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Posted by Yuva Engineers on April 30th, 2010 Technical Paper Title: WASTE HEAT RECOVERY POWER PLANT Authors: SK.ANWAR BASHA, 3rd BTech, EEE College: Prakasam Engineering College, Kandukur Abstract A large quantity of Flue gases at high temperatures is produced by different parts of the heavy industries. They are purified internally by purifying equipment like Electrostatic Precipitators and are left into atmosphere. At the present condition the heat energy of flue gases is wasted. If we are able to trap the heat and thereby using the heat to produce steam, an efficient electric power generation can be achieved. As the heavy industries are located independently and in many cases, neither steam nor hot water is needed in their own plants. The recovery in electric power is most effective method. On the other hand, the main advantages offered by the Waste Heat Recovery Power Plant can be listed as follows: 1) Clean power generation 2) No production of green house gases (ex: CO2) 3) No air polluting gases (NOx, SOx). 4) Reduces 10-12% of Global wAarming effect. The recovery plants can be constructed on the same basis of the thermal power plant with the only difference that flue gases for the production of heat in boilers replace the burning of coal. This difference makes the recovery plant most efficient and clean over conventional plant for same power rating. Hence this project can be treated as the efficient method of utilization of waste gases for the production of electrical energy and one can hope that the “Waste Heat Recovery “ will play an even great role in the industrial development of 21st century. WASTE HEAT RECOVERY POWER PLANT Waste heat recovery is the process of capturing waste heat (thermal) energy for beneficial purposes. Recaptured heat energy is potentially useful for generating electricity. Space heating, water supply and green houses. Heat recovery is a complex system, which requires many parameters to be considered. The exit temperature of the waste heat as well and the application of the regenerated waste heat is key factors in heat recovery systems. There are three temperature ranges of heat recovery. In small, waste heat in industries is recovered from liquids or gases at low temperatures (below 450o F [232oC]). In larger industries, medium temperature recoverable heat (between450o F and 1200o F [232o C–649o C]) may be available for waste heat recovery. High temperature recoverable heat (above 1200o F [649o C]) is usually available only in heat-intensive industries i.e., Heavy Industries Generating Waste Heat • Power and Utility Industries • Heavy Industries: Steel, Aluminum, Copper, Cement, Pulp & Paper, Glass, Soda Ash and Waste Recycle • Refinery, Petrochemical and Gasification plants • Chlor-Alkali & Vinyl plants • Incinerators, Waste to Energy Typical Waste Heat Sources • Fired boilers, gasifiers, heaters/furnaces (gas, diesel, coal, nuclear, refuse, pet
)which are producing huge amount of waste heat.This involves passing the ground raw materials through a preheater stack containing cyclone heaters to a long rotating kiln to create clinker and then cooling this in the clinker cooler.Around 8% of heat from the exit gases of preheater and AQC is used effectively for drying the raw materials and coal. Waste heat is typically mainly vented to atmosphere and if captured and used for power generation. Glass. In Cement plants. Aluminum. as proposed in this Project Activity. Suppose if we place “Waste Heat Recovery Power Plant” in Cement industry the layout diagram will be like this. We can place Waste Heat Recovery plant in many heavy industries (Steel. Soda Ash etc. The layout diagram will be like this: . peaking. the main advantages offered by the Waste Heat recovery power plant can be listed as follows: Clean power generation No production of green house gases (ex: CO2) No air polluting gases (NOx.. combined cycle units • Steam turbine exhaust: and vented steam • Internal Combustion (IC) engine exhaust The total heat generated in these industries is not utilizing full fledged but 45% is discharged through the exit gases from the preheater and through chimney and the gases which are releasing in to atmosphere through this waste heat are NOx & Sox Mercury Vaporized heavy metals etc. an efficient electric power generation can be achieved by this waste heat The recovery in electric power is most effective method. as radiation losses and sensible heat carried out by the clinker. Air Quenching Chamber (AQC).• Gas turbine exhaust – continuous. This difference makes the recovery plant most efficient and clean over conventional plant for same power rating.. Cement.. Out of total heat consumed in the burning process. If we are able to trap the heat and thereby using the heat to produce steam. standby. SOx) etc… The waste heat recovery plants can be constructed on the same basis of the thermal power plant with the only difference that flue gases for the production of heat in boilers replace the burning of coal. The rest 37% is often emitted to the atmosphere without utilization In Cement industries large portion of the energy consumption for the production of cement occurs in the calcinations process in clinker production. Copper. about 90% of total energy is used as heat energy in clinker burning process. around 55% of the heat is utilized for clinker burning and rest 45% is discharged as sensible heat through the exit gases from the preheater (PH). And these gases are causing dangerous health problems to people who are leaving surroundings to these industries and indirectly it is forming 10-12% ofglobal warming effect. On the other hand. can lead to significant greenhouse gas emission reductions. Pulp & Paper.
