Introduction of low-temperature

Waste heat recovery power generation (WHRPG)

technology
in Cement Kiln

Rahbord Engineering Services Co.

Nanjing Triumph Kaineng Environment & Energy CO., LTD.

China National Technical IMP. & EXP.CORP.

2010-11-19
 Contents

1 The development history and current situation of WHRPG technology on new dry
process cement production line ........................................................................................ 1
1.1 The definition of WHRPG technology ................................................................................ 1
1.2 Origin of WHRPG technology ............................................................................................ 1
1.3 Application of WHRPG technology in China ..................................................................... 1
1.4 Maturity and comprehensive application of WHRPG equipment ....................................... 2
1.5 Application of China’s WHRPG technology in abroad....................................................... 2
1.7 Cases of WHRPG in foreign cement plant constructed by China by the end of 2009 ........ 3
2 Investment profits of WHRPG for new dry process cement production lines...... 3
2.1 Economical benefits ............................................................................................................ 3
2.2 Social benefit....................................................................................................................... 3
2.3 Cost of production ............................................................................................................... 4
2.4 Project case of a 5000t/d cement production line................................................................ 4
2.5 Policies of encouraging WHRPG construction in China .................................................... 5
3 Introduction of WHRPG technology of Nanjing Triumph Kaineng Environment &
Energy Co., Ltd. .................................................................................................................... 5
3.1 Company Profile ................................................................................................................. 5
3.2 Available waste heat resources of WHRPG in new dry process cement production lines .. 6
3.3 Connection of low temperature WHRPG with cement production lines ............................ 6
3.4 Thermodynamic system of WHRPG ................................................................................... 7
3.5 Main equipments of low temperature WHRPG .................................................................. 9
3.6 Impact of WHRPG to cement production lines after put into operation ........................... 12
4 Technical R&D and Innovation .......................................................................................... 13
4.1 Initiation of integration of Settling Chamber and AQC boiler .......................................... 13
4.2 Initiatively proposed the flow direction of gas from top to bottom in AQC boiler ........... 13
4.3 Advantages of original created AQC boiler ...................................................................... 13
4.4 Initiatively proposed the technology about second heating the steam in AQC boiler ....... 14
4.5 The technology of cooler air draft ..................................................................................... 14
4.6 Low-temperature exhausts recycling technology .............................................................. 15
4.7 Rotary kiln heat recovery technology ............................................................................... 15
5 Project contracting and technical service advantages ............................................. 15
6 Qualifications and Honors ................................................................................................ 16
7 Typical application cases ................................................................................................. 17
1. The development history and current situation of WHRPG technology on
new dry process cement production line
1.1 The definition of WHRPG technology
The technology of WHRPG technology is utilizing the low-grade steam (low pressure, low
temperature) generated by industrial waste heat ’s temperature between 120 ℃ and 400 ℃, to
push the specially designed low -parameter- steam turbine generator unit to generate electricity.
It has three main characteristics:
•Utilization the waste heat resources of 120℃～400℃;
•Low grate steam and low-parameter- steam turbine generator;
•Without increase of entity heat consumption and additional fuel.

1.2 Origin of WHRPG technology

WHRPG technology started from the late 60s in Europe and the United States, it was put
into practical utility in the mid-70s, and the application of this technology reached a climax in the
early 80s and has become popular since then.
A typical representative was that the United States ALPEND Cement Plant had built 5 sets of
low temperature WHR generators between 1973 and 1978, the capacity of which was 5000 ~
12500KW, while whose boilers’ main steam parameters was 1.37Mpa, 288℃. The capacity of
cement plant waste heat power generation reached 40 billion kwh per year till December of 1980
in the United States.
Japan ranked earlier and much more mature in the research and development of this
technology too. Japan is a resource-shortage country. Since the world oil crisis in 1973, the
government has paid closer attention to energy conservation and began to promote the outside
pre-clinker kiln (up to 90%) and waste heat power generation. In February, 1981, Japan Sumitomo
Cement Company put a set of two 1320- kw heat generators, which were the first sets of heat
generating units in Japan, into operation. Till 1989, 16 cement plants have been installed the waste
heat generators among the 46 cement plants on a national scale, and the recovered energy power
covered 30% of national cement industry power consumption.

1.3 Application of WHRPG technology in China

China has been engaged in waste heat utilization technology for a long time. The first low
temperature WHRPG project in China was a 6480kW waste heat generator which is provided by
KAWASAKI for 4000t/d clinker production line of Ningguo Cement Plant. The project
construction started from Oct.1996 and began to generate electricity in Feb.1998. Equipment were

1
fully provided by Japan. The first case of the national production of the waste heat power
generation project was the 3000kW pour WHG construction by Shanghai Triumph Kaineng and
Nanjing Cement Design Institute for 2000t/d clinker production line of Jiangxi Wannian Cement
plant. This project construction started from 1997 to February 1999, the equipment of which were
all home- made. This WHG line remains on operation, although the first case of domestic waste
heat power generation ranked slightly lower in equipment reliability and efficiency, compared
with Japanese equipment and technology, the project implementation pioneered the WHRPG
technology and equipment nationalization, laying the foundation of the domestic WHRPG
technology development and providing valuable experience.

1.4 Maturity and comprehensive application of WHRPG equipment

On broad absorption of the foreign WHRPG technology, China cement industry has
successfully used domestic equipment and technology in 12 new dry process cement production
lines, constructed 2.0MW, 3.0MW, 6.0MW and 7.0MW of low temperature waste heat generating
units and promoted the WHRPG technology into maturity from 2001 to 2004. Since 2004, the
cement kiln waste heat power generation projects have been under full swing across the country.
By the end of 2009, 50% new dry process cement production line in China has been put into
operation with waste heat power generation. A large number of practices provide with the perfect
opportunity for technology innovation, while practical applications promote the improvement of
technology and equipment. Under such circumstances, WHRPG technology in China has become
much more mature and reliable. China's low temperature WHRPG technology has reached the
international advanced level.

