Case Study 4 - Ceramic Industry

Waste Heat Recovery from exhaust gases and jacket water of Deutz Gas Engine and its utilization in Spray Drier

System Description

Initial Situation

The process plant comprised of natural gas fired engine generator set for Power Generation purpose
Engine generator exhausts huge quantity of flue gases at high temperature to atmosphere and rejects large quantity of heat in jacket water to cooling tower.

Challenges

Recover and utilize waste heat to fulfill requirements of at-least one plant
Design a system that could be integrated with the running plant without affecting its operations

Solution Provided

Waste Heat Recovery System on exhaust gases and jacket water of natural gas fired engine generator.
Provided preheated process air to the hot air generator reducing fuel consumption of HAG
Sophisticated automation to handle fluctuating loads

Results

Parameter	Description
Mode of Heat Recovery	Heat Recovery System on Jacket water and Engine Exhaust Gases to preheat the air for HAG of Spray Drier
Application	Process Use
Temperature of engine exhaust gas	502° C
Flow rate of engine exhaust gas	7332 kg/hr
Net Heat Recovery from Exhaust Gas	8,76,235 kcal/hr
Jacket Water Temperature	Inlet = 82° C , Outlet = 92° C
Net Heat Recovery from Jacket water	1,98,765 kcal/hr
Total Net Heat Recovery	10,75,000 kcal/hr

Process Schematic