Displaying items by tag: WHR
Najran Cement launches trial operations at WHR power plant
13 January 2014Saudi Arabia: Saudi cement producer Najran Cement said that it launched trial operations of the first phase of its waste heat recovery (WHR) on 11 January 2014. The trial will take 10 days to complete and the commercial launch is yet to be announced. The US$45m WHR project is being installed by China's Sinoma Energy Conservation on a turnkey basis.
India: The Competition Commission of India (CCI) is investigating a complaint against a Chinese company offering waste heat recovery (WHR) solutions for the cement industry. This case is believed to be the first instance where a Chinese company has been affected by Indian competition law.
According to sources quoted by the Financial Express, Transparent Energy Systems (TESPL) filed a complaint against the Indian operations of Nanjing Triumph Kaineng (NTK). The complainant alleged the Chinese firm is severely impacting its business by quoting prices for tenders much below the market rates.
NTK specialises in WHR and accounts for a 30% market share of WHR power generation in the Chinese cement industry. It entered the Indian market in 2011 through a joint-venture with Tecpro Systems.
Japan: UBE Industries plans to install a generator powered by waste heat at its cement plant in Kanda, Fukuoka Prefecture. The generator will meet about 40% of the plant's electric power consumption reducing production costs. The US$52.1m project will start providing power as early as the second half of 2015.
The Kanda plant currently produces 11% of its own electricity using a diesel generator. UBE's decision follows similar schemes at UBE's two other domestic cement plants in Japan. The company previously put off this upgrade because of a lull in domestic demand for cement. UBE is acting now because Kyushu Electric Power Co. is preparing for a rate increase in April 2013 that will impact upon production costs.
India: Heidelberg Cement India has received approval to set up a waste heat recovery (WHR) power plant at its clinker plant at Narsingarh, Damoh District in Madhya Pradesh. The proposed plant will produce approximately 12.15MW of power from the available waste heat of pyro-processing system of all three lines at the unit. The project cost is estimated to be in the range of US$26.9m to US$27.8m and it is expected to be operational in January 2015.
Indian power play
01 August 2012The power cuts in northern and eastern India this week will have presented citizens with a situation very familiar to Indian cement producers. With over half the country reported to be without electrical power after three power grids collapsed, industrial users are likely to have been shut down as the authorities try to bring back domestic supplies.
According to figures from the National Council for Cement and Building Materials, Indian cement producers used 79kWh/t of electrical energy in 2009 as production hit 181Mt. The Cement Manufacturers' Association placed these figures at 68-93kWh/t for a modern plant and 100-120kWh/t for older ones. In June 2012 the Central Electrical Authority reported the country's entire installed electrical capacity was 205GW.
It's difficult to estimate how much damage problems in power supply may have caused the Indian cement industry over the last few decades in either reduced volumes or increased running costs. The Cement Sustainability Initiative and European Cement Research Academy broke down the share of electrical power in a dry process plant as follows: 38% for cement grinding, 24% for raw material grinding, 22% for clinker production including grinding of solid fuels, 6% for raw material homogenisation, 5% for raw material extraction and blending and 5% for conveying, packing and loading. Generally speaking, interruption of power causes production losses and low capacity utilisation, idle running of equipment during stops and restarts of the plant, thermal losses during reheating, damage to refractory and other problems such as slowing down the train network.
Subsequently there has been a drive in India towards captive power generation and waste heat recovery (WHR) mechanisms, especially as input energy costs have risen. For example it has been reported that ACC's average cost of electricity per kWh from its captive plants is US$0.067 versus US$0.087 for grid power. Companies like Shree Cement have since gone into the electricity export market with their surpluses and, as shown by SP Ganeshan at the Global CemPower Conference in June 2012, interest in WHR is booming. Currently, the Indian cement industry has about 4000MW of installed captive generation capacity, including coal-based plants, diesel generating sets and wind turbines. Through various greenfield and brownfield expansion projects it is anticipated that another 2000MW of captive capacity will be added by 2016.
One sign of how well the Indian cement industry is coping with its energy requirements is the 74% rise in fourth quarter profit reported by Shree Cement in May 2012, in part due to savings made from captive power generation. Perhaps they could advise the Indian electricity board.
Lucky starts supplying power to grid
04 July 2012Pakistan: Lucky Cement has started supplying 20MW/hr of electricity to Hyderabad Electricity Supply Company Limited (Hesco), according to a company announcement. The company said that it was aiming to start selling the same amount of electricity to Peshawar Electricity Supply Company Limited (Pesco) by the middle of July 2012. Speaking on 2 July 2012, a company spokesman said that the talks were underway on the sale and purchase agreement with Pesco.
Since 2010 Lucky Cement has operated 22MW waste-heat recovery units on two cement plants in Karachi and Pezu. The sale of surplus power has enhanced the company's balance sheet, as it struggles against continued low demand in the Pakistan market.
Global CemPower
19 June 2012The Global CemPower conference took place last week in London, attracting 103 delegates from 25 countries. The conference looked at waste heat recovery options in the global cement industry. 'Back-of-the-envelope' calculations suggest that the value of the waste heat recovery units that could be installed in the global cement industry in the next ten years might total US$50bn - well worth thinking about.
Robert McCaffrey, the conference convenor, gave a listing at the event of the seven megatrends that will shape the future of the global cement industry, including demographic trends (aging of both developing and developed nations), urbanisation (with 70-75% of humanity due to live in cities by 2050), the growth of new country superpowers, the possibility of further climate change, paradigm shifts in the cement industry business model, ever-increasing energy costs and the influence of Rumsfeldian known-unknowns and unknown-unknowns.
Whatever else happens in the next 50 years, increased energy costs and energy efficiency will be the order of the day. In the global cement industry, waste heat recovery is here to stay.
Presentations, videos and a full review of the Global CemPower conference are available here, www.globalcement.com/conferences/global-cempower/introduction.