Energetic and exergetic analysis of waste heat recovery systems in the cement industry

Karellas, Sotiriοs; Leontaritis, Aris-Dimitrios; Panousis, G.; Bellos, Evangelos; Kakaras, Emmanuel

doi:10.1016/j.energy.2013.03.097

Cited by 193 publications

(74 citation statements)

References 10 publications

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“…The first choice of working medium for ORC system is isopentane, because of the highest achievable efficiency of the cycle. The heat recovery system using the ORC [8] CR water Steam cycle is more efficient than the ORC when the flue gas temperature is greater than 310 °C. For cement plants that use old technology and flue gas temperature is high, preferred system is the use of waste heat recovery system with CR water steam cycle.…”

Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

“…For cement plants that use old technology and flue gas temperature is high, preferred system is the use of waste heat recovery system with CR water steam cycle. But for modern cement plants with higher efficiency and lower temperatures there is advisable to use ORC system [8]. In addition, ORC cycle is more flexible and disposable, can operate at a partial load, and has a wide range of stable operation, while the water steam cycle needs a stable and more uniform operation conditions [9].…”

Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

“…Four-stage heater supplies gas temperatures of 300-380 ° C and 5 ÷ 6-stage 200-300 °C. The hot air discharged from the clinker coolers can reach 360 ° C [8]. Both streams of air and flue gases can be directed through the WHRSG steam generator (Waste Heat Recovery Steam Generator, Fig.…”

Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

“…Currently this technics utilization heat from flue gases is implemented in many installation for instant in Rudniki Cement Plant. The waste heat recovery system with the ClausiusaRankine water -steam cycle [8] There is also the possibility of electricity generation in a cement plant in other cogeneration cycles: an Organic Rankine cycle (ORC), Kalina cycle, or in the piston steam engine. Very preferred because of its low installation cost and increased efficiency is the use of the TFC system (Trilateral Flasch Cycle) in screw engines where there is no water evaporation, but the expansion with evaporation [11].…”

Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

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Utilization of waste heat from rotary kiln for burning clinker in the cement plant

et al. 2016

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Abstract. Cement subsector next to the glass industry is counted among one of the most energy-intensive industries, which absorbs approx. 12-15% of the total energy consumed by the industry. In the paper various methods of energy consumption reduction of in the cement industry are discussed. Cement production carries a very large emissions of greenhouse gases, where CO 2 emissions on a global scale with the industry than approx. 5%. Great opportunity in CO 2 emissions reduction in addition to the recovery of waste heat is also alternative fuels co-firing in cement kilns [1], [2]. In the cement sector interest in fitting-usable waste energy is growing in order to achieve high rates of savings and hence the financial benefits, as well as the environment ones [3]. In the process of cement production is lost irretrievably lot of energy and reduction of these losses on a global scale gives a visible saving of consumed fuel. The aim of this study is to investigate the possibility of waste heat use in Rudniki Cement Plant near to Czestochowa. After analyzing of all waste heat sources will be analyzed the heat emitted by radiation from the surface of the rotary kiln at the relevant facility. On the basis of thermal-flow calculations the most favorable radiative heat exchanger will be designed. The calculations based on available measurements provided by the cement plant, a thermal power of the heat exchanger, the heat exchange surface, the geometry of the heat exchanger, and other important parameters will be established. In addition the preliminary calculations of hydraulic losses and set directions for further work will be carried out. Direct benefits observed with the introduction of the broader heat recovery technology, is a significant increase in energy efficiency of the industrial process, which is reflected in the reduction of energy consumption and costs. Indirectly it leads to a reduction of pollution and energy consumption.

