The report then focuses on the indepth analysis of. Waste heat recovery for the cement sector ifc pages 51 90. Industrial example trigeneration, combined heat, power and cooling chpc trigeneration or trigen is the simultaneous generation of following from a single heat source. In this study, design of a waste heat recovery system from the cement kiln was performed by thermoelectric modules. Cement kiln fume incinerator steel reverberatory furnace boiler. It is one of the highly energyintensive industries. Waste heat recovery studies cogeneration plants minerals. Waste heat recovery power plants in cement industry s k gupta s k kaul holtec consulting private ltd. Nagar, gujarat388121 abstract cement production is an energy intensive process. Waste heat recovery installations in the cement industry 15 figure 6. Jcm model project power generation by waste heat recovery. Recovery and utilization of waste heat in a coal based sponge iron process vivek kumar, shabina khanam. The waste fuels used in cement kilns are prepared either offsite by the supplier and in a form suitable for use direct in the kiln, or are prepared or treated onsite by the cement company.
Using waste heat to dry excessive moisture content in the raw feed or fuel reduces the amount of heat available in the exhaust. Waste heat recovery means allowing the waste heat to leave the process, but converting into electricity before it is discharged at lower temperature level to the environment. In a cement plant, waste heat is available mainly from kiln exhaust gases and vent air from the clinker cooler. A 5node fem model was developed to design and analyze the thermoelectric systems. Energy cost is incurred due to the need for large quantities of thermal heat for the kiln. This system is configured as an array of thermoelectric generation units arranged longitudinally on a secondary shell coaxial with the rotary kiln. And the high temperatures do not result in very complete combustion with very low pollution emissions. Waste heat recovery power generation systems for cement.
Cementeras, a network of local groups that are fighting waste incineration in cement kilns, has collected firsthand information of the many affected communities are paying the cement traps with their health and future of their economies. The kalina cycle for cement kiln waste heat recovery power plants abstract. In many world regions, energy cost is 50% to 60% of the direct production cost of cement. Waste heat recovery for the cement sector 43installed whr projects plant kiln typecapacity year started technology provider whr total installed cost comments 1 accholcim gagal number of lines 20 sinoma ec capacity 2 accholcim rabriyawas 20 sinoma ec epc contract 3 ambuja cement rabriyawas dry 6560 tpd 20 ntktecpro 4. Power generation by waste heat recovery in cement industry. This is indeed a very big issue in the environmental field. Cement production is one of the most energy intensive industrial processes in the world. Waste heat from cement kilns is usually used for drying of raw materials and fuel. Cement kiln dry process 620 730 glass melting furnace 1550. The kalina cycle for cement kiln waste heat recovery power. With high temperature heat recovery, a cascade system of waste heat recovery.
Coprocessing of this waste for energy recovery and as an alternative raw material in cement kiln can be an effective management methodology for this waste stream. The first step in planning to install a waste heat recovery system whrs is to work out the net available waste heat that can be used to generate power. As early as the 1980s, japanese companies spearheaded the introduction of whr power systems in the cement industry. The industrial sector accounts for more than 50% of global energy consumption. Research on waste heat recovery has been mostly conducted in various fields. Martin whitworth environment agency block 1 government buildings burghill road westburyontrym. Energetic and exergetic analysis of waste heat recovery systems in the cement industry s. Application of waste heat recovery to the cement industry 9 among its reporting companies was 3,510 mj and 104 kwh. Potential of recovery and conversion of waste heat from. Gases in cement kilns 36 process exhaust gases in the iron and steel industry 37 table typical coke oven gas composition 38. Waste heat recovery systems whr utilize the heat in industrial waste gases for the generation of electrical power.
Cfd modelling of waste heat recovery on the rotary kiln system in the cement industry, 2004. In this paper we propose a novel thermoelectric wasteheatrecovery system to reduce heat losses from cement rotary kilns. Student thermal engineering department of mechanical engineering a. This industrial waste has characteristics of municipal solid waste with percentage of nonbiodegradable waste on the higher side. Where an autoclave expansion test is employed astm c151, the control target will. Cement specific solutions solutions for a sustainable cement production costefficient production and a simultaneous emissions reduction can only be achieved by using components that are perfectly adapted to one another. The waste heat available in the exhaust gases can be recovered and used for drying the moisture in the raw material and coal or for generating power. Whrpg systems whrpg systems used for cement kiln systems operate based on the rankine cycle. The plant utilises waste heat from the kiln process to dry the sludge from 80% moisture down to 40%. Criterion 1 the project utilizes waste heat from a cement production facility by waste heat recovery whr system to generate electricity criterion 2 whr system consists of a suspension preheater boiler sp boiler andor air quenching cooler boiler aqc boiler, turbine generator and cooling tower. High freelime clinker must be blended into mill feed with circumspection to ensure that the resulting cement is not expansive. A comparison of organic and steam rankine cycle power systems for waste heat recovery on large ships clinker and cement energy audit and waste heat recovery system design for a cement rotary kiln in ethiopia clinker and cement safe cement silo clinker and cement. Waste heat recovery for the cement sector ifc pages 1. Over a billion tonnes of cement are made per year, and cement kilns are the heart of this production process.
