Case Study 3 - Cement plant.

Waste Heat Recovery from hot gases exhausted by Preheater of Cement Plant

System Description

Back ground

• In the process of cement production, large quantity of highly dust laden gases is exhausted from the Pre-heater at high temperatures up to 450 Deg C.
• These gases are cooled I GCT consuming large quantity of water
• Then the gases are exhausted to atmosphere after passing through gas cleaning equipments such as ESP, Bag Filters, etc.
• Large amount of heat is wasted to atmosphere through these gases, unless any heat recovery system is installed.

Challenges in Heat Recovery

• The pressure drop across the waste heat recovery system was required to be maintained within the allowable limits of the existing ID fan in Cement Plant

Solution Offered

• Patented Vertical Co-Flow design, wherein dust laden flue gases flow parallel to axis of heat recovery boiler tubes in vertical direction.
• Waste heat recovery boiler is installed on preheater exhaust gas
• Heat is recovered from flue gas in the form of superheated steam
• The superheated steam drives steam turbine generator to produce electric power
• The exhaust steam is condensed in water cooled condenser

System Schematic

Results

System Schematic

System Schematic