Introduction of low-temperature Waste heat recovery power generation (WHRPG)

technology in Cement Kiln

Rahbord Engineering Services Co.

Nanjing Triumph Kaineng Environment & Energy CO., LTD.

China National Technical IMP. & EXP.CORP.

2010-11-19

Contents

1 The development history and current situation of WHRPG technology on new dry process cement production line ........................................................................................ 1 1.1 The definition of WHRPG technology ................................................................................ 1

1.2 Origin of WHRPG technology ............................................................................................ 1

1.3 Application of WHRPG technology in China ..................................................................... 1

1.4 Maturity and comprehensive application of WHRPG equipment ....................................... 2

1.5 Application of Chinas WHRPG technology in abroad ....................................................... 2

1.7 Cases of WHRPG in foreign cement plant constructed by China by the end of 2009 ........ 3

2 Investment profits of WHRPG for new dry process cement production lines ...... 3 2.1 Economical benefits ............................................................................................................ 3

2.2 Social benefit ....................................................................................................................... 3

2.3 Cost of production ............................................................................................................... 4

2.4 Project case of a 5000t/d cement production line................................................................ 4

2.5 Policies of encouraging WHRPG construction in China .................................................... 5

3 Introduction of WHRPG technology of Nanjing Triumph Kaineng Environment & Energy Co., Ltd. .................................................................................................................... 5 3.1 Company Profile ................................................................................................................. 5

3.2 Available waste heat resources of WHRPG in new dry process cement production lines .. 6

3.3 Connection of low temperature WHRPG with cement production lines ............................ 6

3.4 Thermodynamic system of WHRPG ................................................................................... 7

3.5 Main equipments of low temperature WHRPG .................................................................. 9

3.6 Impact of WHRPG to cement production lines after put into operation ........................... 12

4 Technical R&D and Innovation .......................................................................................... 13 4.1 Initiation of integration of Settling Chamber and AQC boiler .......................................... 13

4.2 Initiatively proposed the flow direction of gas from top to bottom in AQC boiler ........... 13

4.3 Advantages of original created AQC boiler ...................................................................... 13

4.4 Initiatively proposed the technology about second heating the steam in AQC boiler ....... 14

4.5 The technology of cooler air draft ..................................................................................... 14

4.6 Low-temperature exhausts recycling technology .............................................................. 15

4.7 Rotary kiln heat recovery technology ............................................................................... 15

5 Project contracting and technical service advantages ............................................. 15 6 Qualifications and Honors ................................................................................................ 16 7 Typical application cases ................................................................................................. 17

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1. The development history and current situation of WHRPG technology on new dry process cement production line 1.1 The definition of WHRPG technology

The technology of WHRPG technology is utilizing the low-grade steam (low pressure, low

temperature) generated by industrial waste heat s temperature between 120 and 400 , to push the specially designed low -parameter- steam turbine generator unit to generate electricity.

It has three main characteristics:

Utilization the waste heat resources of 120400; Low grate steam and low-parameter- steam turbine generator; Without increase of entity heat consumption and additional fuel.

1.2 Origin of WHRPG technology

WHRPG technology started from the late 60s in Europe and the United States, it was put

into practical utility in the mid-70s, and the application of this technology reached a climax in the

early 80s and has become popular since then.

A typical representative was that the United States ALPEND Cement Plant had built 5 sets of

low temperature WHR generators between 1973 and 1978, the capacity of which was 5000 ~

12500KW, while whose boilers main steam parameters was 1.37Mpa, 288. The capacity of cement plant waste heat power generation reached 40 billion kwh per year till December of 1980

in the United States.

Japan ranked earlier and much more mature in the research and development of this

technology too. Japan is a resource-shortage country. Since the world oil crisis in 1973, the

government has paid closer attention to energy conservation and began to promote the outside

pre-clinker kiln (up to 90%) and waste heat power generation. In February, 1981, Japan Sumitomo

Cement Company put a set of two 1320- kw heat generators, which were the first sets of heat

generating units in Japan, into operation. Till 1989, 16 cement plants have been installed the waste

heat generators among the 46 cement plants on a national scale, and the recovered energy power

covered 30% of national cement industry power consumption.

1.3 Application of WHRPG technology in China

China has been engaged in waste heat utilization technology for a long time. The first low

temperature WHRPG project in China was a 6480kW waste heat generator which is provided by

KAWASAKI for 4000t/d clinker production line of Ningguo Cement Plant. The project

construction started from Oct.1996 and began to generate electricity in Feb.1998. Equipment were

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fully provided by Japan. The first case of the national production of the waste heat power

generation project was the 3000kW pour WHG construction by Shanghai Triumph Kaineng and

Nanjing Cement Design Institute for 2000t/d clinker production line of Jiangxi Wannian Cement

plant. This project construction started from 1997 to February 1999, the equipment of which were

all home- made. This WHG line remains on operation, although the first case of domestic waste

heat power generation ranked slightly lower in equipment reliability and efficiency, compared

with Japanese equipment and technology, the project implementation pioneered the WHRPG

technology and equipment nationalization, laying the foundation of the domestic WHRPG

technology development and providing valuable experience.

1.4 Maturity and comprehensive application of WHRPG equipment

On broad absorption of the foreign WHRPG technology, China cement industry has

successfully used domestic equipment and technology in 12 new dry process cement production

lines, constructed 2.0MW, 3.0MW, 6.0MW and 7.0MW of low temperature waste heat generating

units and promoted the WHRPG technology into maturity from 2001 to 2004. Since 2004, the

cement kiln waste heat power generation projects have been under full swing across the country.

By the end of 2009, 50% new dry process cement production line in China has been put into

operation with waste heat power generation. A large number of practices provide with the perfect

opportunity for technology innovation, while practical applications promote the improvement of

technology and equipment. Under such circumstances, WHRPG technology in China has become

much more mature and reliable. China's low temperature WHRPG technology has reached the

international advanced level.

