Applications to Cement Industry

1Sammo Energy Ltd - Q1 2012

The Issue

The Cement industry is a very energy intensive industry. It uses kilns at very high temperatures to prepare the clinker which is one of the main component of cement.Two sources of waste heat are available in Cement plants:• Preheater exit;• Clinker cooler

The industry is permanently looking for ways ofreducing their energy costs and consumption and reducing their emissions and carbon footprint.

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Our business model

Sammo Energy Ltd is proposing to bring a full solution for the issue of the industry.

Sammo Energy proposes to invest on its own resources to bring the solutions to the industry using the following approach:

• Full solution implementation integrating power generation and batch preheating;• No investment needed from the industry, Sammo Energy makes all the necessary

investment from its own resources;• No adversary impact on the production process, the industry benefits only from the upsides;• Performing monitoring system follow up the benefits and performances of the systems;• Based on long term power purchase agreement guaranteeing a price of energy lower

than market price. The industry save money from the very first day of operation of the system;• Base principle is to share all side benefits like carbon emission reduction incentives, grants,

etc. All those programs are managed by Sammo Energy in full transparence;

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Principles

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Heat Recovery In Cement Production Process

Exhaust gas streams from cement production process:

Kiln pre-heater gas Clinker cooler gas

Main Exhaust GasCharacteristics: High dust contentDifferent operating conditions

depending on mill operation, season, plant upsets, etc.

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ORC Turbine

Our Operational approach

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Clinker coolerWaste heat flow

560ºC150 000 m3/hr

560ºC

240ºC Waste heat flowTo the Filters

Power Generationabout 4600 kW

Data based on a 3500 tons per day kiln

Thermal power ofwaste heat flow is ofabout 18037 kWth

Sammo Energy Ltd - Q1 2012

PreheaterWaste heat flow

320ºC100 000 m3/hr

320ºC

140ºC Waste heat flowTo the Filters

Power Generationabout 1100 kWThermal power of

waste heat flow is ofabout 6118 kWth

TotalPower Generation

about 5700 kW

Our Operational approach

High temperature air from the kiln exhaust can be used to both generate power and pre-heat the raw materials.The exhaust of the clinker cooler is not used for raw material drying, but still can be used to generate power.

Power generation should be run through an ORC turbine due to its flexibility and unattended operations.

It is one of the best fit for industrial environment.

This installation has no impact on the process of cement manufacturing as the heat is captured downstream. The temperature of release of the flow after the heat capture is designed to have no impact on the functioning of the dust filtering efficiency.

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Picture 2: Functional principle of an ORC Plant

The core piece of the power plant is a steam turbine. Due to the low waste heat temperature the temperature ofthe steam is low as well. Therefore water vapor can not be used efficiently, both in terms of energy and ofcosts.

Here organic fluids are to be used. Organic media evaporate at relatively low temperatures and condenseagainst ambient air at a pressure over 1 bar, thus no vacuum has to be produced in the condenser.

Between the evaporation and condensation pressure/temperature levels the organic fluid delivers aconsiderable amount of energy when it is expanded in the turbine.

3.1 Heat Extraction

In cement plants the waste heat is normally extracted from two sources: from the clinker cooler air (AQC) andfrom the waste gas after the preheater tower.

Heat source 1, the cooler air (AQC) can be cooled down as much as possible to extract the maximum of heat.Therefore a conversion system with low operating temperatures is advantageous.

Picture 3: Typicalwaste heat sources ina cement plant

Don’t hesitate to contact us for any complementary information you may need

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Email: contact@sammoenergy.comWeb: www.sammoenergy.comLinkedin : http://www.linkedin.com/company/sammo-energy-england-blog : http://smartenergies.wordpress.com/