Analysis of an orc-based waste heat recovery system integrated into a cement production line

Öz

Cement production processes require high energy consumption and generate significant amounts of waste heat. In this study, the energy performance and environmental contributions of an Organic Rankine Cycle (ORC)-based waste heat recovery system integrated into a cement plant with a clinker production capacity of 5,000 tons/day were investigated. The system aims to improve energy efficiency and reduce the carbon footprint of the facility by converting waste heat recovered from preheater and clinker cooler exhaust gases into electrical energy. Considering the advantages of ORC technology in utilizing medium- and low-temperature waste heat sources, the net power generation, cycle performance, and emission reduction potential of the system were analyzed. The results demonstrated that the recovered energy could meet a significant portion of the plant’s electricity demand while substantially reducing grid-based energy consumption and associated CO2 emissions. In addition, the compact structure of ORC-based systems, their low operational requirements, and their ease of integration into existing cement production lines make this technology a strong alternative for sustainable industrial applications.

Anahtar Kelimeler

• Organic Rankine Cycle (ORC)
• waste heat recovery (WHR)
• electrical energy
• CO2 emissions.

Çimento üretim hattına entegre edilen ORC tabanlı atık ısı geri kazanım sistem analizi

Öz

Çimento üretim süreçleri yüksek enerji tüketimi gerektirmekte ve önemli miktarda atık ısı ortaya çıkarmaktadır. Bu çalışmada, 5000 ton/gün klinker üretim kapasiteli bir çimento tesisine entegre edilen Organik Rankine Çevrimi (ORC) tabanlı atık ısı geri kazanım sisteminin enerji performansı ve çevresel katkıları incelenmiştir. Ön ısıtıcı ve klinker soğutucu çıkış gazlarından geri kazanılan atık ısının elektrik enerjisine dönüştürülmesiyle, tesisin enerji verimliliğinin artırılması ve karbon ayak izinin azaltılması hedeflenmiştir. ORC teknolojisinin orta ve düşük sıcaklıktaki atık ısı kaynaklarını değerlendirmedeki avantajları doğrultusunda sistemin net elektrik üretimi, çevrim performansı ve emisyon azaltım potansiyeli analiz edilmiştir. Elde edilen sonuçlar, geri kazanılan enerjinin tesisin elektrik ihtiyacının önemli bir bölümünü karşılayabildiğini ve şebeke kaynaklı enerji tüketimini azaltarak kayda değer düzeyde CO2 emisyon azaltımı sağladığını göstermiştir. Ayrıca ORC tabanlı sistemlerin kompakt yapısı, düşük işletme gereksinimi ve mevcut çimento üretim hatlarına kolay entegre edilebilir olması, bu teknolojiyi sürdürülebilir sanayi uygulamaları açısından güçlü bir alternatif haline getirmektedir.

Anahtar Kelimeler

• Organik rankine çevrimi (ORC)
• ısı geri kazanımı (WHR)
• elektrik enerjisi
• CO2 emisyonu

Kaynakça

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