NUCLEAR&RENEWABLE ENERGY RESOURCES CONFERENCE with INTERNATIONAL PARTICIPATION

28-29 September 2009 ANKARA – TURKEY

ELECTRIC POWER GENERATION IN SHAHROOD CEMENT

FACTORY BY APPLYING WASTE ENERGY OF KILN

Seyyed Ali Akbar Mirmohammadi , Mohammad Reza Behi, Amin Yahyaie

The Faculty of Mechanical Engineering, Shahrood University of Technology, Shahrood, Iran

Abstract

In recent years, worldwide energy concern is growing rapidly, as fast as energy sources are reducing. Large amount
of energy wastes daily in all around the world due to different reasons. Heat waste recovery is a significant issue,
which has drawn vast attention to itself lately. Shahrood Cement Factory requires electric power, which is about 7-
10 MW each day. A combined gas turbine–vapor power cycle is utilized to generate some part of electric power.
Experimental results were extracted by monitoring outlet kiln temperature, and they were applied to simulate cycle.
Heat exchanger is utilized to transfer energy from kiln outlet to cycle. Outlet temperature is about 1300 ok, and
useful graphs are obtained using Engineering Equation Solver (EES).

Keywords: Combined cycle, electric power generation, heat waste recovery, simulation

1. Introduction

Worldwide concern exists due to limitation of fossil fuels and lots of efforts are done to optimize the usage of
these fuels. Fossil fuels are utilized in all around the world extensively in different places such as power plants,
factories, homes, vehicles and etc. Heat waste recovery and energy conservation are issues which could play
major role in providing part of consuming energy and consequently, reducing costs. Recently lots of researches
are done to reduce waste as well as possible or reutilize energy waste.

Automobiles are one of the fuel energy consumers, which lose vast value of energy throughout the world. Novel
idea to utilize the low-grade small-scale energy in vehicle exhaust gas has been proposed [1]. The exhaust gas
from a 2.8L V6 internal combustion engine was used to run a 3 ton absorption chiller which was modified for
hot gas intake. The experiments conducted on the system, prove that the concept is feasible, and could
significantly enhance system performance depending on part-load of the engine. The concept could be used for
refrigeration and air conditioning of transportation vehicles[2].

A typical power cycle is simulated and the amount of achievable work was calculated.By testing different
working fluids, CO2 has been chosen as the best working fluid, due to higher efficiency and work[3].

Investigation on the performance of an IC engine on utilization of exhaust gases had been done by conducting
range of experiments on a Ford 150 (Dover) fuel injection, 6 liter, turbo diesel engine using different
combinations of speed and torque to obtain a range of engine power out put [4]. The investigation of some
operating parameters in the cycle on the cycle performance parameters yielded some important insights to the
plant operation and heat exchange process, and this information can be used in the design, analysis, and
performance improvement of binary geothermal power plants [5].

This study focuses on applying work achieved from kiln and taking advantage of it by a combined gas turbine-
vapor power cycle in order to generate electric power. A combined gas turbine–vapor power cycle is a two-part
cycle which consists of topping and bottoming cycles. Upper cycle uses air as working fluid, whereas the steam
is working fluid of lower part. An external heat exchanger transfers heat from kiln to topping cycle, afterwards
gas turbine produces work and the remained energy in gas turbine outlet would be transferred to bottoming cycle
by an another heat exchanger.

E-mail: saam85@gmail.com

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 NUCLEAR&RENEWABLE ENERGY RESOURCES CONFERENCE with INTERNATIONAL PARTICIPATION
28-29 September 2009 ANKARA – TURKEY

2. Proposed heat recovery system

With a gas turbine–vapor power cycle, applying heat lost from the kiln is accessible. Applied fuel to operate kiln is
natural gas, and outlet gases could be produced in high temperature and high mass flow rate.Generally, for heat
sources with this amount of potential utilizing these cycles are benefitial. The combined cycle has the gas
turbine’s high average temperature of heat addition and the vapor cycle’s low average temperature of heat
rejection, and thus a thermal efficiency greater than either cycle would have individually. For many applications
combined cycles are economical, and they are increasingly being used worldwide for electric power generation.
Figure 1 shows schematic of the proposed concept.

Cycle consists of 2 parts:Gas cycle and steam cycle. Furthermore, turbine, pump,condensor,compressor and heat
exchanger are significant parts of the combined cycle. An internal heat exchanger is applied to transmit the heat
of gas cycle into steam cycle.

Figure 1. Schematic diagram of cycle

3. Modelling assumptions and calculation procedure

Stream is assumed to be steady-state steady-flow and the kinetic and potential energies as well as the heat and
friction losses are neglected. Furthermore, turbine and compressor isentropic efficiency set at different values
(Table 1). In gas power cycle, a temperature difference of 25 °C is supposed at inlet and outlet of the gas heater
between hot stream (exhaust gases of kiln) and air stream. Temperature of hot stream is about 1300 ok which is
recovered by heat exchanger.

