Assessment of energy and exergy efficiencies of a grate clinker cooling system through the optimization of its operational parameters

Ahamed, J.U.; Madlool, N.A.; Saidur, R.; Shahinuddin, M.I.; Kamyar, A.; Masjuki, H.H. (2012) Assessment of energy and exergy efficiencies of a grate clinker cooling system through the optimization of its operational parameters. Energy, 46 (1). pp. 664-674. ISSN 03605442

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Grate coolers are widely used in cement industries to recover heat from hot clinker, coming out from the rotary kiln. This study focuses on improving the energy, exergy and recovery efficiencies of a grate cooling system through the optimization of its operational parameters such as masses of cooling air and clinker, cooling air temperature, and grate speed. It has been found that the energy and recovery energy efficiencies of a cooling system can be increased by 1.1 and 1.9, respectively, with every 5 mass increases of cooling air. Similarly, it has been estimated that energy and recovery energy efficiencies can be increased by 2.0 and 0.4 with every 5 increase of cooling temperature. The exergy and its recovery efficiencies found to be increased by 3.6 and 2.2, respectively, for the same condition. Energy efficiency and energy recovery efficiencies are increased by 3.5 and 1.4 with every 9.1 increase of grate speed. Using heat recovery from the exhaust air, energy and exergy recovery efficiencies of the cooling system found to be increased by 21.5 and 9.4, respectively. It has been found that about 38.10 and 30.86 energy cost can be saved by changing mass flow rate of clinker and mass flow rate of cooling air, respectively.

