Evaluation of Waste Heat Recovery Systems Efficiency in Thermal Plants: A Case Study on Cement Industry
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Abstract
Thermal plants, especially those in the cement industry, lose a large share of energy as waste heat during various stages of production. This study evaluates the theoretical efficiency of three common waste heat recovery systems used in cement plants: Heat Recovery Steam Generators, Organic Rankine Cycle systems, and regenerative heat exchangers. The analysis is based on thermodynamic simulations using MATLAB and actual plant parameters, including exhaust gas temperatures between 250°C and 400°C.
Simulation results show that the Heat Recovery Steam Generator system achieved the highest thermal efficiency at 22.5%, generating a net power output of 4.8 MW. The Organic Rankine Cycle system demonstrated a thermal efficiency of 15.4%, with a power output of 3.1 MW, making it suitable for medium-temperature exhaust streams. The regenerative heat exchanger system did not generate power but improved combustion efficiency, recovering 9.3% of the waste heat for preheating processes.
These results suggest that combining these systems in a hybrid setup could achieve a total output of up to 7.8 MW, increasing energy recovery by over 60% compared to using a single system. The study provides concrete simulation-based evidence to support investment in waste heat recovery systems in the cement industry for enhanced sustainability and efficiency.
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