Bestway Cement Limited

WHRPP
(Waste Heat Recovery Power Plant)

Presenter:
Engr.Nauman Shafique
HITEC University-Taxila

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 Bestway Cement Limited

WHRPP
(Waste Heat Recovery Power Plant)

Presenter:
Engr.Nauman Shafique
(HITEC University-Taxila)
Bestway Cement Ltd,Chakwal

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Program Outlines

 A look on Cement Manufacturing

 Power plants and its classification on the basis of
Energy resources
 WHRPP Basic principal and Rankine Cycle
 Steam Boiler and its types
 Water Chemistry
 Steam Turbine and its classification and
associated system
 Maintenance and its Types

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A look on Cement Manufacturing

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Waste Heat Exchangers/ Steam

Boilers Turbine Generator
Grid

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Power Plants
A power plant is an industrial facility for the generation of electric power.

Types of Power Stations on the basis of Energy Resources

A good way of classifying the electricity power stations is depending on the source
of primary energy used to produce the necessary mechanical energy to generate
electricity:
 Hydroelectric power plants
 Fossil fuel thermal power plants
 Combined cycle power plants
 Nuclear power plants
 Wind power plants
 Solar thermoelectric power plants
 Biomass or urban solid / Waste heat recovery power
plants (WHRPP)

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Waste Heat Recovery Power Plant-Schematics

16MW

Waste Heat Exchangers/ Steam

Boilers Turbine Generator
Grid

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Working Cycle :Rankine Cycle
The Rankine cycle is an idealized thermodynamic cycle of a heat engine that
converts heat into mechanical work while undergoing phase change.
There are four processes in the Rankine cycle. These states are identified by
numbers (in brown) in the T–S diagram.
Process 1–2: The working fluid is pumped from low to high pressure. As the
fluid is a liquid at this stage, the pump requires little input energy.
Process 2–3: The high-pressure liquid enters a boiler, where it is heated at
constant pressure by an external heat source to become a dry saturated
vapor.
Process 3–4: The dry saturated vapor expands through a turbine, generating
power. This decreases the temperature and pressure of the vapor, and some
condensation may occur.
Process 4–1: The wet vapor then enters a condenser, where it is condensed at
a constant pressure to become a saturated liquid.

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Rankine Cycle

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Steam Boiler: Boiler is a Vessel that heats water to become steam
STEAM TO
EXHAUST GAS VENT
PROCESS OUT

STACK DEAERATOR

PUMPS

ECO-
NOMI-
ZER

VENT
BOILER
BURNER
WATER
SOURCE
BLOW DOWN
SEPARATOR FUEL

BRINE
EXHAUST GAS IN SOFTENERS
CHEMICAL FEED

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Types of Boilers

1. Fire Tube Boiler

2. Water Tube Boiler
3. Packaged Boiler
4. Stoke Fired Boilers Chain-grate
5. Waste Heat Boiler

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Waste Heat Boiler or HRSG

• Used when waste heat

available at medium/high
temp
• Auxiliary fuel burners used if
steam demand is more than
the waste heat can generate
• Used in heat recovery from
exhaust gases from gas
turbines and diesel engines

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Water Chemistry
• Water chemistry is continuously monitored for the
purity of steam.
 Ideal Steam;
• Dry steam
• pH 9.0 i-e neutralizing amines
 Steam Purity limits;
• Sodium 5-20 ppb
• Silica 10-20 ppb
• Chloride, Sulpate 3-15 ppb
• Cat ion Conductivity 0.1-0.3 μS/cm

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Water Impurities
Constituent Potential Impacts Means of Treatment
Turbidity Imparts unsightly appearance to water Coagulation, Filtration
Hardness Ca & Mg salts expressed as CaCO3 Demineralization
Alkalinity (HCO3- ,CO32-) Embrittlement of boiler steel Acid treatment
Free Mineral Acid (HCl) Corrosion Neutralization with alkalis
Carbon dioxide Corrosion in water & steam lines Deaeration
pH Varies according to acidic/alkaline Increased by alkalis
Sulphate Combines with Ca to form CaSO4 scale Demineralizer, RO ,EDI
Chloride Increases corrosive character of water Demineralizer, RO ,EDI
Nitrate Useful for control of boiler metal deterioration Demineralizer, RO ,EDI
Sodium Combines with OH- ,causes corrosion in boilers Demineralizer, RO ,EDI
Silica Scale in boilers & cooling water systems Demineralization & RO
Oxygen Corrosion of water lines & heat exchangers Deaeration, sodium sulfite
Dissolved solids Foaming in boilers RO ,EDI
Suspended solids Deposits in heat exchange equipment Filtration
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 Steam
BestwayTurbines
Cement Limited
• A steam turbine is a mechanical device that extracts thermal energy from
pressurized steam, and converts it into rotary motion. This rotary motion
is used to drive an electrical generator– about 80% of all electricity
generation in the world is by use of steam turbines.

