Industries & Applications - Waste Heat Recovery

Application: Waste heat recovery – Co-gen Plant

Industry: Cement, Steel or any industry, which emits hot exhaust gases.

Business Challenge:
At power generation plants, for example, the need for reduced energy costs, lower environmental load and minimized use of raw materials has never been greater. Every power producer is looking for ways to boost performance. This demand is spurring new applications for software products, intelligent control systems, low-consumption components and services. Process automation can make a major contribution to improving energy efficiency.This causes industrial organizations to purchase control and instrumentation systems first on price, even if it means they will require additional labor for implementation and maintenance.

We are committed to provide solutions to our customers as “start with, live with, and grow with”.In order to help operations in industryand realize a greater value and lower cost-of-ownership from their automation technology investments. This approach is applicable to end users in particular& developing regions, which are increasingly concerned about the long-term costs of maintaining their control systems assets. Compact Programmable Logic Controllers (PLCs) to meet the needs of customers with a wide range of industrial infrastructure projects. The Master Logic solution provides the versatility and low cost commonly associated with PLCs and augments it with a global support network and the ability to integrate with the industry’s newest control systems. A versatile line-up of I/O modules and networking options (e.g., Modbus, DeviceNet, Profibus DP, etc.) enables flexibility in how the controller fits into an entire automation scheme. MasterLogic is designed to bring power and robustness to very high-speed logic, interlock and sequencing applications.

What is Waste heat recovery?
Waste heat found in the exhaust gas of various processes or even from the exhaust stream of a conditioning unit can be used to preheat the incoming gas. This is one of the basic methods for recovery of waste heat. Many cement, steel-making plants use this process as an economic method to increase the production of the plant with lower fuel demand. There are many different commercial recovery units for transfer of energy from hot medium space to lower one.

  1. Recuperates: This name is given to different types of heat exchanger that the exhaust gases are passed through, consisting of metal tubes that carry the inlet gas and thus preheating the gas before entering the process. The heat wheel is an example, which operates on the same principle as a solar air conditioning unit.
  2. Regenerators: This is an industrial unit that reuses the same stream after processing. In this type of heat recovery, the heat is regenerated and reused in the process.
  3. Heat pipe exchanger: Heat pipes are one of the best thermal conductors. They have the ability to transfer heat hundred times more than copper. Heat pipes are mainly known in renewable energy technology as being used in evacuated tube collectors. The heat pipe is mainly used in space, process or air heating, in waste heat from a process is being transferred to the surrounding due to its transfer mechanism.
  4. Thermal Wheel or rotary heat exchanger: consists of a circular honeycomb matrix of heat absorbing material, which is slowly rotated within the supply and exhaust air streams of an air handling system.
  5. Economizer: In case of process boilers, waste heat in the exhaust gas is passed along a recuperate that carries the inlet fluid for the boiler and thus decreases thermal energy intake of the inlet fluid.
  6. Heat pumps: Using an organic fluid that boils at a low temperature means that energy could be regenerated from waste fluids.
  7. Run around coil: comprises two or more multi-row finned tube coils connected to each other by a pumped pipe work circuit.
Particulate Filters (DPF) to capture emission by maintaining higher temperatures adjacent to the converter and tail pipes to reduce the amount of emissions from the exhaust.

Benefits of Automation for the waste heat recovery – Cogen Industry:
Generation! Savings in Electrical Power consumption means more power!

  • Interface option to communicate with third-party devices using user-defined protocol.
  • Enhanced redundancy features including fast switchover time, high-speed synchronization and dual ring topology option.
  • Flexibility of network options (Fast Ethernet, Modbus ASCII/RTU/TCP, Device Net, Profibus DP)
  • Variety of I/O modules including channel-to-channel isolation
  • Robust diagnostics (system/error logs, system monitoring, network monitoring, ping test, frame monitor)
  • Tight integration with Experian HS via dedicated protocol
  • Integrated programming and engineering environment with Soft Master.

  • Typical Standard Graphics
  • Typical System Architecture
  • Project Detail
Fig: Air and Flue Gas System

Capacity Analog Input Analog Output Digital Input Digital Output Total I/O Customer Name
7.5 MW CPP 259 17 874 150 1300 AMBUJA Cement