1.5 Application of China’s WHRPG technology in abroad

China's WHRPG technology and equipment has become more and more mature. The
thermodynamic cycle system and the localization equipment have reached the international
advanced level. Thanks to the low investment costs and strong integrated services capability, it has
significant competitive advantage in the international market, in recent years, China's cement kiln
WHRPG technology has been applied into the European and Asian countries quickly.
In 2008, Thailand's SCG Cement Company put two generating units with a total installed
capacity of 27MW into operation in three production lines. Thailand SKK cement plant put a 6th
line, the 9.1MW waste heat generator, into operation, which created a foreign market of China’s
WHRPG technology. The world's leading cement companies such as Lafarge, Heidelberg all
choose the Chinese companies to take charge of waste heat power generation construction when
they have cement branch factories in foreign countries. In 2009, the total installed capacity of
Chinese companies undertaking abroad waste heat power generation projects has achieved

2
247.8MW, which was 8 times of that in 2008. The development speed is amazing.

1.6 China's domestic WHRPG projects’ construction by the end of 2009

Year Production line unit capacity(MW) Designed clinker capacity(10000t/a)

1997～2005 13 14 50 1119

2006 15 14 65.5 1460

2007 86 59 571 10109
2008 149 106 975.2 15899
2009 232 181 1676.8 27670
Total 495 374 3338.5 56257

1.7 Cases of WHRPG in foreign cement plant constructed by China by the end of 2009

State Production line unit capacity(MW) Designed clinker capacity(10000t/a)

Thailand 9 6 102.2 1819
Pakistan 9 4 52.6 100l
India 7 5 48 880
Turkey 2 l 18 310
Philippines 1 l 4.5 78
Total 32 20 225.3 4088

2. Investment profits of WHRPG for new dry process cement production

lines
2.1 Economical benefit
The product of WHRPG is electricity and it can be consumed by oneself. The investment
economical benefit can be seen from two aspects. First, it is the electricity expense. The electricity
price gap between outsourcing and self supplying is the profit, and power generation from waste
heat could satisfy 1/3 of cement production consumption. Second, it is CDM profit. Traditional
power generation consumes fuel such as coal or gas and CO2 generated during the process.
However, waste heat generation does not need any fuel and generates no CO2 emission. The saved
emission could be sold in the world carbon market, which is an addition profit for the enterprise.

2.2 Social benefit

Social benefits are mainly embodied in three aspects. Firstly, operation of waste heat
generation significantly reduces the cost of cement production and improves the enterprise

3
competitiveness, and at the same time saves the energy. Secondly, the boiler of heat recovery
system is equivalent to a pre-dust collector, which reduces the dust emission. Finally, exhaust gas
flows through the boiler for heat exchanging and its temperature decreases a lot in the boiler outlet,
which reduces thermal pollution to the surrounding environment.

2.3 Cost of production

Without any additional fuel, waste heat generation could produce electricity. The production
costs mainly include daily consumption and staff wage etc. The following table shows the detailed
costs.

No. Item No. Item

1 consumable material 2 water

1.1 lubricant 3 staff wage

1.2 chemical water 4 maintenance
1.3 98%Na3PO4
1.4 circulating water drugs

2.4 Project case of a 5000t/d cement production line

No. Item unit value

1 Clinker production t/d 5000
2 Installed capacity kW 9000
3 Actual average power generation kW/h 8250

4 Self consumption rate of power % 7

station
5 Annual operation time h 7200

6 Annual power generation kWh 5940×10

4

7 Annual power supply kWh 5464×10

4

8 Electricity price RMB 0.36

9 Annual benefit RMB 1967×10
4

10 Cost of operation RMB 162×10

4

11 Annual profit RMB 1805×10

4

12 Total investment RMB 7200×10

4

13 Static investment recovery period y 3.98 y

The above economic analysis is based on electricity price of 0.36 RMB/kWh, staff wage of

4
15 000 RMB/y, 18 operators and construction period of one year.

2.5 Policies of encouraging WHRPG construction in China

WHRPG projects belong to energy conservation industry，China strengthened supporting this
project recently, the policy of support waste heat power generation construction is released
successively, mostly involving the following aspects:
1) Financial support. The government provides with loan for energy conservation project priority,
and supports using EMC pattern.
2) Permitting grid connected. Small Thermal Power Generating Units in China are limited to
construction, not allowing grid connection, while turbo-generator of WHRPG allows grid
connection.
3) Award, according to Chinese domestic power generation coal consumption standard, it converts
power generation to standard coal saving, 300 RMB per ton of standard coal saving as a reward,
including 240RMB per ton from central finance and 60 RMB per ton from provincial finance.
4) Income tax preference, WHRPG projects belong to comprehensive utilization of resources
project, the income tax levied in accordance with 90% of the total taxation.

3. Introduction of WHRPG technology of Nanjing Triumph Kaineng

Environment & Energy Co., Ltd.

3.1 Company Profile

Nanjing Triumph Kaineng Environment & Energy Co., Ltd. is composed of key staff of
Shanghai Kaineng Co., Ltd. and Nanjing Cement Design Institute, the main members have
participated in research and implementation of the first low temperature cement waste heat
recovery power generation project in China. Since the company was established, we have built
more than 90 projects (about 140 production lines), and over 60% was dealt with EPC model. The
total installed capacity reached 800MW and annual electricity generation is up to 6 billion kWh.
Every year, nearly 2 million tons standard coal equivalent can be saved and 5 million tons of
carbon dioxide can be reduced.
We are keeping a close cooperation relationship with some large-scale cement enterprises,
such as China United Cement Group Co., Ltd., China Southern Cement Co., Ltd., Huaxin Cement
Co., Ltd., Heidelberg Cement Group, Swiss Holcim Group and so on, our company has 25%
market share of waste heat power generation in domestic cement industries. We have hold the
position ranking in top three and the performance top the list among the industries in 2009 and
2010.
We put forward unique WHRPG technology on the basis of summarizing the waste heat

5
recovery power generation engineering cases implemented by domestic counterparts and the
design and operation practices of over 100 cement kiln waste heat recovery power generation
systems implemented by us. Basing on the process parameters and requirement of customers, we
can achieve the maximization and step of waste heat utilization, and implement best combination
of energy conservation & emission reduction and enterprise benefit, and create maximum
economic and social benefits. All the staff are trying their best to make the company a
world-renowned high-tech enterprise in the field of new energy and energy conservation &
environmental protection.

