Waste Heat Recovery Power Plant - WHRPP Kalina Based Cycle.
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This document summarizes a proposed waste heat recovery plant project at DG Cement's Khairpur site in Chakwal, Pakistan. The project involves installing a Kalina cycle-based waste heat recovery system with three heat recovery vapor generators (HRVGs) totaling 83 tonnes per hour and one 8.6 MW vapor turbo generator. The HRVGs will be installed at the preheater and air quenched cooler ends of the cement kiln. The project is expected to generate 61,301 MWh/year of electricity, displacing grid imports and reducing annual CO2 emissions by 28,542 tonnes. It will contribute to sustainable development through environmental, social and economic benefits.
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Waste Heat Recovery Power Plant - WHRPP Kalina Based Cycle.
- 1. Waste Heat Recovery Plant DG Cement Khairpur, Chakwal Khairpur Site: Duel Fuel (Gas & Oil) Power 33.00 MW Waste Heat Recovery 8.6 MW Total Captive Power 41.6 MW
- 2. Presented By • Muhammad Awais | Roll No. 18250 MS Project Management (Spring 2016) Department: Faculty of Management Sciences
- 3. KAWASAKI Power Plant MARKET 1994～ WH Video Boiler Cement x11 Cement Japan Profit Tech. China : Waste Heat Recovery: CCPP & HRSG DOW Duct KHI Temp COST VERT Supply INQUIRY DATASHEET
- 5. Where DoYou Look? Examples ofWaste Heat Sources Waste heat opportunities at a wide range of projects • Many industrial, but also commercial and institutional sites • From low to high temperatures (~200oF to 3000oF) Overview of Waste Heat Recovery for Power and Heat
- 6. HighTemperature Opportunities About 1000oF and Greater Examples: • Metals Manufacturing and Reheating (Steel, Al, Ni, Cu, Zn, Si…) • Glass • Coke Ovens and Calcining • Fume Incinerators Plus high ends of • Turbine & engine exhausts, heat treating furnaces, drying & baking ovens, cement kilns
- 7. Low & Medium Temperature Opportunities Up to About 1000oF Examples: • Turbine, Engine and Boiler Exhausts • Distillation Columns • Drying, Baking and Curing Processes • Cooling Water from Industrial Processes Plus low ends of • Heat treating furnaces and cement kilns
- 8. What Do You Do With It? Examples of End Uses Steam Generation and Process Heating for Industrial Processes e.g. Steam use at paper mill or refinery • Plant or Building Heating • Electricity Generation • Hot Water Heating Commercial, Industrial & Institutional • Cooling and Chilling Commercial, Industrial & Institutional
- 9. Khairpur Site By moving toward the direction of achieving its vision, management of DGKCC made a strategic decision toward enhancing its power generation capabilities with intention to lowering dependency onWAPDA power supply. In this view, DGKCC installed duel fuel (Gas and Fuel Oil) power generation plant in September 2007 having total power generation capacity of 33 MW. In addition to company's own power generation capacity, WAPDA resource capacity of total 36 MW is also in use, from time to time, for making uninterrupted flow of operations WHR POWER PLANT DG, KHAN CEMENT CO, Chakwal
- 10. Overview of Waste Heat Recovery Plant, Khairpur The proposed project activity involves installation of Kalina cycle based waste heat recovery system which includes three Heat Recovery Vapour Generators (HRVGs) having total capacity of 83tph (tonnes per hour) and one vapour Turbo Generator (TG) having gross electricity generation capacity of 8.6 MW HRVGs shall be installed at Preheater (PH) and Air Quenched Cooler (AQC) ends of the kiln. The project activity shall be commissioned in August 2012; net electricity generated by the project activity (61,301MWh/yr) will displace grid electricity imports and result in annual average emissions reduction of 28,542 tonnes of CO2.
- 11. The project activity will also contribute towards sustainable development of the following: Environmental Development √ significant reduction in the emissions of Greenhouse Gases √ improvement of the local environment by reduction in temperature of the vented hot air √ conservation of local fossil fuel resources by avoiding fossil fuel based grid electricity Social Development √ alleviation of poverty by providing labour employment opportunities to the local community during construction phase √ creation of new permanent jobs during construction and operation phase √ positive impact on local communities by avoiding grid electricity which will become available to domestic consumers √ addition to power generation capacity of Pakistan √ less health impact for the population through less emission of greenhouse gases and particles Economic Development √ employment opportunities for the local people Technology Development √ introducing modern technology in the country (technology transfer) √ setting up an example of sustainable development to be followed by other cement factories
- 12. Starting date of the project activity: >> Starting date of the project activity is October 30, 2010 which is the date of signing contract between DGKCC and FLSmidth A/S. Expected operational lifetime of the project activity: >> 20 years 0 months Starting date:>> 01/11/2012 Environmental impacts IEE Report (Initial Environmental Examination Report) and the accompanying approval request letter were submitted on July 18, 2011. The environmental approval to the project activity was granted on January 10, 2012.The I.E.E report does not raise any particular issue with regard to the environmental impact of the project.
- 13. Assessment and demonstration of additionality As per GUIDELINES ON THE DEMONSTRATION OF ADDITIONALITY OF SMALL-SCALE PROJECT ACTIVITIES, “Project participants shall provide an explanation to show that the project activity would not have occurred anyway due to at least one of the following barriers:
- 14. a) Investment barrier: a financially more viable alternative to the project activity would have led to higher emissions; b) Technological barrier: a less technologically advanced alternative to the project activity involves lower risks due to the performance uncertainty or low market share of the new technology adopted for the project activity and so would have led to higher emissions; c) Barrier due to prevailing practice: prevailing practice or existing regulatory or policy requirements would have led to implementation of a technology with higher emissions; d) Other barriers: without the project activity, for another specific reason identified by the project participant, such as institutional barriers or limited information, managerial resources, organizational capacity, financial resources, or capacity to absorb new technologies, emissions would have been higher”
- 15. Project participants: The table below illustrates the participants involved in the proposed CDM project activity. Contact information is provided in Annex 1.
- 16. Following is the schematic of project activity:
- 17. The project activity shall be commissioned in August 2012. The project technology is not likely to be substituted by other or more efficient technologies within the crediting period of the project activity. The project equipment is brand new and uses environmentally safe state of the art technology. The waste heat recovery system is based on Kalina Cycle technology which is more efficient than the conventional Rankine cycle based WHR systems used in the country. The technology will be transferred from Denmark. A list of major equipment of project activity is given below in Table A.4.2.1.
- 18. Operational characteristics of the turbo-generator are provided below in Table A.4.2.2
- 19. Do you have any question?
- 20. THANK YOU !!!