1.5 Application of Chinas WHRPG technology in abroad

China's WHRPG technology and equipment has become more and more mature. The

thermodynamic cycle system and the localization equipment have reached the international

advanced level. Thanks to the low investment costs and strong integrated services capability, it has

significant competitive advantage in the international market, in recent years, China's cement kiln

WHRPG technology has been applied into the European and Asian countries quickly.

In 2008, Thailand's SCG Cement Company put two generating units with a total installed

capacity of 27MW into operation in three production lines. Thailand SKK cement plant put a 6th

line, the 9.1MW waste heat generator, into operation, which created a foreign market of Chinas

WHRPG technology. The world's leading cement companies such as Lafarge, Heidelberg all

choose the Chinese companies to take charge of waste heat power generation construction when

they have cement branch factories in foreign countries. In 2009, the total installed capacity of

Chinese companies undertaking abroad waste heat power generation projects has achieved

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247.8MW, which was 8 times of that in 2008. The development speed is amazing.

1.6 China's domestic WHRPG projects construction by the end of 2009

Year Production line unit capacity(MW) Designed clinker capacity(10000t/a)

19972005 13 14 50 1119 2006 15 14 65.5 1460 2007 86 59 571 10109 2008 149 106 975.2 15899 2009 232 181 1676.8 27670 Total 495 374 3338.5 56257

1.7 Cases of WHRPG in foreign cement plant constructed by China by the end of 2009

State Production line unit capacity(MW) Designed clinker capacity(10000t/a) Thailand 9 6 102.2 1819

Pakistan 9 4 52.6 100l India 7 5 48 880

Turkey 2 l 18 310 Philippines 1 l 4.5 78

Total 32 20 225.3 4088 2. Investment profits of WHRPG for new dry process cement production lines 2.1 Economical benefit

The product of WHRPG is electricity and it can be consumed by oneself. The investment

economical benefit can be seen from two aspects. First, it is the electricity expense. The electricity

price gap between outsourcing and self supplying is the profit, and power generation from waste

heat could satisfy 1/3 of cement production consumption. Second, it is CDM profit. Traditional

power generation consumes fuel such as coal or gas and CO2 generated during the process.

However, waste heat generation does not need any fuel and generates no CO2 emission. The saved

emission could be sold in the world carbon market, which is an addition profit for the enterprise.

2.2 Social benefit

Social benefits are mainly embodied in three aspects. Firstly, operation of waste heat

generation significantly reduces the cost of cement production and improves the enterprise

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competitiveness, and at the same time saves the energy. Secondly, the boiler of heat recovery

system is equivalent to a pre-dust collector, which reduces the dust emission. Finally, exhaust gas

flows through the boiler for heat exchanging and its temperature decreases a lot in the boiler outlet,

which reduces thermal pollution to the surrounding environment.

2.3 Cost of production

Without any additional fuel, waste heat generation could produce electricity. The production

costs mainly include daily consumption and staff wage etc. The following table shows the detailed

costs.

No. Item No. Item 1 consumable material 2 water

1.1 lubricant 3 staff wage

1.2 chemical water 4 maintenance 1.3 98%Na3PO4 1.4 circulating water drugs

2.4 Project case of a 5000t/d cement production line

No. Item unit value

1 Clinker production t/d 5000

2 Installed capacity kW 9000

3 Actual average power generation kW/h 8250

4 Self consumption rate of power

station

% 7

5 Annual operation time h 7200

6 Annual power generation kWh 5940104 7 Annual power supply kWh 5464104 8 Electricity price RMB 0.36

9 Annual benefit RMB 1967104 10 Cost of operation RMB 162104 11 Annual profit RMB 1805104 12 Total investment RMB 7200104 13 Static investment recovery period y 3.98 y

The above economic analysis is based on electricity price of 0.36 RMB/kWh, staff wage of

5

15 000 RMB/y, 18 operators and construction period of one year.

2.5 Policies of encouraging WHRPG construction in China

WHRPG projects belong to energy conservation industryChina strengthened supporting this project recently, the policy of support waste heat power generation construction is released

successively, mostly involving the following aspects:

1) Financial support. The government provides with loan for energy conservation project priority,

and supports using EMC pattern.

2) Permitting grid connected. Small Thermal Power Generating Units in China are limited to

construction, not allowing grid connection, while turbo-generator of WHRPG allows grid

connection.

3) Award, according to Chinese domestic power generation coal consumption standard, it converts

power generation to standard coal saving, 300 RMB per ton of standard coal saving as a reward,

including 240RMB per ton from central finance and 60 RMB per ton from provincial finance.

4) Income tax preference, WHRPG projects belong to comprehensive utilization of resources

project, the income tax levied in accordance with 90% of the total taxation.

3. Introduction of WHRPG technology of Nanjing Triumph Kaineng Environment & Energy Co., Ltd. 3.1 Company Profile

Nanjing Triumph Kaineng Environment & Energy Co., Ltd. is composed of key staff of

Shanghai Kaineng Co., Ltd. and Nanjing Cement Design Institute, the main members have

participated in research and implementation of the first low temperature cement waste heat

recovery power generation project in China. Since the company was established, we have built

more than 90 projects (about 140 production lines), and over 60% was dealt with EPC model. The

total installed capacity reached 800MW and annual electricity generation is up to 6 billion kWh.

Every year, nearly 2 million tons standard coal equivalent can be saved and 5 million tons of

carbon dioxide can be reduced.

We are keeping a close cooperation relationship with some large-scale cement enterprises,

such as China United Cement Group Co., Ltd., China Southern Cement Co., Ltd., Huaxin Cement

Co., Ltd., Heidelberg Cement Group, Swiss Holcim Group and so on, our company has 25%

market share of waste heat power generation in domestic cement industries. We have hold the

position ranking in top three and the performance top the list among the industries in 2009 and

2010.

