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Energy Efficiency – Ecological and Economic Profitability

Barbara HAWRYLAK
Barbara HAWRYLAK
   | 27 janv. 2021
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Publié en ligne: 27 janv. 2021
Pages: 85 - 92
Reçu: 05 nov. 2020
Accepté: 14 nov. 2020
DOI: https://doi.org/10.21307/acee-2020-032
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© 2020 Barbara Hawrylak published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Figure 1.

Rotary kilns (top view) (1. One of the three old rotary kilns – currently out of service, intended for demolition; 2. One of the three old rotary kilns – currently being demolished; 3. New rotary kiln)
Rotary kilns (top view) (1. One of the three old rotary kilns – currently out of service, intended for demolition; 2. One of the three old rotary kilns – currently being demolished; 3. New rotary kiln)

Fuel and energy consumption for clinker production in the base year [cement plant data]

Type of fuel Fuel consumption [Mg /year] Calorific value [kJ /kg] Fuel chemical energy [GJ /year] Emission factor [Mg CO2 /GJ] CO2 emissions [Mg /year]
Coal 27 922,161 30 511 * 851 933,054 93,080 79 297,928
RDF alternative fuel 55 306,338 18 561 1 026 540,940 87,400 89 719,678
Dry sewage sludge 2 840,095 13 512 38 375,364 89,000 3 415,407
Heating oil 45,149 42 499 1 918,787 74,000 141,989
Sum 86 113,743 1 918 768,145 172 575,002

Electricity consumption data for a new furnace installation

kWh t Kl. kWh/t
September 838 118,4 27 850,4 30,1
October 1 088 692,6 33 979,1 32,0
average 963 405,5 - 31,1

Electricity consumption data for the furnace installation in the base year (before modernization)

kWh t Kl. kWh/t
January 1 223 212,0 30 625,2 39,9
February 597 631,4 13 412,2 44,6
March 1 143 617,9 32 926,0 34,7
April 1 191 783,2 32 393,8 36,8
May 1 287 485,2 37 446,9 34,4
June 1 255 544,9 35 243,6 35,6
July 1 291 080,6 34 320,0 37,6
August 1 239 850,6 33 623,7 36,9
September 1 267 597,4 32 423,8 39,1
October 1 151 178,0 29 759,8 38,7
November 1 256 302,0 34 130,7 36,8
December 1 324 375,0 35 584,2 37,2
average - - 37,7
sum 14 229 658,2 - -

Electricity consumption by a cement plant in September and October after modernization

Parameters Fee Consumption
Unit MWh PLN
The morning peak 12 319,004 3 385 212,31 zl
Afternoon peak 7 059,223 2 347 205,31 zl
The rest of the day 71 444,776 12 451 814,95 zl
Overall 90 823,003 18 184 232,57 zl
Contract power - 2 746 800,00 zl
Variable transmission fee - 2 516 384,48 zl
Power exceeded (PDG) - - zl
Reactive power exceeded - 1 416,81 zl
Capacitive reactive power - 341,54 zl
Subscription fee - 5 280,00 zl
Including fixed fees - 2 752 080,00 zl
Including transmission fees - 2 518 142,84 zl
Including Energy charges - 18 184 232,57 zl
Average price of energy 258,24 -
Energy consumption 90 823,003 23 454 455,40 zl

Fuel prices in the base year

Fuel type Fuel cost before modernization PLN /t Fuel cost after modernization PLN /t
Coal 471,50 350,00
Heating oil 2 521,09 2587,77
RDF 55,35 30,67
Sewage sludge 38,37 48,46

Fuel consumption before and after modernization

Fuel type before modernization PLN/year after modernization PLN/year
Coal 13 165 298,91 7 827 144,50
Heating oil 113 824,69 352 454,27
RDF 3 061 205,81 1 947 038,33
Sewage sludge 108 974,45 41 899,97
Sum 16 449 303,86 10 168 537,08

Electricity consumption by a cement plant in the base year

Parameters Fee Consumption
Unit MWh PLN
The morning peak 12 319,004 3 385 212,31 zl
Afternoon peak 7 059,223 2 347 205,31 zl
The rest of the day 71 444,776 12 451 814,95 zl
Overall 90 823,003 18 184 232,57 zl
Contract power - 2 746 800,00 zl
Variable transmission fee - 2 516 384,48 zl
Power exceeded (PDG) - - zl
Reactive power exceeded - 1 416,81 zl
Capacitive reactive power - 341,54 zl
Subscription fee - 5 280,00 zl
Including fixed fees - 2 752 080,00 zl
Including transmission fees - 2 518 142,84 zl
Including Energy charges - 18 184 232,57 zl
Average price of energy 258,24 -
Energy consumption 90 823,003 23 454 455,40 zl
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