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Energy balance and cogeneration for a cement plant
Affiliation:1. Department of Energy Systems Engineering, Graduate School of Natural and Applied Sciences, Karabük University, Karabük, Turkey;2. Department of Energy Systems Engineering, Faculty of Technology, Karabük University, Karabük, Turkey;3. Department of Energy Systems Engineering, Faculty of Technology, Muğla Sıtkı Koçman University, Muğla, Turkey;1. Département de Génie des Procédés, Faculté de Technologie, Université Blida 1, 270 Route deSoumaa, Blida 090000, Algeria;2. Laboratoire de Génie de la Réaction, Faculté de Génie Mécanique et Génie des Procédés, USTHB, BP, 32 El Alia, Bab Ezzouar 16111, Algeria;3. Technical University Berlin, Institute for Energy Engineering, Marchstr. 18, 10587 Berlin, Germany;1. Energy Systems Improvement Laboratory, School of Mechanical Engineering, Iran University of Science and Technology, Iran;2. Mechanical Engineering Department, Faculty of Engineering, Urmia University, Urmia, Iran;3. Mazandaran Province Gas Company, Iran;4. Mazandaran Cement Plant, Iran;1. Pontifical Catholic University of Minas Gerais, Department of Mechanical Engineering, Av. Dom José Gaspar, 500, 30535-901 Belo Horizonte, MG, Brazil;2. Centro Federal de Educação Tecnológica de Minas Gerais, CEFET-MG, Av. Amazonas 7675, Nova Gameleira, Belo Horizonte, MG CEP 30.510-000, Brazil;3. Ibmec – Belo Horizonte, Rua Rio Grande do Norte, 300, Funcionários, Belo Horizonte, MG, CEP 30.130-130, Brazil;4. Companhia Energética de Minas Gerais, Cemig, Av. Barbacena, 1200, Santo Agostinho, Belo Horizonte, MG, CEP 30.190-131, Brazil;1. Department of Energy Technology, Aalborg University, Aalborg, Denmark;2. Department of Mechanical Engineering, Faculty of Engineering, University of Maragheh, P.O.Box 83111-55181, Maragheh, Iran
Abstract:The cement industry is an energy intensive industry consuming about 4 GJ per tonne of cement produced. A thermodynamic analysis for cogeneration using the waste heat streams is not easily available. Data from a working 1 Mt per annum plant in India is used to obtain an energy balance for the system and a Sankey diagram is drawn. It is found that about 35% of the input energy is being lost with the waste heat streams. A steam cycle is selected to recover the heat from the streams using a waste heat recovery steam generator and it is estimated that about 4.4 MW of electricity can be generated. This represents about 30% of the electricity requirement of the plant and a 10% improvement in the primary energy efficiency of the plant. The payback period for the system is found to be within two years.
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