The CTP Team Italy signed a turnkey EPC contract for Waste Heat Recovery with Sonmez Cimento Yapi ve Madencilik, in March 2019. The project consists of a WHR system with dual-loop configuration, the heat will be recovered from two sources available in the Sonmez Cement plant: the kiln pre-heater and the clinker cooler. Two different heat exchangers fed with thermal oil and designed according to the specific temperature and inlet gas flow to break down the temperature of the exhaust gas coming from the clinker production process.
In the WHR module, a highly efficient turbine of 7.8 MW at 3000 rpm is coupled with a turbo generator of 9.2 MVA to produce electricity to support the internal consumptions of the cement plant. Thanks to its proven record of availability, the new ORC will provide an expected net power generation of 51 million kWh per year, covering approximately 30 % of the current plant’s electricity needs.
From an environment point of view, the new system will drastically reduce CO2 emissions of the cement plant by a total of 23500 t/a. In addition, the system provided by CTP is totally water free, without any need to treat residual waters from the process.
CTP will design a fully automatic system to drastically reduce the presence of operators during the daily operation. Thanks to this specific advantage of organic cycles and to the total absence of water treatments in the process, the OPEX are so reduced by 75 % with respect to an equivalent WHR based on traditional Steam Rankine cycle.
The CTP Team extensive knowledge of process conditions allows ful integration of the WHR in the existing plant guaranteeing a smart tie-in, without affecting production parameters. Furthermore, the CTP Team directly designs and manufactures heat recovery boilers for WHR ensuring our customers the highest standard quality.
The WHR plant is scheduled to start operating within the first six months of 2020 (the next 13 months). The WHR solution designed for the Sonmez Cement plant maximize the electric power production and avoid water consumption for mutual benefits of a lower environmental impact, and lower reliance on the grid.