Waste Heat Recovery Power Generation From Cement Kilns of Derba Cement Factory

Waste heat recovery power generation from cement kiln systems i
ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

SCHOOL OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
WASTE HEAT RECOVERY POWER GENERATION FROM CEMENT KILN SYSTEM
(CASE OF DERBA MIDROC CEMENT INDUSTRY)
A Project Submitted to the Partial Fulfillment of the Requirements for the attainment
of the Degree of Bachelor of Science (BSc.) in Chemical Engineering.
[Focus area: process engineering stream]

By:
Kibrom Seboho
Meaza Kidane
Mebrahtom Masho
Mebrahtu Gebreselassie
Project Advisor: Ing. Hagos Birhane
Adama, Ethiopia
June, 2013
ASTU, Chemical engineering department

June, 2013
Waste heat recovery power generation from cement kiln systems ii
ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

SCHOOL OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
WASTE HEAT RECOVERY POWER GENERATION FROM CEMENT KILN SYSTEM
(CASE OF DERBA MIDROC CEMENT INDUSTRY)
By:
Kibrom Seboho
Meaza Kidane
Mebrahtom Masho
Mebrahtu Gebreselassie
Approved by:
Chairman, Department Signature Date
Advisor Signature Date
Examiner Signature Date

June, 2013
Waste heat recovery power generation from cement kiln systems i
Abstract
Cement production was one of the most energy intensive industrial processes. A considerable
amount of the energy input is lost through different parts of the processing units such as pre-heater
stack, rotary kiln shell and clinker cooler stack. The recovery and utilization of waste heat not only
conserves fuel, usually fossil fuel, but also reduces the amount of waste heat and greenhouse gases
dumped to the environment. Several different medium-temperature waste heat power generation for
cement production have been developed in the past years, including the Steam Rankine Cycle, the
Organic Rankine Cycle and the Kalina Cycle. The Steam Rankine Cycle approach is the common
approach that used in the existing on-site plants. The Organic Rankine Cycle and the Kalian Cycle
are not yet in commercial applications in cement plant.
The aim of this case study was generating power by utilizing waste heat from the dual sources using
Steam Rankine Cycle. In the present work a WHRPG system is designed to recover waste heat for
power generation purpose in the cement manufacturing process. For this purpose a case study of
Derba MIDROC cement industry is considered. Waste gas from the pre-heater with amount of
440,673 kg/hr at 3350C temperature and clinker cooler with amount of 298,667 kg/hr at 305 0C
temperature are exists. Those sources of waste heat have a lot of sensible heat and can be used for
steam generation and this superheated steam which is produced in both AQC and SP boilers are
used to rotate impulse steam turbine. The result, obtained by performing energy balance on each
components of the system such as, on AQC and SP boilers, steam turbine and condenser, shows that
the proposed technology can produce 7.35MW. In addition the thermal and mechanical design
calculations of main equipment are performed. Also, the economic analysis shows that the proposed
technology is viable, with a payback period of approximately six years; cumulative cash position
$10,994,198, net present value of $483,093 and rate of return of investment 17% throughout the 20
years service life of the plant.

June, 2013
Waste heat recovery power generation from cement kiln systems ii
Acknowledgments
We are deeply grateful to our project advisor Ing. Hagos Birhane for his sustainable and appreciable
guidance, tireless advising, for sharing his knowledge, skill, experience and fine-tuning up to the
successful completion of this project work.
Also special thanks to Ing. Mingizium Gashaw has been supporting us from the beginning to the
end of this study supplying us the necessary materials. We would like to thank all teaching
staffs and our class colleagues in chemical engineering department for the assistance they
provided at all levels of the project work.
We would like to thank also all Derba MIDROC Cement factory workers who insisted us to collect
the necessary data for our project work; particularly Ing. Yohanes Gebrekidan, Technical manager
of the factory, and Ing. Abiyi.

June, 2013
Waste heat recovery power generation from cement kiln systems iii
Table of Contents
Abstract .......i
Acknowledgments ..ii
Table of contents.iii
List of tables......v
List of figures...vi
List of Appendices...vi
List of Acronyms and Abbreviations....vii
List of Appendices ................................................................................................................................ vi

1. Introduction....................................................................................................................................... 1
1.1. Background.................................................................................................................................................... 1
1.2. Statement of the problem.............................................................................................................................. 3
1.3. Objective ........................................................................................................................................................ 4
1.3.1. General objective: .................................................................................................................................. 4
1.3.2. Specific objectives: ................................................................................................................................ 4
1.4. Scope of the project ...................................................................................................................................... 5
1.5. Significance of the project ............................................................................................................................ 6
2. Overview of cement production processes and WHR systems ......................................................... 7
2.1. Overview of cement manufacturing processes in Ethiopia ........................................................................ 7
2.2. Background of DMC .................................................................................................................................... 7
2.2.1. Process description of cement production in case of DMC ................................................................ 8
2.2.2. Types of energy used in cement production process ......................................................................... 10
2.2.3. Fuel used in cement kiln system ......................................................................................................... 11
2.2.4. Energy requirement in cement production process ........................................................................... 11
2.3. Introduction to industrial waste heat recovery .......................................................................................... 13
2.3.1. Sustainable development through waste heat recovery ..................................................................... 13
2.3.2. Factors affecting the waste heat recovery .......................................................................................... 14
2.3.3. Benefits of waste heat recovery .......................................................................................................... 15
2.3.4. Commercial Waste Heat Recovery Devices ...................................................................................... 16

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Waste heat recovery power generation from cement kiln systems iv
2.4. Industrial waste heat recovery power generation typical cement kiln system ........................................ 19
2.4.1. Technologies of industrial waste heat recovery power generation ................................................... 19
2.4.2. Selection of WHRPG technology ....................................................................................................... 22
2.4.3. Barriers in adoption of power generation in Ethiopia ....................................................................... 23
3. Methodology .................................................................................................................................... 24
3.1. Literature review ......................................................................................................................................... 24
3.2. Data collection............................................................................................................................................. 24
3.3. Data analysis................................................................................................................................................ 25
4. Waste heat recovery power generation ........................................................................................... 26
4.1. Source of waste heat in cement kiln system .............................................................................................. 26
4.2. Technical consideration for power generation ......................................................................................... 26
4.3. Connection of WHRPG with cement production lines............................................................................. 28
4.4. Basic unit operations of WHRPG ................................................................................................................ 28
4.5. Expansion chamber for dust removal........................................................................................................ 30
4.6. Process description of power generation ................................................................................................... 32
5. Engineering analysis ........................................................................................................................ 34
5.1. Energy balance ............................................................................................................................................ 34
5.2. Sizing and design of main equipment ........................................................................................................ 40
5.2.1. Sizing .................................................................................................................................................... 40
5.2.2. Design of major equipment ................................................................................................................. 41
6. Economic and profitability analysis ................................................................................................ 65
6.1. Cost estimation ............................................................................................................................................ 65
6.2. Profitability analysis ................................................................................................................................... 68
7. Environmental impact ..................................................................................................................... 72
8. Conclusions and Recommendations................................................................................................ 73
8.1. Conclusions ................................................................................................................................................. 73
8.2. Recommendation......................................................................................................................................... 73
References............................................................................................................................................ 74
Appendices .......................................................................................................................................... 75

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Waste heat recovery power generation from cement kiln systems v
List of tables
2.1 Existing cement plant capacities of the country.... 7
2.2 Clinker formation reaction in kiln system..........................10
2.3 The main parameter factors that affect waste heat recovery..........................14
2.4 Summery of waste heat recovery power generation technologies.................22
3.1 The necessary quantity and temperature of the heat steam in kiln system.....25
5.1 Composition of hot air leaving quenching cooler..................34
5.2 System characteristics................................................................................................35
5.3 Composition of exhaust gas leaving from pre-heater........36
5.4 Summary of energy balance ...............39
6.1 Purchased equipment cost........65
6.2 Total capital investment estimation.............66
6.3 Utility cost estimation..............67
6.4 Summary of total production cost....68
6.5 Profitability analysis using non discount rate.........69
6.6 Profitability analysis using discount rate.....70

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Waste heat recovery power generation from cement kiln systems vi
List of figures
2.1 PFD for cement production in DMC.....8
2.2 The use electrical and thermal energy in cement production..........12
2.3 Two pass water tube waste heat recovery boiler................................16
2.4 Economizer.....................................17
2.5 Regenerator.....................................18
2.6 Heat pump ..........................................18
2.7 Waste heat recovery through steam Rankine cycle.........20
2.8 Waste heat recovery through organic Rankine cycle system.........21
2.9 Kalina cycle waste heat recovery...................22
4.1 AQC boiler and SP-boiler .........................................................................................27
4.2 Expansion chamber for dust removal system........................................31
4.3 PFS for steam Rankine Cycle WHRPG ....33
5.1 Steam Rankine cycle power generation for energy balance......34
5.2 Combined velocity diagram...........63
List of Appendices
A: Actual data collected from DMC........75
B: Estimating of capital investment items based on Delivered equipment cost..77
C: Data specification of major equipment......78

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Waste heat recovery power generation from cement kiln systems vii
List of acronyms and abbreviation
AQC -Air quenching cooler
CCP -Cumulative cash position
CCR -Central control room
CF -Cash flow
CHP -Combined heat and power
DPBP -Discount payback period
EEPCO -Ethiopian electric power coloration
FCI -Fixed capital investment
LCR -Local control room
LMTD -Logarithmic mean temperature difference
MIDROC Mohammed international development and research organization center
NPV -Net present value
OPC -Ordinary Portland cement
ORC -Organic Rankine Cycle
PFD -Process flow diagram
PPC -Pozzolanic Portland cement
PVR -Present value ratio
ROROI -Rate of return on investment
SP -Suspension pre-heater
TCI -Total capital investment
WHRPG -Waste heat recovery power generation
WHRSG -Waste heat recovery steam generation
WHR -Waste heat recovery

June, 2013
Waste heat recovery power generation from cement kiln systems 1
1. Introduction
1.1. Background
Cement production is one of the most energy intensive industrial processes. A considerable amount
of energy input is lost through different parts of the processing units such as preheater stack, rotary
kiln shell and clinker cooler stack. The recovery and utilization of waste heat not only conserves
fuel, usually fossil fuel, but also reduces the amount of waste heat and greenhouse gases dumped to
the environment. The priority in the cement industry is to minimize the increase in energy
expenditure, to be more efficient and good competitor both internally and internationally. Also in
current circumstances, both the availability and cost of energy is becoming challenge to local
industrial hubs.
In many countries, energy costs represent the largest component of direct production cost for
cement. Energy cost represents as much as 40% to 60% of cement direct production cost. Energy
cost is incurred due to the need for large quantities of thermal heat for the clinkerization, calcination
and drying processes and electrical energy for operation of motors for grinding mills, fans,
conveyers and other motor driven equipment. Although the fuel use and energy use will depend on
the type of process, equipment, system efficiency and fuel heating value, typical requirements for
coal use is in the range of 150-250 kg per metric tons of cement and typical requirements for
electrical energy use is in the range of 80-125 kWhr per metric tons of cement.[1]
Cogeneration systems have been successfully operating in cement plants in India, China and South-
east Asian countries. WHRPG technology started from the late 1960s in Europe and the United
States, it was put into practical utility in the mid-1970s and the application of this technology
reached a climax in the early 1980s and has become popular since then [3]. The technology of
WHRPG technology is utilizing the low-grade steam (low pressure, low temperature) generated by
industrial waste heat temperature between 120 oC and 400 o C, to push the specially designed low -
parameter- steam turbine generator unit to generate electricity.
Japan is much more mature in the research and development of this technology. Since the world oil
crisis in 1973, the government of Japan has paid closer attention to energy conservation and began
to promote the outside pre-clinker kiln (up to 90%) and waste heat power generation. In February,
1981, Japan Sumitomo Cement Company put a set of two 1320 kw heat generators, which were the

June, 2013
first sets of heat generating units in Japan, into operation.[3] China has been engaged in waste heat
utilization technology for a long time. The first low temperature WHRPG project in China was a
6,480kW waste heat generator which is provided by Kawasaki for 4000t/d clinker production. The
first case of the national production of the waste heat power generation project was constructed to
produce 3000kW by Shanghai Triumph and Nanjing Cement Design Institute [3].
Now a days, in various countries throughout the world it is becoming more common for combined
heat and power (CHP) plant to be installed by recovering the waste heat, which can also produce
hot water for domestic heating as a means of utilizing low grade heat and improving the overall
efficiency of the CHP. It is less common to install heat recovery systems on existing process plant
for use in domestic heating systems. In Ethiopia, the Technology of waste heat power generation in
cement industries has not been developed. Till recent times, energy generation from waste heat
recovery technique was an alien idea to local industry. But now most Ethiopian factories are
planning to have such technologies. Now a day as the country is transforming from agriculture
based economy to industry based economy, the number of industries is increasing all over the
country resulting in huge energy utilization. This further leads to the need of energy efficiency and
waste heat recovery activities. This can help the country to reduce its fossil fuel consumption, thus
improving energy security and improving the countrys balance of payments.

