Waste heat recovery system

In the cement industry, energy costs account for a significant portion of total operating costs. Optimizing plant operations and capturing waste heat can save a significant amount of energy. This saved energy can be converted into electricity using waste heat recovery boilers, which reduces costs and improves overall production efficiency.

Kryvyi Rig Cement (KRC) is considering installing a waste heat recovery system (WHRS) to convert excess heat generated during clinker burning into electrical energy.

The WHRS is projected to generate up to 43 GW of electricity per year. In addition, the installation of this system will reduce the load on the general energy system and reduce CO2 emissions. In Ukraine, for every megawatt-hour of electricity generated, 1.1 tons of CO2 emissions are emitted, which makes the WHRS important in terms of environmental sustainability.

Economic effect

• The recuperation system used in clinker firing allows for a significant increase in economic efficiency by utilizing the heat released during clinker kiln operation. This heat is utilized to generate electricity, which reduces the consumption of external energy resources. As a result, the company reduces energy costs, improves overall energy efficiency and reduces its environmental impact, which is particularly important in the context of rising energy prices and environmental requirements
• At 6 MWh, the recovery system is expected to generate 43 GW annually
• Installation of the system will save the company up to 6.5 mln USD annually in energy costs