We put forward unique WHRPG technology on the basis of summarizing the waste heat

6

recovery power generation engineering cases implemented by domestic counterparts and the

design and operation practices of over 100 cement kiln waste heat recovery power generation

systems implemented by us. Basing on the process parameters and requirement of customers, we

can achieve the maximization and step of waste heat utilization, and implement best combination

of energy conservation & emission reduction and enterprise benefit, and create maximum

economic and social benefits. All the staff are trying their best to make the company a

world-renowned high-tech enterprise in the field of new energy and energy conservation &

environmental protection.

3.2 Available waste heat resources of WHRPG in new dry process cement production lines

Technological Process of Cement Sintering System

1. Material Process:

Limestone transported to crusher-----ground into flour in raw mill-----enter preheater to

preheat and precalcine-----enter rotary kiln to calcine-----drop down to cooler to cool-----sent to

clinker storage bin by conveyor.

2. Grate Cooler Waste Gas Process: Cold air was sent to grate cooler to cool the

material(80~100), and cold air was heated to hot air(250~300), then excreted from grate cooler tail, then entered kiln head dust collector, and finally discharged into atmosphere by

exhaust fan.

3. Preheater Waste Gas Process: Waste gas of preheater outlet(300~350) enters GCT to cool down(300),then provides drying heat source for raw material mill, then enters dust collector, and is discharged into atmosphere.

Heat Balance of Cement Kiln Sintering SystemkJ/kg-kclTypical thermal consumption of domestic 5000T/D cement production line

Heat

Input

Heat of

Clinker Form

Heat Output

of Clinker

Heat Output of

grate cooler

Waste Gas

Heat Output of

Preheater Waste

Gas

Heat

Dissipation

3

135 1682 78 466 684 225

1

00% 53.65% 2.49% 14.86% 21.82% 7.18%

3.3 Connection of low temperature WHRPG with cement production lines

Connection of AQC boiler with cement production line: Because the waste gas temperature

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of grate cooler terminal is low, and direct utilization efficiency is low, the air is taken from the

central part of grate cooler, the waste gas of 380 enters AQC boiler. The waste gas was cooled to about 90 by AQC boiler. Both it and grate cooler tail waste gas(about 120) return to kiln head dust collecting system.

Connection of PH boiler with cement production line: The temperature of preheater waste

gas is about 320, and it enters directly into PH boiler. The waste gas was cooled to about 200 by PH boiler. Then the waste gas enters raw mill and provides drying heat source for it. The PH

boiler is equivalent to bypass of GCT. After The PH boiler was put into operation, the GCT is

exited from operation.

The layout of GCT before high temperature fan: The GCT is parallelly connected with the

high temperature fan. The waste gas of preheater normally runs through PH boiler, and then it is

sent to raw mill by high temperature fan. When PH boiler is failed, the waste gas runs through

GCT, and then it is sent to raw mill by high temperature fan. The PH boiler is to stop.

The layout of GCT behind high temperature fan: Normally running, the waste gas of

preheater enters high temperature fan, then enters raw mill. When raw mill is stopped, the waste

gas goes through GCT, and then enters the dust collector.

3.4 Thermodynamic system of WHRPG

WHRPG system is classified into the single pressure system, flash evaporation, and dual

pressure system according to thermodynamic system.

3.4.1 Single Pressure System

42 soft water from boiler feed water pump is heated to 160~180 by public economizer of AQC boiler, then divided into two parts. One part is sent to the drum of AQC boiler,

the other part is sent to the drum of PH boiler. The superheated steam of AQC and PH boiler are

mixed, then forming 1.15Mpa, 320 superheated steam, which is sent to turbine to generate power. Exhaust-steam post work is condensed to water in the condenser. The water is sent to

deaerator to remove the oxygen by condensate pump, and then sent to boiler by feedwater pump

for recycling.

Main features: The waste gas out of AQC boiler could be decreased to 90~110, only generating single pressure steam. Turbine can adopt single-pressure steam. System is simple and

with low investment. There are no adjustment measures with fluctuation of waste gas temperature.

The temperature of waste gas out of boiler fluctuates with the waste gas. When the temperature of

waste gas fluctuates, the heat of waste gas is not used to the best.

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3.4.2 Flash evaporation system

The uppermost difference between flash and single pressure system is that, soft water from

boiler feed water pump is heated to 160~180 by public economizer of AQC boiler, then divided into three parts. One part is sent to the AQC boiler, and the other part is sent to the PH

boiler. The remaining stuff is sent to flash evaporator to generate 0.1~0.2MPa low pressure

saturated steam. Then it is sent to turbine to work from the central part of turbine. The water,

which is not flashed to steam in flash evaporator, enters feed water line. Then it is sent to boiler for

recycling use by feedwater pumps.

Flash evaporator is one of key equipments of the system. The process principle of flash

evaporator: high pressure, high boiling point and heat content of water. When pressure is

decreased, part of sensible heat is released. The part of heat is absorbed by the way of latent heat,

and part of water is flashed to steam.

Main features: System is configured flash evaporator and dual pressure supplement steam

turbine. Two kinds of different parameters of steam are generated. The sharp fluctuation of flue

gas is actively adjusted by flashing technology. After waste heat of large amounts of fluctuating

flue gas is taken by system (boiler), a few low pressure saturated steam is generated by flashing

technology. The waste flue gas temperature is controlled in about 90. This makes sure that waste heat resources is fully used on waste flue gas temperature fluctuating. The flash efficiency

of flash evaporator is not high. There are large amounts of hot water cycling between feedwater

pump and boiler, so power consumption of pump is increased. Water content of saturated steam is

higher, so the last stage blade is eroded after entered turbine. It goes against long-term operation of

turbine.

