BESTWAY CEMENT LIMITED CHAKWAL

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 Waste Heat Recovery Power Plant

Waste Heat Recovery

Power Plant Training
By : Raja Kamal
(Trainee Engineer)

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 Introduction
 Waste heat recovery power generation add a valuable source of power
to a Cement plant. Waste heat recovery power systems used for cement
kilns operate on the Rankine Cycle. This thermodynamic cycle is the
basis for conventional thermal power generating stations and consists
of a heat source (boiler) that converts a liquid working fluid to high-
pressure vapor (steam, in a power station) that is then expanded
through a turbo-generator producing power, with condensate from the
condenser returned to the boiler feed water pump to continue the cycle.
 Waste heat recovery systems consist of heat exchangers or heat
recovery steam generators (HRSGs) that transfer heat from the exhaust
gases to the working fluid inside, turbines, electric generators,
condensers, and a working fluid cooling system.

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WASTE HEAT RECOVERY POWER PLANT

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 Steam Cycle
 Steam power plants play a key role in electric power generation. Therefore the
Rankine steam power cycle is one of the most important cyclic process used in
industry. The efficiency of electrical power generation has been increased in the
last few years due to process optimization.
 There are four processes in the Rankine cycle.
 Process 1-2: The working fluid is pumped from low to high pressure. As the fluid
is a liquid at this stage, the pump requires little input energy.
 Process 2-3: The high pressure liquid enters a boiler where it is heated at
constant pressure by an external heat source to become a dry saturated vapour.
 Process 3-4: The dry saturated vapour expands through a turbine, generating
power. This decreases the temperature and pressure of the vapour, and some
condensation may occur. The output in this process can be easily calculated using
the chart or tables noted above.
 Process 4-1: The wet vapour then enters a condenser where it is condensed at a
constant pressure to become a saturated liquid.

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RANKINE CYCLE BLOCK DIAGRAM &
CYCLE T-S DIAGRAM

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GENERAL LAY OUT
 STEAM FLOW
BOILER S.HEATER Turbine

condenser
 WATER FLOW
B STEAM
O
I
L
E C COOLING
R O HOT WATER
N TOWER
D
E
N

RO
S
Storage Tanks E
PLANT R
COOL WATER

B.F.P
 Parts of WHRPP

(1) Turbine
(2) Cooling Tower
(3) Waste heat exchangers
(4) Coal Fired Boilers
(5) Gas gensets

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 (1) Steam Turbine
 The steam turbine is a dual pressure, single cylinder, series flow,
impulse condensing steam turbine & it forms a complete set of power
generating equipment with boiler, generator & auxiliary equipment. It’s
power generating capacity is 16MW/hr.
 Steam Turbine Specifications :
1. Steam Pressure : 1.53 Mpa (A)
2. Turbine rated power : 16 MW
3. Turbine rated steam admission : 77.2 T/hr
4. Steam Consumption : 4.76 Ton/MW

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 Turbine Parts

Condenser
 Steam after rotating steam turbine comes to condenser. Condenser refers here to shell
and tubes type heat exchanger installed at the outlet of steam turbine. The condenser is
a heat exchanger which converts steam from gaseous into liquid state.

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 Turbine Parts

Alternator Generator :
An alternator is an electrical generator that converts mechanical
energy to electrical energy in the form of alternating current.[2] For
reasons of cost and simplicity, most alternators use a rotating
magnetic field with a stationary armature.[3] Occasionally, a
linear alternator or a rotating armature with a stationary magnetic field
is used. In principle, any AC electrical generator can be called an
alternator, but usually the term refers to small rotating machines driven
by automotive and other internal combustion engines. An alternator that
uses a permanent magnet for its magnetic field is called a magneto.
Alternators in power stations driven by steam turbines are called turbo-
alternators. Large 50 or 60 Hz three phase alternators in power plants
generate most of the world's electric power, which is distributed by
electric power grids.

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 (2) Cooling Tower

Cooling Tower :
The condensate water after condensation is initially at high temperature. This hot water is
passed to cooling towers. It is a tower in which atmospheric air circulates in direct or indirect
contact with warmer water and the water is thereby cooled. Water, acting as the heat transfer
fluid, gives up heat to atmospheric air, and thus cooled, is re-circulated through the system.

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 Types of cooling tower

(1) Natural draft cooling tower :

Natural draft cooling towers rely on natural convection to circulate air throughout the tower,
which then cools the water. Air movement occurs due to differences in density between the
entering air and the internal air within the tower. Warm, moist air, which is more dense than
cool air, will naturally rise through the tower, while the dry, cool air from outside will fall,
creating a constant cycle of air flow.

