A comprehensive approach for designing, modeling and optimizing of waste heat recovery cycle and power generation system in a cement plant: A thermo-economic and environmental assessment. (1st February 2020)

• Record Type: Journal Article
• Authors: Sanaye, Sepehr; Khakpaay, Navid; Chitsaz, Ata; Hassan Yahyanejad, Mohammad; Zolfaghari, Mojtaba
• Is Part Of: Energy conversion and management. Volume 205(2020)
• Publication Date: 2020-02-01
• Subjects: Waste heat recovery power generation -- Energy -- Exergy -- Economic and environmental modeling -- Optimization -- Exergy destruction -- Payback period; Direct energy conversion -- Periodicals; Energy storage -- Periodicals; Energy transfer -- Periodicals; Énergie -- Conversion directe -- Périodiques; Direct energy conversion; Periodicals; 621.3105
• DOI: 10.1016/j.enconman.2019.112353
• Languages: English
• ISSNs: 0196-8904

Abstract

Highlights: A comprehensive approach for modeling-optimizing of WHRPG is proposed. Modeling is performed in energy, exergy, economic and environmental aspects. Optimum values of system design parameters are also obtained. 2.38 × 10 7 (2.12 × 10 7 ) m 3 NG was recovered and 9.11(8.17) MW electricity is generated. The payback period for the added equipment was 2.45(3.20) years for RC and ORC. Abstract: Mazandaran cement plant in Iran is to be retrofitted for decreasing energy consumption and increasing energy efficiency. This project came up with designing heat recovery from grate coolers (Air Quenching Cooler or AQC boiler) and heat recovery from cyclones' exhaust gases (Suspension Preheater or SP boiler). The procedures of modeling (in energy, exergy, economic and environmental aspects) and optimum design of waste heat recovery and power generation (WHRPG) systems for two parallel lines of cement production which are new and specific to our studied cement plant are reported here. The objective functions were exergy destruction (which was minimized) and relative annual benefit (which was maximized). Results for our case study for Rankine (Organic Rankine) cycle showed that using water (toluene) as working fluid provided 9.14 (6.56) MW power output with exergy destruction ratio of 47.9% (53.5%). Furthermore, the amount of fuel for producing steam and providing the equal value of power output was estimated to be 2.38 × 10 7 (1.7 × 10 7 ) m 3 natural gas and its corresponding cost was 2.1 × 10 6 $/year (1.46 × 10 6 $/year), with 5.36 × 10 4 ton/year (3.81 × 10 4 ton/year) lower CO2 production. The payback period for equipment installed was 3.4 (5.1) years for water (toluene) as the working fluid.