Trends in power generation from waste heat in cement plants

(Source/Quelle: KHI)

1 PH waste heat boiler and turbine/generator house at Taiheiyo Cement

(Source/Quelle: KHI)

(Source/Quelle: HeidelbergCement)

2 ORC system at the Lengfurt plant

(Source/Quelle: HeidelbergCement)

(Source/Quelle: ABB)

3 Possible system capacities as a function of process parameters

(Source/Quelle: ABB)

(Source/Quelle: OneStone

4 Typical system capacities as a function of clinker capacity

(Source/Quelle: OneStone

(Source/Quelle: Sinoma-EC)

5 Waste heat boiler downstream of a kiln preheater

(Source/Quelle: Sinoma-EC)

(Source/Quelle: TESPL)

6 Waste heat boiler downstream of a clinker cooler

(Source/Quelle: TESPL)

(Source/Quelle: Sinoma-EC)

7 Generator house of a WHR system at Siam Cement Group

(Source/Quelle: Sinoma-EC)

(Source/Quelle: Dalian East New Energy Development)

8 18 MW steam turbine with generator

(Source/Quelle: Dalian East New Energy Development)

(Source/Quelle: Sinoma-EC)

9 Recooling system of a WHR system at Siam Cement Group

(Source/Quelle: Sinoma-EC)

(Source/Quelle: OneStone)

10 Flow chart of an ORC process

(Source/Quelle: OneStone)

(Source/Quelle: ABB)

11 ORC system of compact construction

(Source/Quelle: ABB)

(Source/Quelle: OneStone)

12 WHR systems according to process

(Source/Quelle: OneStone)

13 Market shares of WHR systems

(Source/Quelle: OneStone)

(Source/Quelle: KHI)

14 WHR system at Anhui Conch’s Ningguo cement plant

(Source/Quelle: KHI)

(Source/Quelle: Conch Cement)

15 WHR system at Anhui Conch’s Zhongguo cement plant

(Source/Quelle: Conch Cement)

(Source/Quelle: Sinoma EC)

16 WHR system at a Siam Cement Group plant

(Source/Quelle: Sinoma EC)

(Source/Quelle: DEE)

17 AQC waste heat boiler in a Chinese cement plant

(Source/Quelle: DEE)

(Source/Quelle: CITIC HI)

18 PH waste heat boiler in a Chinese cement plant

(Source/Quelle: CITIC HI)

(Source/Quelle: TESPL)

19 PH waste heat boiler at KCP in India

(Source/Quelle: TESPL)

(Source/Quelle: Ormat)

20 4 MW ORC system at A.P. Cement

(Source/Quelle: Ormat)

(Source/Quelle: KHI)

WHR system at India Cement

(Source/Quelle: KHI)

(Source/Quelle: OneStone)

22 Existing WHR systems according to country

(Source/Quelle: OneStone)

23 Market prospects up to 2019/2020

(Source/Quelle: OneStone)

24 Annual electricity savings with WHR systems

(Source/Quelle: OneStone)

Summary: The generation of power from waste heat in cement plants was for a long time the subject of controversial discussion. Today, hardly anyone remains unconvinced by the concept. Depending on the system used, 30–45 kWh/t_clinker can be generated, which is up to 30 % of the electrical power requirement of a cement plant. The benefits of this technology are clear. As electricity and energy costs increase, the plants become more and more cost-effective and the CO₂ emission situation provides additional incentive. This report presents an overview of the technology and system vendors, indicates the reference systems and describes the market prospects.

1 Introduction

Japanese companies spearheaded the introduction of Waste Heat Recovery systems (WHR) in the cement industry. In 1980, Kawasaki Heavy Industries (KHI) put a WHR system into operation at Sumitomo Osaka Cement [1]. The first major system, with a capacity of 15 MW, has been in operation since 1982 at Taiheiyo Cement’s Kumagaya plant (Fig. 1). This system consists of waste heat boilers for kiln and cooler exhaust air with a conventional steam circuit and subsequent steam turbine for the power generation. HeidelbergCement took a different approach. In 1999, they put the cement...