Item Type: Article
  1. Ahamed, J.U.
  2. Madlool, N.A.
  3. Saidur, R.(Department of Mechanical Engineering, Faculty of Engineering Building, University of Malaya, 50603 Kuala Lumpur, MALAYSIA)
  4. Shahinuddin, M.I.
  5. Kamyar, A.
  6. Masjuki, H.H.
Journal or Publication Title: Energy
Additional Information: Export Date: 6 December 2012 Source: Scopus CODEN: ENEYD Language of Original Document: English Correspondence Address: Ahamed, J.U.; Department of Mechanical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia; email: References: Hendriks, C.A., Worrell, E., Jager, D.D., Blok, K., Riemer, P., Emission reduction of Greenhouse gases from the cement industry (2004) In: Greenhouse gas control technologies conference paper - cement. Available from, ,; Rasul, M.G., Widianto, W., Mohanty, B., Assessment of the thermal performance and energy conservation opportunities of a cement industry in Indonesia (2005) Appl Therm Eng, 25, pp. 2950-2965; Kolip, A., Fevzi, S.A., Energy and exergy analyses of a parallel flow, four stage cyclone precalciner type cement plant (2010) Int J Phys Sci, 5 (7), pp. 1147-1163; Saidur, R., Rahim, N.A., Masjuki, H.H., Mekhilef, S., Ping, H.W., Jamaluddin, M.F., End-use energy analysis in the Malaysian industrial sector (2009) Energy, 34 (2), pp. 153-158; Saidur, R., Hasanuzzaman, M., Yogeswaran, S., Mohammed, H.A., Hossain, M.S., An end-use energy analysis in a Malaysian public hospital (2010) Energy, 35, pp. 4780-4785; (2006) U.S. EPA sector strategies Program, ,, SSP Report; Worrell, E., Galitsky, C., (2008) Energy efficiency improvement and cost saving opportunities for cement making, an ENERGY STAR guide for energy and plant managers, , National Laboratory Environmental Energy Technologies Division; Punte, S., Holcim Bulacan plant: use of high efficiency fans and motors for clinker cooler fans energy efficiency guide for industry in Asia, , http://www.energyefficiencyasia.org2005, Available at: ; Worrell, E., Martin, N., Price, L., Potentials for energy efficiency improvement in the US cement industry (2000) Energy, 25 (12), pp. 1189-1214; Saidur, R., Masjuki, H.H., Jamaluddin, M.Y., An application of energy and exergy analysis in residential sector in Malaysia (2007) Energ Policy, 35, pp. 1050-1063; Cengel, A., (2006) Heat and mass transfer: a practical approach, , McGraw Hill; Ahamed, J.U., Saidur, R., Masjuki, H.H., A review on exergy analysis of vapor compression refrigeration system (2011) Renew Sust Energ Rev, 15 (3), pp. 1593-1600; Ari, V., Energetic and exergetic assessments of a cement rotary kiln system (2011) Sci Res Essays, 6 (6), pp. 1428-1438; Sögüt, Z., Oktay, Z., Karakoç, H., Mathematical modeling of heat recovery from a rotary kiln (2010) Appl Therm Eng, 30 (8-9), pp. 817-825; Madlool, N., Saidur, R., Rahim, N.A., Islam, M.R., Hossain, M.S., An exergy analysis for cement industries: an overview (2011) Renew Sust Energ Rev, 16 (1), pp. 921-932; Madlool, N., Saidur, R., Hossain, M.S., Rahim, N.A., A critical review on energy use and savings in the cement industries (2011) Renew Sust Energ Rev, 15 (4), pp. 2042-2060; Punte, S., (2005) Textbook training material cement, energy efficiency guide for industry in Asia, ,, Available from:; Sogut, M.Z., Oktay, Z., Hepbasli, A., Energetic and exergetic assessment of a trass mill process in a cement plant (2009) Energ Convers Manage, 50, pp. 2516-2525; Taufiq, B.N., Masjuki, H.H., Mahlia, T.M.I., Saidur, R., Ms, F., Niza Mohamad, E., Second law analysis for optimal thermal design of radial fin geometry by convection (2007) Appl Therm Eng, 27 (8-9), pp. 1363-1370; Mundhara, P., Sharma, S., (2005) Modeling of clinker coolers: applications to reduction in energy consumption, , IIT Madras; Saidur, R., Ahamed, J.U., Masjuki, H.H., Energy, exergy and economic analysis of industrial boilers (2010) Energ Policy, 38 (5), pp. 1188-1197; Saidur, R., Sattar, M.A., Masjuki, H.H., Abdessalam, H., Shahruan, B.S., Energy and exergy analysis at the utility and commercial sectors of Malaysia (2007) Energ Policy, 35, pp. 1956-1966; Price, L., Hasanbeigi, A., Lu, H., (2009) Analysis of energy-efficiency opportunities for the cement industry in Shandong Province, China, , Ernest Orlando Lawrence Berkeley National Laboratory; Saidur, R., A review on electrical motors energy use and energy savings (2010) Renew Sust Energ Rev, 14 (3), pp. 877-898; Punte, S.P.T., Indocement Tunggal Prakasra, Tbki Instalv variable speed drives (VSD) on 12 fans to reduce electricity use by motors, energy efficiency guide for industry in Asia, ,, Available from:; Touil, D., Belabed, H.F., Frances, C., Belaadi, S., Heat exchange modelling of a grate clinker cooler and entropy production analysis (2005) In. J Heat Tech, 25 (1), pp. 61-68; Engin, T., Ari, V., Energy auditing and recovery for dry type cement rotary kiln systems - a case study (2005) Energ Convers Manage, 46, pp. 551-562
Uncontrolled Keywords: Energy efficiency, Exergy efficiency, Grate clinker cooling, Cooling air, Cooling temperature, Energy and exergy, Energy and exergy efficiency, Energy cost, Energy recovery efficiency, Exergy efficiencies, Exhaust air, Grate coolers, Mass flow rate, Mass increase, Operational parameters, Recovery efficiency, Cement industry, Cooling, Cooling systems, Exergy, Optimization, Pipe flow, Thermoelectric equipment, Waste heat, Recovery, air temperature, cement, construction industry, control system.
Subjects: T Technology > TA Engineering (General). Civil engineering (General)
T Technology > TJ Mechanical engineering and machinery
Divisions: Faculty of Engineering
Depositing User: Mr Jenal S
Date Deposited: 03 Jul 2013 12:07
Last Modified: 03 Jul 2013 12:07

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