3.2 Available waste heat resources of WHRPG in new dry process cement production lines
Technological Process of Cement Sintering System
1. Material Process:
Limestone transported to crusher-----ground into flour in raw mill-----enter preheater to
preheat and precalcine-----enter rotary kiln to calcine-----drop down to cooler to cool-----sent to
clinker storage bin by conveyor.
2. Grate Cooler Waste Gas Process: Cold air was sent to grate cooler to cool the
material(80~100℃), and cold air was heated to hot air(250~300℃), then excreted from grate
cooler tail, then entered kiln head dust collector, and finally discharged into atmosphere by
exhaust fan.
3. Preheater Waste Gas Process: Waste gas of preheater outlet(300~350℃) enters GCT to
cool down(300℃),then provides drying heat source for raw material mill, then enters dust
collector, and is discharged into atmosphere.
Heat Balance of Cement Kiln Sintering System（kJ/kg-kcl）
：（Typical thermal consumption of
domestic 5000T/D cement production line）

Heat Output of Heat Output of

Heat Heat of Heat Output Heat
grate cooler Preheater Waste
Input Clinker Form of Clinker Dissipation
Waste Gas Gas
3
1682 78 466 684 225
135
1
53.65% 2.49% 14.86% 21.82% 7.18%
00%

3.3 Connection of low temperature WHRPG with cement production lines

Connection of AQC boiler with cement production line: Because the waste gas temperature

6
of grate cooler terminal is low, and direct utilization efficiency is low, the air is taken from the
central part of grate cooler, the waste gas of 380℃ enters AQC boiler. The waste gas was cooled
to about 90℃ by AQC boiler. Both it and grate cooler tail waste gas(about 120℃) return to kiln
head dust collecting system.
Connection of PH boiler with cement production line: The temperature of preheater waste
gas is about 320℃, and it enters directly into PH boiler. The waste gas was cooled to about 200℃
by PH boiler. Then the waste gas enters raw mill and provides drying heat source for it. The PH
boiler is equivalent to bypass of GCT. After The PH boiler was put into operation, the GCT is
exited from operation.
The layout of GCT before high temperature fan: The GCT is parallelly connected with the
high temperature fan. The waste gas of preheater normally runs through PH boiler, and then it is
sent to raw mill by high temperature fan. When PH boiler is failed, the waste gas runs through
GCT, and then it is sent to raw mill by high temperature fan. The PH boiler is to stop.
The layout of GCT behind high temperature fan: Normally running, the waste gas of
preheater enters high temperature fan, then enters raw mill. When raw mill is stopped, the waste
gas goes through GCT, and then enters the dust collector.

3.4 Thermodynamic system of WHRPG

WHRPG system is classified into the single pressure system, flash evaporation, and dual
pressure system according to thermodynamic system.

3.4.1 Single Pressure System

42℃ soft water from boiler feed water pump is heated to 160℃~180℃ by public
economizer of AQC boiler, then divided into two parts. One part is sent to the drum of AQC boiler,
the other part is sent to the drum of PH boiler. The superheated steam of AQC and PH boiler are
mixed, then forming 1.15Mpa, 320℃ superheated steam, which is sent to turbine to generate
power. Exhaust-steam post work is condensed to water in the condenser. The water is sent to
deaerator to remove the oxygen by condensate pump, and then sent to boiler by feedwater pump
for recycling.
Main features: The waste gas out of AQC boiler could be decreased to 90~110℃, only
generating single pressure steam. Turbine can adopt single-pressure steam. System is simple and
with low investment. There are no adjustment measures with fluctuation of waste gas temperature.
The temperature of waste gas out of boiler fluctuates with the waste gas. When the temperature of
waste gas fluctuates, the heat of waste gas is not used to the best.

7
3.4.2 Flash evaporation system
The uppermost difference between flash and single pressure system is that, soft water from
boiler feed water pump is heated to 160℃~180℃ by public economizer of AQC boiler, then
divided into three parts. One part is sent to the AQC boiler, and the other part is sent to the PH
boiler. The remaining stuff is sent to flash evaporator to generate 0.1~0.2MPa low pressure
saturated steam. Then it is sent to turbine to work from the central part of turbine. The water,
which is not flashed to steam in flash evaporator, enters feed water line. Then it is sent to boiler for
recycling use by feedwater pumps.
Flash evaporator is one of key equipments of the system. The process principle of flash
evaporator: high pressure, high boiling point and heat content of water. When pressure is
decreased, part of sensible heat is released. The part of heat is absorbed by the way of latent heat,
and part of water is flashed to steam.
Main features: System is configured flash evaporator and dual pressure supplement steam
turbine. Two kinds of different parameters of steam are generated. The sharp fluctuation of flue
gas is actively adjusted by flashing technology. After waste heat of large amounts of fluctuating
flue gas is taken by system (boiler), a few low pressure saturated steam is generated by flashing
technology. The waste flue gas temperature is controlled in about 90℃. This makes sure that
waste heat resources is fully used on waste flue gas temperature fluctuating. The flash efficiency
of flash evaporator is not high. There are large amounts of hot water cycling between feedwater
pump and boiler, so power consumption of pump is increased. Water content of saturated steam is
higher, so the last stage blade is eroded after entered turbine. It goes against long-term operation of
turbine.

