Cement Plant Energy Saving & Emission Reduction
Steam Turbine Generator
Core Power Generation Unit for Waste Heat Recovery Power Plants
Steam turbine generator set, abbreviated as STG, is a complete power generation system that converts thermal energy from steam into electrical energy, rather than a single piece of equipment or component. A standard complete steam turbine generator set typically includes:
Steam turbine
Converts steam energy into mechanical energy
Converts mechanical energy into electrical energy
Complete auxiliary systems
Including lubrication system, control system, protection system, cooling system, etc.
Unlike purchasing steam turbines or generators separately, steam turbine generator sets are engineered, manufactured, factory-tested, and delivered as a complete system. This integrated supply method ensures a high degree of compatibility between the components, improves operational reliability, and significantly reduces the risks associated with on-site installation and commissioning. In industrial whrb power plants, the steam turbine generator system is the core equipment that determines power generation capacity, operational stability, and long-term performance. Its selection and design quality have a decisive impact on the overall efficiency of the waste heat power generation project.
The Role of Steam Turbine Generator Sets in Waste Heat Recovery Power Generation Systems
In a waste heat recovery power plant, the steam turbine generator set is the core power component of the entire system. The steam turbine generator set operates in conjunction with the PH boiler and AQC boiler, converting the waste heat recovered from the cement production process into a stable electrical power output.
Unlike conventional power plant operating conditions, waste heat power generation systems place higher specialized demands on steam turbine generator sets, mainly reflected in:
Lower or medium-low steam parameters
Certain fluctuations in steam flow rate
High requirements for continuous operation and load stability in cement plants
Therefore, the steam turbine generator systems used for waste heat power generation are typically specially designed models, rather than general-purpose power plant equipment. As the core energy conversion equipment in the system, the steam turbine generator set directly determines:
Power generation capacity (MW)
Overall system efficiency
Stability of grid-connected operation
Project economics and return on investment (ROI)
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Types of Steam Turbine Generators for Waste Heat Recovery
Back-Pressure Steam Turbine Generator
A back-pressure steam turbine generator is a type of steam turbine generator where the steam, after performing work, is discharged at a certain pressure directly into a downstream process or heating system, without entering a condensing system.
Condensing system required:
Not required
Applicable steam conditions:
Steam pressure: Medium to low-pressure steam (customized according to the project)
Steam temperature: Suitable for saturated or superheated steam generated by waste heat boilers
Exhaust steam needs to be utilized by downstream processes
Typical application scenario (taking a cement plant as an example):
Waste heat steam is used simultaneously for power generation and process steam supply.
The cement plant has stable steam consumption points.
The project focuses more on overall energy utilization efficiency rather than maximizing power output.
Condensing Steam Turbine Generator
Condensing steam turbine generator sets maximize the work capacity of steam by completely condensing the exhaust steam, creating a larger pressure drop. This is the most common and mature configuration scheme for waste heat power generation in the cement industry.
Condensing system required:
Yes (air-cooled or water-cooled)
Applicable steam conditions:
Steam pressure: Low to medium pressure steam
Steam flow rate: Suitable for a certain range of fluctuations
Suitable for pure low-temperature waste heat steam conditions
Typical application scenario (taking a cement plant as an example):
Pure low-temperature waste heat power generation system (PH + AQC)
No additional steam process requirements
The goal is to maximize self-generated power and reduce purchased electricity
This is currently the mainstream solution for WHR (Waste Heat Recovery) power plants in cement factories.
Extraction/Mixed-Pressure Steam Turbine Generator
Extraction or mixed-pressure steam turbine generator sets can simultaneously utilize steam at different pressure levels or extract a portion of the steam during operation for use in process systems, offering greater flexibility.
