Waste Heat Recovery


WHRS for Cement Plant

WHRS in Cement Plant

TESPL is proud to be the first Indian Company to have successfully launched and commercialised indigenous, in-house developed and patented technology for Waste Heat Recovery Systems (WHRS) for Cement Plants. TESPL has successfully designed, engineered and installed several Turnkey Waste Heat Recovery Power Plants (WHRPP) for Cement Industry. The technology of WHRS in Cement Plant was highly appreciated by the Department of Science and Technology (DSIR), Government of India and TESPL was honored with a National award for in-house R&D efforts in the Clean Energy and Climate Change Category. This first of its kind green technology developed by TESPL supports sustainable development initiatives.

WHRS for Cement Plant

Sources of waste heat

  • Large quantities of Waste gases from preheater cyclones and Clinker cooler outlets in a cement kiln are normally released into the atmosphere without recovery of heat. Even after using part of the heat for raw mill and coal drying, a large amount of heat energy is rejected to the atmosphere.
  • TESPL utilizes the waste heat available in these exhaust gases for conversion into useful form as required by the cement plant.
  • WHRS in cement plants can be designed considering the fluctuating temperature requirement of raw mill, coal mill and slag mill during different seasons and installation of waste heat recovery system does not affect operation of these equipment.

Utilization of Waste Heat

  • Generation of Power by Steam Rankine Cycle
  • Generation of Power by Organic Rankine Cycle (ORC)
  • Integration with Captive Power Plant
  • Fly ash drying
  • Water recycling

Cement Dust characteristics

Dust Load Dust Nature
Preheater 70 to 120 gm/Nm³ Fine, Soft & Sticky
Clinker Cooler 50 to 70 gm/Nm³ Coarse, Hard & Abrasive

Cement Dust characteristics

The patented technology of TESPL for Turnkey WHRPP for cement plants overcomes following challenges.

  • Extremely high dust content in exhaust gas.
  • Sticky & erosive nature of dust.
  • High elevation of Preheater cyclone tower.
  • Limited availability of space.
  • Dust collection.
  • Integration with a running cement plant.