Techno-economical and Environmental Study of Utilizing Alternative Fuel and Waste Heat Reuse in a Cement Plant

Emad Benhelal, Reza Azin, S. Mostafa Jafari Raad


In this work, a cement plant was simulated to estimate heat losses and pollution emission in the process. Also, a waste heat recovery system was introduced to use two main sources of heat losses, i.e. flue gas and hot air streams and produce steam and power. Moreover, the use of natural gas as an alternative to the current energy source, fuel oil, was studied in two cases, associated with and without waste heat recovery system. Results showed that 34.28% of initial energy was lost in the base case, 48% of which is from flue gas and hot vent air streams. Also, changing the fuel source from fuel oil to natural gas results in CO2 emission rate to decrease from 118,693 to 115,367 kg/hr, and emission of NO2 and SO2 was reduced to nearly 100%. In addition to environmental benefits, economical analyses suggest the use of waste heat recovery system as well as change of fuel for this plant.

Key words: Cement plant; Waste heat recovery; Alternative fuel; HYSYS simulation; Air pollution reduction


Cement plant; Waste heat recovery; Alternative fuel; HYSYS simulation; Air pollution reduction

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