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1.2. Statement of the problem
The cement production process is highly energy intensive in a conventional plant like Derba
MIDROC Cement plant the substantial energy contained in the waste heat is not utilized but lost.
This substantial energy loss occurs at the pre-heater stage (where exhaust gasses from the heaters
are cooled and waste heat is vented into the atmosphere) and during the cooling of clinker product
at the air quenching coolers (AQC) stage. In the dry process cement plants nearly 40 percent of the
total heat input is rejected as waste heat from exit gases of preheater and grate cooler. Even for an
optimized cement process, significant heat loss, mainly caused by the heat of the waste gases,
still occurs.
In most of the plants part of the waste heat is utilized for drying of raw material and coal, but even
after covering the need for drying energy in most of the cases, the remaining waste heat is rejected
to the environment resulting in energy lose, air pollution and acid rain to the surrounding
environment. Up to now all Ethiopian cements, including Derba MIDROC Cement, have not
introduced any waste heat recovery systems. A large portion of the Waste heat can be recovered and
used for power generation. Cogeneration of power besides mitigating the problem of power
shortage also helps in energy conservation as well as reducing greenhouse gas emissions. In
existing plants cogeneration technologies based on bottoming cycles have potential to generate up
to 15-30 percent of the power requirement of a plant. Such a development assumes considerable
significance and potential in Ethiopian cement industry in order to achieve economy and
environmental compatibility.

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1.3. Objective
1.3.1. General objective :
The general objective of this project was to recover waste heat from cement kiln system for power
generation in Derba MIDROC Cement industry.
1.3.2. Specific objectives:
To identify the energy inputs, losses, generations

To quantify the energy flow
To design a WHR power generation system

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1.4. Scope of the project
The project discusses about the various technologies and schemes for power generation, recent
developments and evaluation of these technologies/ schemes. After identifying source of waste heat
and the possible use of it, the next step is to select suitable heat recovery system and equipments to
recover and utilize the same. It also highlights the various technical considerations which should be
studies in depth for design of equipment and the cogeneration scheme for installation of
cogeneration system in a cement plant.

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1.5. Significance of the project
This project is the first of its kind in Ethiopia. By adopting advanced technology from developed
countries, the project activity will promote important transfer of technical knowhow to Ethiopia and
can act as a pioneer in promoting the spread of this technology to other cement plants. The
successful completion of the project will make the plant more profitable by recovering waste heat,
which otherwise would lost to the environment and generating power. At the same time the project,
will make the industry more environmentally friendly by reducing thermal pollution and pollutant
emissions. The advantages and barriers in terms of installation of waste heat recovery power
generation system can be a role model for other third world countries like Ethiopia, for sustainable
development.

June, 2013
2. Overview of cement production processes and WHR systems
2.1. Overview of cement manufacturing processes in Ethiopia
The Cement sector is one of the major energy intensive industries while playing an important role
in the economy of a country. Presently there are 6 operating cement plants with a total installed
capacity of about 8,108,000 tons of ordinary Portland cement per annum in Ethiopia. Table 2.1
presents the installed capacities and locations of the cement plants of Ethiopia. But there are a lot of
mini cement industries which are not included in the table below. The cement industry is energy-
based which constitutes 45% of the cost of production. The total average annual consumption off
fuel (coal and oil) by these factories is based on their installed clinker capacity.
Table 2.1: Existing Cement Plants Capacities of the Country [updated 2013].
Sr.no Operating plants Ownership Locality Annual cement Production
capacity (in tone).
1 Mugher Cement factory Public enterprise Mugher 2,200,000(2 lines)
2 Messebo cement factory Private limited Mekelle 2,200,000( 2 lines )
3 Derba MIDROC Cement factory Private limited Derba 2,200,000 (1 line )
4 Abissinia cement factory Private limited Chancho 108,000
5 National cement factory Public enterprise Dire dawa 1,275,000
6 Addis Abeba cement factory Public enterprise Addis Abeba 125,000
Total 8,108,000
[Source: Ethiopian investment agency]
2.2. Background of DMC
Derba MIDROC Cement enterprise is a private owned enterprise established with the purpose of
producing and supplying cement and carrying out such activities that are deemed important for the
attainment objectives. It is located 70km west of the capital, Addis Ababa, towering up its raw
materials ascending up the depth as high as 6.5km by cross country belt conveyor with 4 transfer
stations to the hill of the company and some of the raw materials are brought from different areas. It
is a factory with one production line and the expansion one will commence construction few years
later. Currently, the plant has a production capacity of 5,600 tons of clinker per day and the total
cement production capacity of the factory is 8,000 tons of OPC and PPC per day.

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2.2.1. Process description of cement production in case of DMC
Cement is manufactured by intimately mixing together calcareous and argillaceous and silica
alumina or iron oxide bearing materials, burning them at clinkering temperature and grinding the
resultant clinker so as to produce cement. To manufacture 1 ton of Portland cement about 1.5 to 1.7
tons raw materials, 0.13 ton coal and 1 ton clinker must be ground to dust fineness. The production
process of cement has three major stages. The first stage is mixing and crushing stage which is
responsible to mix certain proportion of clay and limestone and to crush them to powder form. The
second and the most important stage is pyro processing which consumes more than 90% of total
energy. This stage includes pre-heater, calciner, kiln and cooler. Clinker as nodular and well mixed
form is the main product of this stage which then is sent to final grinding and crushing stage of the
cement mill. During third stage, clinker is crushed and grinded to tiny grinds in powder form, mixed
with additives and then is sent to packaging stage. The schematic PFD of DMC plant is shown in
Figure 2.1 below.
Limestone Exhaust gas T = 335 0C

Raw material
Hot air T = 3050C
Clay
Crushing and
grinding
Tertiary air
Pre-
heater
Kiln exhaust Secondary air
Calciner Kiln
Clinker cooler Clinker
grinding
Air Fuel Cement

Fuel
Ambient air
Additives
Fig. 2.1: PFD for Cement production in DMC
As mentioned before, pyro processing is the most important stage in terms of energy and pollution
management in cement plant. In this stage, raw materials which are mixture of clay and limestone is
crushed and mixed in the first crushing stage reaching to 90 sieve grain size. This solid mixture

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enters to the pre-heater at 50C. The pre-heater stages consist of 5 stages of double string cyclones
which are used to preheat raw materials and separate them from the pre-heater gas. In this stage,
feed stream with 50C is heated up to 950C by heat exchange with flue gases entering at 1100C
from calciner. Flue gases then leave the pre-heater stage at 322.7C and 347.50C from each
preheater stack and discharged to the environment. Such a high temperature is a valuable source of
thermal heat. Solid stream at 950C leaves pre-heater stage and is fed to claciner where two
reactions occur to convert 95% of CaCO3 and all amount of MgCO3 to CaO and MgO respectively.
These endothermic reactions which are the major source of CO2 production in cement plant require
too much thermal energy.
The main reactions of each section are given in Table 2.2, along with other data as operating
temperature and heat of reaction [19]. The reaction products are solid materials which consist of
remained CaCO3, CaO, MgO, and the other materials. This solid stream enters to the kiln at 1100C,
where C2S, C3S, C 3A and C4AF are produced as four major components of clinker under several
chemical and physical (phase change) reactions presented in Table 2.2. The required thermal heat is
provided by combustion of coal fuel and hot air sent from coolers. The clinker enters the cooler at
1450C and is cooled down to 80C - 100C. Ambient air which is sent to hot clinker is separated to
three streams and different temperatures by ducts. One stream at 1100C is sent to the kiln, another
one at 1000C is launched to calciner and the last one at 305C is discharged to the environment as
the second major source of thermal heat loss in cement plant. Then, clinker is transported to the
finish mill by a conveyor belt to be ground into fine powder cement. A small amount of gypsum is
added during grinding to control the set properties of the produced cement.

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Table 2.2: Clinker formation reaction in kiln system

Reaction Equation of reaction
Formation of oxide and decomposition reactions
Volatilization of water H2O(l) H2O (v)
Kaolinite decomposition Al 2O3.2SiO2.2H2OAl2O3 + 2SiO2 + H2O
MgCO3 decomposition MgCO3MgO + CO2
CaCO3 dissociation CaCO3CaO + CO2
Formation of intermediate products
Formation of CA CaO + Al2O3CA
Formation of C2F 2CaO + Fe2O3C2F
Formation of C2S 2CaO + SiO2C2S
Clinkering reactions
Formation of C4AF CA + C2F + CaO C 4AF
Formation of C3A 2CA + CaO C 3A
Formation of C3S C2S + CaO C 3S
Overall reactions Kiln Meal Clinker
2.2.2. Types of energy used in cement production process

For each of the process steps within the boundary, the major energy use at that step of clinker
production the combustion of fuel to generate the heat required, not the electricity used to rotate the
kiln. Fuel coal and electricity are the main sources of energy in the cement production. Generally,
energy use is classified in three categories:
Electricity use for raw material preparation

Fossil fuel use for clinker production, and
Electricity use for cement grinding (or finish grinding).
1. Electrical Energy:
The major electrical energy consumption areas are mill drives, fans and conveying systems. About
30% of electric power is consumed for finish grinding, and a little 30% each is consumed by the
clinker burning process.

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2. Thermal Energy:
Thermal energy accounts for almost half the energy costs incurred in cement manufacture. A
variety of fuels such as coal and heavy fuel oil are used in the cement plant. The major use of
thermal energy is in the kiln and pre calciner. In plants using coal, an external coal or oil fired
furnace is used for generation of hot air required for coal mills.
2.2.3. Fuel used in cement kiln system

Fuels that have been used for primary firing include coal and heavy fuel oil. High carbon fuels such
as coal are preferred for kiln firing, because they yield a high luminous flame. The clinker is
brought to its peak temperature mainly by radiant heat transfer and hot flame is essential for this.
2.2.4. Energy requirement in cement production process
The cement industry is essentially a chemical process industry entailing various engineering unit
operations. Thus raw meal grinding, mixing, burning and cement grinding are the main operations
entailed in the manufacture of cement. There are different types of equipment available for
transportation of materials, crushing and grinding of materials, mixing of materials. The thermal
efficiency of the pre-heater depends on the number of the stages in the pre-heater and the capacity
of the flow ratio of the gas and the kiln feed of materials.
The fed entering to the calciner is 95% calcined before it enters the rotary kiln. The hot combustion
air for the calciner arrives in a tertiary duct directly from the cooler, bypassing the kiln. In clinker
burning, the raw meal is fed to the kiln system where it is dried, preheated, calcined and sintered to
produce cement clinker. Thermal energy mainly coal, is consumed in the kiln for the pyro
processing of limestone to produce clinker. Theoretically only 430Kcal/ Kg clinker of heat is
required for burning 1 Kg of clinker, but in practice twice or more times this is necessary[14]. The
shell heat loses from the rotary kiln can represent a considerable proportion of the total energy loss,
specially, in kiln plants with small throughout the heat loss through the shell of rotating the kiln lies
in the range of 200-600 KJ/kg of clinker depending on the productivity of the kiln and if the kiln
system have with or without tertiary air duct.

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Diesel for loader, & compressor Limestone mining
Transport
Diesel for dumpers & trucks/
Electrical energy for rap way
Crushing
Electrical energy for crushing
Electrical energy for drive and fan

Raw mill
Heat energy from kiln off gases
Heat energy from fuel input Electrical energy for mill drive
Pre calcinations
Electrical energy for kiln drive fans
and ESP
Pyro-processing Coal milling

Heat energy from fuel input
Electrical energy for drive Clinker cooling Heat energy from fuel input
& clinker breaker
Electrical energy for mill drives & fans Cement grinding Gypsum
Packaging and dispatch
Fig.2.2: The use of electrical and thermal energy in cement production

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2.3. Introduction to industrial waste heat recovery
Waste heat is heat, which is generated in a process by way of fuel combustion or chemical reaction,
and then dumped into the environment even though it could still be reused for some useful and
economic purpose. Waste heat recovery refers to the recuperation of heat that is discharged as a
byproduct from one process to provide supplemental energy needed by another process. Captured
and reused waste heat is an emission free substitute for costly purchased fuels or electricity. Heat
recovery options can be broadly classified into three strategies [13]:
Recycling energy back into the process

Recovering energy for other on-site uses
Using it to generate electricity in combined heat and power systems.
2.3.1. Sustainable development through waste heat recovery

Industrial waste heat refers to energy that is generated in industrial processes without being put to
practical use. Many industrial processes require large quantities of thermal energy, much of which
is eventually exhausted to the environment, either to the atmosphere or water. Recovering this
waste heat represents the largest opportunity for reducing industrial energy consumption. The exact
quantity of industrial waste heat is poorly quantified, but various studies have estimated that as
much as 20 to 50% of industrial energy consumption is ultimately discharged as waste heat. Waste
heat reduces losses by improving equipment efficiency or installing waste heat recovery
technologies. Waste heat recovery entails capturing and reusing the waste heat in industrial
processes for heating or for generating mechanical or electrical work [16].
A sustainable energy system is one which balances energy production and consumption with
minimal negative impact on the environment. The multi-criteria decision-making procedure for any
sustainable energy system includes: technology (primary energy ratio), economy (investment cost),
environment (CO2 emission) and society (job creation).

