Energy Saving Seminar in Mexico WasteWaste HeatHeat RecoveryRecovery PowerPower GenerationGeneration (WHRPG)(WHRPG) forfor CementCement PlantPlant 22nd November 2007
KAWASAKIKAWASAKI PLANTPLANT SYSTEMS,SYSTEMS, LTD.LTD.
1 Content
1. Waste Heat Recovery Power Generation & Energy Saving
2. Diffusion of WHRPG in Cement Plants
3. Technology of Kawasaki’s WHRPG
4. Operational reliability
2 2 Waste Heat Recovery Power Generation for Cement Plant for Cement Plant AQC Boiler
Turbine / Generator Building PH Boiler Demineralizer Building
Cooling Tower
3 3 4 4 Expected Power Generation EXPECTED POWER OUTPUT Generated power can cover 35~ 40% of 20,000 electric consumption in a cement plant
15,000
10,000 45 kW/ ton-clinker
Power Generation (kW) 5,000
0 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000
Clinker Production (ton/day)
5 5 Expected Profits Next Decade (18,500kw)
200 193
150 145
100 Milion US$ 96 77 50 58 39 29 19 10 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 66 Year Content
1. Waste Heat Recovery Power Generation & Energy Saving
2. Diffusion of WHRPG in Cement Plants
3. Technology of Kawasaki’s WHRPG
4. Operational reliability
7 7 Kawasaki Market of WHRPG in Cement Plants
Japan : 10 plants Korea : 1 plant Taiwan : 3 plants China : 13 plants F Pakistan : 1 plant
India : 1 plant
Thailand : 1 plant
Vietnam : 1 plant
8 8 Total 20 Plants
Myojo Cement Itoigawa Factory Mitsubishi Material Kawasaki :10 Plants Aomori Factory
Denkikagaku Kogyo Hachinohe Cement Oumi Factory Hachinohe Factory
Sumitomo Cement Taiheiyo Cement Gifu Factory Ofunato Factory
To-so Hitachi Cement Nan- yo Factory Hitachi Factory
Tokuyama Taiheiyo Cement Nan- yo Factory Osaka Kumagaya Factory
Taiheiyo Cement Chichibu Factory
Mistubishi Material Kitakyusyu Factory Tokyo Taiheiyo Cement Fujiwara Factory
Sumitomo Cement Mistui Kouzan Ako Factory Tagawa Factory
Osaka Cement Taiheiyo Cement Kochi Factory Kawara Factory Taiheiyo Cement Tosa Factory Taiheiyo Cement Tsukumi Factory
WHRPG in Japanese Cement Plants 9 9 Kawasaki’s Supply List of WHRPG for Cement Plants
Company Nationality Factory Production (t/d) Mother Facility Output (kW) Date Sumitomo Osaka Cement Japan Gifu 5,700 AQC 2,640 1980 Hachinohe Cement Japan Hachinohe 4,400 AQC 2,200 1981 Taiheiyo Cement Japan Kumagaya 12,000 PH/AQC 15,000 1982 Mitsui Kozan Japan Tagawa 7,000 PH/AQC 9,000 1984 Mitsubishi Materials Japan Aomori 4,500 PH/AQC 7,300 1984 Toh Soh Japan Nanyou 9,000 PH/AQC (9000) 1984 Taiheiyo Cement Japan Chichibu 4,800 PH/AQC 8,000 1985 Taiheiyo Cement Japan Fujiwara 8,300 PH/AQC 12,000 1987 Hitachi Cement Japan Hitachi 4,000 PH (1500) 1989 Taiheiyo Cement Japan Kumagaya - AQC 1,000 1989 Taiwan Cement Taiwan Suou 13,000 PH/AQC 15,100 1990 Tokuyama Cement Japan Tokuyama 12,000 PH/AQC (13000) 1991 Jiaxin Cement Taiwan Gongshan 7,000 PH/AQC 9,650 1992 Ninguo Cement China Ninguo 4,000 PH/AQC 7,200 1998 Taiwan Cement Taiwan Heping 25,880 PH/AQC 34,000 2001 Ha Tien 2 Cement Vietnam Ha Tien 3,000 PH 2,950 2002 The India Cements India Vishnupurm 4,000 PH/AQC 7,700 2004 Liuzhou Cement China Liuzhou 3,300 PH/AQC 5,700 2004 Tongyang cement Korea Samchok 19,200 AQC 19,700 2004 Anhui Ningguo Cement Plant China Ningguo 5,000 PH/AQC 9,100 2006 Anhui Jiande Conch Cement China Jiande 5,000 PH/AQC 8,300 2006 Anhui Chizhou Conch Cement China Chizhou 10,000 PH/AQC 17,000 2006 Anhui Tongling Conch Cement China Tongling 9,500 PH/AQC 16,300 2007 Anhui Zongyang Conch Cement China Zongyang 10,000 PH/AQC 18,300 2007 Anhui Digang Conch Cement China Digang 10,000 PH/AQC 18,500 2007 Yingde Longshan Cement China Yingde 15,000 PH/AQC 27,000 2007 Anhui Tongling Conch Cement China Tongling 20,000 PH/AQC 30,500 2008 Anhui Chizhou Conch Cement China Chizhou 8,000 PH/AQC 11,000 2008 Anhui Zongyang Conch Cement China Zongyang 10,000 PH/AQC 15,000 2008 Anhui Huaining Conch Cement China Huaining 10,000 PH/AQC 18,000 2008 Siam Cement Thailand Kaeng Khoi 5,500 PH/AQC 9,100 2008 Bestway Cement Pakistan Chakwal 10,700 PH/AQC 14,900 2009