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Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

Section: The Use Of Heat Of Flue Gases and Clinker Cooling Airmentioning

confidence: 99%

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Utilization of waste heat from rotary kiln for burning clinker in the cement plant

et al. 2016

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“…They have also been applied for power generation and energy efficiency on offshore oil and gas processing platforms [33], also in combination with wind farms [34]. In addition, over the years, the ORC has also seen applications in the petroleum refining industries from multiple waste-heat sources [35], and in heat recovery from (rotary) kilns in the cement [36] and steel industries [37]. In these systems, an intermediate oil or water loop is employed to recover heat from the waste-heat stream before it is subsequently passed on the working fluid in the cycle.…”

Section: Introductionmentioning

confidence: 99%

Case Study of an Organic Rankine Cycle (ORC) for Waste Heat Recovery from an Electric Arc Furnace (EAF)

et al. 2017

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The organic Rankine cycle (ORC) is a mature technology for the conversion of waste heat to electricity. Although many energy intensive industries could benefit significantly from the integration of ORC technology, its current adoption rate is limited. One important reason for this arises from the difficulty of prospective investors and end-users to recognize and, ultimately, realise the potential energy savings from such deployment. In recent years, electric arc furnaces (EAF) have been identified as particularly interesting candidates for the implementation of waste heat recovery projects. Therefore, in this work, the integration of an ORC system into a 100 MWe EAF is investigated. The effect of evaluations based on averaged heat profiles, a steam buffer and optimized ORC architectures is investigated. The results show that it is crucial to take into account the heat profile variations for the typical batch process of an EAF. An optimized subcritical ORC system is found capable of generating a net electrical output of 752 kWe with a steam buffer working at 25 bar. If combined heating is considered, the ORC system can be optimized to generate 521 kWe of electricity, while also delivering 4.52 MW of heat. Finally, an increased power output (by 26% with combined heating, and by 39% without combined heating) can be achieved by using high temperature thermal oil for buffering instead of a steam loop; however, the use of thermal oil in these applications has been until now typically discouraged due to flammability concerns.

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Efficiency Measurement and Modeling of a High‐Performance Mg₂(Si,Sn)‐Based Thermoelectric Generator

et al. 2022

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Mg2(Si,Sn) is an attractive material class due to its excellent thermoelectric (TE) properties, its eco‐friendly constituents, its low mass density, and its low price. A lot of research has been done on optimizing its TE properties; however, works on its use in thermoelectric generators (TEG) are scarce. Herein, the first conversion efficiency measurement of a functional, fully Mg2(Si,Sn)‐based TEG, approaching a maximum value of 4% for an applied ΔT = 375 °C, is shown. A maximum power density of 0.9 W cm−2 (related to the cross‐sectional area of the TE legs) at ΔT=375 °C is also reported, which is among the highest performance of silicide‐based modules reported in literature. Efficiency measurements can be tricky due to the uncertainty of heat flow measurement and parasitic heat losses; therefore, assessing the measurement reliability by confronting it to theoretical calculations is necessary. TEG device simulation in a constant property model is used to compare measured data to expected values and a good match is found (<1% deviation for current at maximum power, <4% difference for maximum power output, deviation within measurement uncertainty range for heat flows and efficiency). The significant discrepancy between measurement and calculations of the inner electrical resistance reveals room for improvement. Cracks form due to thermally induced mechanical stress, which dramatically increase the inner electrical resistance. It is shown that by avoiding those cracks, the maximum power output and conversion efficiency of the TEG could be improved by 30%.

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Energetic and exergetic analysis of waste heat recovery systems in the cement industry

Cited by 193 publications

References 10 publications

Utilization of waste heat from rotary kiln for burning clinker in the cement plant

Utilization of waste heat from rotary kiln for burning clinker in the cement plant

Case Study of an Organic Rankine Cycle (ORC) for Waste Heat Recovery from an Electric Arc Furnace (EAF)

Efficiency Measurement and Modeling of a High‐Performance Mg₂(Si,Sn)‐Based Thermoelectric Generator

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Energetic and exergetic analysis of waste heat recovery systems in the cement industry

Cited by 193 publications

References 10 publications

Utilization of waste heat from rotary kiln for burning clinker in the cement plant

Utilization of waste heat from rotary kiln for burning clinker in the cement plant

Case Study of an Organic Rankine Cycle (ORC) for Waste Heat Recovery from an Electric Arc Furnace (EAF)

Efficiency Measurement and Modeling of a High‐Performance Mg2(Si,Sn)‐Based Thermoelectric Generator

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Efficiency Measurement and Modeling of a High‐Performance Mg₂(Si,Sn)‐Based Thermoelectric Generator