Cement Industry 2021
Cement Plant Waste Heat Recovery
Designed and commissioned a comprehensive waste heat recovery system for a major cement manufacturer, capturing thermal energy from kiln exhaust gases.
Key Results
8 MW
Heat Recovered
-22%
Fuel Reduction
$2.4M
Annual Savings
Before & After Comparison
| Metric | Before | After |
|---|---|---|
| Flue Gas Temperature | 380°C | 180°C |
| Overall Efficiency | 52% | 61% |
The Challenge
The cement plant was losing significant thermal energy through exhaust gases at temperatures exceeding 380 degrees C. This wasted heat represented a major inefficiency and increased operating costs.
Our Solution
We engineered a custom waste heat recovery system that captures thermal energy from the kiln exhaust and preheater tower. The recovered heat is used for raw material drying and power generation through an ORC system.
Results Achieved
The waste heat recovery system dramatically improved plant efficiency and reduced fuel consumption. Annual savings exceeded projections, delivering strong ROI for the client.