CASE STORY

Alfa Laval Aalborg waste heat recovery boilers cut fuel costs and emissions

Karachi, Pakistan

Lucky Cement Limited (LCL), one of Pakistan’s largest cement manufacturers, was looking for new ways to reduce fuel consumption of its engine power plant at its Nooriabad cement production facility located northeast of Karachi.

To improve the overall efficiency of the plant, Orient Energy Systems (Pvt.) Ltd. (OES), one of the leading multinational engineering companies in Pakistan, transformed the cement factory’s existing 70 MWel engine power plant into a combined cycle power plant (CCPP). To supply the waste heat recovery (WHR) system, OES turned to Alfa Laval Aalborg Oy.

The system achieved 27 MWth in total waste heat recovery, which generates 6 MWel of electric output from a steam turbine. This contributed to significant reductions in fuel costs and plant emissions.

Efficiency and sustainable development are among the corner stones of Lucky Cement’s overall philos-ophy and business practices. So it comes as no surprise that improving fuel efficiency and reducing

CASE STORY

100002783-1-EN 2008Alfa Laval Aalborg Oy

tel. +358 10 838 3800, email: sales.rauma@alfalaval.comUp-to-date Alfa Laval contact details for all countries are always available on our website at www.alfalaval.com Alfa Laval reserves the right to change specifications without prior notification.

About the solution

The Alfa Laval Aalborg AV-6N is a robust, highly efficient heat recovery steam generator that improves a plant’s total efficiency.

With the Aalborg AV-6N, waste heat from flue gas is recovered from sources such as industrial processes, diesel and gas en-gines or gas turbines, in order to generate steam and/or heated water. The solution ensures flexible operation and is easy to install – even at existing facilities.

Fast facts

The customerOne of Pakistan’s largest cement manufacturers, Lucky Cement produces 7.75 million tons of quality dry pro-cess cement each year.

The challengeTo reduce fuel consumption of and emissions from a multi-engine power plant consisting of 11 engines from Caterpillar MaK, Rolls-Royce Bergen and Wärtsilä.

The solutionEleven Aalborg AV-6N WHR boilers along with associated auxiliary equipment.

The benefitsSignificant reductions in fuel costs and emis-sions due to a total waste heat recovery of 27 MWth which is transformed into 6 MWel of electric output from a steam turbine.

Start up2015

Lucky Cement Waste Heat Recovery System.

Feed water pumps

Feed water tank

Condenser

WHR boiler, Aalborg AV-6N

Exhaust gas in

Exhaust gas out

Steam turbine

G

emissions were priorities for Mr. Intisar ul Haq Haqqi, Director of Power Generation at Lucky Cement.

Years of experience, a deep understanding of CCPP processes and boiler systems, and a proven track re-cord with hundreds of high-efficiency WHR boilers work-ing around the globe convinced OES to select Alfa Laval Aalborg as its WHR system supplier. Working together, OES and Alfa Laval Aalborg assured the end-user Lucky Cement of a superior WHR solution for the CCPP at the Nooriabad facility.

For capturing excess heat from the engine exhaust gas, the system consists of 11 Aalborg AV-6N WHR boilers along with associated auxiliary equipment.

“The performance of Aalborg WHR boilers exceeded our customer’s expectations because the waste heat recov-ery was actually better than guaranteed,” says Mr. Zaki ul Haq, General Manager of Engineering, at OES. “Lucky Cement is very satisfied with the overall performance and delivery of the plant.”

High-performance heat recovery, fast payback

These highly efficient WHR boilers generate superheat-ed steam for use in a steam turbine. By retrofitting the Nooriabad power plant for combined cycle operation, Lucky Cement was able to recover a total of 27 MWth from exhaust gas waste heat, which increased plant electrical output by approximately 10%. This significantly reduced plant fuel con sumption and emissions as well as provided fast return on investment for the CCPP upgrade.

After the upgraded power plant had been in operation for a year, Mr. Syed Hassan Mazhar Rizvi, General Manager of the Nooriabad power plant, told Alfa Laval Aalborg that he is very satisfied with the plant’s stable and reliable performance. The plant’s proven perfor-mance convinced Lucky Cement to continue to work with OES and Alfa Laval Aalborg in order to install anoth-er WHR system at its engine power plant in Pezu. This is the company’s largest cement production plant, located in the Khyber Pakhtunkhwa province of Pakistan.