3.4.3 Dual Pressure System

Dual pressure system is set into two drums in the AQC boiler. Two kinds of different

parameters of steam are generated and enter turbine. Soft water from feedwater pump is heated to

160~180 by public economizer of AQC boiler, then divided into three parts. One part is sent to the high pressure drum of AQC boiler, and the other part is sent to the PH boiler. The remaining

is sent to low pressure drum of AQC boiler, and generated low pressure superheated steam by set

low pressure superheater. With flash system difference, grate cooler is configured dual pressure

boiler, and low pressure steam is superheated steam

Main features: Dual pressure system is configured dual pressure boiler and dual pressure

supplement steam turbine. Two kinds of different parameters of steam are generated. The sharp

fluctuation of flue gas is active adjusted by dual pressure boiler. After waste heat of large amounts

of fluctuating flue gas taken by boiler, a few low pressure superheated steam is generated by low

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pressure boiler. The waste flue gas temperature is controlled in about 90. This makes sure that waste heat resources is fully used on waste flue gas temperature fluctuating. Compared to flash

system, the erosion of turbine will be reduced by superheated steam. It can make sure of the

long-term safety operation of turbine. There is less cycling water in system, so the power

consumption of pump will be decreased. The water temperature of PH boiler could be chosen, so

the waste flue gas temperature of PH boiler could be decreased to a lower level.

3.4.4 The comparison of three kinds of thermal system

Item Single pressure

system

Flash evaporation

system

Dual pressure

system

Suitability for fluctuation of

working condition of kiln head Small adaptation Adaptation Adaptation

Projection investment Small Large Larger

Power generation Small Net increase 2~3% Net increase 3~5%

Plant power consumption Low Higher High

Duct system Simple More complex Complex

Operating life of steam turbine Better Worse Better

Operating condition Convenient Complex Convenient

Domestic More in the early A few More

3.4.5 Choice of three kinds of thermal system in engineering application

Nanjing Triumph Kaineng Environment & Energy Co., Ltd. has built many projects by three kinds

of thermodynamic system in China. According to engineering experience, for two or more heat

sources in cement waste heat, the system of dual pressure, flash and single pressure can be applied

based on optimal design of thermodynamic system and concrete analysis. In boiler heat balance

calculation, when the released heat of flue gas is completely absorbed by designed and Selected

single pressure system (the temperature of waste gas out of boiler is about 90~100) and achieves the cascaded utilization of energy at the same time, the single pressure system will be

simply, easily operated, low investment and more reasonable. When the part of heat is not

completely utilized, to use low pressure system to generate steam, then it is sent to supplement

steam part of turbine. In this case, the design of dual pressure and flash will be adopted. The dual

pressure system is recommended firstly in the dual pressure and flash system.

3.5 Main equipments of low temperature WHRPG

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3.5.1 WHR boiler

There are several fixed types of WHR boiler. AQC boiler is generally chosen vertical located,

which adopt tube and box type structure and modular design. The component of heat exchange is

adopted spiral fin coil.

There are two types of PH boiler: vertical and horizontal. Because dust content of waste gas

out of preheater is high, small particle size and no cohesiveness, the heat exchange component of

preheater is adopted in smooth tube and mechanical oscillating dust-cleaning mode.

3.5.1.1 Vertical WHR boiler

Vertical boiler is generally adopted natural circulation. Flue gas is flowed from top to bottom.

The heat exchange component is vertical to the flow direction of flue gas. The mechanical

oscillating dust-cleaning mode is adopted. Deposit of dust is sent to original production line by

conveyor.

3.5.1.2 Horizontal WHR boiler

Horizontal boiler generally adopts forced circulation. Water is forced to flow by circulating pump in the boiler. Flue gas is flowed horizontally, and the heat exchange component is vertically arranged. The mechanical oscillating dust-cleaning mode is adopted. Deposit of dust is sent to original production line by conveyor.

3.5.1.3 The comparison of vertical and horizontal boiler

Item Horizontal boiler Vertical boiler

Heat transfer characteristics

Forced circulation, ash fouling resistance, better heat transfer

Natural circulation, more ash fouling ,general better heat transfer

Thermal expansion

Temperature maldistribution, Expansion maldistribution

Temperature distribution, Expansion distribution

Air leakage More Less Steam-water circulation

Forced circulation, More self-consumption electricity

Natural circulation, Reliable operation

Steel consumption

Lower Higher

Dust removal Better Worse

3.5.2 Turbo-generator set

The turbine flow passage is designed by using three-dimensional technology for structure

optimization. Application of aft-loaded cascades and three dimensional design of twisted blades

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enhances the turbine overall efficiency. Turbine bodys design satisfies the main steam parameters

varying from 0.68 to 1.57MPa and 280 to 390, which could be adapted to fluctuation of cement production. Considering different heat source and thermal dynamic system and combining

with Mitsubishi turbine technology, we have developed turbines of single pressure and dual

pressure with inlet steam pressure of 0.75MPa, 1.05MPa, 1.37MPa, 1.6MPa respectively. For

turbine with induction steam, a mixing chamber is designed according to mixing flow

characteristic of the main and induction steam. This design minimizes flow loss of the steam and

increases overall efficiency of the turbine. And in the normal operation, the induction steam could

be regulated to satisfy turbine working condition and in the emergency the induction steam could

be cut off to prevent the accident.

3.5.3 Cooling unit of exhaust steam from turbine

3.5.3.1 Water-cooling unit

Water-cooling unit adopts water as cooling medium for exhaust steam condensation, which

is composed of condenser, condensate pump, cooling tower and water basin. Water from basin is

pressured and sent to condenser for heat absorption, and exhaust steam from turbine is condensed.

The water absorbed heat and turned back to the cooling tower for cooling with the help of

mechanical draft fans.

3.5.3.2 Air-cooling unit

Air-cooling unit adopts air as cooling medium for exhaust steam condensation, which is

composed of exhaust equipment and air cooler. The air is sent to the surface of cooling pipes to

cool exhaust steam from turbine in the cooling pipes.