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2.3.2. Factors affecting the waste heat recovery
The amount of heat in the waste gases that can be utilized or recovered depends primarily on the
waste gas mass flow rate, temperature of the waste heat gas and thermal capacity of the waste gas.
Evaluating the feasibility of waste heat recovery requires characterizing the waste heat source and
the stream to which the heat will be transferred. Depending on the above parameters, for a 5,000 t/d
kiln, it is expected to be in the range of 6 MW to 14 MW net electricity generations through a
WHRPG technologies. Factors that influence these parameters or otherwise affect the design
capacity of the power plant include the following:
Table.2.3: The main Parameter factors that affect waste heat recovery
No. Parameter
1 Heat quantity and Heat temperature / quality
2 Minimum allowed temperature.
3 Cement production capacity and Plant layout
4 Efficiency of cement production process
5 Water-cooled or air-cooled condensers
6 Design ambient temperature and humidity
7 Diversions of waste heat for coal and limestone drying
8 Chemical composition of the waste gases
These parameters allow for analysis of the quality and quantity of the stream and also provide
insight into possible materials and design limitations.
i). Heat Quantity and heat Quality: The quantity or heat content is a measure of how much
energy is contained in a waste heat stream. The quantity of waste heat contained in a waste stream
is a function of both the temperature and the mass flow rate of the stream:
= Cp T
Where is the waste heat loss (KJ/hr); is the waste stream mass flow rate (Kg/hr)

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ii). Waste stream composition
Although chemical compositions do not directly influence the quality or quantity of the available
heat, the composition of the stream affects the recovery process and material selection. The
composition and phase of waste heat streams will determine factors such as thermal conductivity
and heat capacity, which will impact heat exchanger effectiveness. Meanwhile, the process specific
chemical makeup of off gases will have an important impact on heat exchanger designs, material
constraints, and costs.
iii). Minimum allowable temperature
The minimum allowable temperature for waste streams is often closely connected with material
corrosion problems. Depending on the fuel used, combustion related flue gases contain varying
concentrations of carbon dioxide, water vapor, NOX, SOX, un oxidized organics, and minerals. If
exhaust gases are cooled below the dew point temperature, the water vapor in the gas will condense
and deposit corrosive substances on the heat exchanger surface. The most common method for
preventing chemical corrosion is designing heat exchangers with exhaust temperatures well above
the dew point temperature.
2.3.3. Benefits of waste heat recovery
Benefits of waste heat recovery can be broadly classified in two categories:
1. Direct benefits:
Recovery of waste heat has a direct effect on the efficiency of the process. This is reflected by
reduction in the utility consumption & costs, and process cost.
2. Indirect benefits:
Reduction in pollution:
A number of toxic combustible wastes such as CO gas, sour gas, carbon black off gases,
Acrylonitrile and other plastic chemicals releasing to atmosphere if/when burnt in the incinerators
serves dual purpose i.e. recovers heat and reduces the environmental pollution levels.

June, 2013
Reduction in equipment sizes:

Waste heat recovery reduces the fuel consumption, which leads to reduction in the flue gas
produced, results in reduction in equipment sizes of all flue gas handling equipments such as fans,
stacks, ducts, burners, etc.
Reduction in auxiliary energy consumption:
Reduction in equipment sizes gives additional benefits in the form of reduction in auxiliary energy
consumption like electricity for fans, pumps etc.
2.3.4. Commercial Waste Heat Recovery Devices

Waste Heat Boilers
Waste heat boilers are ordinarily water tube boilers in which the hot exhaust gases from cement kiln,
furnace, gas turbines, incinerators and etc. pass over a number of parallel tubes containing water.
The water is vaporized in the tubes and collected in a steam drum from which it is drawn off for use
as heating or processing steam. Because the exhaust gases are usually in the medium temperature
range and in order to conserve space, a more compact boiler can be produced if the water tubes are
finned in order to increase the effective heat transfer area on the gas side. The pressure at which the
steam is generated and the rate of steam production is depends on the temperature of waste heat
available. The pressure of a pure vapor in the presence of its liquid is a function of the temperature
of the liquid from which it is evaporated. If the waste heat in the exhaust gases is insufficient for
generating the required amount of process steam, auxiliary burners which burn fuel in the waste
heat boiler or an after-burner in the exhaust gases flue are added.
Steam out Flue gas out
Feed water in
Hot waste gas

in WHR boiler
Fig.2.3: Two-pass water tube

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Economizer
In case of boiler system, economizer can be provided to utilize the flue gas heat for pre-heating the
boiler feed water. On the other hand, in an air pre-heater, the waste heat is used to heat combustion
air. In both the cases, there is a corresponding reduction in the fuel requirements of the boiler.
Flue gas outlet
Water inlet
Water outlet Economizer coils
Flue gas inlet
Fig.2.4: Economizer
Regenerator
The Regeneration which is preferable for large capacities has been very widely used in glass,
cement kiln and steel melting furnaces. Important relations exist between the size of the regenerator,
time between reversals, thickness of brick, conductivity of brick and heat storage ratio of the brick.
In a regenerator, the time between the reversals is an important aspect. Long periods would mean
higher thermal storage and hence higher cost. Also long periods of reversal result in lower average
temperature of preheat and consequently reduce fuel economy. Accumulation of dust and slagging
on the surfaces reduce efficiency of the heat transfer as the furnace becomes old.

June, 2013
Gas
Chimney
Fluid
Gas regenerator regenerator Fluid
Fig.2.5: Regenerator
Heat Pipe
The Heat Pipe comprises of three elements a sealed container, a capillary wick structure and a
working fluid. The capillary wick structure is integrally fabricated into the interior surface of the
container tube and sealed under vacuum. Thermal energy applied to the external surface of the heat
pipe is in equilibrium with its own vapor as the container tube is sealed under vacuum. Thermal
energy applied to the external surface of the heat pipe causes the working fluid near the surface to
evaporate instantaneously. Vapor thus formed absorbs the latent heat of vaporization and this part
of the heat pipe becomes an evaporator region. The vapor then travels to the other end the pipe
where the thermal energy is removed causing the vapor to condense into liquid again, thereby
giving up the latent heat of the condensation.
Vaporized fluid Heat in

condenses and gives up
Liquid
Vapor
Heat out Heat evaporates

Fig.2.6: Heat pump working fluid

June, 2013
2.4. Industrial waste heat recovery power generation typical cement kiln system
Generating power from waste heat typically involves using the waste heat from cement kiln system
to create mechanical energy that then drives an electric generator. When considering power
generation options for waste heat recovery, an important factor to keep in mind is the
thermodynamic limitations on power generation at different temperatures. The efficiency of power
generation is heavily dependent on the temperature of the waste heat source. In general, power
generation from waste heat has been limited to only medium to high temperature waste heat
sources. However, advances in alternate power cycles may increase the feasibility of generation at
low temperatures. While maximum efficiency at these temperatures is lower, these systems can still
be economical in recovering large quantities of energy from waste heat.
2.4.1. Technologies of industrial waste heat recovery power generation
Steam (Conventional) Rankine cycle:
The most commonly used system for power generation from waste heat involves using the heat to
generate steam in a waste heat boiler, which then drives a steam turbine. Steam turbines are one of
the oldest and most versatile prime mover technologies. Heat recovery boiler and steam turbine
systems operate thermodynamically as a Rankine Cycle, as shown in Figure 2.7 In the steam
Rankine cycle; the working fluid water is first pumped to elevated pressure before entering a heat
recovery boiler. The pressurized water is vaporized by the hot exhaust and then expanded to lower
temperature and pressure in a turbine, generating mechanical power that can drive an electric
generator. The low-pressure steam is then exhausted to a condenser at vacuum conditions, where
heat is removed by condensing the vapor back into a liquid. The condensate from the condenser is
then returned to the pump and the cycle continues.

June, 2013
Turbine
G
Boiler
Cooling
tower
Pump Pump
Condenser
Fig.2.7: waste heat recovery through Steam Rankine Cycle
Organic Rankine Cycle:
It is one of the methods to convert thermal energy to electrical energy. It is a closed loop system
filled with an organic liquid having a low boiling temperature. The Organic Rankine cycle (ORC) is
named for its use of an organic, high molecular mass fluid with a liquid-vapor phase change, or
boiling point, occurring at a lower temperature than the water - steam phase change. The fluid
allows Rankine cycle heat recovery from lower temperature sources such as biomass combustion,
industrial waste heat, geothermal heat, solar ponds etc. The low - temperature heat is converted into
useful work that can itself be converted into electricity. The working principle of the organic
Rankine cycle is the same as that of the Rankine cycle: the working fluid is pumped to a boiler
where it is evaporated, passes through a turbine and is finally re- condensed. In the ideal cycle, the
expansion is isentropic and the evaporation and condensation processes are isobaric. In the real
cycle, the presence of irreversibility lowers the cycle efficiency.

June, 2013
Turbine
G
Evaporator-
Boiler
Cooling
tower
Pump Pump
Condenser
Fig.2.8: WHR through Organic Cycle system
Kalina Cycle:
The Rankine cycle has also been improvised using binary fluid of ammonia and water as the
working fluid in place of only water for improving the overall efficiency of conventional systems.
In this system efficiency gains of up to 50% for low temperature heat sources (200-280oC) and up
to 20% for higher temperature heat sources have been claimed as compared to conventional
Rankine cycle based power plants. Kalina Cycle takes advantage of the ability of ammonia-water
mixture at any given pressure to boil or condense at a Variable temperature. Moreover,
conventional axial flow turbines can be used in these plants as molecular weights of ammonia and
water are almost similar. Further, the turbines used may be smaller in size and hence less costly as
back pressure turbines can be used as condensing turbines.

June, 2013
Fig.2.9:Kalina Cycle Waste heat recovery system

Table.2.4. summary of waste heat recovery power generation technologies
Sr. No Thermal Conversion Temperature Typical Sources of Waste Heat
Technology Range
1 Steam Rankine Cycle Medium, high Exhaust from gas turbines, reciprocating
engines, furnaces and cement kiln.
2 Kalina Cycle Low, medium Gas turbine exhaust, boiler exhaust, cement
kilns
3 Organic Rankine Cycle Low, medium Gas turbine exhaust, boiler exhaust, heated
water, cement kilns
4 Thermoelectric Generation Medium- high Not yet demonstrated in industrial applications
5 Piezoelectric generation Low Not yet demonstrated in industrial applications
6 Thermal Photovoltaic Medium- high Not yet demonstrated in industrial
Applications
2.4.2. Selection of WHRPG technology
Several different medium temperature waste heat power generation technologies for cement
production have been developed in the past few years, including Steam Rankine Cycle, the Organic
Rankine Cycle and the Kalina Cycle. The Steam Rankine Cycle approach is the most common
approach that is used in existing on-site power plant. The organic Rankine Cycle and Kalina Cycle
are not yet in commercial applications in cement plant. Because of the availability, low cost and
easy thermodynamic properties the working fluid, low maintenance, easy for installation, high
production of power and environmental friendly as compering with the other technologies Steam
Rankine Cycle is preferable and selected.
June, 2013
2.4.3. Barriers in adoption of power generation in Ethiopia

The main constraints identified for non-adoption of the technology by Ethiopian cement industry
can be broadly classified into three main categories.
Technical/ Technological Barriers

No availability of proven technology indigenously.
Design of waste heat recovery boiler suitable to withstand high dust load in the waste gases.
High performance risk due to lack of demonstration.
Financial Barriers
Large capital requirement and financial constraints.
Viability remains to be established.
High cost of technology and access to funds.
Depressed cement marketing scenario.
Institutional Barriers
Lack of incentives for adoption of technology.
Lack of capacity building efforts resulting in lack of operating experience and confidence
level.
Nevertheless, the Ethiopian cement industry is quite keen to adopt the cogeneration systems to
achieve the national objectives of energy conservation and pollution control.

June, 2013
3. Methodology
In this case study the researcher works with the main temperature source, and do the study in order
to generate power from these waste heat source as maximum as possible. The methods employed to
achieve the objectives of the project are:
3.1. Literature review
A review of literature was conducted on the area of industrial energy use and efficiency in relation
to cement factory. Available books, case studies, previous project work and guidelines are surveyed
in order to have a clear understanding of the subject matter.
3.2. Data collection
The primary approach to this case study involved walk-through surveys of the whole plant and in
depth interviews and questionaries with the Technical Manager and shift engineers to collect the
necessary data for the project. Some particular data are collected from CCR and LCR. The
necessary data are: Clinker Production Capacity of the plant and number of Preheater stages,
quantity of exhaust gas at the exit of preheater and at the exit of cooler, exhaust gas temperature at
the preheater outlet and cooler outlet and the current energy requirement to produce a unit product
(specific electrical and fuel consumptions).
The case study has also assessed the existing heat released condition from the gas analyzer. This is
used to know the flue gas components and their concentration as well as the flue gas
temperature from which one can calculate the amount of different losses. And also the power
and fuel requirement of the major energy intensive equipment of the pyro processing are assessed.
Then the data are analyzed quantitatively and qualitatively. Depending on the assessed data
opportunities to reduce energy loses by recovering to power generation are done. The detailed
collected data from the company are listed in appendix A.

June, 2013
Table 3.1: The necessary quantity and temperature of the heat stream in kiln system
Sr.no Unit Amount
1 Exhaust gas quantity at preheater outlet Nm3/hr 310,330
2 Exhaust gas temperature at preheater outlet Deg.C 335
3 Hot air quantity at the cooler outlet Kg/hr 296,667
4 Hot air temperature at the cooler outlet Deg.C 305
3.3. Data analysis
The data obtained can be analyzed either quantitatively or qualitatively. The average temperature of
exhaust gas from preheater is 335 0C and the temperature of hot air from grate cooler is 305 0C.
Therefore, the temperature obtained is classified at medium temperature range qualitatively and at
this temperature, the amount of energy that can be rejected to atmosphere is quantitatively
calculated as follows:
The amount of energy lost in the cement from preheater is:

Q = *Cp*T = 440,673 Kg/hr*1.068kJ/kg0C*3350C = 43,796kJ/sec
The amount of energy lost in the cement from grate cooler is:
Q=*Cp*T=298,667kg/hr*1.0615*305 = 26,860kJ/sec
As mentioned above, there is a huge energy loss at the Derba MIDROC Cement factory. This
unrecovered heat energy in the DMC may also cause many problems. Such as:
High energy cost.

