Design and analysis of a cogeneration plant using heat recovery of a cement factory

There is a more potential in a cement factory for electric power generation using waste heat recovery compared to the other industries. A case study has been done at a cement factory having two units, 1600 TPD and 5500 TPD, identified three waste heat rejections at 176 °C, 330 °C and 420 °C and designed a suitable power plant configuration. In this work, an attempt has been made to quantify the power generation capacity with plant analysis. It has been resulted that 12.5 MW of power can be produced with the available heat recovery against a cement factory demand of 15 MW. The available process heat for cement production and power generation has been estimated at a capacity range from 5000 to 9000 TPD. The analysis recommended a low steam pressure for power generation at above said heat recovery gas temperature.