1 – steam pipeline 9 – rotor disc 21 – bearing pedestal

2 – inlet control valve 10 – rotor 22 – safety governor
3 – nozzle chamber 11 – journal bearing 23 – main oil pump
4 – nozzle-box 13 – thrust bearing 24 – centrifugal governor
5 – outlet 14 – generator rotor 25 – turning gear
6 – stator 15 – coupling 29 – control stage impulse blading
7 – blade carrier 16 – labyrinth packing
8 – casing 19 – steam bleeding (extraction)

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How does the steam turbine work?
• Impulse stage –
whole pressure drop
in nozzle (whole
enthalpy drop is
changed into kinetic
energy in the nozzle)

• Reaction stage –
pressure drop both in
stationary blades and
in rotary blades
(enthalpy drop
changed into kinetic
energy both in
stationary blades and
in the moving blades
in rotor)

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Classification of Steam Turbines
a) rotational speed
b) inlet steam pressure
- high pressure (p>6,5MPa)
- intermediate pressure(2,5MPa <p<6,5MPa)
- low-pressure (p<2,5MPa)
c) way of energy utilisation
-Single Stage/Multi-stage
- condensing/Non-condensing
- extraction/admission
- back-pressure
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Steam turbine
•Single Cylinder Multistage
Condensing Impulse Reaction
Secondary Injection Turbine
•Make: NTC-Chinese
•16MW
•12 Stages
•Secondary Steam injection
:08th stage
•Rated Steam Temp:320 C
•Rated Steam Pressure:14.7
bar

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Classification of Steam Turbines

a) rotational speed
- regular
- low-speed
- high-speed
b) inlet steam pressure
- high pressure (p>6,5MPa)
- intermediate pressure(2,5MPa <p<6,5MPa)
- low-pressure (p<2,5MPa)
c) way of energy utilisation
- condensing
- extraction
- back-pressure

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Classification of steam turbines

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Classification of steam turbines

a) rotational speed
- regular
- low-speed
- high-speed
b) inlet steam pressure
- high pressure (p>6,5MPa)
- intermediate pressure(2,5MPa <p<6,5MPa)
- low-pressure (p<2,5MPa)
c) way of energy utilisation
- condensing
- extraction
- back-pressure

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Classification of steam turbines

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Classification of steam turbines

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Condenser
 Steam after rotating steam turbine comes to condenser. Condenser refers here to shell
and tubes type heat exchanger installed at the outlet of steam turbine. The condenser is
a heat exchanger which converts steam from gaseous into liquid state.

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Cooling Tower
The condensate water after condensation is initially at high temperature. This hot water is
passed to cooling towers. It is a tower in which atmospheric air circulates in direct or indirect
contact with warmer water and the water is thereby cooled. Water, acting as the heat transfer
fluid, gives up heat to atmospheric air, and thus cooled, is re-circulated through the system.

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Turbine Associated Systems

1. Lubrication Oil system

2. Control Oil system
3. Vacuum system
4. Condensate water system
5. Circulating water system
6. Seal steam system
7. Steam bypass system

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Turbine Safeties

1. RPM
2. Power
3. Vibrations
4. Bearings temperatures
5. Return Oil Temperature
6. Vacuum
7. Axial Displacement
8. Casing expansion
9. Over temperature
10. Flow rate
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WHRPP

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Operation & Maintenance Procedure

• O&M is a critical component of the Power plant. The overall program
should contain five very distinct functions making up the organization;
Operations, Maintenance, Engineering, Training, and Administration.

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Benefits of WHRPP

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Condition Monitoring
Sr. No’s Condition Applications
01 Vibration analysis Misalignment, out of balance weights, wear of
bearings etc
02 Thermography Overloading, excessive friction or wear, abnormal
analysis electric resistance
03 Oil analysis Contamination, breakdown of lubrication properties,
signs of wear
04 Current Electric overloads, faulty bearings, current leakage
measurement
05 Visual inspection General defects that can be detected by human
senses of sight, hearing and feeling
06 Insulation tests Check status of electric insulation
07 Power rate Bearing failures, damaged turbine blades, vacuum
loss
08 Voltage Brush failure, excitation faulty, insulation failure
measurement
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