Causes environmental pollution.

June, 2013
4. Waste heat recovery power generation

4.1. Source of waste heat in cement kiln system
In general 54% of the fuel energy consumption is required for the chemical reaction of the kiln fed
to produce clinker. About 16% of the fuel energy consumption is consumed for drying of the raw
materials in the raw mill. The total of this energy percent gas about 70% corresponded to the useful
energy. The remaining 30% of the energy is needed to cover energy losses,
(wall heat loss, kiln exhaust gas, cold clinker and other losses). There are a few major heat loss
sources that would be considered for heat recovery. These heat losses are:
i. Cement rotary kilns surface:
Whole section kilns Surface temperature can be up to 260-280 when rotary kilns works, air-
cooled method is currently used and a lot of heat is directly distributed into the atmosphere, which
not only causes a waste of a lot of heat, but also causes high temperatures pollution around the kiln.
According to the needs of enterprises, waste heat recovery can be used to heat water or air, and hot
water can be used for life and refrigeration.
ii. Grate cooler waste gas process:
Cold air is sent to grate cooler to cool the material 80 up to 100, and cold air is heats to hot air of
305, then excretes from grate cooler tail, then enters to kiln head dust collector, and finally
discharge into atmosphere by exhaust fan.
iii. Preheater waste gas process:
Waste gases of preheater outlet from the two double strings preheater, 322.7 and 347.5 lose
occur then discharged into atmosphere. The average temperature of the flue gas is 335 0C.
4.2. Technical consideration for power generation

The various considerations for the design of appropriate cogeneration scheme for a particular plant
will need in-depth study of the following technical details [15]:
Availability of waste heat for power generation
The heat available for recovery entirely depends on the design of the cement plant and its
configuration. The pyro process system design itself plays a crucial role. The parameters that are
important are plant capacity, heat consumption, type of system such as preheater kiln or pre-calciner

June, 2013
kiln, either with one string or two strings of preheater, number of stages of preheater and type of
clinker cooler. Next aspect is the drying and grinding system utilized for raw materials and fuel.
Some of the crucial parameters are the quantity of material to be ground their moisture content,
their grind ability, type of grinding system etc.
Location of waste heat boiler
Another factor that could be important is the location of heat recovery unit in the process circuit,
namely before or after process fan, in the down-comer at an elevated position or at ground level,
and before or after the pollution control device such as electrostatic precipitator or a bag filter.
These could play a role in estimating the heat that could be recovered as well as in the design and
layout of plant.
Suitability of waste heat recovery boiler
The waste gases from preheater and cooler exhaust contain high dust concentrations. Accordingly
the waste heat recovery boiler should be able to withstand high dust loads. Moreover, the operating
conditions in cement plants require design of waste heat recovery boilers which should be able to
withstand the problems of heavy coating formation resulting in drastic reduction of capacity and the
wear of tubes due to coarse clinker particles. As such, the characterization of the dust in the waste
gases with regard to particle size, stickiness, abrasiveness should be studied in detail for evaluation
of the suitability/ design of the waste heat recovery boiler.
Maximum flue gas temperature
There is a limit at the upper scale of the temperature of the waste gases for cement plant application
as the flue gases contain dust comprising. These components make the dust sticky and aggressive at
temperatures more than 400oC which is considered as the highest gas temperature for steam
production. The material used for waste heat boiler tubes and plates is also not too expensive if the
gas temperature is less than 400oC.
Quantity of heat recovery
Ideally, higher the temperature of the gases, the better the heat transfer efficiency, as the gases at
higher temperatures can be cooled down to a much lower temperature in the waste heat recovery

June, 2013
boiler. The critical parameters such as steam flow rate, pressure and superheat gas outlet
temperature are to be optimized for each plant in order to achieve maximum power generation.
4.3. Connection of WHRPG with cement production lines
Cement kiln waste heat power systems encounter one major requirement which complicate the cost
effective utilization. The technical difficulty in utilizing both sources of heat from cement kiln in a
single unified power system, this is caused by the differences in the initial, and especially in the
final temperatures of the two heat sources. Thus, the efficacy of any power system utilizing heat
from a cement kiln depends not only on the system's thermal efficiency, but also on the system's
ability to utilize the maximum amount of heat from these two different heat sources. Therefore, any
power system utilizing heat from a cement kiln will have at least two parallel boilers, because the
flue gas and the hot air cannot be mixed.
Connection of AQC-boiler: Because the waste gas temperature of grate cooler terminal is low, and
direct utilization efficiency is low, the air is taken from the central part of grate cooler, the waste
gas of 305 0C enters AQC boiler. The waste gas was cooled to about 110 0C by AQC boiler. Both
1100C and grate cooler tail waste gas about 140 0C return to kiln head dust collecting system.
Connection of SP-boiler: The average temperature of preheater waste gas is about 335 0C, and it
enters directly into SP-boiler. The waste gas was cooled to 215 0C by SP-boiler. Then the waste gas
enters raw mill and provides drying heat source for it. The SP-boiler is equivalent to bypass of gas
conditioning tower.
4.4. Basic unit operations of WHRPG

AQC and SP boilers
AQC boiler will be installed next to the kiln head of the cement line, producing superheated steam
and a dedusting chamber will be set up to alleviate the boiler abrasion . For AQC boiler, the heat-
receiving surface of the boiler is divided into three stages: The first stages main superheated steam
stage, and the second stage is low pressure superheated steam stage, and the third stage is hot water
stage.
SP boiler will be connected to the pre-heater exit, producing a superheated steam. For SP boiler, the
heat-receiving surface of the boiler is divided into three stages: The first stage is main superheated
steam stage, second stage is low pressure superheated steam stage and the water after being

June, 2013
deaerated is pumped to AQC boiler second and third stage. Then, the outgoing hot water from AQC
third stage is used as feed water of AQC boiler second stage and SP boiler first stage. The
superheated steam produced in AQC boiler first stage and SP boiler second stage merge together
and then is introduced to the turbine main stream inlet. At the same time, the low pressure
superheated steam produced in AQC boiler second stage and SP boiler second stage merge together,
and then is introduced to the turbine supplement inlet. The main stream and low pressure steam is
used to promote the turbine for power generation. Exhaust steam of turbine after work is condensed
to water, and then pumped to a deaerator, thus a complete thermodynamic circulation system forms.
Superheated steam
Superheated steam
Low pr. superheated
steam
Low pr.
superheateds
team
Hot water b
a
Fig.4.1: (a) AQC boiler and (b) SP-boiler
Turbine
The purpose of the turbine is to change the potential energy of pressurized gasses into rotational
kinetic energy. The stream of high-pressure vapor of organic fluid expands in the turbine, causing
its internal part to rotate. The rotor is connected by a shaft to the generator which changes rotational
kinetic energy into electricity. The expansion process is considered adiabatic and a steady sate of
operation is assumed. Knowing the isentropic efficiency of the turbine ( t), which is given by the
manufacturer, generated power can be calculated as follows [8]:
gen = wf(h1 h 2) = wf t(h1 h2s)
Where state 2s corresponds to exhaust from ideal isentropic turbine

June, 2013
Condenser
Water-cooling unit adopts water as cooling medium for exhaust steam condensation, which is
composed of condenser, condensate pump, cooling tower and water basin. Water from basin is
pressurized and sent to condenser for heat absorption, and exhaust steam from turbine is condensed.
The water absorbed heat and turned back to the cooling tower for cooling with the help of
mechanical draft fans.
Pump
This is used to deliver cooling water from condenser to heat exchanger by application of pressure
difference. Using the same assumptions that were used for the turbine, power consumed by the feed
pump can be calculated as:

p = wf(h2 h1) = wf
Where p is the isentropic pump efficiency and state 2s corresponds to ideal isentropic pump.
4.5. Expansion chamber for dust removal

An expansion chamber is an apparatus for the removal of solid particles from a stream of gas, in
particular (but not limited to) gas used as a heat source in a power system. An example of this
situation can be found in power systems based on the use of waste heat from cement plants, where
the hot gas is heavily laden with abrasive cement dust. Removal of these particles by various sorts
of filters cause substantial difficulties; such a filter would have to operate at very high temperature
and in the case that a large amount of solid particles is high, the filter becomes clogged in a short
time, causing substantial maintenance problems. The use of cyclone separation apparatus is
problematic in that it causes substantial losses of pressure in the stream of gas. Moreover, abrasive
solid particles can cause substantial erosion in the cyclone apparatus itself.
A stream of gas, laden with solid particles and moving at high speed enters into the inlet duct of the
apparatus. Due to the high velocity of the gas the kinetic energy of the stream is high, which
enables the stream to carry solid particles. This stream then enters into an expanding duct. As the
cross-section of the expanding duct increases, the velocity of the stream decreases and according to
Bernoulli's Principle, the pressure of the stream increases. The decrease in the velocity of the stream
corresponds to a reduction of its kinetic energy (in proportion to the second power of velocity).
Therefore the ability of the stream to carry solid particles is drastically decreased. Thereafter, the

June, 2013
low velocity stream enters into a separation chamber where, due to the low velocity of the gas, the
solid particles fall down into dust collector, located at the bottom of the separation chamber.
Due to the fact that the pressure in the collection chamber is elevated, the solid particles in the dust
collector is easily removed through openings the bottom of the dust collector. Thereafter, the gas
from the separation chamber enters into a converging duct, where it's velocity increases and
pressure decreases. Thereafter, the stream of gas enters into an outlet duct and can be directed as
needed. An expansion chamber used for dust removal has the following advantages compared to
conventional filters:
It can separate a substantial quantity of solid particles without causing blockage of a filter.
It can easily work with high temperature or low temperature gas without need for special
high temperature filters.
It has no moving parts and as a result is reliable.
Converging
Inlet duct Expanding duct Duct
Separation
chamber
Outlet duct
Dust collector
Fig.4.2: expansion chamber for dust removal subsystem

June, 2013
4.6. Process description of power generation
Fully condensed, basic working fluid (water) with parameters as at point 1, corresponding to a state
of saturated liquid, enters into a feed pump, P1, where its pressure is increased, obtaining
parameters as at point 2, corresponding to a state of a sub cooled liquid. Stream 2 now passes
through a preheater (regenerator), HX-3, where it is heated and vaporized in counter flow by a
returning stream of condensing working fluid (9-10, see below) and gives parameters as at point 3,
corresponding to a state of vapor- liquid mixture.
Stream 3 is divided in to streams 4 and 5 which are then sent into a heat recovery vapor generator,
(AQC), HX-1 and heat recovery vapor generator (SP-boiler), where it is heated, fully vaporized and
superheated, in counter flow with a stream of hot air (50-51) and a stream of exhaust gas (40-41)
respectively. The working fluid enters and leaves at the same pressure, which means no pressure
drop in both boilers. Therefore, both streams 6 and 7 are now superheated and then combined by the
valve corresponding to a state of superheated steam as at point 8. The adjusted operating condition
of the steam is now sent in to the turbine (TR-1), where it expands, producing work and obtaining
parameter as at point10, corresponding to a state of super vapor and to a parameter of 9, which is
used to produce mechanical energy. Stream 10 is now sent into regenerator (HX-3), where it
desuper-heated, providing heat for process stream 2-3 and obtains parameters as at point 11,
corresponding to a state of liquid-vapor mixture (see, below). Thereafter, stream 11 is sent into the
final condenser (HX-4), where it is cooled and fully condensed by a stream coolant (30-31, water,)
and obtains parameters as at point 1 (see below). Generally, the summarized process of power
generation using conventional Rankine cycle is as follows: The water exiting the condenser and
makeup water is pumped to the regenerator where it is preheated. Then, the hot water directly enters
to the AQC boiler and meanwhile to the SP-boiler to produce steam. The steam is now superheated,
heated to a temperature above its saturation temperature at the actual pressure conditions. The
superheated steam expands in the turbine, generating power. This line reflects the turbine at its
operating efficiency. The expansion decreases the steam temperature and pressure. The steam/water
exiting the turbine is condensed to liquid form in the condenser.

June, 2013
Raw material inlet

DR-2
7
0 8
Exhaust gas @ 335 C
TR-1
40 HX-2
51
HX-1
AQC-boiler
6 Turbine 9
G
SP-boiler
Superheater Super heater
Evapo D
P10 P5 Evapo
rator
D rator
10
Economizer
P9 P4 Economizer
5 4 3
P8 P3 HX-3
Regenerator
41
30
50
P7 P2 11
Daeretor
DR-1
HX-4
Condenser Cooling
P6 P1 2 tower
P
1
0
P
Hot air @ 305 C
31
Pre-
Calciner
Rotary kiln
Clinker cooler
Clinker
Fig.4.3: PFS for Steam Rankine Cycle waste heat recovery power generation

June, 2013
5. Engineering analysis
5.1. Energy balance
Energy balance on AQC boiler
Heat Stream data:
a. Clinker Cooler air available for Heat recovery for Power generation:
Mass flow rate of exhaust hot air (ha) = 298,667kg/hr
Mass flow rate of working fluid (wf-in) =?
Dust load = 59.8gms/Nm3
Exhaust temperature (Tex) = 305 0C
HX-2
40
SP- Boiler TR-1 G-1
Steam turbine Generator
41 5 G
HX-1
50 AQC Boiler 3
6 HX-3 CT-1
Condenser Cooling tower
30
51 2
P-1 31
Pump 1
Fig.5.1: PFD for Steam Rankine cycle power generation for energy balance
Table 5.1: composition of hot air leaving air quenching cooler

Contents Hot air composition @ AQC stack (%) Cp
O2 21 1.003
N2 79 1.077
Cp,hotair = 21%*Cp,O2 + 79%*Cp,N2 = 0.21*1.003 + 0.79*1.077 = 1.0615kJ/kg.0C

June, 2013
Table.5.2: System characteristics

Sr. No System parameters Efficiency (%)
1 Boiler 85.00
2 Turbine mechanical 95.00
3 Generator electrical 99.00
4 Generator mechanical 98.00
5 Environmental temperature 25.00C
6 Environmental pressure 1.013bar
T = 3050C T steam =2850C

ha-in = 298,667kg/hr P= 1.5MPa
Cp = 1.0615kJ/kg.0C HX-2
AQC-boiler
ha-out= 298,667.0kg/hr wf-AQC= ?

