,
using hot waste air in the supply system,
thermal insulation of all pipeline elements transporting hot air,
adaptation of existing blowers and fans to the new operating parameters.

Results

The modernization brought measurable benefits:

reduction in energy consumption: approx. 139.7 GWh per year,
financial savings: PLN 3.23 million per year,
improved combustion efficiency and boiler operating stability,
reduction of heat losses and CO₂ emissions,
better use of waste energy.

The total investment cost amounted to PLN 6.8 million.

Conclusions

Optimization of air delivery systems to burners in cement kilns shows that the use of hot waste air and pipeline insulation can significantly reduce energy consumption.

Investment in modernization, although requiring expenditures for adapting existing equipment, pays off through savings and increased process efficiency.

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