Power-Augmented Steam Power Plant in a Cogeneration Cement Factory
Publication: Journal of Energy Engineering
Volume 143, Issue 1
Abstract
Cement factories have more potential to generate power from waste heat compared to other industries. Pressurized water flashing into wet steam at the end of a boiler’s economizer augments 15% of the plant’s output by increasing waste heat recovery compared to a regular steam power plant (Rankine cycle with a deaerator). A double-flash steam power plant is considered for theoretical demonstration of power augmentation with a cement factory’s waste heat recovery compared to a regular steam power plant. The hot water from the final flash chamber is used for feedwater heating and the saturated steam from the two flash chambers is supplied to the turbine. The current work is focused on selection of heat-recovery steam generator’s (HRSG) pressure and location of the high-pressure flasher (HPF) and low-pressure flasher (LPF). The flash fluid mass can be analyzed for better heat recovery as it influences the exhaust gas temperature. A low pressure has been recommended for the HRSG as it increases the heat recovery and power production at a fixed pinch point. The suggested temperature ratio for HPF and LPF is 0.5. The theoretical results are validated with a case study conducted at a cement factory.
Get full access to this article
View all available purchase options and get full access to this article.
References
Amirante, R., and Tamburrano, P. (2015). “Novel, cost-effective configurations of combined power plants for small-scale cogeneration from biomass: Feasibility study and performance optimization.” Energy Convers. Manage., 97, 111–120.
Chandra, K., and Palley, J. N. (1983). “Cement plant cogeneration opportunities.” IEEE Trans. Industry Appl., IA-19(1), 37–42.
Clarke, J., and McLeskey, J. T., Jr. (2014). “The constrained design space of double-flash geothermal power plants.” Geothermics, 51, 31–37.
Engin, T., and Ari, V. (2005). “Energy auditing and recovery for dry type cement rotary kiln systems—A case study.” Energy Convers. Manage., 46(4), 551–562.
He, W. F., Han, D., Xu, L. N., Yue, C., and Pu, W. H. (2016). “Performance investigation of a novel water-power cogeneration plant (WPCP) based on humidification dehumidification (HDH) method.” Energy Convers. Manage., 110, 184–191.
Karellas, S., Leontaritis, A. D., Panousis, G., Bellos, E., and Kakaras, E. (2013). “Energetic and exergetic analysis of waste heat recovery systems in the cement industry.” Energy, 58, 147–156.
Khatita, M. A., Ahmed, T. S., Ashour, F. H., and Ismail, I. M. (2014). “Power generation using waste heat recovery by organic Rankine cycle in oil and gas sector in Egypt: A case study.” Energy, 64, 462–472.
Khurana, S., Banerjee, R., and Gaitonde, U. (2002). “Energy balance and cogeneration for a cement plant.” Appl. Therm. Eng., 22(5), 485–494.
Li, W., Zhao, J., Fu, L., Yuan, W., Zheng, Z., and Li, Y. (2015). “Energy efficiency analysis of condensed waste heat recovery ways in cogeneration plant.” Energy Convers. Manage., 101, 616–625.
Lu, Y., Wang, Y., Bao, H., Yuan, Y., Wang, L., and Roskilly, A. P. (2015). “Analysis of an optimal resorption cogeneration using mass and heat recovery processes.” Appl. Energy, 160, 892–901.
Madloola, N. A., Saidura, R., Hossaina, M. S., and Rahim, N. A. (2011). “A critical review on energy use and savings in the cement industries.” Renew. Sustainable Energy Rev., 15(4), 2042–2060.
Pambudi, N. A., Itoi, R., Jalilinasrabady, S., and Jaelani, K. (2015). “Performance improvement of a single-flash geothermal power plant in Dieng, Indonesia, upon conversion to a double-flash system using thermodynamic analysis.” Renew. Energy, 80, 424–431.
Pradeep Varma, G. V., and Srinivas, T. (2015). “Design and analysis of a cogeneration plant using heat recovery of a cement factory.” Case Stud. Therm. Eng., 5, 24–31.
Sarr, J. A. R., and Potvin, F. M. (2015). “Improvement of double-flash geothermal power plant design: A comparison of six interstage heating processes.” Geothermics, 54, 82–95.
Shankar Ganesh, N., and Srinivas, T. (2013). “Thermodynamic assessment of heat source arrangements in Kalina power station.” J. Energy Eng., 99–108.
Shankar Ganesh, N., and Srinivas, T. (2015). “Energy efficient power generation systems at low and medium heat recoveries.” Int. J. Energy Technol. Policy, 11(4), 358–370.
Srinivas, T., and Gupta, A. V. S. S. K. S. (2007). “Thermodynamic analysis of Rankine cycle with generalization of feed water heaters.” J. Inst. Eng. (India) Mech. Eng. Div., 87, 56–63.
Srinivas, T., and Reddy, B. V. (2014). “Hybrid solar-biomass power plant without energy storage.” Case Stud. Thermal Eng., 2(C), 75–81.
Wang, J., Dai, Y., and Gao, L. (2009). “Exergy analyses and parametric optimizations for different cogeneration power plants in cement industry.” Appl. Energy, 86(6), 941–948.
Ziya Sogut, M. (2012). “A research on exergy consumption and potential of total emission in Turkish cement sector.” Energy Conserv. Manage., 56, 37–45.
Information & Authors
Information
Published In
Journal of Energy Engineering
Volume 143 • Issue 1 • February 2017
Copyright
© 2016 American Society of Civil Engineers.
History
Received: Oct 31, 2015
Accepted: Feb 24, 2016
Published online: Apr 22, 2016
Discussion open until: Sep 22, 2016
Published in print: Feb 1, 2017
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.