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Modeling, exergy analysis and optimization of cement plant industry

Abutorabi Hossein, Kianpour Ehsan

Journal of Mechanical and Energy Engineering

2022

Vol. 6, No 1

55--65

This study investigates the recovery of wasted heat in the cement plant industries (Neka Cement Factory) in order to reduce the use of fossil fuels and greenhouse gas emissions. Cement is the most widely used man-made material. The global cement industry produces about 3.3 billion tons of cement annually. A lot of energy is needed to produce cement. About 200 kg of coal is used to produce each ton of cement. The cement industry also produces about five percent of the world's greenhouse gases. The method studied in this research is based on heat recovery from boilers installed at the outlet of a clinker cooler and a preheater in a cement factory. Due to the low temperature of the gases available, three different fluids, i.e. water, R134a and R245fa were considered as the operating fluids. Also, energy and exergy analyses are performed in a Rankin cycle and the selection of optimal parameters is considered by using genetic algorithm. The results of this study showed that water with optimized parameters leads to an increase in the production capacity from 5 to 9 MW. However, fluid R134a with optimized parameters leads to a 4% increase in exergy losses and it also increases the production capacity from 5 to 9 MW.