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 Types of cooling tower

(2) Induced draft cooling tower :

A mechanical draft cooling tower with a fan at the discharge which pulls air through
tower. The fan induces hot moist air out the discharge. This produces low entering
and high exiting air velocities, reducing the possibility of recirculation in which
discharged air flows back into the air intake.

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 Types of cooling tower

(3) Forced draft cooling tower :

A mechanical draft cooling tower with a blower type fan at the intake. The fan forces air into
the tower, creating high entering and low exiting air velocities. The low exiting velocity is
much more susceptible to recirculation. With the fan on the air intake, the fan is more
susceptible to complications due to freezing conditions. Another disadvantage is that a forced
draft design typically requires more motor power than the equivalent induced draft design.
The forced draft benefit is its ability to work with high static pressure.

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(3)Waste Heat Exchanger/Waste Heat Boiler

AQC Boiler :
Air quenching cooler boiler as the name indicates, it capture the waste heat
gases of kiln cooler to generate the steam. Its steam generating capacity is
21 TPH.
PH Boiler :
Pre heater boiler , as the name indicates it capture the waste heat gases from
pre heater and generates steam upto 24.1TPH.

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 (4) Coal Fired Boilers

Coal Fired Boiler:

 A coal-fired boiler is an industrial boiler that generates thermal energy
by burning coal that is blown into the firebox.
 This type of boiler dominates the electric power industry, providing
steam to drive large turbines. Coal boilers provides the thermal energy
which produces about 50% of the world's electric supply.

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 Chain-Grate or Traveling-Grate Stoker Boiler
 Coal is feed onto one end of a moving steel chain grate. As grate moves
along the length of the furnace, the coal burns before dropping off at the
end as ash. Some degree of skill is required, particularly when setting up
the grate, air dampers and baffles, to ensure clean combustion leaving
minimum of un-burnt carbon in the ash.
 The coal-feed hopper runs along the entire coal-feed end of the furnace.
A coal grate is used to control the rate at which coal is fed into the
furnace, and to control the thickness of the coal bed and speed of the
grate. Coal must be uniform in size, as large lumps will not burn out
completely by the time they reach the end of the grate. As the bed
thickness decreases from coal feed end to rear end, different amounts of
air are required- more quantity at coal-feed end and less at rear end.

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Chain-Grate or Traveling-Grate Stoker Boiler

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 Boiler Mountings & Accessories
Boiler mountings :
1. Water level indicator ( Water level gauge)
 It is fitted in front of the boiler and generally present two in number.
It is used to indicate the water level inside the boiler. It shows the instantaneous level of water
that is present inside the steam boiler which is necessary for its proper working.
2. Pressure gauge
 It is also present in front of the boiler.
 It is used to measure the pressure of the steam inside the boiler.
 The pressure gauges generally used are of Bourden type
3. Safety valves
 Safety valves are attached to the steam boiler chest.
 It is used to prevent explosion due to excessive internal pressure. When the internal
pressure inside the boiler exceeds its working pressures than the safety valves blow off the
steam and maintains the internal pressure.
 Generally two safety valves are present on a boiler.
4. Stop valve
 It is usually fitted on the highest part of the boiler with the help of a flange.
 The main function of the stop valve is
 To control the flow of steam from the boiler to the main steam pipe.
 To completely shut off the steam supply when required.

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 Boiler Mountings & Accessories
Boiler mountings :
5. Blow Down Valve
 It is fitted at the bottom of the boiler drum.
The functions of blow down valve is
 To empty the boiler whenever required.
 To discharge the scale, mud and sediments which gets collected at the bottom of the boiler.
6. Feed check valve
 It is non-return valve and fitted to a screwed spindle to regulate the lift.
 It is fitted to the shell slightly below the normal water level of the boiler. A boiler must have
its spindle lifted before the pump is started.
 It regulates the supply of water which is pumped into the boiler by feed pump.
7. Fusible Plug
 It is fitted to the crown plate of the furnace or firebox.
 Its function is to extinguish fire in the furnace when the water level in the boiler falls to an
unsafe limit. This avoids the explosion that may takes place because of the overheating of
the furnace plate.

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 Boiler Mountings & Accessories
Boiler Accessories :
The boiler accessories are the integral parts of the boiler. They are used in the boiler to
improve its efficiency.
1. Air pre-heater
 It is used to recover heat from the exhaust gases.
 It is installed between the economiser and the chimney.
2. Super heater
 It is placed in the path of hot flue gases from the furnace.
 A super heater is an important accessory used in the boiler. Its main function is to increase
the temperature of saturated steam without raising its pressure.
3. Economiser
 It is used to heat the feed water by the utilization of heat from the hot fuel gases before it
leaves the chimney.
 A economiser improves the economy of the steam boilers.
4. Feed pump
 It is used to deliver water to the boiler.

