Optimizing Thermal Energy in Cement Manufacturing

Cement plants that have 4 and 5 stage preheaters have a significant amount of available energy that can be recovered from the kiln exhaust. Most also have available energy from the hot air produced in the clinker cooler. By installing waste heat boilers in these hot gas streams, steam can be produced and used to power a generator (producing electricity) or to drive a fan (offsetting electricity consumption). With temperatures in excess of 600°F, these systems can be cost effective.

Customized Cement Kiln Heat Recovery Solutions

Every cement plant has unique characteristics – whether it is the type of fuel fired in the kiln, the number of preheater stages, utility incentives, or the cost of power – these factors differ at every site. As a result, system designs are customized to maximize the overall financial and operational benefit for the plant.

Steam-based Systems: Steam is normally the fluid of choice for these systems. There are hundreds of waste heat systems globally using steam to turn a turbine generator for electricity production. However, when utility incentives exist for reducing motor-driven loads, driving ID fans directly with steam turbines can be an advantageous design strategy. AirClean designs tailored systems to achieve optimal returns for facility requirements.

Organic Rankine Cycle (ORC): Organic fluids are used in lieu of steam when energy is available at lower temperatures. These fluids boil at lower thresholds, making them particularly useful for clinker cooler exhaust streams where temperatures are reduced. AirClean partners with ORC equipment providers to integrate turnkey systems that deliver dependable thermodynamic performance.