The high cost of fuel in the kiln of your industry can be measured through some studies. Check out!
Fuels are one of the most important parts of an industry. They generate energy for the kiln to perform their processes. However, since it is very important for industrial operations, it can also end up generating a high cost for these companies, since they take between 1 and 10%, or even more, of costs and expenses.
In today’s post from Dynamis we will show you how you can measure if your kiln is spending heavily on fuels and present ways to work around the situation for your industry to achieve a reduction in these costs. Check it out below!
What causes a high cost of fuel in the kiln?
As mentioned above, fuels are the main source of energy for the kiln. Without them, there is no combustion process and, consequently, some of the industrial operations stop.
The high cost of fuel for the kiln, in most cases, is due to the inefficiency, which happens due to a false air intake, incomplete combustion and exhaust gases at high temperatures, which generates greater fuel consumption and increases costs with them.
However, the efficiency of its operations can be improved through some processes and studies.
How do I measure if I am having a high cost with fuel in the kiln?
A study of energetic efficiency in your industrial processes can help you to measure if your operations are having a high cost with fuel in the kiln or not, because this type of study aims to identify the operating conditions that reduce the efficiency of the system.
The Dynamis team, for example, uses its vast experience in the thermal, energy and fluids areas to identify processes that can be optimized and propose alternatives for an increase in the energetic efficiency of the kiln, which attend the customer’s needs, respecting the limitations system operation.
In this study, Dynamis will execute:
- Analysis of the actual operating conditions of the system or equipment to be studied, identifying possible points of inefficiency;
- Evaluation of alternatives to reduction the loss;
- Preparation of a report with the detected results and the opinion of the technical team.
How to reduce high fuel costs in the kiln?
With a study of energetic efficiency in the operations of your kiln, the Dynamis team will be able to evaluate alternatives so that you can reduce these costs and also improve the performance of your processes.
However, there are also other ways to reduce this high cost of fuel in the kiln and one of them is the use of waste and alternative fuels in the calciner or in the main burner.
Since our first alternative fuel combustion system project, in 2004, we have already carried out more than 50 jobs involving the use of alternative fuels. All of them with different types of alternative fuel and for the plants of the main cement groups, which allowed us to define the minimum characteristics to be attend by an alternative fuel handling and injection system, so that it is highly robust and highly reliable (and thus it can reach replacement levels above 70% without compromising the operations or the quality of the clinker), but still maintaining simplicity in its concept and installation.
This was possible based on the use of CFD software simulations on the basis of all technology. With that, Dynamis developed a method for defining the optimum quantity and the best injection points for these fuels, whether in the calciner or in the smoke chamber / rise duct box.
For this, several operating parameters were taken into account, such as temperatures, oxygen concentration and gas velocities; in addition to the geometry of the calciner and the characteristics of the fuels.
In addition, a great way to reduce the high costs of fuel in the kiln with alternatives and some residues, is the installation of a main burner like D-Flame, for example, which was developed to improve the combustion of both the regular fuels and of alternatives fuels.
Learn more about our solutions!
Dynamis Team