Tf = 110 0C Twf-in =70 0C
P = 1.5MPa
In the boiler, steam is produced using the waste heat from the gas. Energy balance was carried out
to determine the flow rate of steam produced.
ha-inCp ha T =wf-AQC *(hout-hin)
Where, ha-in and wf-AQC are the exhaust gas and steam flow rates in AQC boiler respectively
T =is the temperature difference between inlet and outlet exhaust gas temperature.
At pressure of 1.5 Mpa and 70 0C from steam table the enthalpy using interpolation is
hin= 292.98KJ/Kg and At pressure of 1.5 Mpa and 285 0C from superheated steam table the enthalpy
is hout =3003.9KJ/Kg. Then,
0.85*298,667Kg/hr*1.0615KJ/Kg0C*(305 0C-1100C) = wf(3,003.9-292.98)KJ/Kg
By rearranging;
0.85298667Kg/hr1.0615KJ/Kg0C(3050C1300C)
wf= = 5.3Kg/sec
(3003.9292.98)KJ/Kg

June, 2013
Energy balance on SP-boiler:
Heat stream data
a. Preheater exhaust gas
Volumetric flow rate of exhaust gas = 310,333Nm3/hr
Mass flow rate of exhaust gas = 440,673 kg/hr
Dust load = 19.6 gms/Nm3
Exhaust gas temperature (Tex) = 335 0C
Table 5.3: composition of exhaust gas leaving from pre-heater

Contents Exhaust gas composition @ preheater (%) Average composition (%) Cp(KJ/Kg.K)
CO 0.02 0.03 0.025 1.0891
O2 3.54 3.62 3.58 0.9964
NO 695 716 ppm 705.5 ppm 0.9950
The specific enthalpy of the exhaust gas:

Cp,exgas = 0.025%*Cp,CO + 3.58% *Cp, O2 + 0.7055*10-3% *Cp, NO
= 1.068kJ/kg.0C.
Therefore, the required data which entered to the SP-boiler are:
ex,in= 440,673 Kg/hr P=1.5MPa
Tex,in = 3350C Tout=300 0C
Cp= 1.068kJ/kg0C
HX-1
SP-boiler
ex,out= 440,673.0kg/hr
Tex= 2150C P = 1.5MPa
Tin=700C
The amount of energy transferred in the SP-boiler is;
From steam table @Tin=700C and P=1.5MPa hin =292.98KJ/Kg and @Tout=3000Cand P=1.5MPa
hout= 3037.3KJ/Kg

June, 2013
Qtrans = ex,in * Cp*T =wf*(h in-hout) , by rearranging
, T .068( )
wf = = = 4.6Kg/sec
. .
The amount of energy and temperature that comes from the two boilers in the mixing line before
entering turbine is:
Average temperature= =297.50C and enthalpy =3020.5KJ/Kg
The mass flow rate at the inlet of turbine = 5.3+4.6=9.9kg/sec
Energy balance in steam turbine
Assume efficiency of turbine to be: = 95%
T= 297.50C TR-1 Qoutput=?

Turbine
wf = 9.9kg/sec h1= 3020.6 KJ/kg
wf = 9.9/sec
T = 95 0C
Assuming the inlet conditions of the turbine equals to the average of the two boilers (i.e. 297.3C
and 1.6MPa, the wetness fraction (quality of the steam) of steam is calculated as follows:
From steam tables, inlet conditions at T 1= 297.5 C and P1=1.6MPa are: then entropy is calculated
by interpolation:
@280 0C =6.8381KJ/Kg.K,@297.50C=?and@3200C=6.9938KJ/Kg.K
. .
= , then S1=6.91 KJ/Kg.K and h1= 3020.6 KJ/kg
. .
At the out let of the turbine with a temperature 950C the pressure from steam table is equal to
0.0846MPa and for the isentropic expansion entropy is constant (i.e. S1=S2)
Where Sf and Sg are the saturated liquid and vapor entropies. Taking saturated liquid and vapour
entropies from steam tables at 95 0C and 0.08464MPa, Sf=1.25KJ/Kg.K; Sg= 7.42KJ/Kg.K
The wetness fraction or quality(X) can be calculated
June, 2013
. .
X= = = 0.083
. .
The turbine outlet enthalpy for an isentropic expansion can be calculated from
h2= Xhf+ (1-X) hg
hf and h g are the saturated liquid and vapor enthalpies. Taking saturated liquid and vapor enthalpies
from steam tables at 950 C and 0.846MPa, hf =397.96KJ/Kg. h g = 2770.9 KJ/Kg
h2= 0.083*397.96 + (1-0.083) *2770.9
h2= 2214.8 KJ/ kg
For a single stage expansion with isentropic efficiency of 95%
h2= h 1 (h 1 h2)
h2= 3020.6 0.95 (3020.6-2214.8) = 2255.1 KJ/ kg
The actual wetness fraction (X) can be calculated from:
h2= X*h f+ (1-X) h g
Where hf and hg are the saturated liquid and vapor enthalpies
h2 = X* + (1-X) *
. .
X = = = 0.002
. .
Power generated (W) from the turbine is

W = wf (h1 h2) = 9.9Kg/sec*(3020.6-2255.1) KJ/Kg = 7,578.45KW
= 7.58 MW
Net power from generator
Pnet = Pturbine* elec * mech =7.58*0.99*0.98
= 7.35 MW

June, 2013
Energy balance in condenser

wf-in= 9.9Kg/sec wf-out=9.9Kg/sec
CONDENSER
Twf-in= 650C Twf-out = 25 0C
cw out =? cw-in =?
Tcw-out = 35 0C Tcw-in= 10 0C
The amount of heat transfer in to cooling water from the working fluid is:
Q trans =wf(h 1-h2) =cw*CPT
Where, h1 is enthalpy of working fluid at 650C from saturation vapor steam table = 272.06KJ/Kg
h2 is enthalpy of working fluid at 250C from saturation liquid steam table = 104.89KJ/Kg
CP =specific capacity of water at the average temperature 22.5 0C = 4.183KJ/Kg.0C
( ) . ( . . )
cw = = = 1.6Kg/sec
.
Amount of cooling water required = 1.6kg/s
Table.5.4: Summary of energy balance

Unit operations In Out
AQC-boiler Qwf + Qex = 1,552 + 26,860 Qwf + Qex = 15,921+9,687

= 28,412kJ/sec = 25,608kJ/sec
SP-boiler Qwf + Qex = 1,347+ 43,796 Qwf + Qex = 13,973+28,107
= 45,143kJ/sec = 42,080kJ/sec
Turbine Qwf,AQC+Qwf,SP =15,921+13,973 Qisen + Qoutput = 21,927+7,580
= 29,894kJ/sec = 29,507kJ/sec
Generator Qoutput = 7,580kJ/sec Quseful = 7,350kJ/sec

June, 2013
5.2. Sizing and design of main equipment
5.2.1. Sizing
SP-boiler
From the energy balance, the energy transfer is:
Qhot, in = ha-inC p ha T = 440,673*1.068*(335-215) = 56,476,651.7kJ/hr = 15,687.96 kJ/sec
The inlet and outlet temperature of AQC boiler are the log mean temperature of the boiler, TLMTD:
Hot air Working fluid

Temperatures ( c ) 335 300
215 70
T1 = 335 - 300 = 35 0C
T2 = 215 - 70= 1450C

Then, TLMTD = = 77.4 0C
( )
R= = = 0.522

S= = = 0.868
Figure 12.19 [10], Ft versus S at various R, Ft = 0.77 Then,
TLMTD = 0.77 x 77.4 = 59.6C
Table 11-2 [9], Assume Uo = 2250w/m2K, Then the area can be calculated as:
.
A= = = 117 m2
.
Turbine
Power output from the turbine is:

P = wf (h1 h2) = 9.9Kg/sec*(3020.6-2255.1) KJ/Kg = 7,578.45KW
= 7.58 MW
The power for design or sizing is expressed by horse power, so.
P = 7.58MW

June, 2013
5.2.2. Design of major equipment
Design of Boiler
Design data
Exhaust hot air

Inlet temperature (Texin) = 305 0 c
Outlet temperature (Texout) = 110 0c
Mass flow rate of the hot air(ex) =298,667Kg/hr =83Kg/sec
Specific heat capacity of hot air =1.128KJ/Kg.K
Amount of heat transferred into working fluid (Qtrans)= 17172.7KJ/Kg.
Working fluid (water)
Inlet temperature (Twf in) = 700c
Outlet temperature (Twfout) = 2850c
Mass flow rate of water (w ) = 19,080Kg/hr=5.3kg/sec
Specific heat capacity (CPw) =4.13KJ/Kg.K
1. Fluid allocation
Allocating the fluids with the lowest flow rate to the shell side will normally give the most
economical design and also the higher pressure stream should be allocated to the tube side. High
pressure tubes will be cheaper than a high pressure shell [9]. By economical consideration here, hot
air is on shell side and working fluid on tube side.
2. Heat transfer area
Table 11-3 [9], the designing overall heat transfer coefficient for hot air-water system is in the range
of 400 1000 Btu/(hrft2oF) i.e. 2271.32 5678.3 W/(m2oK) and it includes total dirt factor 0.0005
(hrft2oF)/Btu i.e. Df= 8.81 10 -5(m2oK)/W.
Assume Ud= 4300 W/m2K
3. Exchanger type and dimensions
An even number of tube passes arrangement and counter-current flow is usually the preferred.
Start with one shell pass and 2 tube passes.

T1 = 305 - 285 = 20 0C

June, 2013
T2 = 110 - 70 = 400C

So the mean temperature (TLMTD) = = 28.850C
( )

R= = = 2.91

S= = = 0.915
Figure 12.19[10], Ftversus S at various R, Ft = 0.95 Then,

True mean temperature T*LMTD = 0.95*28.85 = 27.5c
Table 11-2 [9], Assume Uo = 4300w/m2K,
Then the area can be calculated as:
,
A=
= .
= 145.72 m2
Let us choose tube characteristics as follows [10]:
Outer diameter of tube (do) = 30 mm
Heat transfer length of tube (L) = 6.8m
Inner diameter of tube (d i) = 28mm
4. Physical properties
Physical properties of water at average temperature of 178C ;
Specific heat = Cp= 4.399 kJ/kg. K
Viscosity = = 5.073 *10-5N.sec/m2
Thermal conductivity = k = 0.674 W/m. K
Density = = 888.95kg/m3
5. Tube-side heat transfer coefficient
Area of tube neglecting thickness of tube sheet:
Area of one tube (At) = x Do xL = 3.14x.03x6.8 = 0.641m2

.
Number of tube (Nt) = = = 228
.
So, for two passes, tubes per pass = 228/2 = 114
Tube cross sectional area (Ats) = x d i2/4 = 3.14 x 0.028 2 /4 = 0.000615 m2

June, 2013
So area per pass = 114 x 0.000615 = 0.0706 m2
.
Volumetric flow rate (Vt) = = = 0.0061m3/sec
.
.
Tube side velocity ( u t) == == = 0.087m/sec
.07068
Bundle and shell diameter:
Table 12.4,[10] for square pinch and 2 tube passes arrangement, K1=0.156, n1=2.207,p t=1.25d o
228
Db=di( ) =28( .
) . =760.6mm
For a pull-through floating head the typical shell clearance is 100mm,so the shell inside diameter
fig.12.10[10].
ds=760.6+100=860 mm= 0.86m
. . .
Nre = = =42,686
.
. .
Npr = =
.
= 0.33
For , = =243 and Nre =42,686 from fig12-23.[10]
j h = 6.1*10-2
Therefore, Nu = j hNreNpr0.33 =6.1*10 -2*42,686*(0.33)0.33
=1,806.03
Tube side heat transfer coefficient (hi)
, . .
hi = Nu = =43,474 w/m2K
.

June, 2013
6. Shell side heat transfer coefficient
Physical properties of exhaust gas average temperature of 207.5C :
Viscosity = = 4.2 *10-5N.sec/m2
Thermal conductivity = k = 0.065W/m. K
Shell diameter (d s)= 1160.6mm
As first trial take baffle spacing (lbaff) =d s/5=232mm
Pt =1.25do = 1.25*30= 37.5mm

( ) ( . ) .
Area of shell (As) = .
= 0.53m2
For square pinch arrangement the shell side equivalent diameter (hydraulic diameter),d e
. .
de = ( 0.78 )= (37.3 0.78 30 = 29.82mm
Volumetric flow rate of shell side,Vs
.
Vs = = = 66 .2m3/sec
.
Shell side velocity
.
us = = =12.23m/sec
.
. . .
Nre = = = 59,579
.
. .
Npr = =
.
Using the segmental baffles with a 25% figure12-23[10]
jh = 8.6*10-2
Therefore, shell side heat transfer coefficient is:

June, 2013
Nu = j hNreNpr0.33 =8.6*10 -2*59,579*(0.721)0.33 = 4,599.5
Shell side heat transfer coefficient (hs)

, . .
hs =Nu = .
=43,474 w/m2K =10,027
7. Overall heat transfer coefficient
1/Uo= (1/ho) + (1/hi ) *(do/di) + Df
= + * +Df
= ,
+ ,
* +8.81*10-5
U0 = 5016w/m2.K
.
Required heat transfer area (Atrans) =
= .
Atrans = 124.5m2125m2
Here is less than the corrected (available) heat transfer area. Therefore, this value of Uo is good
enough.