3.4.3 Dual Pressure System

Dual pressure system is set into two drums in the AQC boiler. Two kinds of different
parameters of steam are generated and enter turbine. Soft water from feedwater pump is heated to
160℃~180℃ by public economizer of AQC boiler, then divided into three parts. One part is sent
to the high pressure drum of AQC boiler, and the other part is sent to the PH boiler. The remaining
is sent to low pressure drum of AQC boiler, and generated low pressure superheated steam by set
low pressure superheater. With flash system difference, grate cooler is configured dual pressure
boiler, and low pressure steam is superheated steam
Main features: Dual pressure system is configured dual pressure boiler and dual pressure
supplement steam turbine. Two kinds of different parameters of steam are generated. The sharp
fluctuation of flue gas is active adjusted by dual pressure boiler. After waste heat of large amounts
of fluctuating flue gas taken by boiler, a few low pressure superheated steam is generated by low

8
pressure boiler. The waste flue gas temperature is controlled in about 90℃. This makes sure that
waste heat resources is fully used on waste flue gas temperature fluctuating. Compared to flash
system, the erosion of turbine will be reduced by superheated steam. It can make sure of the
long-term safety operation of turbine. There is less cycling water in system, so the power
consumption of pump will be decreased. The water temperature of PH boiler could be chosen, so
the waste flue gas temperature of PH boiler could be decreased to a lower level.

3.4.4 The comparison of three kinds of thermal system

Item Single pressure Flash evaporation Dual pressure
system system system
Suitability for fluctuation of
Small adaptation Adaptation Adaptation
working condition of kiln head
Projection investment Small Large Larger
Power generation Small Net increase 2~3% Net increase 3~5%
Plant power consumption Low Higher High
Duct system Simple More complex Complex
Operating life of steam turbine Better Worse Better
Operating condition Convenient Complex Convenient
Domestic More in the early A few More

3.4.5 Choice of three kinds of thermal system in engineering application

Nanjing Triumph Kaineng Environment & Energy Co., Ltd. has built many projects by three kinds
of thermodynamic system in China. According to engineering experience, for two or more heat
sources in cement waste heat, the system of dual pressure, flash and single pressure can be applied
based on optimal design of thermodynamic system and concrete analysis. In boiler heat balance
calculation, when the released heat of flue gas is completely absorbed by designed and Selected
single pressure system (the temperature of waste gas out of boiler is about 90℃~100℃) and
achieves the cascaded utilization of energy at the same time, the single pressure system will be
simply, easily operated, low investment and more reasonable. When the part of heat is not
completely utilized, to use low pressure system to generate steam, then it is sent to supplement
steam part of turbine. In this case, the design of dual pressure and flash will be adopted. The dual
pressure system is recommended firstly in the dual pressure and flash system.

3.5 Main equipments of low temperature WHRPG

9
3.5.1 WHR boiler
There are several fixed types of WHR boiler. AQC boiler is generally chosen vertical located,
which adopt tube and box type structure and modular design. The component of heat exchange is
adopted spiral fin coil.
There are two types of PH boiler: vertical and horizontal. Because dust content of waste gas
out of preheater is high, small particle size and no cohesiveness, the heat exchange component of
preheater is adopted in smooth tube and mechanical oscillating dust-cleaning mode.

3.5.1.1 Vertical WHR boiler

Vertical boiler is generally adopted natural circulation. Flue gas is flowed from top to bottom.
The heat exchange component is vertical to the flow direction of flue gas. The mechanical
oscillating dust-cleaning mode is adopted. Deposit of dust is sent to original production line by
conveyor.

3.5.1.2 Horizontal WHR boiler

Horizontal boiler generally adopts forced circulation. Water is forced to flow by circulating
pump in the boiler. Flue gas is flowed horizontally, and the heat exchange component is vertically
arranged. The mechanical oscillating dust-cleaning mode is adopted. Deposit of dust is sent to
original production line by conveyor.

3.5.1.3 The comparison of vertical and horizontal boiler

Item Horizontal boiler Vertical boiler

Heat transfer Forced circulation, ash fouling Natural circulation, more ash
characteristics resistance, better heat transfer fouling ,general better heat transfer
Thermal Temperature maldistribution, Temperature distribution, Expansion
expansion Expansion maldistribution distribution
Air leakage More Less
Steam-water Forced circulation, More Natural circulation, Reliable
circulation self-consumption electricity operation
Steel
Lower Higher
consumption
Dust removal Better Worse

3.5.2 Turbo-generator set

The turbine flow passage is designed by using three-dimensional technology for structure
optimization. Application of aft-loaded cascades and three dimensional design of twisted blades

10
enhances the turbine overall efficiency. Turbine body’s design satisfies the main steam parameters
varying from 0.68 to 1.57MPa and 280℃ to 390℃, which could be adapted to fluctuation of
cement production. Considering different heat source and thermal dynamic system and combining
with Mitsubishi turbine technology, we have developed turbines of single pressure and dual
pressure with inlet steam pressure of 0.75MPa, 1.05MPa, 1.37MPa, 1.6MPa respectively. For
turbine with induction steam, a mixing chamber is designed according to mixing flow
characteristic of the main and induction steam. This design minimizes flow loss of the steam and
increases overall efficiency of the turbine. And in the normal operation, the induction steam could
be regulated to satisfy turbine working condition and in the emergency the induction steam could
be cut off to prevent the accident.

3.5.3 Cooling unit of exhaust steam from turbine

3.5.3.1 Water-cooling unit
Water-cooling unit adopts water as cooling medium for exhaust steam condensation, which
is composed of condenser, condensate pump, cooling tower and water basin. Water from basin is
pressured and sent to condenser for heat absorption, and exhaust steam from turbine is condensed.
The water absorbed heat and turned back to the cooling tower for cooling with the help of
mechanical draft fans.

3.5.3.2 Air-cooling unit

Air-cooling unit adopts air as cooling medium for exhaust steam condensation, which is
composed of exhaust equipment and air cooler. The air is sent to the surface of cooling pipes to
cool exhaust steam from turbine in the cooling pipes.

