Case Study 2 - Cement plant.

Waste Heat Recovery based Thermal Oil Heater on hot gases exhausted by Clinker Cooler of Cement Plant to drive Organic Rankine Cycle Power Plant

System Description

Initial situation

• The cement plant exhausts huge quantity of flue gas at high temperature from Pre heater and Clinker Cooler.
• High temperature ESP is installed at clinker cooler outlet to remove dust from clinker cooler exhaust gases.
• The hot flue gases are exhausted to atmosphere at outlet of ESP.

Challenges

• The pressure drop across the waste heat recovery system was required to be maintained within the allowable limits of the existing Cooler fan.

System Schematic

Solution offered

• Waste Heat Recovery based thermal oil heater is installed on Clinker Cooler exhaust gas at outlet of Cooler ESP and prior to the cooler fan.
• Exhaust gases were free of dust hence vertical cross flow type thermic fluid heater with lesser capital cost was installed
• Heat is recovered from the flue gas to heat thermal oil to drive Organic Rankine Cycle based power plant

Process Schematic

Results

Installation Photographs