The ORC Option in Cement Plant

WASTE HEAT RECOVERY 87
The ORC option

Steam turbine technology has been favoured over organic Rankine cycle (ORC) modules
technology for waste heat recovery (WHR) at cement plants. However, improvements in
cement production offer scope for the increased uptake of WHR through the ORC process.
n by AQYLON, France
I n terms of heat generated in industrial

processes, approximately 50 per cent
of the fuel used to produce power in
AQYLON’s ATM-1000H ORC solution
conventional plants and 60 per cent of

the energy used in industrial processes
is wasted, according to the International
Energy Agency (IEA). Typically, a cement
process absorbs around 53 per cent of
the energy produced. Out of the 47 per
cent of wasted heat, some 34 per cent
could be recovered to generate up to 30
per cent of the plant’s electrical needs.
Although waste heat recovery (WHR) is
a proven technology, until now it has
not been widely implemented except in
China. According to the International electricity price increases • Because of continuous improvements
Finance Corporation (IFC), around 850 • increasing plant reliability in cement production technology
WHR installations exist worldwide (mainly • improving margins and market and major improvements in grate
in China), with 739 mainly using steam competitiveness cooler technology, the exhaust gas
turbine technology. • reducing CO2 emissions and temperature, both at preheater and
For the cement industry, WHR is an decreasing a factory’s environmental cooler levels, has dropped dramatically
important tool as it can reduce operating footprint. in the past decade. At the same
costs and increase EBITDA by 10-15 per According to the IFC, the market time, the potential efficiencies of
cent. Electrical power expenses usually potential for WHR in the cement industry the conventional steam cycles have
account for around 25 per cent of total is estimated at US$5bn or 2GWe for just dropped significantly:
operating costs. WHR advantages include: 11 countries – with India alone accounting - to operate optimally, the steam
• reducing energy costs of a plant for US$1.4bn. Energy efficiency in the turbines need at least 280˚C (536˚F)
• reducing reliance on grid power Indian cement industry is already high, - lower pressure and lower
• mitigating the impact of future but the roadmap guided by the Cement temperature steam conditions result
Sustainability Initiative (CSI) is in steam condensation in the turbine,
very ambitious with an emissions causing blade erosion.
reduction target of 45 per cent by • To compensate for the low
2050. temperature of the exhaust gas, the
temperature has been raised in some
Issues with steam turbine cases by additional fuel burning,
heat recovery increasing the fuel cost to dramatic
As previously mentioned, the most levels.
commonly used Rankine cycle • To increase the waste gas
system for WHR is the traditional temperature, the recovery point is set
water steam cycle. Today it at the middle of the air cooler exhaust,
represents 96.5 per cent of worldwide resulting in WHR of only 50 per cent of
WHR systems in the cement industry. the available power.
Despite wide availability from various • One of the main issues for the steam
suppliers (resulting in a relatively low turbine is the varying temperature of
cost basis in US$/W terms), steam the exhaust gas, ranging, for example,
Figure 1: estimated realised and remaining turbines were never designed for from 265-500°C (509-932°F) for a
technical potential and investment in WHR
low-grade heat and today face a Jordanian cement factory.
deployment (source: IFC)
number of issues: • At partial load, the small steam
©Copyright Tradeship Publications Ltd 2017

MAY 2017 INTERNATIONAL CEMENT REVIEW
88 WASTE HEAT RECOVERY
turbines are both inefficient and by producing and using green electricity. based factory. These compact and scalable
unstable as most steam turbines under AQYLON proposes a range of solutions units allow for rapid implementation
10MW are not designed to overcome for up to 10MWe. The system recovers and low erection costs. Bypasses on the
flow fluctuations. exhaust heat from the preheater and/or thermal oil loop as well as on the organic
• Condensing pressure is below clinker coolers. The process is kept safe fluid closed loop prevent any interference
atmospheric pressure, resulting in as a bypass is intalled on the stack and with normal cement plant operations. Low
the need for complex and expensive equipment complies with a producer’s pressure design and low revolution speed
vacuum and purging equipment. process. of the turbine offer simplicity in operation,
• Maintenance costs are increased by Electricity can be produced from 3MWth reliability and minimal maintenance
the need to have two operators in many and 180°C with AQYLON’s ATM-1000H requirements.
cases. system. High electrical efficency of up to Advantages of the design include:
• The steam turbine’s necessity to use a 23.6 per cent can be achieved. In addition, • high availability (above 97 per cent),
cooling water tower is also an issue: the system has a low footprint as it is fully • high efficiency of the cycle with typical
– there is always a risk of blowdown containerised. isentropic efficiency of the turbine
– the cooling tower needs chemical For its ORC solution, AQYLON proposes: (above 85 per cent)
pre-treatment as well as make- • complete turnkey solutions • retention of efficiency at partial load,
up water, leading to increased • standard high temperature ORC even at very low partial load
maintenance costs. modules in containers offering • a fully automated design with no
• In case of shutdown, the risk of easier transportation (ISO standard overnight operator.
freezing is high in some countries. containers), easier and faster on-site
• In case of failure, the complete system installation (everything is pre-piped and Untapping potential
needs to shut down. pre-connected), and avoidance of heavy The market potential for WHR at a cement
civil works (only some concrete plots factory is huge. AQYLON is well positioned
The AQYLON ORC solution are needed to put the containers on) with its containerised products to
The AQYLON ORC solution is to use this • complete financed solutions, where implement the benefits of ORC solutions
untapped potential by valorising waste the end-user does not need to invest. worldwide.
heat into electricity. In addition, AQYLON In terms of technical flexibility, all To date, AQYLON’s heat recovery
ORC solutions allow industries to meet equipment is mounted in standard 20ft or projects worldwide total about 30MW and
energy transition regulations requirements 40ft containers at the company’s France- demand is growing. n
INTERNATIONL CEMENT REVIEW MAY 2017 ©Copyright Tradeship Publications Ltd 2017

The ORC Option in Cement Plant

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WASTE HEAT RECOVERY 87

The ORC option

I n terms of heat generated in industrial

conventional plants and 60 per cent of

©Copyright Tradeship Publications Ltd 2017

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