The WHR system in the project activity consists of one set of PH boiler. Coming in to operation of W H R in cement industries.The production process of this project is an energy conversion process. and final product – electric energy is generated. The AQC boiler has been installed between the exhaust exit at the middle of the kiln entry clinker and the exhaust electric precipitator at kiln front. The heat energy is converted into kinetic energy in steam turbine to enable turbine rotor to rotate at high speed. The steam from SP boiler and AQC boiler will be united and fed to steam turbine generator for power generation. Expected Power Generation: . The first section of the AQC boiler produces overheated steam and the second section produces hot water. the project entity has equipped a WHR system for the cement clinker production line. and then steam is fed into steam turbine through the steam pipe. and then drive the generator to rotate. Steam turbine generator has equipped for the two boilers. The amount of the heat contains in the low temperature (lower than 400 °C) waste gas. The proposed project activity adopts wasteheat recovery technology to utilize waste heat from PH and AQC for power generation In the project activity. The PH boiler has been installed between the exhaust exit of the kiln rear pre-heater and the kiln rear high-temperature fan. one set of AQC boiler. which is vented by the PH. is more than 37 percent of the total amount of the heat consumed in the calcinations process of clinker. The waste heat from PH and AQC will be fed to PH boiler and AQC boiler to generate steam. Feed water recovers the heat energy of low-temperature waste heat exhausted by clinker production line through PH heat recovery boiler and AQC heat recovery boiler.Boiler and Air Quenching Chamber (AQC). the calcinations process of clinker wastes a lot of energy. and water circulation system and dust-removal system etc. to convert it into superheated steam. one steam turbine generator.
ADVANTAGES: 30% of the plant power consumption is met by the internal generation through waste heat recovery… 40% of the waste heat is recovered… Reducing the carbon dioxide emission into atmosphere by about 45. v Electrical Power generation potential from Waste Heat Recovery power plant is below .000 tons per year… 30% off power is saved for producing ton cement Economical for 1 MW to 25 MW Power Plants.
v Cost comparison of Waste Heat Recovery Power Plant with other sources of Power Plants: v Cost comparison of Waste Heat Recovery Power Plant with Renewable Energy Recourses .
Advantages of Waste Heat Recovery Power Plant (REUSABLE ENERGY): Each MW of Power Generation (compared to coal fired plant) Eliminates : Each MW of Power Generation (compared to coal fired plant) Eliminates : 21 Tons NOx 59 Tons Sox 8615 Tons of CO2 • Power Generated with Zero Emissions • Renewable Energy Credits • Integrated Multi-Pollutant Reduction System • Zero Emission Power Plants • Efficient Power from Flue Gas. Hot Water/Fluids • Saves Valuable Water Resources • High Internal Rates of Return • Supports Distributed Generation • Solar. Biomass & Geothermal Standalone Power Plants . Steam.
or else increasing its availability to other important process.• Combined Cycle Diesel Engine Power Plants • Provides Emission Credits By all this Advantages. . WHY NOT CLASSIFY “REUSABLE ENERGY” AS “RENEWABLE ENERGY”? Conclusion: Heat recovery technology is an excellent tool to conserve energy. The W H R activity would be able to replace electricity generated by grid-connected power plant thus saving further exploitation and depletion of natural resources – coal. The electricity generated from the W H R would help to reduce carbon dioxideemission and other associated pollution at thermal power plats By placing Waste Heat Recovery power plants in heavy industries which are generating huge amount of waste heat. we can reduce 10-12% of Global Warming effect. Both comments and pings are currently closed. This will help full for Nation too… This project can be treated as the efficient method of utilization of waste gases for the production of electrical energy and one can hope that the “Waste Heat Recovery “will play an even great role in the industrial development of 21stcentury. The WasteHeat Recovery brings in related economic benefits for the local community and would lead to sustainable economy and industrial growth in the region.
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