Total 395,640kW / 32 Plants 10 Japan / Taiheiyo Cement / 15,000 kW
Kumagaya Plant Started Operation in 1982, 4,000 t/d + 7,600 t/d = 11,600 t/d operating for 25 years successfully
PH Boiler
Turbine / Generator House
11 Taiwan Cement Corporation / 34,000 kW
Hoping Plant Started Operation in 2001, 8,000 t/d x 3 kilns operating for 7 years successfully
PH Boiler
AQC Boiler
12 Vietnam / Ha Tien 2 / 2,950 kW
Ha Tien 2 Plant Starter Operation in 2002, 3,000 t/d operating for 6 years successfully
PH Boiler
Turbine / Generator House
Demineraliser Demineralised House Tank
13 India / India Cement Limited / 7,700 kW Waste Heat Recovery Power Generation
Vishnupuram Plant Started Operation in 2004, 4,000 t/d operating for 4 years successfully
14 China / CONCH / 9,100 kW
New Ningguo Plant Started Operation in 2006, 5,000 t/d operating for 1 year successfully
PH Boiler
AQC Boiler
15 15 Content
1. Waste Heat Recovery Power Generation & Energy Saving
2. Diffusion of WHRPG in Cement Plants
3. Technology of Kawasaki’s WHRPG
4. Operational reliability
16 16
EXPERIENCED RANGE OF DUST CONCENTRATION & INLET GAS TEMPERATURE
No. Heat Source 1 LD Converter 2 Cokes Dry Quenching 3 Slab Heating Furnace 4 DL Sintering 5 Nickel Flash Smelter 6 Copper Flash Smelter 7 Copper Converter 8 Zinc Roaster 9 Pyrite Roaster 10 Reformed Gas (Ammonia) 11 NH3-Burning (Nitric Acid) 12 Crude Oil Heating Furnace 13 Suspension Preheater 14 Air Quenching Cooler 15 Incinerator of Municipal Waste 16 Incinerator of Industrial Waste 17 Gas Turbines 18 Diesel
17 PHPH BoilerBoiler
Tubes located horizontal
Gas flow
Gas flow
Tubes located vertical Kawasaki Other Company 18 PH Boiler PH Boiler Inlet Gas Temp. Outlet Gas Temp. PH GAS TEMP. NO. Outlet Temp NO. Year 420~ 439? 1 300 3 1984 400~ 419? 4 280 2 1991 380~ 399? 9 270 1 1989 6 ~ 1992 250 360~ 379? 6 1 1997 340~ 359? 7 6 ~ 1997 230 320~ 339? 15 7 1998~ 300~ 319? 10 200 26 2006~
19 19
Without modification of AQC
20 20 Modification of AQC
21 21 AQCAQC BOILERBOILER
Modules of tubes
22 22 AQCAQC BoilerBoiler
Modules Type Low draft loss !
Installation – easy !
Compact !
23 23 Content
1. Waste Heat Recovery Power Generation & Energy Saving
2. Diffusion of WHRPG in Cement Plants
3. Technology of Kawasaki’s WHRPG
4. Operational reliability
24 24 China / LIUZHOU CEMENT / 6,500 kW 3,300t/d
PH Boiler Turbine / Generator AQC Boiler ITEM UNIT PH BOILER AQC BOILER TYPE Forced Circulation Natural Circulation EVAPORATION RATE T/H 22.32 8.1 BOILER CONDITION STEAM PRESS. MPa 1.67 1.67 STEAM TEMP. ? 335 350 TYPE Condensing Turbine STEAM TURBINE OUTPUT KW 6,500 CAPACITY KVA 7,000 GENERATOR TERMINAL VOLTAGE V 6,706
25 LiuZhou Plant / Operating Rate of WHRPG
800 100 100 100 100 100 100 100 100 99 100 100 100 100 100 100 100 100 100 99 97 96 90 700
80 600 70
500 60
400 50
40 300
30 WHRPG Operating Rate [%] Monthly Operation Hours [h] 200 Average : 99.5% in 2 years operation 20 100 10
0 0
2005/012005/022005/032005/042005/052005/062005/072005/082005/092005/102005/112005/122006/012006/022006/032006/042006/052006/062006/072006/082006/09 Kiln Operation Time WHRPG Operating Time WHRPG Operating Rate 26 CONCLUSIONCONCLUSION
KAWASAKI WASTE HEAT RECOVERY POWER GENERATION SYSTEM
NO INFLUENCE TO EXISTING FACILITY
ENVIRONMENTALLY AND ECONOMICALLY FRIENDLY
GREAT BENEFIT – CUT YOUR ENERGY COST
27 27 Thank you for sharing your valuable time
KAWASAKIKAWASAKI PLANTPLANT SYSTEMS,SYSTEMS, LTD.LTD.
28 28