June, 2013
Design of condenser
A. Thermal design of condenser
The condenser is a horizontal condenser designed to condense 9.9 kg/s of water vapor coming from
the regenerator of 65C and at a pressure of 84.6kpa. But the degree of superheat is very less; hence
assuming water vapor is at saturated temperature only. The coolant used is water, which is supplied
at an inlet temperature of 10C and leaves at an outlet temperature of 35C.
1. Heat balance
Amount of heat removed from the working fluid (Q) = wf(h1-h2) = 1,660.33kW
Amount of water to be circulated (cw) = 1.6Kg/sec
2. Logarithmic mean temperature difference (LMTD)
The log means temperature of the condenser, TLMTD:
Cooling water Working fluid

Temperatures ( c ) 10 25
35 65
T1 = 65-35 = 30 0C
T2 = 25-10 = 15 0C

Then, TLMTD = = 22 0C
( )

Since condensation occurs at constant temperature, hence correction factor is not needed.
3. Fluid allocation
Allocating the fluids with the lowest flow rate to the shell side will normally give the most
economical design and also the higher pressure stream should be allocated to the tube side. High
pressure tubes will be cheaper than a high pressure shell [9]. Here water is available at atmospheric
pressure and steam is available at vacuum. Hence take steam on shell side and cooling water on
tube side.

June, 2013
4. Heat transfer area
Table 11-3 [9], the designing overall heat transfer coefficient for steam-water system is in the range
of 400 1000 Btu/(hrft2oF) i.e. 2271.32 5678.3 W/(m2oK) and it includes total dirt factor 0.0005
(hrft2oF)/Btu i.e. Df= 8.81 *10-5(m2oK)/W. Assume Ud= 2,500 W/m2K
.
Total heat transfer area = A =
=30.2 m2
Let us choose tubing characteristics as follows [9]:
Outer diameter of tube (do) = 1= 25.4 mm
Inner diameter of tube (di) = 0.9= 22.86 mm
Allowing 50 mm thickness for tube sheets: Now length of tube is 20ft i.e. 6.096 m
Thus length available for heat transfer = L =6.096 0.050 = 6.05 m
Area per tube = *d0*L = 0.483 m2/tube
Therefore, number of tubes, Nt = 30.2/0.483 = 62.663
Tube count table [9],
For tube O.D. of 1 inch for square pitch [9]
No. of shell passes = 1
No. of tube passes, (Np) = 4
Nearest tube count, (Nt) = 68
I.D. of shell (ds) = 2250 mm [10]
Corrected heat transfer area, A = 68*0.483 = 32.84m2
.
Corrected U = = = 2,298 W/m2K
.

June, 2013
5. Film heat transfer coefficients
a. Shell side
Temperature of vapor coming in (Ts) = 65C
Average temperature of cooling water = (35 + 10)/2 = 22.5C

.
Wall temperature, Tw= = 43.8C
.
Film temperature, Tf = = = 54.4C
So the property of water are taken at film temperature i.e. 54.4C [11]
Viscosity = = 0.586 10-3N.sec/m2
Thermal conductivity = k = 0.647 W/mK
Density, = 985.7 kg/m3
Specific heat, Cp = 4.184 kJ/kgK
.
Mass flow rate per unit length, () = / = /
= 0.0982kg/m. sec
.
.
Renolds number, (Nre) = = = 670.5
.
/
. /
Outer film coefficient, ,
. [( . . .
ho =
( . )
] (880.55)-1/3 = 1.51 *2043.8

= 5357.3W/m2K
b. Tube side
Average temperature of water = 22.5C
Physical properties of water at 22.5C
Viscosity = = 0.854 *10-3 N. sec/m2
Thermal conductivity = k = 0.6017 W/m. K

June, 2013
. .
Prandtl number (Npr) = = = 5.94
.6017
Mass flow of cooling water = cw= 1.6kg/s
.
Flow area (at) = * = * = 0.00698m2/pass
.
Velocity of cooling water = = = 0.23m/s
. .
. . .
Renolds number, (Nre) = = = 68,753>10000
.
DittusBoletere equation can be used:
Nu = 0.023 *(Nre)0.8*(Npr)0.3 = 0.023 *68753 0.8 *5.94 0.3= 290.87
. .
hi = = = 7764W/m2oK
.
6. Overall heat transfer coefficient
= + +
.
= + + 8.81 10 = 4.18*10-4m2K/W
. .
Therefore, Uo= 2393W/m2K
.
Required area (A) = =
22
= 31.54 m2
Here is less than the corrected (available) heat transfer area. Therefore, this value of Uo is good
enough.

June, 2013
7. Pressure drop calculations
a. Tube side
The Renolds number as calculated before for tube side is = Nre = 59464.93
Now f = 0.079(Nre)-1/4 = 0.079 *(68,753)-1/4= 0.00489
The pressure drop due to friction is given by
( )
Pf =
( )
g
( . . .
= ( . . )
997.5 9.81
= 170.725N/m2
The pressure drop due to the velocity of fluid is given by
.
Pv= = 1.25 [997.5 *(0.23)2] = 65.96N/m2
Therefore total pressure drop is given by
Pt= Np*(Pf+ Pv) = 4 *(170.725N/m2+ 65.96N/m2) = 0.947kPa < 70kPa
This is within the permissible limit of a maximum pressure drop of 70 kPa in the tube side for no
phase change.
So this pressure drop is acceptable.
(b) Shell side
Saturation temperature of vapor = Tvap= 65C
Viscosity of water vapor () 1.2*10 5 Ns/m2
Fluid flow-rate on the shell-side, kg/s, (v)= 9.9 kg/s
Density of vapor ( vap) = 985.9 kg/m3

( )
Flow area for shell side (shell) ={ }
Where Pt= square pitch = 1.25*do= 31.75 mm and baffle spacing (lB)= 0.2 ds to ds
Assume, lB =0.6d s

June, 2013
Shell diameter (d s)= 2250mm
Assume, lB= 0.6d s = 0.7*2250= 1350mm
( ) ( . . )
Therefore for cross-flow (As) = [ ]= [ ] = 0.6075 m2
.
Equivalent diameter (d e)fora square pitch arrangement:

. ( . . ( . . . )
de =[
] =[ ]= 0.013 m
.
. /
Mass velocity(Gs)= = = 16.3 kg/sec .m2
.6075
. .
(Nre)vap = = = 17,658.33
.
.
Number of baffles, now Nbaff= = =4
.
To calculate pressure drop for shell side, we have to consider three zones.
End zones, pe(there are two end zones)

Cross flow zones, p c , (Nbaff 1) crosses
Window zones, p w(Nbaffzones)
Thus total pressure drop is:
(ps)t = 2 *pe+ (Nbaff1) pc+ Nbaff *pw
P in cross flow section

pc=

Cross-flow area at or near centerline for one cross-flow section, Sm =0.7969

Where figure (11-25-b) [9] friction factor, fk= 0.5, b = 0.002,

Number of tubes row crossed in one cross flow section, Nc = { }
lc= baffle cut = 0.25 *d s = 0.25*2250mm= 0.563 m

Pp = pitch parallel to flow = * Pt= 0.866*31.75 = 27.4963 mm

June, 2013
.
.
.
Therefore, Nc = { }= 40
.
( . . . )
Thus pc= = 8.82 kPa
. .
P in end zones
= [1 + ]
Where Ncw= number of effective cross flow rows in each window
. .
= =
.
= 18.33
.
Thus, = 8.82 (1 + ) = 12.86 kPa
P in window zones
[ (2 + 0.6 )]
=

Where, b = 6.22310 -4
Sw= area of flow through windows = SwgSwt
Swg= gross window area
Swt= area occupied by tubes = [1 ]
Fc= fraction of tubes in each cross flow
Here, = 0.25 and d s =2,250mm (87.3inch)
Figure 11-8,[9]
Swg = 1000 in 2 = 0.6452 m2
Figure 1-6,[9]
Fc = 0.75

June, 2013
( )
Therefore, = (1 0.75) 0.0254 = 0.0043m2
Thus Sw= 0.6452 0.0043 = 0.641 m2

4 2
= [6.22310 9.9 2+0.618.3( )
Hence, 0.79690.6410.7
] = 2.2kPa
(ps)t = 2 *12.86 + (3*8.820)+ (4*2.2) = 56.82kPa
But actual pressure drop is 40% of this value.
Therefore (ps) t = 0.4 *56.82 = 22.73kPa
This is also within the permissible limit of a maximum pressure drop of 14kPa. So this is acceptable.

June, 2013
B. Mechanical design of condenser
Problem specification:
Working pressure: P = 0.846bar
Working temperature = Maximum temperature of the fluids = 650C
Design pressure: by adding a minimum of 10% to the maximum working pressure.
Design temperature: 10oC higher than the maximum temperature that any part of the exchanger is
likely to attain in course of operation. .
1. Shell Side:
Material of construction: Carbon steel
Design pressure = 0.846 bar + 0.1*0846bar = 0.931bar 1 bar = 0.1N/mm2.
Design temperature = 65 + 10 = 750C
Shell inside diameter, ds= 2250 mm = 2.250 m
No. of shell passes = 1
No. of tube passes = 4
Design stress for carbon steel @ 750C= 130N/mm2
Fluid: water vapor
Inlet temperature = 65C
Outlet temperature = 250C
1.1. Shell thickness
Minimum thickness of shell plates excluding of corrosion allowance in mm, Where taking joint
efficiency to be J = 0.85
. /
ts = = = 1.02mm
/ . . /
But minimum thickness of shell with corrosion allowance is 8 mm.

June, 2013
1.2. Nozzle diameter
Mass flow rate of vapor (v)= 9.9 kg/s and flow
Density, = 997.8 kg/m3
Velocity =10m/s

v =
.
dn2= = 1.263m2, dn = 35.5mm
997.
Take it as 40 mm.
1.3. Nozzle thickness
The thickness of nozzle is given by
. /
tn = (J = 1 for seamless pipes) = = 0.0154mm
/ . /
Nozzle thickness with corrosion allowance = 3 mm
1.4. Head thickness
Tori spherical head: The thickness of such heads is given by:

th =
Where, C = (1/4)*[3 + (Rc/RK)1/2]
J = 1 for ends made from one plate and attached to shell with a straight flange.
Rc= crown radius (it is equal to or less than the diameter of shell)
Choose Rc= shell diameter = 2250 mm
RK= knuckle radius (at least 6% of shell I.D) = 0.060 *2250 = 135 mm
Thus, C = 1.77
.
2250 .
t h= = 1.532mm, Using same thickness as that of the shell = 8 mm
/ 2

June, 2013
1.5. Transverse baffles
Baffle Spacing, lB = 0.6d s = 0.6*2250 = 1350mm
Number of baffles, Nbaff= 1 = 1 = 3.48 4
Thickness of baffles = 6 mm
Height of baffle = 0.75*ds = 0.75*2250 = 1687.5 mm
1.6. Flange standard
Design pressure = 0.1 N/mm2
Design temperature = 75oC
Flange material =BS: 4504-class - 1
Bolting steel = 0.5% Carbon Molybdenum steel
Gasket material = asbestos composition
Shell inside diameter = 2250 mm
Shell thickness, t s = 8mm
Shell outside diameter = 2250 + 2*ts = 2250 + 2*8 = 2,266 mm
Allowable stress of flange material = 100kN/m2
Allowable stress of bolting material = 138kN/m2
1.6.1. Determination of gasket width
( )
=[ ] 1/2
( )
do and di are outer & inner diameters of the gasket.
Assume gasket thickness of 3.2 mm, from literature
M = gasket factor = 2
y = minimum design yield stress = 11 N/mm2
( . )
=[ ] 1/2 = 1.005
. ( )

June, 2013
Let, di = Dos, (Dos = outside diameter of shell).
Therefore, di = 2,266 mm = 2.266 m and do= 1.005*2.266 = 2.277 m

. .
Gasket width, lR= = 0.0135m = 13.5 mm
1.6.2. Estimation of bolt load
( ) . ( ) .
Total pressure force, H = = = = 403.3kN
Gasket reaction due to pressure, Hg= *(2b)*G*m*Pd
The gasket width calculated is above the minimum gasket spacing width, (bo = 10mm), so the
effective width is:
lo = 2.5 = 2.510 = 7.9mm, therefore the gasket reaction due the pressure is:
. .
Hg= *( )*( + 2 )*m*Pd = *( )*(2250 +2*8)*2*0.1 = 5,624N = 5.624kN
Minimum required bolt load under operating condition
Wmb= H + Hg = 403.3kN + 5.624kN = 408.92kN
Load to seat gasket under bolting up condition
Wg = *b*G*y = *7.9*2266*11= 618.63kN
Since Wg>Wmb, controlling load = 618.63kN
Calculation of minimum bolting area:
Total cross sectional area of bolt required for gasket seating, Am= Ab=
Sg = allowable bolt stress at ambient temperature (30C) = 138 kN/m2
618.
Therefore, Ab= = 4.483m2
Calculation of optimum bolt size:
2266
Minimum bolt required (Actual number of bolts), n b = = 90.64 92

