Name: MORALES, KATHLYN KYLE M.

Schedule: 1-2 PM MWF

Course and Year: BSME-3A Date: DECEMBER 3, 2021

Research Topic: THERMAL ENGINEERING

Research Titile: DESIGN AND ANALYSIS OF A COGENERATION PLANT USING HEAT RECOVERY OF A CEMENT
FACTORY

Objectives:
1. To design and analyze a cogeneration plant using heat recovery cement factory.
2. To quantify the power generation capacity with plant analysis

Statement of the Problem:

1. How much power can be produced with the available heat recovery against a cement factory?
2. What is the most appropriate method to solve the cogeneration plant?

LITERATURE REVIEW/SYNTHESIS MATRIX

Authors Year Literature Objectives Methods Sample Conclusions Comments

Titles (If not
applicable
write N/A)
Kanis 2020 The Measures To measure the Measuring the Sylhet Gas Technical It is highly
Fatama of Efficiency of performance of performance of Turbine efficiency has recommended
Ferdushi, Power power power generation Power Station declined over to monitor
Anton Generation generation plants and (Sylhet the reference power
Abdulbasah Plants in Sylhet plants in Sylhet calculating the GTPP, 150  period. Tests for distribution
Kamil, Saleh of Bangladesh region of efficiency of a MW), different null companies to
Ahmed, and Bangladesh power plant Fenchuganj hypotheses excel their
Luthful Alahi considering using trans-log Combined showed that the efficiency and
Kawsar twenty-four- production model Cycle Power presence of combat the
month monthly Plant one-sided error sufferings for
dataset during (Fenchuganj component was mass people.
2013-14. CCPP, 97  justified by the With regard to
MW), Sylhet LR test plant operation
Combined individually, and
Cycle Power which was maintenance,
Plant (Sylhet recorded there is a need
CCPP, 150  significant for for the BPDB to
MW), these models. make further
Shahjibazar We found that improvements
Power Station the trans-log to the technical
(PS, 330  stochastic level of its
MW), and frontier employees by
Desh Energy production providing
(DE, 10 MW). model is more training and so
preferable than forth. In
the C-D addition,
stochastic restructuring is
frontier currently
production underway at
model. The BPDB in line
variation in the with government
observed level reforms of the
of output is not power sector,
just due to and thus,
random shocks careful
but also can be monitoring of
explained by the the situation is
differences in necessary. 
the levels of
technical
efficiency in the
power plants.
The truncated
(at zero) normal
distribution is
preferable to the
half-normal
distribution for
the technical
inefficiency
 effects. The
technical
inefficiency
effect varies
significantly over
time. It is
observed that
the monthwise
and plantwise
truncated
normal
distribution gives
higher mean
technical
efficiency
estimates than
the half-normal
distribution.
Yana 2014 Waste Heat To analyze the Analysis of WRH The countries Waste Heat
Gorbatenko Recovery for the current status of potential and were selected Recovery
and Cement Sector: Waste Heat enabling factors based on (WHR) is a
Alexander Market and Recovery in eleven country their robust proven
Sharabaroff. Supplier (WRH) markets in Africa, cement technology, but
Bruce Analysis technology South Asia, industries and until now WHR
Hedman and deployment in Middle East, markets, uptake has been
Jigar Shah. developing Latin America, prospects for limited except in
countries and and East Asia. near- and China.
investigates the mid-term Regulatory
success factors economic measures and
in countries growth and lower capital
where WRH has expanding costs have been
become widely cement key factors
spread. To consumption, behind China’s
identify and market success in
emerging factors that mainstreaming
markets where encourage WHR
WHR power WHR technology.
generation may adoption, Waste Heat
have significant such as Recovery
 growth potential power (WHR) can
and strong reliability reduce the
market drivers. concerns, operating costs
rising and improve
electricity EBITDA margins
prices and/or of cement
environmental factories by
and about 10 to 15
sustainability percent.
initiatives. Structured
financing is key
to realize the
untapped WHR
potential. There
is a strong
potential for
WHR in Asia
and Latin
America.
Opportunities in
selected
countries in
Africa and
Middle East are
also profound.
Stanley 2017 The generation Determining the Evaluating the The case The volumetric It is
Ngari Irungu, of power from a potential potential that the study plant flow rate of the recommended
Peter cement kiln electrical energy plant has for has a full cooler and for the
Muchiri & waste gases: a generation from generating cement preheater installation of a
Jean Bosco case study of a waste heat electrical power process line exhaust gas steam rankine
Byiringiro plant in Kenya recovery from the hot from mining to streams was cycle for the
through actual waste gases cement finish measured and power
data measured vented into the grinding. It thermal dynamic generating
in the plant for atmosphere and has a balance carried plant. In this
the volumetric it was found that production out to quantify work the
gas flow rates of the plant has the capacity of the thermal authors
both the potential to 1700 tons of energy content. designed the
preheater and generate 3.4 clinker and The potential steam boilers
cooler exit gas MWh of electrical 4000 tons of electrical energy for the waste
streams power cement. The that could be heat recovery
clinker generated from plant for
produced is exhaust gas conversion of
not sufficient streams by thermal energy
to make all conversion to electrical
