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Assuming a preheater waste-gas temperature of 350°C and grate cooler exhaust-air temperature of 275°C, approximately 1,100 kJ/kg (clinker) of unused heat is lost. When firing coal of a net calorific value of 23,000 kJ/kg, the annual loss to be attributed to unused process heat is approximately US $1.0 – $1.6 million; a very significant expense for lost energy. The preferred approach to overcome this economically unsatisfactory situation is to use the waste heat for the generation of electrical power. In the past some cement plant operators have installed waste heat steam boilers in their plants and have utilized the process heat to operate a steam turbine generator set. However, the conventional steam technology has certain implicit drawbacks with respect to the cement production process. In particular, the use of the relatively low temperature grate-cooler exhaust air, available at continuously varying temperatures, ranging from 170°C to 300°C, involves difficulties with respect to stable steam turbine operation due to the high moisture content in the turbine exhaust and pinch point interference problems in the boiler. To overcome this drawback, exhaust air temperatures have been raised, in some cases beyond the level required for clinker burning, through additional fuel gas firing. This has increased the fuel consumption in the plant to unacceptable levels. Figure 1 – The Lengfurt Cement Heat Recovery Power Plant B. Gold Creek Power Plant A 6.5 MW Power Plant operating an ORC was commissioned in June 1999 as a bottoming system for an RB211 gas turbine driven compressor station at Gold Creek, in Alberta, Canada. (Figure 2). The main characteristics of the plant are: (a) gross generating capacity, 7.2 MW; (b) net output to the grid, 6.5 MW, and (c) net to the grid guaranteed capacity, 5.85 MW at design conditions of +2oC ambient temperature at an elevation of 700 meters asl.PDF Image | ORGANIC RANKINE CYCLE POWER PLANT FOR WASTE HEAT RECOVERY
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