Then, Ab = , db= 249mm

June, 2013
Bolt circular diameter, Cb = Do + 2b d + 12 = 2277 + 2*249 +12= 2,787mm
1.6.3. Calculation of flange thickness
. . .
tf =Gm ( ) = 2266 .
(0.3 403.3 2266 + 1.5 408.92 13.5
tf = 40mm
2. Tube Side:
Tube and tube sheet material: stainless steel
Number of tubes = 68
Outside diameter of tube = 25.4 mm
Length of tube = 6.05 m
Fluid: cooling water
Pitch (square) =1.25do = 31.75 mm
Allowable stress = 155N/mm2 @ T= 75 oC, stainless steel.
Design pressure = 0.1N/mm2
Inlet temperature = 10C
Outlet temperature = 35C
2.1. Thickness of tube
( )
=
(2 + )
J =1 (for fully radiographed)
(0.125.4)
Therefore, = = 0.0082mm
(21551+0.1)
No corrosion allowance since the tube is made of stainless steel.
Therefore, thickness of tube = 1mm

June, 2013
2.2.Tube sheet thickness
The effective tube sheet thickness is:

( . ) 1/2
= [ ]
F = the value of F varies according to type of heat exchanger, in most cases it is taken as one.
G = mean diameter of gasket = 2,266 mm

( . . ) 1/2
Therefore, = 1 2266 [ ] = 28.78mm
2.3. Channel and channel cover
The effective thickness of the flat channel cover is calculated from the formula.
( ) 1/2
= [ ]
K = 0.3 for ring type gasket
Material of construction is carbon steel.
So allowable stress f = 93.2N/mm2
. .
Therefore t = 2266*( ) = 40.65mm
.
Use 45 mm thickness including corrosion allowance.
2.4. Nozzle thickness
Assume inlet and outlet diameter = 75 mm
.
Thickness of nozzle, tn= =( = 0.04 mm
. ) .
With corrosion allowance, thickness = 4 mm

June, 2013
2.5. Saddle support for horizontal vessels
Material: Low carbon steel
Vessel diameter = 2250 mm
Length of shell = 6.05 m
Tori spherical head:
Crown radius = 2250 mm
Knuckle radius = 135 mm (6% of shell diameter)
Working pressure = 0.0846N/mm2
Shell thickness = 8 mm
Head thickness = 8 mm
Depth of head = 257 mm
Corrosion allowance = 3 mm
Permissible stress = 93.2N/mm2
Distance of saddle center line from shell end, A = this distance is usually 0.2 to 0.25D and less than
0.2L.
Therefore A = 0.225 *D = 0.225*(2250) = 506.25mm < 0.2L
2.5.1. Longitudinal bending moment
The bending moment at the support is
1 +
= [ ]
1+
Q = load carried by each support = [ + ], Where Wv = Weight of fluid and vessel
Weight of shell material:

2 2
( )
= 4
, where, shell material= 7820 kg/m3

June, 2013
2 2
2.266 2.250 6.059.817820
= = 26.34kN
4
Weight of tubes:
[ ( )
= , where, tube material= 7750 kg/m3
[ ( . . ) .
= =11.95kN
Weight of tube sheets:
. . .
= = = 17.65kN
Liquid load in the shell:
( ) ( )
=( ) = 985.7
4 4
. .05 .
= 9.81 985.7
= 232kN
Liquid load in tubes:
( . . )
= = = 1.62kN
Therefore, total weight, Wtotal = W1+ W2+ W3+ W4+ W5 = 289.56kN
Hence, = [6.05 + ], (assume H= Do= 2.25m)
Q = 1.31MNm
= [ ] = 0.124MNm

June, 2013
Design of turbine
In a steam turbine, high-pressure steam from the boiler expands in a set of stationary blades or
vanes (or nozzles). The high-velocity steam from the nozzles strikes the set of moving blades (or
buckets). Here the kinetic energy of the steam is utilized to produce work on the turbine rotor. Low-
pressure steam then exhausts to the condenser and the total pressure drop occurs across the
stationary blades (or nozzles). This pressure drop increases the velocity of the steam.
Isentropic heat drop (hisen)is obtained as follows
hisen= (h 1 h2) = (3020.6- 2255.1) KJ/kg
= 765.5 KJ/kg
Velocity at the exit of nozzle (C1)
C1= 44.72 h = 44.72397.4
= 1237.3 m/s
Assuming the blade or diagram efficiency (b)and blade coefficient (k) are 0.7 and 0.6 and from the
relationship between blade velocity and diagram efficiency (b) the blade velocity become (U):
b = 4U/C1(Cos U/C1)
0.7 = 4*U/1237.3(cos200 U/1237.3) , U= 230.62m/sec
The nozzle angle (1) is assumed to be 20.
Nozzle exit diameter
Assume the pressure drop at nozzle is equal to the turbine. From steam table at 0.0846Mpa the
specific volume the steam at saturated vapor Vg=1.982m3/Kg
Then, A(area) =v*steam/C1 =1.982m3/Kg*9.9Kg/sec/1237.3 m/s
=0.0363m2
And, A= D2/4 ,D=0.142m

June, 2013
Cw1
Cw2 A U C
2 1 2 1
C2
Ca2 V1
V2 Ca1
C1
Cw
Fig.5.2: Combined velocity diagram
.Applying the cosine rule to the
V12=U2+C12-2UC1cos
=230.62 2+1237.32 - 2*230.62*1237.3Cos200
= 1024.0m/sec
Blade coefficient (k)=0.6then
V2= V1*k=0.6*1024m/sec= 614.2m/sec
Velocity of whirl at the inlet
Cw1= C1cos = 1237.3m/sec*cos200
= 1163m/sec
Axial component at the inlet
Ca1 =C1sin =1237.3m/sec*sin200
= 423.2m/sec
Blade angle at the inlet

.
tan1 = = = 0.454
.
Therefore,1 =tan-(0.454) = 25 0=2

June, 2013
Cos2 = , and Cw2=V2Cos2- U
Cw2 =614.2Cos250230.62m/sec = 326m/sec
And: C a2= (U+Cw2) tan2
Ca2= (230.62+326) tan250 = 260m/sec
Tangential force on blades
= steam (Cw1 +Cw2) = 9.9Kg/sec (1163+326) = 14.74KN
Axial force on blades
= steam(C a1 +Ca2) = 9.9Kg/sec(423.2+260) = 6.764KN
Work done on blades
=Tangential force on blades*blade velocity
= steam (Cw1 +Cw2)*U =9.9Kg/sec (1163+326)*230.62 =3.4MW
Kinetic energy supplied to turbine
=1/2steam*C 12=0.5*9.9Kg/sec*1237.3m/sec2
=7.58MW

June, 2013
6. Economic and profitability analysis
6.1. Cost estimation
1. Purchased Equipment Cost
Table 6.1: purchased equipment cost

Eq. No. Eq. Name Size Quantity Material Unit Amount
price($1000) ($1000)
HX-2 SP-boiler 117m2 1 Stainless steel 615 615
HX-1 AQC-boiler 125m2 1 Stainless steel 569 569
TR-1 Turbine 7.58MW 1 Carbon steel 273 273
HX-4 Condenser 32m2 1 Carbon steel 7.5 7.5
2
HX-3 Regenerator 2.62m 1 Carbon steel 1.2 1.2
DR-1 Expansion 4.55m3/sec 2 Stainless steel 19 38
chamber
G-1 Generator 7.35MW 1 Stainless steel 235 235
P-1 Pump 9.9kg/sec 2 API-610 cast 9 18
steel casing
D-1 Dearetor 1 Carbon steel 0.5 1.0
CT-1 Cooling tower 1 Carbon steel 1.3 1.3
Total 1,759

June, 2013
2. Total fixed capital investment
Table 6.2: Total capital investment estimation

Ratio factors Reasonable ratio Cost
suggested in factors ($1000)
Table
Direct Cost
Purchased equipment cost 100 100 1,759
Purchased equipment installation 47 23.5 413
Instrumentation and control 36 18 317
Piping 68 34 598
Electrical system 11 5.5 97
Buildings 18 9 158
Yard Improvement 10 5 88
Service facilities 70 35 616
Total direct cost 360 180 3,166
Indirect costs
Engineering and supervision 33 16.5 581
Construction expenses 41 20.5 361
Legal expenses 4 2 36
Contractors fee 22 11 194
Contingency 44 22 387
Total indirect cost 144 72 1,267
Total fixed capital investment 504 252 4,433
Working capital (15% of total 89 45 792
capital)
Total capital investment 593 297 5,224

June, 2013
3. Production cost
Labor cost
A Steam cycle waste heat power plant built within a cement facility will not require additional
operating personnel. The controls of the waste heat power plant will be integrated with the cement
plant control system to prevent any possible impact of an upset situation on cement production. For
example, a tube leak in the HRSG would cause the power plant to be immediately isolated from the
cement kiln.
Utilities
The volume (V) of process water required to produce steam with 3 minutes residence time is:
. .
V= = 0.0099m3/sec *180sec = 1.782m3
1000 /
Assuming 10% loss of water during processing and equal amount of water is added to the gap is:
V = 1.782m3*1.1 = 1.96m3
Table 6.3: utility cost estimation

Annual consumption Unit price($/unit) Amount($/year)
Electricity 0.67%*52,920Mwh 32$/Mwh 11,296
3
Process water 1.96m *7*42 0.54$/m3 311
Cooling water 0.192m3*7*42 0.54$/m3 31
Total 11,638
Depreciation
Fixed capital investment = $4,433,000

Salvage value = 10%
Service life = the life span of the cement plant = 20 years
Annual depreciation = 4,433,000*0.9 /20 = $199,485

June, 2013
Summary of total production cost

Table 6.4: summary of total production cost
Estimation method Amount Unit Cost
($/year) ($/kwhpower)
I. Manufacturing cost
A. Direct production cost
1. Utilities Direct calculation 11,638 0.22
2. Maintenance and repairs 3% of FCI 132,990 2.513
3. Operating supplies 0.5% of FCI 22,165 0.420
B. Fixed charges
1. Depreciation Direct calculation 199,485 3.770
2. Financing 5% of TCI 261,200 4.936
3. Insurance 0.5% of FCI 22,165 0.420
II. General Expenses Neglect
III. Total Production Cost 649,643 12.279
6.2. Profitability analysis
Non-discounted Profitability analysis standards method

Total product annual sale estimation:
Tax (Ethiopia) = 34%

Based upon the EEPCO payment standard, the average unit price of electricity can be taken as
0.032 $/kwh, and the annual product sale revenue is:
$
R= annual product sale revenue=annual production capacity( ) ( )
.
= 52,920,000Kwh* = $1,693,440

June, 2013
Table 6.5: profitability analysis using non discounting rate

Invest. dk FCI- d R($) COMd CF after CF($) Com.CF
Yr. ($) ($) ($) Tax($) tax($)
1 - 4,433,000 - -5,225,000
5,225,000 5,225,000
2 199,485 4,233,515 1,693,440 649,643 287,066 756,731 756,731 -4,468,269
3 199,485 4,034,030 1,693,440 649,643 287,066 756,731 756,731 -3,711,538
4 199,485 3,834,545 1,693,440 649,643 287,066 756,731 756,731 -2,954,807
5 199,485 3,635,060 1,693,440 649,643 287,066 756,731 756,731 -2,198,076
6 199,485 3,435,575 1,693,440 649,643 287,066 756,731 756,731 -1,441,345
7 199,485 3,236,090 1,693,440 649,643 287,066 756,731 756,731 -684,614
8 199,485 3,036,605 1,693,440 649,643 287,066 756,731 756,731 72,117
9 199,485 2,837,120 1,693,440 649,643 287,066 756,731 756,731 828,848
10 199,485 2,637,635 1,693,440 649,643 287,066 756,731 756,731 1,585,579
11 199,485 2,438,150 1,693,440 649,643 287,066 756,731 756,731 2,342,310
12 199,485 2,238,665 1,693,440 649,643 287,066 756,731 756,731 3,099,041
13 199,485 2,039,180 1,693,440 649,643 287,066 756,731 756,731 3,855,772
14 199,485 1,839,695 1,693,440 649,643 287,066 756,731 756,731 4,612,503
15 199,485 1,640,210 1,693,440 649,643 287,066 756,731 756,731 5,369,234
16 199,485 1,440,725 1,693,440 649,643 287,066 756,731 756,731 6,125,965
17 199,485 1,241,240 1,693,440 649,643 287,066 756,731 756,731 6,882,696
18 199,485 1,041,755 1,693,440 649,643 287,066 756,731 756,731 7,639,427
19 199,485 842,270 1,693,440 649,643 287,066 756,731 756,731 8,396,158
20 199,485 642,785 1,693,440 649,643 287,066 756,731 756,731 9,152,889
21 792,000 199,485 443,300 2,136,740 649,643 437,788 1,049,309 1,841,309 10,994,198
Payback period (PBP)
The time when cumulative cash flow reaches -$792,000(which is land +WC, land cost is 0).it is
between 6th and 7 th year.
( , , , )
By interpolation t= 6+ = 6.86 year
( , , , )
Since the plant startup at the end of 1 st year, PBP=5.86year
Cumulative cash position (CCP)
The value of the project after completion of the project =$10,994,198

June, 2013
Cumulative cash ratio (CCR)
The sum of all positive cash flow divided to the sum of all negative cash flow.
756,731 756,731 756,731 , , $ , ,

CCR = = =2.99 3
, , $ , ,
Rate of return on investment (ROROI)
The discount rate that gives profit with FCI
$756,731
ROROI = = = 0.17=17%
$ , ,
Discount rate method
Table.6.6: Profitability analysis using discount rate

Year CF($) discount factor present value cumulative CF
1 -5,225,000 0.893 -4,665,925 -4,665,925
2 756,731 0.797 603,115 -4,062,810
3 756,731 0.712 538,792 -3524018
4 756,731 0.636 481,281 -3,042,737
5 756,731 0.567 429,066 -2,613,671
6 756,731 0.507 383,663 -2,230,008
7 756,731 0.452 342,042 -1,887,966
8 756,731 0.404 305,719 -1,582,247
9 756,731 0.361 273,180 -1,309,067
10 756,731 0.322 243,667 -1,065,400
11 756,731 0.287 217,182 -848,218
12 756,731 0.257 194,480 -653,738
13 756,731 0.229 173,291 -480,447
14 756,731 0.205 155,130 -325,317
15 756,731 0.183 138,482 -186,835
16 756,731 0.163 123,347 -63,488
17 756,731 0.146 110,483 46,995
18 756,731 0.13 98,375 145,370
19 756,731 0.116 87,781 233,151
20 756,731 0.104 78,700 311,851
21 1,841,309 0.093 171,242 483,093
Discount factor = , where k = year and i = internal rate (12%)

( )

June, 2013
Discounted Pay Back Period (DPBP)
Discounted value of Land + WC = 0 + 792,000/1.122 = $707,143
It is in between 11 th and 12th year.
848,218 ,
By interpolation, t = 11 + = 11.72
848,218 653,738
Since the plant startup at the end of 1st year, DPBP=10.72 years
Net present value, NPV = $483,093
, , ,
Present value ratio, PVR = = 1.1
, ,
Therefore, the project is feasible.

