Emission reduction technologies and waste heat recovery system

The European Green Deal provides a roadmap with actions to achieve net-zero greenhouse gas emissions by 2050. To do this the decarbonisation and modernisation of energy-intensive industries such as cement is essential.

How can cement producers modernising and decarbonising their plants?

A far as stack emissions are concerned, the Best Available Techniques (BAT) is the official document used as reference for preventing or minimizing emissions and impacts on the environment. However, emissions control equipment are all energy consuming. In some cases, may have a considerable impact on the production cost and, on top of that, contribute to improve emission of GHG (CO2).

The Waste Heat Recovery system can balance the environmental footprint of the cement factory in terms of GHG generation and could put the bar back in the centre.

In the picture the PH Boiler installed in Sonmez Cement, turkey.
The PH boiler combined with AQC boiler have a max Thermal Power 38.777 kWt.

CTP Team and CTN Group

CTP is an engineering company based in Italy with 50 years experience in the fields of environmental systems and Heat recovery. With innovative products in the field of Filtration, Gas Cleaning, Heat Exchangers and Waste Heat Recovery, CTP is a reliable EPC partner able to study effective solutions and guarantee the proper execution and performance of each systems in the whole process.

CTN Group, based in Turkey, with a team up to 140 people, is specialized in heavy manufacturing of steelworks at the highest standards of quality certified by TUV. A qualified team of site supervisor complete the staff for the most demanding customers looking to EPC contracts. In the month of August CTN Group, installed a solar energy system: the system allows to save 3949 trees, avoid the use of 29 tons of coal and reduced 72.28 tons of CO2 emissions.

In order to help cement producers in the modernization and decarbonization of the plants, CTP Team focus on the emission of dust particulate (thin dust particulate PM10, PM 2,5) and explore the latest challenges for high temperature filtration, ESP Filter and study DeNox and DeSox systems in case of process with levels of pollutant emissions above the limits.

The technologies mentioned above can guarantee a complete control of the pollutants released in the environment by the exhaust gas. However, emissions control equipment are obviously all energy consuming; in some cases, high abatement efficiency can have a considerable impact on the production cost and, on top of that, contribute to improve emission of GHG (CO2). The installation on a Waste Heat Recovery system, can give an effective contribution to balance the environmental footprint of the cement factory.

Waste Heat Recovery (WHR) is a profitable, low-carbon, environmentally friendly system to produce electricity by recovering heat from industrial processes. One of the most common technology used to produce power from a waste heat is based on Organic Rankine Cycle.

the benefits of ORC:

  • Energy sustainability: the thermal energy is recovered and converted into electricity feeding a circular energy system.
  • Environment-friendly: it doesn’t make use of natural resources such as water
  • Low-emissions: the energy produced by WHR system cut the CO2 emissions normally produced by the other energy sources.
  • Dependency from the grid: protect from unforeseen blackout.
  • Internal power production cut the cost of electricity bill.

One step towards a truly sustainable future

Emission controls system combined with Waste heat recovery technology potentially allow to keep under control the level of emissions at the stack, increasing the plant energy efficiency. Internal power production save the cost of electricity bill.

In the recent year CTP and CTN has partnered for the successfully installation of two Waste Heat Recovery systems in Sonmez and Cimko Narli in Turkey. The waste heat recovery boiler designed by CTP capture the waste heat from clinker cooler (in Cimko Narli) and both clinker cooler and kiln preheater (in Sonmez cement).

The WHR based on Organic Rankine Cycle produces clean energy respecting the environment: the internal power generation system operates without the use of water, a precious natural resources, and save thousands ton of equivalent CO2emissions each year.

Client name Application Nm3/h m2 Inlet°C kwt
Sonmez Cimento Cement Plant CLINKER COOLER (AQC Thermal oil Heat Exchanger) 225.608 27.482 400 23.816
Sonmez Cimento Cement Plant KILN (PH Thermal oil Heat Exchanger) 345.750 9.015 305 14.961
CIMKO CIMENTO – kahramanmaras plant KILN (PH Thermal oil Heat Exchanger) 320.000 30.241 380 26.248

Recently, CTP and CTN will partner for the Waste Heat Recovery systems which will be installed in Outão Cement factory, Portugal. The project consists of several new developments to provide a highly customized solution to feed a double-loop system (thermal oil + Organic), to recover waste heat and produce electricity from three different sources: kiln pre-heater and clinker cooler of the existing 4000 TPD cement unit N°9 and a new solar field, that SECIL will install nearby the production line.

Automation and industry 4.0

Any physical surveillance is needed to run the system, all the waste heat recovery systems mentioned are fully automatic , equipped with remote monitoring system and 4.0 technology.

CTP believes in applications increasingly smart and digital (IoT) capable to monitor the industrial processes, including the WHR system, prevent its changes according to the operating conditions and adapting the control strategy. Today several customers choose increasingly smart and digital systems that can adapt according to external changes and no longer suffer them.

Two renewable combined

The true challenge of the portuguese project: waste heat and solar energy, two renewables will be combined to produce the electricity needed to partially cover the internal consumption of in Outão Cement factory, Portugal.