Utilization of waste heat from rotary kiln for burning clinker in the cement plant (original) (raw)
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IJERT-Waste Heat Recovery in Cement plant
International Journal of Engineering Research and Technology (IJERT), 2014
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Waste Heat Recovery ( Energy Efficient Technique0
This report provides the basic information about the recovery of the waste heat generated from the various chemical and industrial processes which makes the whole process economically feasible, technically efficient and environmentally acceptable. Waste heat recovery is the process of utilizing the waste heat released during various processes to provide heat for existing process as well as to provide energy for the new process.
Potential of waste heat in Croatian industrial sector
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Waste heat recovery in Croatian industry is of the highest significance regarding the national efforts towards energy efficiency improvements and climate protection. By recuperation of heat which would otherwise be wasted, the quantity of fossil fuels used for production of useful energy could be lowered thereby reducing the fuel costs and increasing the competitiveness of examined Croatian industries. Another effect of increased energy efficiency of industrial processes and plants is reduction of greenhouse gases i.e. the second important national goal required by the European Union and United Nations Framework Convention on Climate Change. Paper investigates and analyses the waste heat potential in Croatian industrial sector. Firstly, relevant industrial sectors with significant amount of waste heat are determined. Furthermore, significant companies in these sectors are selected with respect to main process characteristics, operation mode, and estimated waste heat potential. Data collection of waste heat parameters (temperature, mass flow and composition) is conducted. Current technologies used for waste heat utilization from different waste heat sources are pointed out. Considered facilities are compared with regard to amount of flue gas heat. Mechanisms for more efficient and more economic utilization of waste heat are proposed.
Investigation of Waste Heat Recovery in Cement Industry: A Case Study
In recent years, there has been an increasing interest in waste heat recovery in the cement industry. The aim of this work is to determine the waste heat recovery by utilizing the waste exit gases from the pre-heater and grate cooler to generate electricity, furthermore estimation of cost saving. The results based on the operational data which is collected from Al-Muthanna Cement Plant. The net power output of 834.12 kJ/kg was estimated. A 6.673 ×103 MWh/yr electricity generation were achieved. The cost saving was estimated of 467,110.00 USD/yr in addition to 20 months was expected as the simple payback period.
IJERT-Efficiency Analysis of Waste Heat Recovery Systems using the Case Study of A Cement Plant
International Journal of Engineering Research and Technology (IJERT), 2021
https://www.ijert.org/efficiency-analysis-of-waste-heat-recovery-systems-using-the-case-study-of-a-cement-plant https://www.ijert.org/research/efficiency-analysis-of-waste-heat-recovery-systems-using-the-case-study-of-a-cement-plant-IJERTV10IS080232.pdf This paper analyses the efficiency of Waste Heat Recovery System (WHRS) at a cement manufacturing plant of a Cement major which is a pioneer in sustainable cement manufacturing in India. The paper also identifies factors possibly affecting the efficiency while using data to evaluate models, including a novel mathematical model for the effect of impurity concentration on efficiency. Analyses of a few alternatives have also been provided. Therefore, this paper provides a detailed efficiency analysis of smart energy systems in cement manufacturing and other such industrial processes in order to generate energy or electricity.
E3S Web of Conferences, 2021
Waste Heat Recovery (WHR) Systems are spreading more and more in cement factories and are essential in achieving the energy performance required by the European Directives, legislation, and standards. Using WHR Systems may assure an important percentage of the energy required by the manufacturing process, with no additional fuel and no additional greenhouse gas emissions. Using the waste heat as a power generation source, increases the energy efficiency of the process and decreases the thermal energy losses. As long as the kiln is functional, so is the WHR powerplant, generating the energy in an efficient manufacturing process with low operational costs and increased reliability. This paper aims at evaluating the actual technic and economic performance of a WHR System compared to the estimated performance determined in the feasibility study which was done prior to the investment in order to prove the viability of the technology in the cement manufacturing industrial sector. The pape...
Investigation of a low-grade industrial waste heat recovery system
Nowadays, while the energy prices are continuously growing, the dispositions which try to increase the energy efficiency are getting more and more important in all industrial areas. This is especially true for the energy-intensive industrial processes. Because of this, the producing companies pay more attention every year on suggesting and supporting projects, which aim to decrease the energy consumption of their own factory. One way of increasing the energy efficiency is to use the waste energy of the installations to redeem other energy sources.