3.5.4 Make-up device

The make-up water is to provide qualified desalted water for boiler, and the make-up water

unit includes pretreatment, reverse osmosis and mixed bed process, vacuum deaerator and desalt

water pump. The feed water of heat recovery boiler originates two parts, one is from condensate

water and the other is from desalted water. After the two parts jointing in the vacuum deaerator,

oxygen in the water is removed and then the deaerated water is supplied to boiler by the feed

pump.

3.5.5 Automatic control

WHRPG adopts integrated control system, and controls model usage distribution control

system (DCS). Control network includes three-layer structures. The first layer is controlling

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distribution level. The second layer is monitoring centralized operation level. The third is

integrated information management level. High way data access (HW) local area net (LAN) are

adopted for connection among levels. Communication network is employed on one level for

message transmission between different equipments.

3.6 Impact of WHRPG to cement production lines after put into operation

3.6.1 Positive effect Impact on electrical dust collector of cooler: Dust concentration of gas entering electrical dust

collector is lower. This can be explained as the following. On one hand, after grate cooler is

transformed, exhaust from the middle of grate cooler is predusted through the AQC boiler, and

some sediment in the boiler. On the other hand, because of the middle suction of the grate cooler,

the exhaust flow rate of coolers terminal pipe reduces to 1/2 of its original. Thus less dust is

carried with exhaust.

Impact on high temperature fan of preheater: High temperature fans load reduces when

station is in service. As the stack gas passes through PH boiler, gas temperature decreases and

density increases, so fans flow rate falls down and total pressure rises. The total pressure raise

compensates the pressure loss of about 800Pa as the installation of PH boiler. And at the same

time, less dust content of the gas weakens abrasion of fan. Compared with original, the high

temperature fan could still satisfys the working condition just because its working state point

moves to another point compared to the original one.

Impact on dust collector of preheater: As long as the moisture in the gas is regulated, specific

resistance of the dust in the electrical dust collector will be better controlled. If an arrester is

adopted in WHRPG, the performance of dedusting will be improved.

3.6.2 Negative effect

Impact on electrical dust collector of grate cooler: If the electrical dust collector inlet

temperature decreases from 220-330 to about 90, specific resistance of the dust will be affected. From curves of specific resistance of the kiln dust, when the gas temperature ranges from

140 to 190, dust specific resistance is too high, which is bad for electrical dust collector operation. When in the 90, dust specific resistance is about 2.51010cm which is on a acceptable scope ( demand dust specific resistance of electrical dust collector is 10451010cm).

Impact on the exhaust fan of grate cooler: As a heat recovery steam generator (AQC boiler) is

installed and grate cooler is transformed correspondingly, exhaust pressure loss between the grate

cooler and the fan increases about 800Pa. The increased pressure could be compensated by fans

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total air pressure raise due to the flow rate falling about 1/3-1/2 of its original.

Impact on drying ability toward raw mill: WHRPG is designed according average water

content of raw material of local settings. If the water content varies on a large scale, the raw

material drying performance will be affected because more drying gas is directed to PH boiler. But

this negative impact can be weakened by adjusting bypass pipe line of the heat recovery steam

generator (PH boiler).

4. Technical R&D and Innovation 4.1 Initiation of integration of Settling Chamber and AQC boiler

Initiatively proposed to cancel the settling chamber, the total resistance of system is less

than 800Pa, using the self-brought settling chamber of AQC boiler, reducing the resistance of

AQC boiler system. The power of exhaust fan does not increase, so the operation cost of WHRPG

is reduced. In addition, the generated energy is increased when canceling the external settling

chamber, simplified the flue gas duct, reducing the occupied area, saving the primary cost as well

as reducing the heat loss.

4.2 Initiatively proposed the flow direction of gas from top to bottom in AQC boiler

We are studying on the mechanism of ash deposition and wearing, using the flow direction of

gas from top to bottom in AQC boiler, proposing two measures to solve the problem of ash

deposition and radical wearing: Firstly, pre-separation of large particles of dust before using the

waste heat of gas, reducing the big particle size dust into AQC boiler; Secondly, reducing the

velocity of dust in AQC boiler.

4.3 Advantages of original created AQC boiler

Our AQC boiler has three main advantages by the above two technical innovations:

A: Reduce the settling chamber investment and the heat preservationwear prevention cost B: Increase the inlet gas temperature 10-15, which enters the boiler. Because the settling

chamber and some flue pipe are not to use multiply, heat dissipation has been reduced

significantly.

C: Reduce the resistance (about 500Pa) of boiler system, so the load of exhaust fan has

been reduced significantly.

The comparison of using conventional settling chamber + WHG with flue gas from top to

bottom and using the integrated of settling chamber and AQC boiler on 5000t / d cement

production line are listed as follows:

NO. Items Air-quanity(Nm3/h) Air Generation(

14

temperature() kWh) 1 External Settling

Chamber AQC boiler

200000 350 3438

2 Patental AQC boiler 200000 360 3661

3 save electricity power 91

4 More electrical energy

supply

542

The patent integration of settling chamber and AQC boiler belongs to Nanjing Triumph Kaineng

Environment & Energy Co., Ltd. and the product is unique through a ministerial appraisal in

China domestic low temperature heat power industry, reaching international advanced level.

4.4 Initiatively proposed the technology about second heating the steam in AQC boiler

The low-temperature (below 300)superheated steam generated by PH boiler and got access to Mix steam box in AQC boiler ,then heated the steam to 360-380 (Compared to the steam in mix steam box improved 50-60 )by public superheater in AQC boiler before pumped in turbo-generator; it improved the enthalpy of steam admission and enhanced the system power

generation efficiency, It can reach 36-38 kWh/t.cl, this technology has passed through Chinese

ministerial appraisal, reaching domestic advanced level.