Condensing system required:
Usually equipped with a condensing system (condensing type)
Applicable steam conditions:
Steam pressure: Multiple pressure levels for combined steam operation
Complex steam sources (e.g., PH + AQC combined steam supply)
Typical application scenarios (taking a cement plant as an example):
Large-scale clinker production lines
Significant variations or fluctuations in steam parameters
Simultaneous demand for power generation and steam for certain process applications
Projects requiring high system control capabilities
Request a Customized Steam Turbine Generator Solution
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How to Choose the Suitable Steam Turbine Generator Set for You?
In waste heat power generation projects at cement plants, the selection of the steam turbine generator system typically depends on the following key factors:
Whether process steam is required
Waste heat boiler steam parameters (pressure, temperature, flow rate)
Power generation target (maximizing power generation or integrated utilization)
Cooling water or air cooling conditions
Project investment and operating cost requirements
In practical engineering applications, condensing steam turbine generator sets are the preferred solution for waste heat power generation in cement plants, while back-pressure or extraction-condensing units are more commonly used in integrated energy projects with specific process steam requirements. AGICO can customize the most suitable steam turbine generator set solution for waste heat power generation projects based on the customer’s site conditions, ensuring safe, stable, and efficient system operation.
Typical Technical Parameters of Steam Turbine Generator Set
For the convenience of customers to conduct technical evaluation and scheme comparison in the early stage of the project, the following is a list of typical technical parameter ranges for steam turbine generators in industrial waste heat power generation projects. All parameters are for reference only, and the specific configuration will be customized according to the actual working conditions of the project.
| Item | Reference Range |
|---|---|
| Power Output | 6 – 25 MW (single unit) |
| Steam Pressure (Inlet) | 0.8 – 3.5 MPa |
| Steam Temperature (Inlet) | 180 – 450 °C |
| Turbine Type | Back-pressure / Condensing / Extraction or Mixed-pressure |
| Rotational Speed | 3,000 rpm (50 Hz) / 3,600 rpm (60 Hz) |
| Generator Type | Synchronous Generator |
| Generator Set Efficiency | 85% – 95% (depending on operating conditions) |
| Grid Frequency | 50 Hz / 60 Hz |
| Grid Voltage | Customized according to local grid standards |
| Operating Mode | Continuous operation, suitable for industrial production lines |
Why AGICO Steam Turbine Generator
The steam turbine generator (STG) offered by AGICO are not general-purpose equipment, but rather are specifically optimized and designed based on extensive experience in Waste Heat Recovery (WHR) projects, tailored for continuous operation conditions in industries such as cement and steel manufacturing. We can deeply integrate the steam turbine and generator with the waste heat boiler system, from thermal balance calculations and unit selection to overall grid connection scheme design, ensuring power generation efficiency, operational stability, and project economics. Leveraging its mature turnkey EPC capabilities and extensive experience in implementing multiple overseas projects, AGICO can deliver reliable and long-lasting industrial waste heat power generation solutions to its customers.
AGICO Steam Turbine Generator Successful Projects
Cement plant WHR power generation project in Indonesia
| Project Item | Description |
|---|---|
| Project Location | Indonesia |
| Project Name | Cement Plant Low-Temperature Waste Heat Recovery Power Generation Project |
| WHRB Configuration | 2 × PH Boiler + 2 × AQC Boiler |
| Steam Turbine Generator Type | Condensing Steam Turbine Generator |
| Number of Generator Sets | 2 sets |
| Unit Capacity | 9 MW per unit |
| Total Installed Capacity | 18 MW |
| Application Features | Efficient recovery of waste heat from kiln exhaust gas and clinker cooler air, enabling stable grid-connected power generation |
Oman Cement Production Line WHR Power Plant
| Project Item | Description |
|---|---|
| Project Location | Oman |
| Project Name | Cement Clinker Line Waste Heat Recovery Power Generation Project |
| WHRB Configuration | 1 × PH Boiler + 1 × AQC Boiler |
| Steam Turbine Generator Type | Condensing Steam Turbine Generator |
| Number of Generator Sets | 1 set |
| Installed Capacity | 9 MW |
| Application Features | Primarily designed for captive power generation, significantly reducing plant electricity costs and improving energy self-sufficiency |