Waste Heat Recovery

Power Generation

Prepared by
Eagle Group S.A.E
2013
 It is the technology that transfers the waste
heat of the flue gas coming from both the
pre-heater and the clinker cooler at rear
and front of the kiln respectively in to
Electrical power.

Contents
Pure Low Temperature Waste Heat Recovery
Power Generation Technology Configure and
Targets

Definitions and features of the first and second

1 generations of pure low-temperature WHR power
technologies for cement kilns.

The construction of the first and second

2 generation of pure low-temperature WHR
technologies for cement kilns.

Study on some key issues between 1st Generation

3 and 2nd Generation Pure Low Temperature Waste
Heat Recovery Power Generation Technology.

4 Impacts of WHR power plants on cement kilns.

Target of pure low temperature WHR power

5 generation technology for cement kilns.
1 Definition and features of the first generation of pure low-
temperature WHR power technologies for cement kilns.

Definition:

The first generation of pure low-temperature WHR power technology

for cement kilns:
It is the technology that converts the flue gas waste heat below 350°• C from both
the pre-heater at the kiln bottom and the clinker cooler at the kiln top into power
energy by using 0.69MPa~1.27MPa — 280•°C ~ 340••°C steam without impairing
the production quantity & quality of cement clinker, lowering the cement kiln
operation rate, changing cement production technology process & machines, or
increasing the consumption of power energy and heat as the premise.

Features:

Separate steam
superheated, increase
running rate and
stability of power plant
An separate steam super
heater is set at the cooler so
The cooler has two that the temperature of primary
or more flue gas steam from the turbine is
extraction outlets for adjustable but not going along
power generation. the temperature fluctuation of
the flue gas from the kiln.

Circulation air An adjustable unit is set inside SP boiler

to regulate the temperature of the flue
gas at the SP boiler outlet in order to
meet the drying requirement according
to different.

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2 The Construction of the 1st Generation Technology of pure
low-temperature WHR power generation for cement kilns.

Key Points of the Technology:

Construction Model for Thermodynamic System

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The features of this generation :
1) Extract the total flue gas exhausted by the clinker cooler from the cooler as two segments.
2) The waste heat of the flue gas exhausted from the preheater is used for producing
steam through SP boiler. The steam generated by SP boiler and the steam & hot
water generated by AQC boiler respectively mix before converting into power energy
through a set of steam turbine & generator.
3) As the most important characteristic, the parameters of the primary steam for
power generation totally vary at range of 0.69~1.27MPa-280•~330••°C.

The differences among the three modes are shown as:

1) while the AQC is producing the low pressure & low temperature steam at
0.69~1.27MPa-280~330•°C, it is reproducing either saturate low pressure & low
temperature steam at 0.1~0.5MPa-saturated~160•°C or hot water at 105~180•°C.
2) Steam turbine is used as the type of either with or without secondary steam.
3) Due to the same flue gas parameter, the power generation capacity will be 100%
if based on the first mode, about 101.5%~102% if based on the second mode and
about 102~103% if based on the third mode.
4) The first mode is not affected by the relative location between the steam turbine
house and the cooler. The second mode (i.e. combined flash evaporation with secondary
steam) is proper for the case that the steam turbine house locates far away from
the cooler. The third mode is proper for the case that the (dual-pressure with
secondary steam) steam turbine house locates closely to the cooler.

Problem:
the advantage is generating power with simple systems and low investments, while
the disadvantage is:
1) Low theoretical calculated power generation capacity.
2) Non-adjustable steam temperature so as to impact the lifetime of steam turbine.
3) Non-adjustable drying temperature.
4) Bad adaptability for the fluctuation of the cement kiln.
5) Mutual influence between AQC boiler and SP boiler.
6) High investment per KW.

Power generation capacity

basing on per tonnage of clinker

<140KJ/kg-35kW·h
WHR power generation

4000kW

8130kW

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2 The Construction of the 2nd Generation Technology of pure low-
temperature WHR power generation for cement kilns.

Waste heat distribution of cooler

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 Adjusting Unit C2 Superheater Multi-stage Waste Heat Extraction
for Temperature for Cascade Utilization of Waste Heat

ASHSuper heater for

Adjusting Steam Parameter

Air Circulation
Multi-stage Mixed Pressure Admission 1.57~3.43 MPa Relative High Pressure Steam Segment
(With Steam-additional) Steam Turbine 0.15~0.5 MPa Low Pressure Steam Segment
100~130•°C Hot Water Segment Arranging Heat Surface

The thermodynamic system of power plant adopts relative high temperature & pressure
primary steam parameter of 1.57~3.43MPa-340~435•°C so as to provide guarantee
for improving WHR power generation capacity.