3.5.4 Make-up device

The make-up water is to provide qualified desalted water for boiler, and the make-up water
unit includes pretreatment, reverse osmosis and mixed bed process, vacuum deaerator and desalt
water pump. The feed water of heat recovery boiler originates two parts, one is from condensate
water and the other is from desalted water. After the two parts jointing in the vacuum deaerator,
oxygen in the water is removed and then the deaerated water is supplied to boiler by the feed
pump.

3.5.5 Automatic control

WHRPG adopts integrated control system, and controls model usage distribution control
system (DCS). Control network includes three-layer structures. The first layer is controlling

11
distribution level. The second layer is monitoring centralized operation level. The third is
integrated information management level. High way data access (HW) local area net (LAN) are
adopted for connection among levels. Communication network is employed on one level for
message transmission between different equipments.

3.6 Impact of WHRPG to cement production lines after put into operation
3.6.1 Positive effect
Impact on electrical dust collector of cooler: Dust concentration of gas entering electrical dust
collector is lower. This can be explained as the following. On one hand, after grate cooler is
transformed, exhaust from the middle of grate cooler is predusted through the AQC boiler, and
some sediment in the boiler. On the other hand, because of the middle suction of the grate cooler,
the exhaust flow rate of cooler’s terminal pipe reduces to 1/2 of its original. Thus less dust is
carried with exhaust.
Impact on high temperature fan of preheater: High temperature fan’s load reduces when
station is in service. As the stack gas passes through PH boiler, gas temperature decreases and
density increases, so fan’s flow rate falls down and total pressure rises. The total pressure raise
compensates the pressure loss of about 800Pa as the installation of PH boiler. And at the same
time, less dust content of the gas weakens abrasion of fan. Compared with original, the high
temperature fan could still satisfys the working condition just because it’s working state point
moves to another point compared to the original one.
Impact on dust collector of preheater: As long as the moisture in the gas is regulated, specific
resistance of the dust in the electrical dust collector will be better controlled. If an arrester is
adopted in WHRPG, the performance of dedusting will be improved.

3.6.2 Negative effect

Impact on electrical dust collector of grate cooler: If the electrical dust collector inlet
temperature decreases from 220-330℃ to about 90℃, specific resistance of the dust will be
affected. From curves of specific resistance of the kiln dust, when the gas temperature ranges from
140℃ to 190℃, dust specific resistance is too high, which is bad for electrical dust collector
operation. When in the 90℃, dust specific resistance is about 2.5×1010Ωcm which is on a
acceptable scope ( demand dust specific resistance of electrical dust collector is 104～5×1010Ω
cm).
Impact on the exhaust fan of grate cooler: As a heat recovery steam generator (AQC boiler) is
installed and grate cooler is transformed correspondingly, exhaust pressure loss between the grate
cooler and the fan increases about 800Pa. The increased pressure could be compensated by fan’s

12
total air pressure raise due to the flow rate falling about 1/3-1/2 of its original.
Impact on drying ability toward raw mill: WHRPG is designed according average water
content of raw material of local settings. If the water content varies on a large scale, the raw
material drying performance will be affected because more drying gas is directed to PH boiler. But
this negative impact can be weakened by adjusting bypass pipe line of the heat recovery steam
generator (PH boiler).
4. Technical R&D and Innovation
4.1 Initiation of integration of Settling Chamber and AQC boiler
Initiatively proposed to cancel the settling chamber, the total resistance of system is less
than 800Pa, using the self-brought settling chamber of AQC boiler, reducing the resistance of
AQC boiler system. The power of exhaust fan does not increase, so the operation cost of WHRPG
is reduced. In addition, the generated energy is increased when canceling the external settling
chamber, simplified the flue gas duct, reducing the occupied area, saving the primary cost as well
as reducing the heat loss.

4.2 Initiatively proposed the flow direction of gas from top to bottom in AQC boiler
We are studying on the mechanism of ash deposition and wearing, using the flow direction of
gas from top to bottom in AQC boiler, proposing two measures to solve the problem of ash
deposition and radical wearing: Firstly, pre-separation of large particles of dust before using the
waste heat of gas, reducing the big particle size dust into AQC boiler; Secondly, reducing the
velocity of dust in AQC boiler.

4.3 Advantages of original created AQC boiler

Our AQC boiler has three main advantages by the above two technical innovations:
A: Reduce the settling chamber investment and the heat preservation，wear prevention cost
B: Increase the inlet gas temperature 10-15℃, which enters the boiler. Because the settling
chamber and some flue pipe are not to use multiply, heat dissipation has been reduced
significantly.
C: Reduce the resistance (about 500Pa) of boiler system, so the load of exhaust fan has
been reduced significantly.
The comparison of using conventional settling chamber + WHG with flue gas from top to
bottom and using the integrated of settling chamber and AQC boiler on 5000t / d cement
production line are listed as follows:

NO. Items Air-quanity(Nm3/h) Air Generation(

13
 temperature(℃) kWh)
1 External Settling 200000 350 3438
Chamber AQC boiler
2 Patental AQC boiler 200000 360 3661
3 save electricity power 91
4 More electrical energy 542
supply
The patent integration of settling chamber and AQC boiler belongs to Nanjing Triumph Kaineng
Environment & Energy Co., Ltd. and the product is unique through a ministerial appraisal in
China domestic low temperature heat power industry, reaching international advanced level.

4.4 Initiatively proposed the technology about second heating the steam in AQC boiler
The low-temperature (below 300℃)superheated steam generated by PH boiler and got access
to Mix steam box in AQC boiler ,then heated the steam to 360-380℃ (Compared to the steam in
mix steam box improved 50-60 ℃)by public superheater in AQC boiler before pumped in
turbo-generator; it improved the enthalpy of steam admission and enhanced the system power
generation efficiency, It can reach 36-38 kWh/t.cl, this technology has passed through Chinese
ministerial appraisal, reaching domestic advanced level.
Conventional single pressure, flash, dual pressure thermodynamic system constitutes the first
generation thermodynamic system of low temperature; WHRPG technology we are using in
place of the first heating one, forms the second generation, that is, single pressure, flash, dual
pressure thermodynamic system.