Conventional single pressure, flash, dual pressure thermodynamic system constitutes the first

generation thermodynamic system of low temperature; WHRPG technology we are using in

place of the first heating one, forms the second generation, that is, single pressure, flash, dual

pressure thermodynamic system.

4.5 The technology of cooler air draft

The technology of air draft at grate cooler is very important to WHRPG in cement plant, the

level of air temperature and the size of air quantity directly affects the generated energy and safe

operation of WHRPG system, we have analysis and calculation of different cement production

lines relying on the grate cooler R&D team of Nanjing Triumph Cement Technology Engineering

Co., Ltd. Then we analyze and summarize the distribution of energy and air quantity in grate

cooler. Without affecting the heat consumption of cement production line premise, we have

developed the middle air draft technology, which means the air draft location, air quantity, air

temperature of grate cooler changes with running situation on different operation lines. According

to our analysis and calculation, the air temperature between 350 and 400 is appropriate, because this air temperature does not affect the heat consumption of cement production line.

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4.6 Low-temperature exhausts recycling technology

During actual operation in cement line, cooler is designed for better cooling effect, but the

central exhaust temperature is low, generally just reaching 300 , in order to further improve the efficiency of waste heat recovery system, we are initiatively proposing low-temperature exhaust

recycling technology according to engineering practice of WHRPG industry, and application of

WHRPG project on 5000t / d production line of Huaihai China United Cement Plant in 2006, to

achieve greater success.

Low- temperature exhaust recycling technology is the exhaust (about 100) from electricity dust collector into the inlet of the cooling fan ,the cooling fan is located in the middle of grate

cooler. The cooling air temperature of clinker and the entrance exhaust temperature of AQC boiler

are improved correspondingly, the generated energy of WHR system is also improved. The degree

of improvement remains about 8~10% based on the original technology.

4.7 Rotary kin heat recovery technology

From the above analysis we know that heat balance in cement kiln burning system heat loss

covers about 7 ~ 8% in total, much of heat loss comes from rotary kiln, the temperature is over

300,which is quite valuable. In order to recover heat, we develop a cement kiln heat recovery system, which is composed

of heat collector, fixing device and adjusting device. This system can be used on heating,

refrigerating, providing hot water or WHRPG system.

Heat collector consists of heating surface, hoop and external thermal insulation system. Soft

water is used as medium, flowing through the heating surface. Heat is to transfer with radiation

and convection, heat collection device serves as modular units, which is laid out along the cement

kiln length. Each heat collector is arranged in parallel, the benefit of which is to switch flexibly,

not affecting heat dissipation while repairing of cement kiln.

5. Project contracting and technical service advantages A professional consultation aptitude to undertake the formation works for project proposals

and feasibility report.

B Professional thermal condition calibration qualification and strong technical personnel,

which can take charge of any scale of cement production line thermal condition calibration works.

C National mandatory provisions engaging in power engineering design B-class certificate

qualificationand put- into- operation project achievements and rich design experiences. (1) We can provide accurate ordering technical documents for Heat recovery boiler and

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turbine generator, and undertake conceptual design cooperate with boiler factory.

(2) We can fulfill connection to power systems conceptual design and cooperate with local

electric utilities.

(3) We can accomplish the basic design that for engineering design and construction direction

quickly and exactly and formulate reference value datum for budgetary estimates.

(4) We can provide the professional services at the job site and accomplished working

drawing design quickly and exactly.

(5) According to owners requirements we can supply the complete equipment of waste heat

generation, not only helping to accelerate engineering design progress, but also cut equipment

procurement costs.

(6) We have integrated and completed technical service and cooperation system

(7) We can provide the service for power stations operation management and technician training.

(8) The Technicians of our company have rich experiences on power stations construction

and management, to cooperate with Installation unit in projects installation work.

(9) The Technicians of our company have rich experience on power stations debugging and

commissioning operation, to cooperate with Installation unit in projects Commissioning works.

(10) We can provide the detailed training plans for power plant operating staff, and simulate

various common fault handling.

6. Qualifications and Honors

Nanjing Triumph Kaineng Environment & Energy Co., Ltd relies on China Building

Materials Group and Nanjing Triumph Cement Technology Engineering Co., Ltd , we have three

designing certificates including Class A certificate of Construction Building Materials, Class

A certificate of Cement industry, Class B certificate of power industry, we have the most

comprehensive qualification of waste heat power generation ,the technology of WHRPG

recommended to be the most social value technology of Energy conservation and Environmental

Protection in 2009 years, and we Obtained High-tech Product Certificate awarded by Science

and Technology Department of Jiangsu Province.

There are two projects we designed were awarded the first prize and the second prize

respectively, the two projects were EPC project of waste heat recovery power generation for

5000t/d cement clinker production line in China United Cement Huaihai Co., Ltd. And EPC project of waste heat recovery power generation for 5000t/d cement clinker production line in

Guangzhou Zhujiang Cement Co., Ltd.

We have paid much attention to Innovation, with dozens of patented technology about

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cement and steel waste heat recovery power generation. WHRPG system in cement kiln which

independently developed by our company and the development of build-in settling chamber AQC

boiler have past the experts appraisal (provincial level) of China Construction Materials

Federation Organization.