The premises: without impacting the heat consumption of cement clinker; meeting
the required temperature of 170~220•°C for raw meal & fuel drying. without changing
cement production technology process & machines; without impacting the production
of cement kiln.
1) The waste heat is able to generate either sub-medium pressure or medium pressure
steam of saturated-overheat 450•°C, low pressure and low temperature steam of
0.1~0.5MPa saturated-180•°C, and hot water of 85~130•°C at the same time.
2) That thermodynamic circulation system is able to use medium pressure and medium
temperature parameters, to improve the thermodynamic circulation system efficiency,
and to realize the principle of heat utilization in cascade as per the fluctuation of
temperature as well as making full use of the waste heat contributed by various flue
gas temperature from the cement kiln.
3) The flue gas waste heat from cement
kiln is converted by its quality into the Power generation Power generation
power energy to the maximum extent capacity 3140KJ/Kg-38~45kW·h/t
so that the WHR power generation 12.5%~31.25%
capacity is improved highly.
4) It solves the problem of the lifetime of the steam turbine.

5) It creates the conditions for the steam turbine operation with smooth parameters
of primary steam pressure and temperature in a large various range.
Primary steam Actual permissible
pressure various range
& temperature of the turbine
The 2nd Generation Technology 2.29MPa-370•°C 1.27~2.47MPa, 325•°C~400•°C
The 1st Generation Technology 0.689MPa-317°C 0.49~0.98MPa, 292•°C~330•°C

6) The adjustable unit is set up at SP boiler. 5

 7) A separate steam super heater is equipped inside the second stage of the preheater.

For example basing on a new type of dry cement kiln with capacity of
5500TPD and outlet temperature of 330•°C of flue gas at the preheater:

Power capacity Power Generating Power Generating Annual power

2.5% Independently Independently generation 2.5%

Does equipping a C2 superheater increase the heat consumption of cement clinker?

8) Circulation air is used for FD fans of clinker cooler;

The waste heat utilization of the flue gas from the clinker
cooler is further improved and the power capacity is further
improved more than 5~10%.
9) Combining the technology for WHR system for dry type of long kilns and the
2ndGeneration Technology for pure low temperature WHR system can realize the
recovery of the high temperature of waste heat ranging of 1000•~1250•°C from the
bypass discharge at the preheater and change into power energy in high efficiency,
thus reduce the added energy consumption due to the bypass discharge for the cement
clinker production.

Technical Specifications (1ST Generation)

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Technical Specifications ( 2nd Generation )

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Study on some key issues

1) Investment.
2) Safety, Stability, High-Efficiency & Adaptability of WHR System to Fluctuation of
Cement Production.
3) Efficiency, Service Life and Adaptability of Steam Turbine to Emergent Interruption
of Cement Kiln.
4)WHR Utilization Rate of Hot Air of Clinker Cooler.
5)Simplicity & Convenience of Operation Control.
6)Regulation & Control of Flue Gas Temperature for Raw Meal & Coal Drying and Impact
of WHR System on Deducting Effect of ESP for Preheater.
7)About the Weight of the Boilers (Heat-transferring surface of the boilers)
8)About Heat Efficiency of Waste Heat Recovery Boiler.
9)About the Reform ability of the WHRPP.
10)About the Evaluation & Acceptance of the WHRPP.
11)About the stability of power generation output of the WHRPP.
12)About some key points to focus on site visit in WHR power plant.
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4 Impacts of WHR power plants on cement kilns

1) HT ID Fan at SP: the load for HT Fan decreases after the power plant is put into
operation.
2) GCT: will adjust water spray quantity according to power plant’s operation or stop
until water spray stops or totally opens.
4) ESP at SP: dust collection will be affected after the power plant is put into operation.
6) ESP at the cooler: the temperature of ESP will decrease greatly, and the dust load
correspondingly decreases.
7) Operation of kiln system: As two HRSGs are added to the kiln system, and the flue
gas is both from and to the kiln.

5 The 3rdGeneration Technology of medium & low temperature

WHR power generation for cement kilns

The premises:
For new type dry kilns, guarantee the parameters of flue gas for raw material and coal
mill drying, the cement production isn’t impacted, the heat and power consumption
of clinker aren’t increased, the heat source of raw fuel for cement production isn’t
changed and the cement production process isn’t changed

the power generation capacity The power of generating sets

basing on per tonnage of clinker for
3140kJ/kg-48•~52.5kW·h a cement kiln with real output
of 5500t/d 12000•~15000kW.

The ultimate aim:

In cement clinker production, besides the fuel consumption of 3140~3350Kj/kg in
cement clinker production, the electricity consumption is zero.

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