4.5 The technology of cooler air draft

The technology of air draft at grate cooler is very important to WHRPG in cement plant, the
level of air temperature and the size of air quantity directly affects the generated energy and safe
operation of WHRPG system, we have analysis and calculation of different cement production
lines relying on the grate cooler R&D team of Nanjing Triumph Cement Technology Engineering
Co., Ltd. Then we analyze and summarize the distribution of energy and air quantity in grate
cooler. Without affecting the heat consumption of cement production line premise, we have
developed the middle air draft technology, which means the air draft location, air quantity, air
temperature of grate cooler changes with running situation on different operation lines. According
to our analysis and calculation, the air temperature between 350℃ and 400℃ is appropriate,
because this air temperature does not affect the heat consumption of cement production line.

14
4.6 Low-temperature exhausts recycling technology
During actual operation in cement line, cooler is designed for better cooling effect, but the
central exhaust temperature is low, generally just reaching 300 ℃, in order to further improve the
efficiency of waste heat recovery system, we are initiatively proposing low-temperature exhaust
recycling technology according to engineering practice of WHRPG industry, and application of
WHRPG project on 5000t / d production line of Huaihai China United Cement Plant in 2006, to
achieve greater success.
Low- temperature exhaust recycling technology is the exhaust (about 100℃) from electricity
dust collector into the inlet of the cooling fan ,the cooling fan is located in the middle of grate
cooler. The cooling air temperature of clinker and the entrance exhaust temperature of AQC boiler
are improved correspondingly, the generated energy of WHR system is also improved. The degree
of improvement remains about 8~10% based on the original technology.

4.7 Rotary kin heat recovery technology

From the above analysis we know that heat balance in cement kiln burning system heat loss
covers about 7 ~ 8% in total, much of heat loss comes from rotary kiln, the temperature is over
300℃,which is quite valuable.
In order to recover heat, we develop a cement kiln heat recovery system, which is composed
of heat collector, fixing device and adjusting device. This system can be used on heating,
refrigerating, providing hot water or WHRPG system.
Heat collector consists of heating surface, hoop and external thermal insulation system. Soft
water is used as medium, flowing through the heating surface. Heat is to transfer with radiation
and convection, heat collection device serves as modular units, which is laid out along the cement
kiln length. Each heat collector is arranged in parallel, the benefit of which is to switch flexibly,
not affecting heat dissipation while repairing of cement kiln.

5. Project contracting and technical service advantages

A professional consultation aptitude to undertake the formation works for project proposals
and feasibility report.
B Professional thermal condition calibration qualification and strong technical personnel,
which can take charge of any scale of cement production line thermal condition calibration works.
C National mandatory provisions engaging in power engineering design B-class certificate
qualification，and put- into- operation project achievements and rich design experiences.
(1) We can provide accurate ordering technical documents for Heat recovery boiler and

15
turbine generator, and undertake conceptual design cooperate with boiler factory.
(2) We can fulfill connection to power systems conceptual design and cooperate with local
electric utilities.
(3) We can accomplish the basic design that for engineering design and construction direction
quickly and exactly and formulate reference value datum for budgetary estimates.
(4) We can provide the professional services at the job site and accomplished working
drawing design quickly and exactly.
(5) According to owners requirements we can supply the complete equipment of waste heat
generation, not only helping to accelerate engineering design progress, but also cut equipment
procurement costs.
(6) We have integrated and completed technical service and cooperation system
(7) We can provide the service for power stations operation ，management and technician
training.
(8) The Technicians of our company have rich experiences on power stations construction
and management, to cooperate with Installation unit in projects installation work.
(9) The Technicians of our company have rich experience on power stations debugging and
commissioning operation, to cooperate with Installation unit in projects Commissioning works.
(10) We can provide the detailed training plans for power plant operating staff, and simulate
various common fault handling.

6. Qualifications and Honors

Nanjing Triumph Kaineng Environment & Energy Co., Ltd relies on China Building
Materials Group and Nanjing Triumph Cement Technology Engineering Co., Ltd , we have three
designing certificates including “Class “A” certificate of Construction Building Materials, Class
“A” certificate of Cement industry, Class “B” certificate of power industry”, we have the most
comprehensive qualification of waste heat power generation ,the technology of WHRPG
recommended to be “ the most social value technology of Energy conservation and Environmental
Protection in 2009 years”, and we Obtained “High-tech Product Certificate” awarded by Science
and Technology Department of Jiangsu Province.
There are two projects we designed were awarded the first prize and the second prize
respectively, the two projects were “EPC project of waste heat recovery power generation for
5000t/d cement clinker production line in China United Cement Huaihai Co., Ltd.” And “EPC
project of waste heat recovery power generation for 5000t/d cement clinker production line in
Guangzhou Zhujiang Cement Co., Ltd.”
We have paid much attention to Innovation, with dozens of patented technology about

16
cement and steel waste heat recovery power generation. WHRPG system in cement kiln which
independently developed by our company and the development of build-in settling chamber AQC
boiler have past the expert’s appraisal (provincial level) of China Construction Materials
Federation Organization.