Energetic and exergetic analysis of waste heat recovery systems in the cement industry
Energy, 2013
This paper presents waste heat recovery as a way to gain energy from the exhaust gases in a cement plant. In a typical cement producing procedure, 25% of the total energy used is electricity and 75% is thermal energy. However, the process is characterized by significant heat losses mainly by the flue gases and the ambient air stream used for cooling down the clinker. About 35% -40% of the process heat is lost by those waste heat streams . Approximately 26% of the heat input to the system is lost by dust, clinker discharge, radiation from the kiln and pre-heater surfaces, and convection from the kiln and pre-heaters. A heat recovery system could be used to increase the efficiency of the cement plant and thus lower the CO 2 emissions. Moreover, it would reduce the amount of waste heat to the environment and lower the temperature of the exhaust gases. Waste heat can be captured from combustion exhaust gases, heated products, or heat losses from systems. This study aims at the identification of a best practice example for energy utilization in an existing commercial cement production plant with a waste heat recovery system as a new component. Two different methods will be examined, using the commercial software IPSEpro™ by Simtech. Firstly, a water-steam Rankine cycle will be analyzed and then an Organic Rankine Cycle (ORC) with an intermediate pressurized water circuit will also be investigated. Another aim of this paper is the optimization of the working fluid, the maximum pressure and temperature of the two cycles as well as the components arrangement, in terms of system efficiency and output power. Finally, an exergetic analysis is done for both cycles.
Using the adsorption chillers for utilisation of waste heat from rotary kilns
EPJ Web of Conferences, 2018
Waste heat utilisation and its reclamation is important for increasing the efficiency of the electric power production and for decreased consumption of primary energy. Waste heat can be utilised for the electric power production or for manufacturing and processing purposes. According to long-term forecasts, the consumption of electric power with current consumption of about 150 TWh, can be increased to about 230 TWh in around 2040, what may lead to the increased energy consumption from fuels and the increased emission of harmful contaminants to the atmosphere. The cement subsector, next to the glass industry, is among the most power-consuming industries, and it consumes about 12-15% of total energy consumed by industry in total, whereas the CO2 emission from such industry exceeds about 5% in worldwide scale. In the cement sector, there is an increasing need for useful reclamation of waste energy, in order to obtain high energy-saving factors, and hence the financial and environmenta...
Investigation of Using Kalina Cycle for Waste Heat Recovery in a Cement Plant
Journal of Al-Azhar University Engineering Sector
The cement industry is considered one of the most energy intensive industrial processes in the world. The energy cost average is about 55% of the total cost of cement production. Massive energy cost is due to both heat consumption in kiln operations and electrical power consumption for different operations of grinding mills, fans, and motors. Waste heat recovery is a way to reduce the total power consumption for the cement production process by using a heat recovery system to generate electrical energy with no more fuel or electrical power consumption. In a typical cement plant, 25% of the total energy is electrical energy, and 75% is thermal energy. About 35-40% of the total process heat is lost through waste heat streams. In a cement plant, 26% of heat input is lost through the kiln, preheater surfaces, convection from the kiln, and preheaters. This article reports on waste heat recovery from a typical cement plant in Egypt. Measurements and analyses have been performed to determine the waste heat from different stages of the cement manufacturing lines. The annual heat losses from the kiln surface, preheater, and the cooler are estimated as 79.23, 44.32, and 43.6 GWh at average temperatures of about 314, 314, and 254℃, respectively. Analysis and optimization of using the Kalina cycle for Waste Heat Recovery (WHR) from the kiln shell, cooler, and preheater to produce electricity have been carried out using ASPEN software. A parametric study has been carried out to determine the design parameters for the Kalina cycle including turbine inlet pressure, mass flow rate, and ammonia water concentration. Two design alternatives have been investigated using separate and combined WHR from the kiln, cooler, and preheater. The value of net power output using combined WHR is about 7.35 MW as compared to 6.86 using a separate WHR design with a total cost saving of about 23%.