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 Boiler Parts
De aerator :
A deaerator is a device that is widely used for the removal of oxygen
and other dissolved gases from the feed water to steam-generating
boilers.

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 Boiler Parts
Economizer :
Economizers in steam power plants is to capture the waste heat from
boiler stack gases (flue gas) and transfer it to the boiler feed water. This
raises the temperature of the boiler feed water, lowering the needed
energy input, in turn reducing the firing rates needed for the rated boiler
output.

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 Boiler Parts

Air Pre heater :

 Air preheater are heat exchanger to preheat or air heating of the combustion air
by means of flue gas, steam, water or thermal oil. Air preheaters are used when
exhaust temperatures of combustion systems are particularly high.
 Boilers are provided with economizer and air pre-heaters to recover heat from the
flue gases. An increase of about 20% in boiler efficiency is achieved by providing
both economizer and air pre-heaters. Providing economizer alone gives only 8%
efficiency increase and so designers provide both.
 Most of the high capacity boilers firing coal operate with an efficiency of around
86% on the Higher Heat Value basis. Loss of around 14% can be attributed to
various losses of which the dry gas loss is about 35% of the total. When both
economizers and air pre-heaters are not provided the boiler efficiency drops to
around 66% from 86%.
 When air pre-heater is not provided the boiler efficiency will be around 74 % only.
Thus we can conserve about 20% extra fuel when we provide both economizers
and air pre-heaters in boilers.

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 Boiler Parts

Super heater :
 A superheater is a device used to convert saturated steam or wet steam
into superheated steam or dry steam. Super-heaters are used in
steam turbines for electricity generation, steam engines, and in
processes such as steam reforming.

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Benefits of WHRPP

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 Gas Gensets

Heat Engine & Types :

Heat engine is a system that converts thermal energy to mechanical energy,

which can be used to do mechanical work

Types:
 External Combustion EC
 Internal Combustion

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 Gas Gensets

Classification by Strokes:
1. 04 Stroke
2. 02 Stroke

Four Strokes:
• Intake
• Compression
• Power
• Exhaust

For electric power generation, four-stroke

engines are predominately used.

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 Gas Gensets

Four Strokes

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Gas Gensets

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 Gas Gensets

Two Strokes:

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 Gas Gensets

Wartsila 18W220SG Gas Gensets

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 Gas Gensets

In a power plant, many SG or diesel ICEs are grouped into blocks

called generating sets.
Every engine is connected to a shaft which is connected to its
electric generator.
These generating sets provide modular electric generating capacity
and come in standardized sizes.

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 Gas Gensets

Wartsila 18W220SG Gas Gensets

• 12.8 MW
• 3.2MW rated capacity
• 04 nos. of Gensets in total

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 Gas Gensets

Wartsila 18W220SG Gas Gensets

 Fuel Flexibility
Natural gas, light fuel oil, heavy fuel oil, biodiesel, bio-fuels, and crude oil
 Diesel engines are generally more efficient than SG engines, but also
produce more nitrogen oxides (NOx), sulfur dioxide (SO2), and particulate
matter (PM).
 In SG engines, premixing of air with the fuel to produce “lean” conditions
(more air than is needed for combustion) has the effect of lowering the
combustion temperature and impeding NOx formation
 Dual-fuel (DF) engines are designed with the ability to burn both liquid and
gaseous fuels. When operating in gas mode, the gaseous fuel is premixed
with air, injected just after the compression stroke and ignited by a pilot fuel
flame. In this process, the pilot fuel flame acts a “spark plug” to ignite the
lean gas-air mixture. DF engines retain the ability to use a backup liquid fuel
when gas supply is interrupted.
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 Gas Gensets

Wartsila 18W220SG Gas Gensets

 Gas System
 Lube Oil System: On-engine filter, thermostatic valve, heat
exchanger, pre-lube pump and
piping included; plant oil storage and transfer equipment not
included.
 Start Air System
 Cooling System: Low temperature and high temperature
thermostatic valves included.
radiator, piping and valves
 Exhaust System: Silencer, expansion bellows, ventilation fan and
rupture disk included

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 Gas Gensets

Wartsila 18W220SG Gas Gensets

• 12.8 MW
• 3.2MW rated capacity
• 04 nos. of Gensets in total

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