7．Typical application cases

Technology comparison of different enterprises
Nanjing
Enterprise Kawasaki Heavy Some Domestic cement
Triumph
Item Industries designing institute
Kaineng

Clinker production t/d 5000 5000 5000

3
3 3 200000 Nm /h
Gas from grate cooler 200000 Nm /h 360℃ 200000 Nm /h 360℃
380℃
3
3 3 330000 Nm /h
Gas from suspend preheater 330000 Nm /h 320℃ 330000 Nm /h 320℃
320℃
Natural
Natural circulation Natural circulation circulation
Waste gas flow up to Waste gas flow up to Waste gas flow
AQC boiler
down down up to down
finned tube finned tube finned
tube
exhaust recycling No No Yes
The built-in
Independent external Independent external
AQC boiler settling chamber settling
settling chamber settling chamber
chamber
Vertical
arrangement,
Horizontal Vertical arrangement,
natural
arrangement, forced natural circulation,
PH boiler circulation,
circulation, oscillating oscillating
oscillating
dust-cleaning, tube dust-cleaning, tube
dust-cleaning,
tube
Thermal dynamic system Single pressure+ flash Single pressure Dual pressure

Main steam pressure MPa 1.2+0.15 1.2 1.2+0.34

Pressure loss of grate cooler
waste heat recovery system 1200 1200 <700
Pa
Installed capacity kW 9000 9000 9000

17
 Nanjing
Enterprise Kawasaki Heavy Some Domestic cement
Triumph
Item Industries designing institute
Kaineng

Power generation kW 8404.4 8255.8 8627.3

Power generation per
36.67 36.02 39.82
clinker(kWh/ t(clinker))
Self consumption rate of
8.2 7.8 7.0
power station %
Operation availability % 96-97 94-95 >98
It can be seen that, many of our technical parameters has a better performance compared
with counterpart both at home and abroad. By using domestic equipment, lower investment and
noticeable economic profit endows us with strong market competitiveness.

ACHIEVEMENT LIST OF RECENT PROJECTS

NO. PROJECT NAME CAPACITY SCOPE STATUS

Guangzhou Zhujiang Cement Co.,Ltd. E Power
5000t/D
1
7500KW generating
Zhejiang Shuangshi Building Material E Power
2500t/D
2 Co.,Ltd.
4000KW generating
Yixing Jinshu Cement Co.,Ltd. E Power
2500t/D
3
4000KW generating
Jiamusi Hongji Group Co.,Ltd. E Power
1000t/D+2500T/D
4
7500KW generating
Zhejiang Huaye Building Material Co.,Ltd. E Power
1500T/D
5
2000KW generating
Chongqing Jinjiang Cement Co.,Ltd. 2500+5000T/D E commissioning
6
12000KW
E Power
1100T/D
7 Heilongjiang Beijiang Group Co.,Ltd. (Ⅰ)
2000KW generating
1800T/D E commissioning
8 Heilongjiang Beijiang Group Co.,Ltd.(Ⅱ)
3000KW
E Power
Fujian Chunchi Group Xinfeng Cement 2×2500T/D
9
Co.,Ltd. 7500T/D generating

18
 E Power
2500T/D
10 Zhejiang Tianma Cement Co.,Ltd.
4500KW generating
E Power
Chengdu Sitong Automatic Project Co.,Ltd. 5000T/D
11
(Wulan Ⅱ) 9000KW generating
E Power
2×2500T/D
12 Tieling Tiexin Cement Co.,Ltd.
8000KW generating
E Power
6000T/D
13 Guotou Hainan Cement Co.,Ltd.
12000KW generating
E Power
2500T/D
14 Wuhan Xinlingyun Cement Co.,Ltd.
4500KW generating
E Power
2500T/D
15 Zhejiang Sanyuan Group Co.,Ltd.
4500KW generating
E Power
2500T/D
16 Zhejiang Huying Cement Co.,Ltd.
4500KW generating
E Power
2×5000T/D
17 Huizhou Guangda Cement Co.,Ltd.
18000KW generating
E Power
Hubei Jinglan Group Sanyuan Cement 1500+4000t/d
18
Co.,Ltd. 9000KW generating
E Power
4000t/d
19 Inner Mongolia Mengxi Cement Co.,Ltd.
9000KW generating
E Under
Sichuan Taihe Cleaning Energy Co.,Ltd. 3200t/d
20
(Fuquan Lisen) 6000KW construction
E Under
4800 t/d
21 Jiangxi Southern Cement Nancheng Co.,Ltd.
9000KW construction
E Under
4500 t/d
22 Jiangxi Southern Cement Yongfeng Co.,Ltd.
9000KW construction
E Under
4500 t/d
23 Shanggao Southern Cement Co.,Ltd.
9000KW construction
2 2
1×265m +2×240m E designing
24 Hebei Puyang Iron&Steel Co.,Ltd.
20000KW
E Under
5000 t/d
25 Huichang Hongshi Cement Co.,Ltd.
9000KW construction
E Under
2500 t/d
26 Hebei Jihong Cement Co.,Ltd.
5000KW construction
Huizhou Guangda Cement Co.,Ltd. 2×4500T/D E Under
27
(Longjiang Cement Co.) 18000KW

19
 construction
E Under
2500 t/d
28 Shaoxing Southern Cement Co.,Ltd.
4500KW construction
E Under
2000 t/d
29 Jiangxi Southern Cement Anfu Co.,Ltd.
3000KW construction
E Under
5000t/D
30 Gansu Jinglan Cement Co.,Ltd.
9000KW construction
E Under
3500t/D
31 Guizhou Dujun Haolong Cement Co.,Ltd.
7500KW construction
Guizhou Liupanshui Haolong Cement 5000t/D E designing
32
Co.,Ltd. 9000KW
E Under
5000 T/D
33 Jiangxi Southern Cement FengCheng Co.,Ltd.
9000KW construction
E Under
3200 T/D
34 Taiyuan Jinyuan cement Co.,Ltd.
6000KW construction
2
2×240m E designing
35 Hebei Qianjin Steel Group Co.,Ltd.
15000KW
Power
5000t/D
36 China United Cement Huaihai Co.,Ltd.(Ⅰ) EPC
9000KW generating
Power
2#2500T/D+3#2500T/
37 Wulanchabu Jianghe WHG Co.,Ltd. EPC
D8000KW generating
1#2000T/D+2#2500 Power
Xiangtan Tianhao Shaofeng Building Material
38 T/D EPC generating
Co.,Ltd.
9000KW
Power
5000T/D
39 China United Cement Lunan Co.,Ltd. EPC
10000KW generating
Power
6000T/D
40 China United Cement Qingzhou Co.,Ltd. EPC
12000KW generating
Power
2500T/D
41 Yingde Baojiang Cement Co.,Ltd. EPC
5000KW generating
Power
2500T/D
42 Anhui Dajiang Cement Co.,Ltd. BOT
5000KW generating
Power
1300TD+1800T/D
43 Nanjing Sanlong Cement Co.,Ltd. EPC
5000KW generating
Power
4000T/D
44 Dazhou Lisen Cement Co.,Ltd. EPC
6000KW generating

