I. Project Background
With energy costs continuing to rise and countries increasingly demanding energy conservation and emission reduction, the cement industry is accelerating the energy efficiency upgrade of its production systems. Waste heat recovery power generation, as a mature and reliable energy-saving technology for cement plants, can convert the large amount of low-grade waste heat generated during clinker production into electrical energy, thereby reducing production costs and significantly improving energy utilization efficiency.
Located in Oman, this project is a waste heat recovery power generation project integrated with a 2500 t/d cement clinker production line. The project recovers waste heat from the exhaust gases of the kiln preheater (PH) and clinker cooler (AQC), utilizing a complete waste heat boiler and steam turbine generator system to achieve stable, grid-connected power generation. This provides continuous and reliable power support for the cement plant.
II. Project Overview
| Item | Description |
|---|---|
| Project Location | Oman |
| Project Type | Cement Clinker Line Waste Heat Recovery Power Generation Project |
| Clinker Production Capacity | 2,500 t/d |
| WHRB Configuration | 1 × PH Boiler + 1 × AQC Boiler |
| Steam Turbine Type | Condensing Steam Turbine Generator |
| Number of Units | 1 Set |
| Installed Capacity | 4.5 MW |
| Grid Connection Mode | Grid-connected operation |
| Control System | DCS centralized control |
III. System Configuration and Technical Solution
This project adopts the mature and reliable PH + AQC dual-heat source waste heat power generation technology. The system recovers the medium and low-temperature waste heat generated during the cement clinker production process through a waste heat boiler, converting it into stable steam to drive a condensing steam turbine for power generation.
The steam turbine generator set is specifically designed based on the operating conditions of the cement plant, with a focus on optimizing the following aspects:
Adaptable to waste heat steam conditions with low temperature, low pressure, and significant parameter fluctuations.
Optimized partial load operation performance to ensure stable unit operation during changes in clinker line load.
Utilizes a condensing system to improve overall power generation efficiency.
A comprehensive protection and speed control system ensures safe and reliable grid-connected operation.
Explanation of the steam turbine generator working principle
In this project, a waste heat boiler recovers the waste heat from the exhaust gases generated during the cement clinker production process, heating water and converting it into stable steam. The steam, under specific pressure and temperature conditions, enters a steam turbine, driving the turbine’s internal blades to rotate at high speed.
The turbine and generator are rigidly connected by a coupling, and mechanical energy is directly converted into electrical energy. After releasing its energy, the steam enters the condensation system, condenses into water, and returns to the system cycle, forming a complete and continuous power generation process.
This process is the working principle of a steam turbine generator, and its core advantages are:
No additional fuel consumption
Full utilization of waste heat from industrial production processes
Stable operation and long service life
Particularly suitable for continuous production conditions such as those in cement plants
The entire waste heat power generation system is highly integrated with the existing cement production line, enabling continuous and stable power generation without affecting clinker production or production schedule.
IV. Project Implementation and Commissioning Process
During the project implementation, construction and commissioning were carried out strictly in accordance with the standard procedures for waste heat power generation projects in the cement industry. The project scope included:
Civil construction of the main plant and auxiliary systems
Installation of PH and AQC waste heat boilers
Installation of steam pipelines, steam turbines, generators, and auxiliary systems
Commissioning of the lubrication system, cooling system, and electrical system
During the unit commissioning phase, key procedures such as boiler boiling, steam blowing, turbine speed increase and overspeed testing, protection parameter setting, and DCS system integrated testing were completed in sequence. Ultimately, the unit achieved successful grid connection on the first attempt, with stable operating parameters and all technical indicators meeting design requirements.
V. Project Performance
After the Oman cement clinker production line waste heat power generation project was put into operation, the waste heat power generation system has been running stably. The main operational achievements include:
Designed annual power generation of approximately 32 million kWh
Satisfies a significant portion of the cement plant's electricity needs
Significantly reduces the proportion of purchased electricity and lowers overall electricity costs
Improves the factory's energy self-sufficiency and operational stability
VI. Economic and Environmental Benefits
The implementation of the waste heat power generation project allows the cement plant to convert the heat from exhaust gases, which would otherwise be released into the atmosphere, into clean electricity without increasing fuel consumption. This offers significant economic and environmental benefits.
Reduced electricity consumption per unit of clinker production, shortened project investment payback period, reduced carbon dioxide and other pollutant emissions, compliant with local energy conservation, emission reduction, and sustainable development policies.
This project fully demonstrates the value of waste heat power generation technology in medium-scale cement clinker production lines.
VII. Project Summary
The successful implementation of the waste heat power generation project for the Oman cement clinker production line has verified the maturity and reliability of the PH + AQC waste heat boiler and condensing steam turbine power generation system in the cement industry. Through reasonable system matching and rigorous engineering implementation, the project achieved stable grid-connected power generation and excellent economic returns.
This case provides valuable engineering experience for energy-saving renovation and energy optimization of similar scale cement plants, and also demonstrates AGICO’s engineering capabilities in integrating waste heat power generation systems and selecting steam turbine generator sets for cement plants.