Basic conditions of combined cycle are tabulated below:

Table 1. Basic cycle conditions
Item Value Unit
Pressure ratio for gas compressor 14 -
Gas compressor inlet temperature 300 k
Gas turbine inlet temperature 1275 k
Steam turbine inlet temperature 725 k
Steam boiler pressure 10 MPa
Steam condenser pressure 100 kPa
Open feedwater pressure 600 kPa
air inlet pressure 100 kPa
Turbine efficiency 80 %
Pump efficiency 85 %
Compressor efficiency 75 %
Heat exchanger effectiveness 90 %

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 NUCLEAR&RENEWABLE ENERGY RESOURCES CONFERENCE with INTERNATIONAL PARTICIPATION
28-29 September 2009 ANKARA – TURKEY

Mass flow rate of air in gas power cycle is calculated as below. h

and m ex are defined as heat exchanger
effectiveness and mass flow rate of kiln exhaust gases respectively.

m ex hex10 hex9
m gas (1)
h
qmax

And the amount of qmax can be computed by following formula:

q1 h 10,ex10 h 9 when T10 approches Tex10 (2)

q max min(q1 , q 2 ) when
q2 h ex10 h 9,ex9 when Tex9 approches T9

Correspondingly, mass flow rate of steam power cycle (bottoming cycle) could be calculated like mass flow rate
of gas power cycle (topping cycle). Net work of combined power plant and thermal efficiency could be
computed by employing the following equations:

W net,steam  steam Wsteam,turb (W

m (Wsteam, pump1 _ Wsteam, pump2 ) (3)

W net, gas  gas Wgas,turb Wgas,comp

m (4)

W net  gas Wgas,turb Wgas,comp

m  steam Wsteam,turb ((W
m Wsteam, pump1 _ Wsteam, pump2 ) (5)

W net (6)
m gas qin
th

Where qin is calculated as follow:

qin h10 h9 (7)

4. Results and Discussion

Some graphs are illustrated to describe performance of cycle. As it can be seen, producing work is major issue
that it is been considered vastly. All the figures are based on changing pressure ratio of gas and steam power
cycles. β1 represents pressure ratio of gas compressor and β2 is a symbol for gas heater pressure to condenser
pressure. Depending upon the cycle, efficiency parameter of components has been changed and different results
have been obtained.

In figures 2 and 3 effect of changing efficiency and pressure ratio on net work has been presented. In both
figures, the maximum value can be seen in some ranges and graphs trend downward generally. As it is obvious,
in figure 2 efficiency of gas turbine is consonant while efficiency of compressor changes from 0.65 to 0.95, but
in figure 3 it is vice versa.

Figure 4 and 5 show net work of bottoming cycle (steam power cycle) in two different forms of effeciency. In
accordance with figure 4 and 5 by increasing pressure ratio, net work raises continually. When efficiency of pump
is consonant (about 0.75) and efficiency of steam turbine changes, net work of steam cycle varies from one
amount of efficiency to another.However, by changing the efficiency of pump and increasing pressure ratio net
work doesn't differ notably(Figure 5) .Indeed, graphes are close to eache other dramatically and net work of steam
power cycle changes from 975 kW to 1125 kW.

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Figure 2. Net work versus pressure ratio Figure 3. Net work versus pressure ratio

Figure 4. Net work of steam cycle Figure 5. Net work of steam cycle

Figure 6. Net work of gas cycle Figure 7. Net work of gas cycle

It is worth mentioning that the behavior of net work of gas cycle is similar to the net work of combined power
plant behavior. Based on the figures 6 and 7, at first the net work of gas power cycle has been increasing with a

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 NUCLEAR&RENEWABLE ENERGY RESOURCES CONFERENCE with INTERNATIONAL PARTICIPATION
28-29 September 2009 ANKARA – TURKEY

steep slope and achieving the maximum value, then net work decreases with a closely smooth slope in lower
values and steep slope in higher values. This scenario is correct for both conditions.

Figure 8. Net work of gas cycle Figure 9. Net work of gas cycle

Thermal efficiency is another significant issue that has been investigated. It can be observed that raising the
efficiency of gas turbine and compressor brings about increasing the thermal efficiency. Furthermore, gas turbine
and compressor with higher efficiency result in late fall of thermal efficiency. When the efficiency of gas turbine
and compressor are 0.95 and 0.85, no fall can be seen in graph untill the pressure ratio of 20 (Figures 8 and 9).

5. Conclusions

The exhaust gas from kiln of cement factory is utilized to operate a combined gas turbine-vapor power cycle and
subsequently to supply consuming electric power in the factory. Explicitly, electric power is an important issue
in a huge factory,and proposed system is an apropriate mean to recover large amount of heat which waste during
cement production process daily. Researches reveal that about 26 percent of daily electric power consumption
could be produced by new method when the production line is fully involved. However,it reaches to 37 percent
when the production line is semi involved. The produced power could be delivered to different sections of
factory directly and even it could be used as emergency electric power. It is interested to note that, the cycle
operation by means of heat waste could decrease costs in the factory noticeably; as a result, the most optimized
production is accessible. Authors hope to construct a hardware prototype in the near future to confirm the design
concept experimentally and to get the realistic testing data for the further analysis and to render a novel method
to decline costs in Shahrood Cement Factory.

Acknowledgments

The authors would like to thank "Shahrood Cement Factory" for providing the experimental results.

References

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automobile industry to reduce vehicles fuel consumption" Appl Therm Eng 2005;25(14–15):2041–53
[2] Hugues L. Talom, Asfaw Beyene, Heat recovery from automotive engine" Applied Thermal Engineering 29
(2009) 439–444
[3] Farzaneh-Gord M., Meisam Sadi, Shahram Hashemi, Hamid Nikzad, "Simulation of CO2 power cycle and
Theoretical investigation of its application in internal combustion engine", Proceeding of the Third
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[4] M.Sadi, M.R.Behi, A.Yahyaie, S.A.A.Mirmohammadi, "Comparative study on the capability of different
refrigerants in producing work", Proceeding of the International Conference on Fluid Mechanics, Heat
Transfer and Thermodynamics, Tokyo, Japan, May 27-29 2009
[5] Mehmet Kanoglu, Ali Bolatturk, "Performance and parametric investigation of a binary geothermal power
plant by exergy", Renewable Energy 33 (2008) 2366–2374

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[6] Michael J.Moran, Howard N.Shapiro, "Fundamentals of Engineering Thermodynamics". 5th ed. John Wiley
and Sons, Inc; 2006.

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