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Energy Analysis of Waste Heat Recovery Boiler used in Cement Industry


Prof. M. K. Holkar , Guru Gobind Singh Polytechnic, Nashik; Prof. S. V. Kasar, Guru Gobind Singh Polytechnic, Nashik; Prof. N. A. Jadhav, Guru Gobind Singh Polytechnic, Nashik; Prof. S. R. Upasani, Guru Gobind Singh Polytechnic, Nashik; Prof. Permindur Singh, Guru Gobind Singh Foundationc, Nashik


Waste heat recovery, PH Boiler, AQC Boiler, Energy Analysis, Cement Plant


Cement production is an energy intensive process. Known energy sources exhausted from cement industries. Effective utilization of these sources is required in order to improve the efficiency of the plant. In this dissertation work Preheater boiler and Air quench cooling (AQC) boiler is designed in order to recover the waste heat from the exhaust gases. The detail boiler design is carried out considering the various limitations to produce the superheated steam at higher temperature from the waste heat recovery boilers. Thermal design of both the boilers is carried out according to Babcock & Wilcox design guidelines. The steam pressure is limited around 16 to 17 bar so that cogeneration cycle efficiency is higher. Pinch point temperature imposed the certain limitations in the design. Higher pinch point temperature may reduce the external irreversibility but on the other side it would increase the required heat transfer area. Pinch point temperature is limited to 15 °C so that effective heat transfer takes place in evaporators and superheaters. The exhaust gas temperature is limited above the acid dew point temperature to avoid the corrosion problems over the tubes.

Other Details

Paper ID: IJSRDV7I110481
Published in: Volume : 7, Issue : 11
Publication Date: 01/02/2020
Page(s): 734-737

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