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8/10/2019 Cement Kiln Cogeneration
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Cement kiln cogeneration
Some of the waste heat generated in rotary kilns may bereused to preheat raw materials but a significant quantity is
lost. To reduce the amount of heat loss and maximise the
energy potential of the fuel used in kilns, the excess waste
heat can be redirected into a generation plant to produce
electricity for reuse within the plant.
Cogeneration in cement plants
The installation of electricity generation facilities in cement
plants is not a new practice. Asia–Pacific Partnership
(APP) countries such as Japan, China and India areinstalling these units in greater numbers to improve the
overall efficiency in energy conversion and to capitalise on
potential cost and energy savings and (for China and India
in particular) clean development incentives.
China in particular is installing smaller scale plants
to capitalise on the waste heat potential. Unlike other
cogeneration systems in which process steam and
electricity are produced simultaneously, these plants are
commonly referred as ‘bottoming cycle’ plants in that they
scavenge the available waste heat to produce electricity.
Cogeneration demonstration project
The demonstration project is designed to test the feasibility
of installing suitable cogeneration technologies in cement
plants in Australia.
An Australian company, Boral Limited, volunteered one of
its plants in Berrima NSW to be the test site for the project.
A feasibility study will examine the technical and financial
options for installing a plant including such considerations
as connection to existing plant, energy and greenhouse gas
savings and the implications on other factors such as water
use. If the project appears feasible, the study will also carry
out preliminary scoping for a business case to assist the
company in the implementation of the project.
At the time of writing (August 2007), a consultant has been
appointed to carry out the feasibility study.
Project support
The project is jointly supported by Boral Pty Ltd and the
Australian Government. The project is a demonstration project
for the Asia–Pacific Partnership on Clean Development andClimate (AP6).
AP6 is a ground-breaking climate change approach
bringing together key developed and developing countries
on practical, pro-growth, technology-driven efforts.
The Australian Government has committed
$100 million to support projects within the
AP6 framework.
Cement production is an energy intensive process. Energy in the form of electricity is used
to power various drive motors to run various systems such as mills, crushers, fans and
conveyors. However, the greatest energy use is in the production of heat for the pre-treatment
of raw materials and the combining of raw materials into clinker in the kiln section of the
cement plant. Kiln temperatures in rotary kilns, for example, may be 1500°C or higher and
fossil fuels such as coal, gas or oil are typically burnt to achieve those temperatures.
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