June, 2013
7. Environmental impact
According to the relevant Environmental Impact Assessment Regulation for Derba WHRPG Project,
an Environmental Impact Assessment is not required. Developing countries like Ethiopia have been
agreed to ongoing their development according Kyoto Protocol. As the project boundary is in the
border of the plant, the project does not have any impact on environment. This project deals with
Clean Development Mechanism (CDM). Also in the project waste heat which already exists in the
plant will be used for electricity generation and the generated electricity will be used in the plant. So
all the project activities take place in the plant boundary.

June, 2013
8. Conclusions and Recommendations

8.1. Conclusions
In this work, the use of medium-grade waste heat energy from a cement manufacturing plant (which
is currently being rejected into the environment, thus causing energy wastage and environment
pollution) to generate electricity using Steam Rankine Cycle system proposed in this work has been
established to be an economically viable and environmentally friendly project. Although, the use of
exhaust waste heat to generate power using the Steam Rankine Cycle has been in existence for a
long time throughout the world, but in Ethiopia, has never previously occurred. Therefore, this
project through its theoretical study has been able to establish that this same technology can be
adequately transferred to other processes where waste heat is in existence.
The waste heat rejected from the AQC stack and pre-heater exhaust stack can be used to drive a
heat source Steam Rankine Cycle system to generate about 7.35MW (net) which is about 18%of the
electricity needed in the Derba MIDROC cement manufacturing industry. The economic analysis
shows that at an average electricity of $0.032/kWh the proposed project will give an NPV of about
$483,093 with a cumulative cash position $10,994,198, rate of return of investment 17% and
payback period of six years making it an economically feasible throughout the 20years service life
of the plant.
8.2. Recommendations
One major challenge encountered during the work of this study was to obtain reliable cost and
performance data from Steam Rankine Cycle manufacturers. And also, another constraint that was
happen during preparing of this project was the chemical engineer alone could not perform the
exact power generated without other professions. This constraint can be overcome by developing
simulation and control in corporation with electrical and mechanical engineers in order to verify
some of the data obtained from the published literature.
Therefore, further research should be carried out to develop an experiment heat source Steam
Rankine cycle system which could be used to validate the theoretical design already proposed in
this work. This will not only generate more insight into the operation of the system but will also
reposition this university as a center for the study of the waste heat to electricity process, since none
is currently in existence in Ethiopia.

June, 2013
References
[1]. Mark D. M.irolli, Chief Technology Officer, Recurrent Resources, LLC, 1079-9931/07 @ 2007
IEEE
[2]. Fuel Economy in furnaces and Waste heat recovery-PCRA
[3]. Rahbord Engineering Services Co,. Introduction of low-temperature Waste heat recovery
power generation (WHRPG) technology in Cement Kiln, 2010-11-19
[4]. The new Generation Kalina at ENGINE MWZ-Eng, 14.09.06 by Dr. Manfred Renz, Manfred
Engelhard.
[5]. Cement industry, A reference book for the industry
[6]. Engr. ZulfiqarKhattak, Engr. Jamil Ahmad Khan, Engr. Aasar Ahmad, Engr. Sifat Shah, Engr.
SheryarMasaud: Co-Generation of Power Through Waste Heat Recovery.
[7]. S. Katja, S. Jayant, Indias Cement Industry: Energy Efficiency and Carbon Emissions,
http://eetd.lbl.gov/ea/ies/suni6/industry/41842.pdf.
[8]. DiPippo, R. 2008: Geothermal power plants: Principles, Applications, Case Studies and
Environmental Impact, Elsevier, Oxford.
[9]. Robert H. perry.Don W. Green. Perrys chemical engineers handbook
[10]. Coulson and Richardsons R.K. Sinott. Chemical engineering design, Volume 6
[11].John H. Lienhard. IV a, Heat Transfer Text Book Third Edition.
[12]. Rama S.R. Gorla, AijazA.Khan. Turbo-machinery, Design and Theory, Cleveland State
University, Cleveland, Ohio, U.S.A and N.E.D. University of Engineering and Technology.
[13].Khan, F. (2008) Waste Heat Recovery. Process Systems Engineering Department Cranfield
University, United Kingdom. http://www.jase-w.eccj.or.jp/technologies/index.html
[14]. Alsop, P. (2001). Cement plant operations handbook for dry process plants, Trade ship
Publications Ltd., Portsmouth, United Kingdom.
[15]. BCS, Engineering Scoping Study, pp. 1516, 2006.
[16]. Cement manufacturing process description [Online]. Available:
www.inece.org/mmcourse/chapt6.pdf
[17]. www.matche.com
[18]. http://www.mhhe.com/engcs/chemical/peters/data/
[19]. Mujumdar, K.S., & Ranade, V.V. (2006). Simulation of Rotary Cement Kilns Using a One-
Dimensional Model. Chemical Engineering Research and Design, 84(A3), 165-177.

June, 2013
Appendices
Appendix A: Actual data collected from DMC
Table.1A: Pre-heater exhaust gas outlet.

Sr. no Unit Kiln (value )
1.1 Clinker production capacity Ton/day 5,600
1.2 Cement production capacity Ton/day 8,000
I Type Twin
Ii Make Stainless steel
Iii No of preheater stages 5 double string
cyclone
Iv Exhaust Gas Quantity at Preheater outlet Kg/hr.
Nm3/hr 310,333
V Exhaust Gas Temperature at Preheater outlet Deg. C 322.7
347.5
Vi Dust load gms/Nm3 19.6
Table.2A: Hot air at the cooler outlet

Sr. no Unit Kiln(value)
I Type Grate, Claudius
peters
Ii Make Stainless steel
Iii Exhaust gas quantity at the cooler outlet kg/hr. 298,667
Nm3/hr
Iv Exhaust Gas Temperature at Cooler outlet Deg. C 305
V Dust load gms /Nm3 59.8

June, 2013
Table.3A: Exhaust Gas composition (% by volume):

Content Pre Heater exhausts gas composition (%)
CO 0.02-0.04
O2 3.54-3.62
NO 695-716
Table.4A: Average energy consumption in MIDROC Cement industry.

Type of requirement Units Amount
Thermal energy Kcal/tone clinker 741,000
Electrical energy Kwh/tone cement 93
Coal requirement Tones/day 750-800
Power requirement Mw 43
Total annual cost of power for the whole plant EBirr/year 24,000,000
Fig.1A: photo for pyroprocessing in DMC

June, 2013
Appendix B: Ratio factors for estimating capital investment items based on delivered equipment
cost

June, 2013
Appendix C: data sheet specification of major equipment

Equipment No.- HX-1
AQC-BOILER HEAT EXCHANGER DATA SHEET Description.(function)-boiler
Sheet No-1
Operating data
Size=125m2 Type-shell and tube No. of Uint-1
Performance of one Unit
Shell side Tube side
Fluid circulating exhaust gas Steam(working fluid)
Mass flow rate (kg/sec) 83 5.3
IN OUT IN OUT
Exhaust gas To(0C) 305 110
Working fluid To(0C) 70 285
Viscosity (N.sec/m2) 4.2*10-5 5.073*10-5
Specific heat (KJ/Kg.K 1.128 4.399
Thermal conductivity(W/m2.K) 0.065 0.674
Volumetric flow rate(m3/sec) 66.2 0.0061
Velocity(m/sec) 12.23 0.087
No.of passes 1 2
No.of tube 114
Heat trans. coefficient .(W/m2K) 10,027 43,474
Fouling resistance (m2oK)/W) 8.81 *10-5

June, 2013
Equipment No.-HX-4
CONDENSER DATA SHEET Description (function)-condensing
Sheet No-2
Operating data
Size=32m2 Type-shell and tube No. of Uint-1
Performance of one Unit
Shell side Tube side
Fluid circulating Steam(saturated liquid) Cooling water
Mass flow rate (kg/sec) 9.9 1.6
IN OUT IN OUT
Vapour To(0C) 65 25
Water T o(0C) 10 35
Viscosity (N.sec/m2) 0.586*10-3 0.854*10-3
Specific heat (KJ/Kg.K 4.184 4.183
Thermal conductivity(W/m2.K) 0.647 0.601
Velocity(m/sec) 0.23
No.of passes 1 4
No.of tube 68
Heat trans. coefficient .(W/m2K) 5357.3 7764
Fouling resistance (m2oK)/W) 8.81 *10-5

June, 2013
Equipment No.- HX-4
CONDENSER MECHANICAL DESIGN DATA SHEET Description(function)-condensing
Sheet No-3
Construction one Unit
Shell side
Size=125m2 Shell diameter=2025m head thickness= 8mm
Design pressure =1bar Shell thickness=8mm
Design temperature=750C Design stress=130N/mm2
Material of construction =carbon steel
Nozzle and bolt
Nozzle dia.=40mm Bolt area = 4.483m2 Bolt number = 92
Nozzle thickness=3mm Bolt load = 408.92kN Flange thickness= 40mm
Tube side
Design pressure= 1bar Tube diameter =25.4mm
Design temperature = 750C Length of tube =6.05m
Material of construction =stainless steel Allowable stress =155N/mm2

June, 2013

Waste Heat Recovery Power Generation From Cement Kilns of Derba Cement Factory

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Waste heat recovery power generation from cement kiln systems i

ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

WASTE HEAT RECOVERY POWER GENERATION FROM CEMENT KILN SYSTEM

(CASE OF DERBA MIDROC CEMENT INDUSTRY)

[Focus area: process engineering stream]

Project Advisor: Ing. Hagos Birhane

ASTU, Chemical engineering department

ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

WASTE HEAT RECOVERY POWER GENERATION FROM CEMENT KILN SYSTEM

(CASE OF DERBA MIDROC CEMENT INDUSTRY)

Chairman, Department Signature Date

Advisor Signature Date

Examiner Signature Date

ASTU, Chemical engineering department

ASTU, Chemical engineering department

ASTU, Chemical engineering department

List of Acronyms and Abbreviations....vii

List of Appendices ................................................................................................................................ vi

ASTU, Chemical engineering department

ASTU, Chemical engineering department

2.2 Clinker formation reaction in kiln system..........................10

2.4 Summery of waste heat recovery power generation technologies.................22

5.1 Composition of hot air leaving quenching cooler..................34

5.2 System characteristics................................................................................................35

5.3 Composition of exhaust gas leaving from pre-heater........36

5.4 Summary of energy balance ...............39

6.1 Purchased equipment cost........65

6.2 Total capital investment estimation.............66

6.3 Utility cost estimation..............67

6.4 Summary of total production cost....68

6.5 Profitability analysis using non discount rate.........69

6.6 Profitability analysis using discount rate.....70

ASTU, Chemical engineering department

2.2 The use electrical and thermal energy in cement production..........12

2.3 Two pass water tube waste heat recovery boiler................................16

2.6 Heat pump ..........................................18

2.7 Waste heat recovery through steam Rankine cycle.........20

2.8 Waste heat recovery through organic Rankine cycle system.........21

2.9 Kalina cycle waste heat recovery...................22

4.1 AQC boiler and SP-boiler .........................................................................................27

4.2 Expansion chamber for dust removal system........................................31

4.3 PFS for steam Rankine Cycle WHRPG ....33

5.1 Steam Rankine cycle power generation for energy balance......34

5.2 Combined velocity diagram...........63

A: Actual data collected from DMC........75

B: Estimating of capital investment items based on Delivered equipment cost..77

C: Data specification of major equipment......78

ASTU, Chemical engineering department

List of acronyms and abbreviation

AQC -Air quenching cooler

CCP -Cumulative cash position

CCR -Central control room

CHP -Combined heat and power

DPBP -Discount payback period

EEPCO -Ethiopian electric power coloration

FCI -Fixed capital investment

LCR -Local control room

LMTD -Logarithmic mean temperature difference

MIDROC Mohammed international development and research organization center

NPV -Net present value

OPC -Ordinary Portland cement

ORC -Organic Rankine Cycle

PFD -Process flow diagram