Introduction of WHR System in Cement Plant
The waste heat power generation system installed at the cement production line mainly utilizes the waste heat resources of the grate cooler and preheater of the clinker production line to build a pure low-temperature waste heat recovery power plant. It is mainly composed of a steam turbine & generator unit and its auxiliary equipment, PH boiler, AQC boiler, cooling tower, demineralized water treatment plant, etc. Combined with the characteristics of waste heat resources and the purpose of "determining electricity by waste heat resources", aiming at the characteristics of high fluctuation of waste heat temperature and flow of the new dry process cement kiln system, Conch Kawasaki has studied and developed the pure low-temperature and low-pressure flash thermal system technology. The process flow of the whole thermal system is a complete process of water vapor recycling. Waste heat recovery boilers are respectively set at the grate cooler side and preheater side of the clinker production line for heat exchange. The superheated steam generated after heat exchange is led into the steam turbine for work done, and the steam turbine drives the generator to generate electricity.
Technology Features
1. Conch Kawasaki is the pioneer of the waste heat recovery power plant in the cement industry in China who has rich industry experience and has conducted in-depth research on the characteristics of different industrial waste gas resources. Relying on the technical support of Kawasaki Heavy Industries, Ltd., Conch Kawasaki can develop a proprietary high-efficiency thermal system and waste heat recovery boiler for different waste gas resources to ensure the organic combination of power generation system and clinker production line system. It can realize the utilization of waste heat truly on the premise of not increasing the coal consumption of the clinker production line system.
2. Conch Kawasaki has a highly skilled technical team with strong design ability. The company uses internationally advanced design software to ensure the system safety, beautiful layout, high efficiency, and accuracy of the drawing. Also, our design can meet the requirements of the National Standard of P.R. China, American Standard, Japanese standard, and other design specifications according to the needs of the project. At present, Conch Kawasaki's reference projects cover more than ten countries such as China, Japan, Thailand, and Laos.
3. Conch Kawasaki’s WHR system has high reliability and good stability. The intelligent distributed control system developed by Conch Kawasaki has stable and reliable operations, high labor productivity, high automation, and high intelligence. It effectively reduces the labor intensity of the factory and improves the operation reliability of the WHR system.
By the end of December 2024, the company has promoted 302 sets of cement waste heat power generation units (including 40 sets from abroad) in nearly 60 cement enterprise groups across 24 provinces, municipalities and autonomous regions in China, involving 385 cement clinker production lines. The products have also been exported to countries such as Thailand, Pakistan, Myanmar, Turkey, Vietnam, Brazil, Indonesia, India, Laos and South Korea. The installed capacity has reached 3,504.3 megawatts, with an annual power generation of 26.63 billion kilowatt-hours. Calculated on the same basis as thermal power generation, it saves 9.587 million tons of standard coal and reduces 24.582 million tons of carbon dioxide emissions annually. The environmental and economic benefits are very significant.