7Typical application cases Technology comparison of different enterprises

Enterprise Item

Kawasaki Heavy Industries

Some Domestic cement designing institute

Nanjing Triumph Kaineng

Clinker production t/d 5000 5000 5000

Gas from grate cooler 200000 Nm3/h 360 200000 Nm3/h 360 200000 Nm3/h

380

Gas from suspend preheater 330000 Nm3/h 320 330000 Nm3/h 320 330000 Nm3/h

320

AQC boiler Natural circulation Waste gas flow up to down finned tube

Natural circulation Waste gas flow up to down finned tube

Natural circulation Waste gas flow up to down

finned tube

exhaust recycling No No Yes

AQC boiler settling chamber Independent external settling chamber

Independent external settling chamber

The built-in settling chamber

PH boiler

Horizontal arrangement, forced circulation, oscillating dust-cleaning, tube

Vertical arrangement, natural circulation, oscillating dust-cleaning, tube

Vertical arrangement, natural circulation, oscillating dust-cleaning, tube

Thermal dynamic system Single pressure+ flash Single pressure Dual pressure

Main steam pressure MPa 1.2+0.15 1.2 1.2+0.34 Pressure loss of grate cooler waste heat recovery system Pa

1200 1200

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Enterprise Item

Kawasaki Heavy Industries

Some Domestic cement designing institute

Nanjing Triumph Kaineng

Power generation kW 8404.4 8255.8 8627.3 Power generation per clinker(kWh/ t(clinker)) 36.67 36.02 39.82 Self consumption rate of power station % 8.2 7.8 7.0

Operation availability % 96-97 94-95 >98 It can be seen that, many of our technical parameters has a better performance compared

with counterpart both at home and abroad. By using domestic equipment, lower investment and

noticeable economic profit endows us with strong market competitiveness.