the required through a Steam energy, selected
cement and rankine cycle a commercial
therefore the was evaluated. steam turbine
plant import A heat audit was and evaluated
some clinker done and its economic
to meet the several heat feasibility and
deficit. balances carried established that
out for the new the designed
plant layout to plant would
quantify the have a simple
thermal energy payback period
content in the of 2.7 years.
waste gases
steam that could
be recovered for
power
generation. It is
noted that not all
gasses from the
preheater exit is
available for
power
generation as
some was
reserved for raw
material and fuel
drying. The
paper focused
on recovering
the heat
previously lost in
the GCT. The
paper focused
on recovering
 the heat
previously lost in
the GCT. The
source of
thermal energy
to run the waste
heat recovery
Power plant was
purely the waste
gases from the
kiln and there is
no other source
of thermal
energy that was
considered in
the research
work.
G.V. 2015 Parametric The work is A case study has Waste heat A cement An accurate
Pradeep analysis of focused on been conducted recoveries factory prediction of the
Varma, T. steam flashing finding the best at a cement cement plant cogeneration performance of
Srinivas in a power plant operational factory, whose plant, the a power plant,
using waste conditions for Telangana, India capacity is conventional with the
heat of cement the high with 4000 TPD steam power corresponding
factory pressure cogeneration plant has been detailed
flashing and low plant having replaced by a evaluation of its
pressure flashing double flash thermodynamics
flashing in a technology. The steam power variables, allows
cogeneration high pressure plant. The to avoid
plant applied to water is flashed results are undesirable or
a cement into wet steam at focused to abnormal
factory. two pressure search the best operating
levels (high condition for conditions or to
pressure flashing HRSG pressure, anticipate
and low pressure HP flasher, LP solutions to
flashing) to flasher and certain unusual
increase the flashing amount. operating
power There is a conditions like
generation. The relation between those derived
hot water from flash mass and from
 the flashing exhaust gas maintenance
chamber is used temperature. An labours.
for the optimum flash Currently, the
regeneration of mass ratio can electric is the
the cycle and the be selected at a most important
steam is supplied minimum flue form of energy
to the turbine at gas used in the
the relevant temperature. world. For this
location. The current reason, power
work suggests plants
0.5 temperature necessary to
ratio for both HP study as the
flasher and LP crucial energy
flasher. The systems
suggested flash
mass ratio is
0.25 to result
approximately
90oC of exhaust
gas temperature
at AQC. On
overall basis
double flashed
system proves
over
conventional
plant by
increasing heat
recovery and so
power output
Adem 2012 Thermodynamic To indicate a Manufacture of The main raw Energy and The exergy
Atmaca and analysis of a detailed Portland cement. materials exergy analysis
Mehemt pyroprocessing thermodynamic Energy and used in the efficiencies were indicates that
Kanoglu. unit of a cement analysis of a exergy analyses cement determined for there is a signifi
Mohamed plant: A case pyroprocessing in the manufacturin the cant potential
Gadalla study unit and waste pyroprocessing g process are pyroprocessing for i ncreasing
heat recovery uni are limestone, unit in a cement exergy effi
system that performed by sand, clay, plant using the ciency by
would represent using the first shale and iron actual decreasing
a valuable and second laws ore. operational data. irreversibilities.
contribution to of The energy and It is clear that a
the performance thermodynakics. exergy efficiency conscious and
improvement of values of the planned effort
cement industry. pyroprocessing towards building
unit are an energy
determined to management
be 52.2% and structure within
39.5%, the plant is
respectively. needed to
The rate of heat improve exergy
losses from the utilisation in the
surface of the pyroprocessing
pyroprocessing unit.
unit cyclones is
22.775 MW.
Insulating the
cyclones and
gas channels
can increase the
energy and
exergy
efficiencies to
63.6% and
47.3%,
respectively.
Further studies
may focus on
the selection of
the most
appropriate
insulation
material for
different
sections of the
factory.
Installation of a
waste heat
recovery steam
generator can
provide
electricity
production at a
rate of 1056.7
kW. This
represents 8.2%
of current
electricity use in
the plant. This
system prevents
the emission of
5183.2 tons of
CO2 to the
atmosphere
yearly. The
payback period
of this
investment is
estimated to be
18 months. The
effect of ambient
air temperature
on the efficiency
values is
demonstrated. It
is seen that the
energy and
exergy effi
ciency values of
the system
strongly depend
on the ambient
temperature. In
winter season,
the energy and
exergy effi
ciency values of
the unit
 decrease to
47.9% and
35.2%,
respectively.
The highest effi
ciency values
are obtained in
summer season

References:
1. https://www.hindawi.com/journals/ijmms/2020/9308174/
2. https://www.ifc.org/wps/wcm/connect/f0394a25-3645-4765-8291 ea33d9f09594/IFC+Waste+Heat+Recovery+Report.pdf?
MOD=AJPERES&CVID=kqgTRfZ
3. https://onlinelibrary.wiley.com/doi/pdf/10.1002/ese3.153
4. https://www.researchgate.net/publication/
311467212_Parametric_Analysis_of_Steam_Flashing_in_a_Power_Plant_Using_Waste_Heat_of_Cement_Factory
5. https://www.researchgate.net/publication/
261008787_Thermodynamic_analysis_of_a_pyroprocessing_unit_of_a_cement_plant_A_case_study