20
 2×5000T/D construction
45 Shanxi Fulong Cement Co.,Ltd. EPC
18000KW
Power
4000T/D
46 Huaxin Cement (Chibi) Co.,Ltd. EPC
7000KW generating
Power
2×4000T/D
47 Huaxin Cement (Xiangfan) Co.,Ltd. EPC
2×7000KW generating
Power
3200T/D
48 Deyang Lisen Cement Co.,Ltd. EPC
6000KW generating
Power
Jiangxi Guoxing Group Dongfanghong Yudu 1200TD+2500T/D
49 EPC
Cement Co.,Ltd. 7500 KW generating
Power
2500T/D
50 China United Cement Xingtai Co.,Ltd. EPC
4500KW generating
Power
5000T/D
51 Huaxin Cement (Chenzhou) Co.,Ltd. EPC
9000KW generating
Power
6000T/D
52 Huaxin Cement (Zhuzhou) Co.,Ltd. EPC
9000KW generating
Power
5000T/D
53 Guangxi Yinfeng Cement Co.,Ltd. EPC
9000KW generating
Power
4500T/D
54 Huaxin Cement Chongqing Fuling Co.,Ltd. EPC
9000KW generating
Power
5000T/D
55 China United Cement Linyi Co.,Ltd. EPC
10000KW generating
Power
3000+3500 T/D
56 Shandong Lvye Cement Co.,Ltd. EPC
12000KW generating
Power
2500T/D
57 Yichang Hualin Cement Co.,Ltd. EPC
5000KW generating
Power
2×2500T/D
58 Jiangxi Jiujiang Lanfeng Cement Co.,Ltd. EPC
9000KW generating
Power
2500T/D
59 Jiangxi Lanyuan Cement Co.,Ltd. EPC
5000KW generating
Power
5000t/D
60 China United Cement Huaihai Co.,Ltd.(Ⅱ) EPC
9000KW generating
Power
4500T/D
61 Anhui Tiepeng Haibao Cement Co.,Ltd. BOT
9000KW generating
2500T/D Power
62 Chaohu Weili Cement Co.,Ltd. EPC
4500KW

21
 generating
Power
Jiangxi Southern Wannianqing Cement 5000T/D
63 EPC
Co.,Ltd. 9000KW generating
Power
2500 T/D
64 Hunan Southern Longhui Cement Co.,Ltd. EPC
4500KW generating
4500 T/D construction
65 Nanjing Sanlong Cement Co.,Ltd. EPC
9000KW
Power
2500 T/D
66 Fujian Quanzhou Meiling Cement Co.,Ltd. EPC
4500KW generating
Power
4500T/D
67 China United Cement Anxian Co.,Ltd. EPC
9000KW generating
Power
4000 T/D
68 Lvxian Riguang Cement Clinker Co.,Ltd. EPC
9000KW generating
Power
5000 T/D
69 Hunan Southern Cement Shaofeng Co.,Ltd. EPC
9000KW generating
Power
3500+2300 T/D
70 Huaxin Cement (Yichang) Co.,Ltd. EPC
12000KW generating
Power
1000+2000 T/D
71 Huaxin Cement (Tibet) Co.,Ltd. EPC
7500KW generating
Power
2200+5700 T/D
72 Huaxin Cement (Huangshi) Co.,Ltd. EPC
15000KW generating
Power
5000 T/D
73 Zibo Zichuan Baoshan Cement Co. EPC
9000KW generating
Power
4000 T/D
74 Huaxin Cement (Daoxian) Co.,Ltd. EPC
7500KW generating
Huaxin Cement (Kunming Dongchuan) 2000 T/D construction
75 EPC
Co.,Ltd. 4000KW
Power
1200+4800 T/D
76 Gezhouba Dangyang Cement Co.,Ltd. EPC
12000KW generating
Under
2×2400 T/D
77 Shanxi Jigang Cement Co.,Ltd. EPC
9000KW construction
2 Under
2×180m
78 Xingtai Iron&Steel Co.,Ltd. EMC
12000KW construction
Under
4500 T/D
79 Hunan Southern Cement Changde Co.,Ltd. EPC
9000KW construction

80 Shaoyang Southern Cement Co.,Ltd. 4500 T/D EPC Under

22
 9000KW construction
Under
2500+4000 T/D
81 Hunan Southern Cement Leiyang Co.,Ltd. EPC
4500+9000KW construction
Under
4000 T/D
82 Huaxin Cement (Zhaotong) Co.,Ltd. EPC
7500KW construction
Under
4500 T/D
83 China United Cement Anyang Co.,Ltd. EPC
9000KW construction
Under
2×4500 T/D
84 Guangxi Jinli Cement Co.,Ltd. EPC
18000KW construction
Under
3200 T/D
85 Guangxi Huying Cement Co.,Ltd. EPC
6000KW construction
1300+2500 T/D construction
86 Yunnan Yuanjiang Yongfa Cement Co.,Ltd. EPC
7500KW
3200 T/D designing
87 Hunan Southern Anren Cement Co.,Ltd. EPC
6000KW
2500T/D construction
88 Songci Shuangqi Cement Co.,Ltd. EPC
4500KW
2500+4000 T/D construction
89 Hubei Jinlong Cement Co.,Ltd. EPC
9000KW
Under
2×2500T/D
90 China United Cement Lunan Co.,Ltd. EPC
9000KW construction
Under
4500T/D
91 Chaohu Tiedao Cement Co.,Ltd. EPC
10000KW construction
Under
4500T/D
92 Hunan Yuanda Cement Co.,Ltd. EPC
6000KW construction

23