ACHIEVEMENT LIST OF RECENT PROJECTS

NO. PROJECT NAME CAPACITY SCOPE STATUS

1 Guangzhou Zhujiang Cement Co.,Ltd. 5000t/D

7500KW E Power

generating

2 Zhejiang Shuangshi Building Material Co.,Ltd. 2500t/D 4000KW

E Power

generating

3 Yixing Jinshu Cement Co.,Ltd. 2500t/D

4000KW E Power

generating

4 Jiamusi Hongji Group Co.,Ltd. 1000t/D+2500T/D

7500KW E Power

generating

5 Zhejiang Huaye Building Material Co.,Ltd. 1500T/D

2000KW E Power

generating

6 Chongqing Jinjiang Cement Co.,Ltd. 2500+5000T/D 12000KW E commissioning

7 Heilongjiang Beijiang Group Co.,Ltd. () 1100T/D 2000KW E Power

generating

8 Heilongjiang Beijiang Group Co.,Ltd.() 1800T/D 3000KW E commissioning

9 Fujian Chunchi Group Xinfeng Cement Co.,Ltd. 22500T/D 7500T/D

E Power

generating

19

10 Zhejiang Tianma Cement Co.,Ltd. 2500T/D 4500KW E Power

generating

11 Chengdu Sitong Automatic Project Co.,Ltd. (Wulan ) 5000T/D 9000KW

E Power

generating

12 Tieling Tiexin Cement Co.,Ltd. 22500T/D 8000KW E Power

generating

13 Guotou Hainan Cement Co.,Ltd. 6000T/D 12000KW E Power

generating

14 Wuhan Xinlingyun Cement Co.,Ltd. 2500T/D 4500KW E Power

generating

15 Zhejiang Sanyuan Group Co.,Ltd. 2500T/D 4500KW E Power

generating

16 Zhejiang Huying Cement Co.,Ltd. 2500T/D 4500KW E Power

generating

17 Huizhou Guangda Cement Co.,Ltd. 25000T/D 18000KW E Power

generating

18 Hubei Jinglan Group Sanyuan Cement Co.,Ltd. 1500+4000t/d 9000KW

E Power

generating

19 Inner Mongolia Mengxi Cement Co.,Ltd. 4000t/d 9000KW E Power

generating

20 Sichuan Taihe Cleaning Energy Co.,Ltd. (Fuquan Lisen) 3200t/d 6000KW

E Under

construction

21 Jiangxi Southern Cement Nancheng Co.,Ltd. 4800 t/d 9000KW E Under

construction

22 Jiangxi Southern Cement Yongfeng Co.,Ltd. 4500 t/d 9000KW E Under

construction

23 Shanggao Southern Cement Co.,Ltd. 4500 t/d 9000KW E Under

construction

24 Hebei Puyang Iron&Steel Co.,Ltd. 1265m2+2240m2

20000KW E designing

25 Huichang Hongshi Cement Co.,Ltd. 5000 t/d 9000KW E Under

construction

26 Hebei Jihong Cement Co.,Ltd. 2500 t/d 5000KW E Under

construction

27 Huizhou Guangda Cement Co.,Ltd. (Longjiang Cement Co.) 24500T/D 18000KW

E Under

20

construction

28 Shaoxing Southern Cement Co.,Ltd. 2500 t/d 4500KW E Under

construction

29 Jiangxi Southern Cement Anfu Co.,Ltd. 2000 t/d 3000KW E Under

construction

30 Gansu Jinglan Cement Co.,Ltd. 5000t/D 9000KW E Under

construction

31 Guizhou Dujun Haolong Cement Co.,Ltd. 3500t/D 7500KW E Under

construction

32 Guizhou Liupanshui Haolong Cement Co.,Ltd. 5000t/D 9000KW

E designing

33 Jiangxi Southern Cement FengCheng Co.,Ltd. 5000 T/D 9000KW E Under

construction

34 Taiyuan Jinyuan cement Co.,Ltd. 3200 T/D 6000KW E Under

construction

35 Hebei Qianjin Steel Group Co.,Ltd. 2240m2

15000KW E designing

36 China United Cement Huaihai Co.,Ltd.() 5000t/D 9000KW EPC Power

generating

37 Wulanchabu Jianghe WHG Co.,Ltd. 2#2500T/D+3#2500T/D8000KW EPC Power

generating

38 Xiangtan Tianhao Shaofeng Building Material Co.,Ltd. 1#2000T/D+2#2500 T/D 9000KW

EPC Power

generating

39 China United Cement Lunan Co.,Ltd. 5000T/D 10000KW EPC Power

generating

40 China United Cement Qingzhou Co.,Ltd. 6000T/D 12000KW EPC Power

generating

41 Yingde Baojiang Cement Co.,Ltd. 2500T/D 5000KW EPC Power

generating

42 Anhui Dajiang Cement Co.,Ltd. 2500T/D 5000KW BOT Power

generating

43 Nanjing Sanlong Cement Co.,Ltd. 1300TD+1800T/D 5000KW EPC Power

generating

44 Dazhou Lisen Cement Co.,Ltd. 4000T/D 6000KW EPC Power

generating

21

45 Shanxi Fulong Cement Co.,Ltd. 25000T/D 18000KW EPC construction

46 Huaxin Cement (Chibi) Co.,Ltd. 4000T/D 7000KW EPC Power

generating

47 Huaxin Cement (Xiangfan) Co.,Ltd. 24000T/D 27000KW EPC Power

generating

48 Deyang Lisen Cement Co.,Ltd. 3200T/D 6000KW EPC Power

generating

49 Jiangxi Guoxing Group Dongfanghong Yudu Cement Co.,Ltd. 1200TD+2500T/D 7500 KW EPC

Power

generating

50 China United Cement Xingtai Co.,Ltd. 2500T/D 4500KW EPC Power

generating

51 Huaxin Cement (Chenzhou) Co.,Ltd. 5000T/D 9000KW EPC Power

generating

52 Huaxin Cement (Zhuzhou) Co.,Ltd. 6000T/D 9000KW EPC Power

generating

53 Guangxi Yinfeng Cement Co.,Ltd. 5000T/D 9000KW EPC Power

generating

54 Huaxin Cement Chongqing Fuling Co.,Ltd. 4500T/D 9000KW EPC Power

generating

55 China United Cement Linyi Co.,Ltd. 5000T/D 10000KW EPC Power

generating

56 Shandong Lvye Cement Co.,Ltd. 3000+3500 T/D 12000KW EPC Power

generating

57 Yichang Hualin Cement Co.,Ltd. 2500T/D 5000KW EPC Power

generating

58 Jiangxi Jiujiang Lanfeng Cement Co.,Ltd. 22500T/D 9000KW EPC Power

generating

59 Jiangxi Lanyuan Cement Co.,Ltd. 2500T/D 5000KW EPC Power

generating

60 China United Cement Huaihai Co.,Ltd.() 5000t/D 9000KW EPC Power

generating

61 Anhui Tiepeng Haibao Cement Co.,Ltd. 4500T/D 9000KW BOT Power

generating

62 Chaohu Weili Cement Co.,Ltd. 2500T/D 4500KW EPC Power

22

generating

63 Jiangxi Southern Wannianqing Cement Co.,Ltd. 5000T/D 9000KW EPC

Power

generating

64 Hunan Southern Longhui Cement Co.,Ltd. 2500 T/D 4500KW EPC Power

generating

65 Nanjing Sanlong Cement Co.,Ltd. 4500 T/D 9000KW EPC construction

66 Fujian Quanzhou Meiling Cement Co.,Ltd. 2500 T/D 4500KW EPC Power

generating

67 China United Cement Anxian Co.,Ltd. 4500T/D 9000KW EPC Power

generating

68 Lvxian Riguang Cement Clinker Co.,Ltd. 4000 T/D 9000KW EPC Power

generating

69 Hunan Southern Cement Shaofeng Co.,Ltd. 5000 T/D 9000KW EPC Power

generating

70 Huaxin Cement (Yichang) Co.,Ltd. 3500+2300 T/D 12000KW EPC Power

generating

71 Huaxin Cement (Tibet) Co.,Ltd. 1000+2000 T/D 7500KW EPC Power

generating

72 Huaxin Cement (Huangshi) Co.,Ltd. 2200+5700 T/D 15000KW EPC Power

generating

73 Zibo Zichuan Baoshan Cement Co. 5000 T/D 9000KW EPC Power

generating

74 Huaxin Cement (Daoxian) Co.,Ltd. 4000 T/D 7500KW EPC Power

generating

75 Huaxin Cement (Kunming Dongchuan) Co.,Ltd. 2000 T/D 4000KW EPC

construction

76 Gezhouba Dangyang Cement Co.,Ltd. 1200+4800 T/D 12000KW EPC Power

generating

77 Shanxi Jigang Cement Co.,Ltd. 22400 T/D 9000KW EPC Under

construction

78 Xingtai Iron&Steel Co.,Ltd. 2180m2

12000KW EMC Under

construction

79 Hunan Southern Cement Changde Co.,Ltd. 4500 T/D 9000KW EPC Under

construction

80 Shaoyang Southern Cement Co.,Ltd. 4500 T/D EPC Under

23

9000KW construction

81 Hunan Southern Cement Leiyang Co.,Ltd. 2500+4000 T/D 4500+9000KW EPC Under

construction

82 Huaxin Cement (Zhaotong) Co.,Ltd. 4000 T/D 7500KW EPC Under

construction

83 China United Cement Anyang Co.,Ltd. 4500 T/D 9000KW EPC Under

construction

84 Guangxi Jinli Cement Co.,Ltd. 24500 T/D 18000KW EPC Under

construction

85 Guangxi Huying Cement Co.,Ltd. 3200 T/D 6000KW EPC Under

construction

86 Yunnan Yuanjiang Yongfa Cement Co.,Ltd. 1300+2500 T/D 7500KW EPC construction

87 Hunan Southern Anren Cement Co.,Ltd. 3200 T/D 6000KW EPC designing

88 Songci Shuangqi Cement Co.,Ltd. 2500T/D 4500KW EPC construction

89 Hubei Jinlong Cement Co.,Ltd. 2500+4000 T/D 9000KW EPC construction

90 China United Cement Lunan Co.,Ltd. 22500T/D 9000KW EPC Under

construction

91 Chaohu Tiedao Cement Co.,Ltd. 4500T/D 10000KW EPC Under

construction

92 Hunan Yuanda Cement Co.,Ltd. 4500T/D 6000KW EPC Under

construction