Known energy sources exhausted from cement industries. Pdf heat recovery analysis of a rotary kiln in cement industry. Depending on the humidity of the raw materials and the cooler technology, additional waste heat is available from the kiln gases preheater exit gas and cooler exhaust air. Waste heat recovery from cement kiln radiant cooling. Dioxins are emitted from cement kiln stacks, whether the kiln is fired with conventional fuels or with hazardous waste.
Pdf heat recovery analysis of a rotary kiln in cement. On burning hazardous waste in cement kilns buildinggreen. Pdf waste heat recovery power generation systems for. In a next step the dried sludge is 100% recovered in the cement kiln. On burning hazardous waste in cement kilns dear editor, i am writing to comment on your recent article on cement. Journal of applied science and engineering innovation. A case study 2985 grate cooler to cool the clinker.
Waste heat recovery system does not need any additional fuel and can. A cement rotary kiln is a nonlinear, multivarible, distrubted paramete system. Hence, optimization of the heat recovery system in this study was oriented towards harvesting energy from industrial waste heat such as cement factory. Sources of waste heat include equipment inefficiencies hot combustion gases discharged to the. Report prepared for the european commission in the. Update on solid waste derived fuels for use in cement kilns. Pdf waste heat recovery power generation systems for cement. I really appreciated it, except for the part about hazardous waste.
In the second stage, the rawmix is fed into the kiln and gradually heated by contact with the hot gases from combustion of the kiln fuel. Waste heat recovery system an overview sciencedirect topics. One of potential tools for implementing the waste of heat recoveryis kiln in the cement industry. West heat recovery in messebo cement factory introduction cement plant is a plant which produce cement. In this paper we propose a novel thermoelectric waste heat recovery system to reduce heat losses from cement rotary kilns. Waste heat recovery from cement kiln radiant cooling, solar. The amount of waste heat available for recovery depends on the kiln system design and production, and amount of heat required for drying in the raw mill system, solid fuel system and cement mill system. Installed costs for waste heat recovery systems 16 figure 7. The generation of power from the cement kiln waste heat gases is an energy saving opportunity and it entails the recovery of the heat energy contained in the waste gases that are emitted into the atmosphere from the cement kiln. Waste heat recovery from cement production for faecal. This boiler for short aqc boiler, along with the waste heat boiler for kiln rear preheater in the cement production line for short sp boiler forms the waste heat recovery system.
Cement factory where the project is implemented is connected to a. Cogeneration of power utilising waste heat in cement manufacture. Kalex has developed a power system and auxiliary technology that greatly improves the efficiency and reduces the cost of utilizing waste heat from cement kilns for power generation. Energy audit and waste heat recovery system design for a cement rotary kiln in ethiopia. Environment agency on solid waste derived fuels for use in cement and lime kilns an international perspective, completed in 2001. In any study of waste heat recovery, it is absolutely necessary that there should be some use for the recovered heat. Waste heat recovery system an overview sciencedirect.
In those countries both cement kilns and waste to energy plants work side by side in the waste management system. A maximum composite free lime for the cement should be established and used for control. Received 1 october 2011 received in revised form 26 january 2012 accepted 7 march 2012. Improvement of clinker production efficiency has almost been circulated. Kakaras national technical university of athens, laboratory of steam boilers and thermal plants, heroon polytechniou 9, 15780 zografou, athens, greece. Waste heat recovery power generation has a possibility of reducing clinker production cost by up to 10%. Update on solid waste derived fuels for use in cement. Whr systems are common in cement and lime plants and other pyroprocess industries where rotary kilns are used and the price and reliability of grid power supply make the investment economically feasible. Waste heat recovery system for cement i ndustry emgem. German industry releases 200 billion kilowatthours of thermal energy a year into the environment as unused waste heat roughly equivalent to the entire energy consumption of.
Whr system has not been introduced to a corresponding cement kiln of the project prior to its implementation 5. Waste heat is also available from the exhaust of diesel engines of dg set. Waste heat recovery for the cement sector ifc pages 1 50. Scribd is the worlds largest social reading and publishing site. The whole electrical energy usage of the kiln system safely used from the generated power. Waste heat recovery technologies generally, there are two sources of waste heat available in a clinker production line. Amsenergy designs waste heat recovery solutions andor can provide heat pipe heat exchangers featuri. Therefore, after the efficiency of a cement plant has been driven to the economic optimum, the remaining waste heat is converted into electricity. Waste heat recovery technologies and applications sciencedirect. Rotary cement kiln dry process with cyclonic preheaters. Burning waste chlorinated hydrocarbons in a cement kiln. Kiln this report swl47a describee work performed for the office of solid waste wider contract no. The generation of power from a cement kiln waste gases. This product is the waste heat boiler for cement kiln head calcination cooler in the cement production line.
Industrial waste heat refers to energy that is generated in industrial processes without being put to practical use. Recovery of waste heat has a direct effect on the efficiency of the process. Mirolli, the kalina cycle for cement kiln waste heat recovery. Waste heat r ecovery system for cement i ndustry cost savings through environmentally friendly way electricity captures great portion of clinker production cost.
So, the factory could keep 800,000 usdyear by using the generated power for production of clinker. Cement industry has a 5% share of the global industrial energy consumption. Department of chemical engineering, national institute of technology, rourkela769008, orissa, india a r t i c l e i n f o article history. Businett 2000 international we are an importer of all kinds of industrial and replacement parts for the cement. October 21, 1976congress passes the resources conservation and recovery act rcra public law 94580 which requires epa to develop regulations governing the identification and management of hazardous waste. The cooled clinker is then transported to the clinker concrete silo for storage. Pdf design of cement plant waste heat recovery generation. The recovered heat is conveyed to the orc by two different loops using thermal oil and water. Therefore, after the efficiency of a cement plant has been driven to the economic optimum, the remaining waste heat is. Typical examples of use would be preheating of combustion air, space heating, or preheating boiler feed water or process water. Industrial waste heat recovery represents a very diverse range of.
Research paper waste heat recovery using stirling engine. One of the most effective and simple waste heat recovery methods is the preheating of the raw material prior to it being fed into the kiln. The organic part is a fuel replacement for the coal, whereas the mineral part of the sludge on dry basis around 40% is replacing virgin raw materials. Orc waste heat recovery system using kiln exit and cooler. Only few whr applications in cement in europe and americas waste heat recovery whr in cement heat balance of a dry cement kiln total energy input 3000 3500 gjtcli 35% of input heat is available for drying and power production kiln exhaust temp. The report then focuses on the indepth analysis of whr potential and enabling factors in eleven. Waste heat recovery research on the particular types of dry kilns has been conducted by several researchers. In its sicement product family, siemens links automation, drive, and power supply systems to form one overall solution.
Environmental protection agency, cement kilns that burn hazardous waste emit dioxins in their stack gases at rates more than 80 times higher than those of cement kilns that burn conventional fuels. Generating electricity from industrial waste heat youtube. Recovery and utilization of waste heat in a coal based. Turkey is the fourthlargest producer of cement in the world and the largest one in europe.
Industry uses waste heat recovery cement industry glass industry steel industry non ferrous furnaces refineries icengines and gas turbines 9. Textbook chapter on waste heat recovery that forms the basis of this powerpoint presentation but has more detailed information quiz ten multiple choice questions that trainees can answer. Cement kiln dust wastes special wastes wastes us epa. This heat can be used for steam and electric power production. The ashes of the fuel used to heat the kiln drops into the glowing material and reacts with the hot minerals to become an integral part of the endproduct clinker. Project site tuban, republic of indonesia category of project energy efficiency description of project the proposed project is planned to introduce a waste heat recovery. Industrial waste heat recovery represents a very diverse range of potential power. Waste heat recovery free download as powerpoint presentation. In addition to the plan of reducing of energy consumption in cement production process, the recovery. Turboden was also awarded an order for a 4 mw orc unit to recover heat in the cement industry in slovakia. Cement kiln dust is included as one of the six special wastes. Cement kilns are used for the pyroprocessing stage of manufacture of portland and other types of hydraulic cement, in which calcium carbonate reacts with silicabearing minerals to form a mixture of calcium silicates.
Energetic and exergetic analysis of waste heat recovery. Pdf using waste energy from the organic rankine cycle. Eligibility criteria criterion 1 the project utilizes waste heat from a cement production facility by waste heat recovery system whr to generate electricitycriterion 2 whr system consists of a suspension preheater boiler sp boiler andor air quenching cooler boiler aqc boiler, turbine generator and cooling towercriterion 3 whr system utilizes only waste heat and does not utilize. Design of cement plant waste heat recovery generation. A thermoelectric wasteheatrecovery system for portland. Exhaust gases in rotary kiln process figure 1, the raw material mixture is introduced from the top of the cyclone preheater tower. Environmental impact of incineration of calorific industrial waste. Recovering the waste heat can be conducted through various waste heat recovery technologies to provide valuable energy sources and reduce the overall energy consumption. The plant produces 4 mw by recovering waste heat from the exhaust gas of the kiln and clinker cooler. This report analyzes the current status of waste heat recovery whr technology deployment in developing countries and investigates the success factors in countries where whr has become widely spread. May 09, 2016 additional materials that can be used for the training session are available on. Waste heat recovery power generation systems for cement production process. By installing waste heat boilers in these hot gas streams, steam can be produced and used to power a generator producing electricity or to drive a fan offsetting electricity consumption.