Waste Heat Recovery Power Generation Engineering Technical Guidance. For Dalian EAST

Transcription

1 Waste Heat Recovery Power Generation Engineering Technical Guidance For Dalian EAST Prepared By May

2 Content 1 Company Profile 3 2 CV of Chief Technical Director 10 3 The 1 st Generation Technology of Pure Low Temperature Waste Heat Recovery Power Generation for Cement 13 Plant 4 The 2 nd Generation Technology of Pure Low Temperature Waste Heat Recovery Power Generation for Cement Plant 18 The Typical Technical Specification for the 2 nd & 1 st 5 Generation Technology of Pure Low Temperature Waste Heat Recovery Power Generation for Cement Plant 24 Low Temperature Waste Heat Recovery Power 6 Generation Technology with Additional Fuel Boiler for 32 Cement Plant 7 Patent Technology of Dalian EAST 34 8 Introduction about Power Generation Capacity & Associated Issues

3 1. Company Profile Dalian East New Energy Development Co., Ltd. was founded in December of 2005, as a specialized company that puts the technology into the first priority and integrates all that R&D on technology, engineering design, whole package of equipment, project construction and operation & management in one, engaging in the development of new energy industries such as recovering industrial waste heat energy etc. The company has been certified by ISO2000 quality system authentication in 2007 and been identified as high-tech enterprise in the same year, obtained the design qualification Certificate of Class B on Electric Power Industry (New Energy Power Generation) and related Mechanical Equipment Installation Certificate in The company currently has a number of practical innovation patents for pure low temperature waste heat recovery power generation for cement kiln, one invention patent technology for long kilns to improve the output and one invention patent technology for changing the waste heat power plant with additional fuel boiler for new type of dry cement kiln into a pure low-temperature waste heat power generation. The company is mainly engaged in: Technology consultation, technology services, technology transfer and project design, whole package of equipment, project management, project services, project contracting for the corresponding application in new energy technology of industrial waste heat energy, solar energy, wind energy, wave (tide) energy, geothermal energy, biogas energy, trash energy, etc. Investment, operation & associated energy contract management for the above mentioned projects. R & D, manufacture, assembly and sales on the technology of the process & equipment for energy saving and other regenerative new energy resources. The company has an excellent management & technical team, which takes the honor of being engaged in energy saving, environmental protection and the earth's resources protection as a job of benefiting the human beings, committed in continuous improvement of the technology of energy saving and comprehensive utilization of resource for China and in achieving the goal of sustainable development to realize their life values and beliefs dedicatedly, step by step. The company currently has a total of 248 employees, wherein, 22 senior engineers and 86 engineers, 5 first level project managers and 10 second level project managers

4 The technical backbone of the company has participated in and held the introduction, digestion, R & D and promotion for the waste heat recovery power generation for cement kiln in China for many years and made indelible contribution to the development history of the technology of the waste heat recovery power generation for cement kiln in China. The company has the following technologies: (1) The 1 st generation thermodynamic system technology of high-temperature two-stage waste heat recovering power generation for long kiln; design and manufacturing technology for horizontal high temperature waste heat boiler equipment, with the primary steam parameters of 1.6~2.45MPa 360~400. (2) The 2 nd generation thermodynamic system technology of high-temperature two-stage waste heat recovering power generation for long kiln; design and manufacturing technology for horizontal high temperature waste heat boiler equipment, with the primary steam parameters of 3.82MPa 450. (3) The 3 rd generation thermodynamic system technology of high-temperature two-stage waste heat recovering power generation for long kiln; design and manufacturing technology for vertical high temperature waste heat boiler equipment, with the primary steam parameters of 3.82MPa 450. (4) Technology of low temperature waste heat recovery power generation with additional fuel boiler for cement kiln (for new type of dry Kiln and various types of preheater kiln) & the design and manufacturing technology of additional fuel (coal powder) boiler, the 1 st Generation suspension preheater waste heat recovery boiler (SP boiler) and the 1 st Generation clinker cooler waste heat recovery boiler (AQC boiler) - 4 -

5 (5) Technology of low temperature waste heat recovery power generation with additional fuel (poor quality fuel like gangue and trash) boiler for cement kiln (for new type of dry kiln and various types of preheater kiln) & the design and manufacturing technology of fluid-bed boiler, the 2 nd Generation suspension preheater waste heat recovery boiler (SP boiler) and the 2 nd Generation clinker cooler waste heat recovery boiler (AQC boiler) (6) Technology of pure low temperature waste heat recovery power generation-for low parameters mixed pressure steam admission (with secondary steam) type of turbine stable secondary steam thermodynamic system configuration. (7) 1 st Generation Technology of pure low temperature waste heat recovery power generation for new type of dry kiln

6 (8) The 3 rd Generation of design and manufacturing technology for high temperature & two-stage waste heat recovery power generation for long kiln & vertical high & low temperature waste heat boiler equipment, and low pressure & large capacity of secondary steam type of turbine with stable secondary steam parameter thermodynamic system configuration. The steam parameters are: 1.27~3.82MPa 340~450 for primary steam and 0.15~0.3MPa saturated~180 for secondary steam. (9) The technology renovation of long kilns to increase the output and the thermodynamic system technology of medium-temperature & two-stage waste heat recovery power generation by using the technology of calciner and 1-2 stage pre-heater, and the design and manufacturing technology of changing the corresponding high-temperature waste heat boiler into a vertical medium-temperature and vertical low-temperature waste heat boiler

7 (10) The design and manufacturing technology of clinker cooler waste heat boiler (AQC boiler) and the waste heat recovery boiler integrated with additional fuel boiler in one piece. (11) The design and manufacturing technology of the 3 rd generation preheater waste heat recovery boiler (natural cycle SP boiler) and the 3 rd generation clinker cooler waste heat recovery boiler (natural cycle steam and hot water AQC boiler); and the thermodynamic system technology of low-temperature two-stage supplementary waste heat recovery boiler for cement kiln which is used Biofuels as the fuel. (12) The technology of low energy consumption for new type of dry cement production with a medium temperature two-stage waste heat recovery power generation system, and the design and manufacturing technology of corresponding vertical medium-temperature and low-temperature waste recovery heat boiler(hph Boiler HPL Boiler), steam turbine with secondary steam, two-stage preheater and calciner equipment

8 (13) The 2 nd generation of pure low-temperature waste heat power generation technology for new type of dry cement kiln has determined the technical approach improvement for pure low-temperature waste heat power generation for cement kiln,a number of specific technical measures has been invented correspondingly to make the generating capacity technology of pure low-temperature waste heat power generation for cement kiln been improved 12.5% % and the operation rate for power plant 2.5% than the 1 st generation

9 - (14) The process technology & equipment design and manufacture technology of waste heat recovery from cement kiln shell for domestic purpose, such as heating service, refrigeration and air conditioning. (15) DCS technology for power plant and cement production line. (16) The design and manufacturing technology of auxiliary equipment for waste heat recovery power generation (valve actuators, special cleaning device for boiler, special deaerator, special pump condenser without power and recycled water pump, ect.) (17) The technology of waste heat recovery power generation for industries such as steel & iron making, metallurgical, glass etc

10 2. CV of Chief Technical Director Chief Technical Director of the company Mr. Tang Jinquan, Professor Senior Engineer: - After graduated from Harbin Institute of Technology majoring thermal energy and power engineering, Mr. Tang began his career in TCDRI (Tianjin Cement Industry Design & Research Institute) - Engaged in design for cement production process from 1983 to June of Engaged in cement production process, heating service & ventilation and waste heat recovery power generation from June of 1985 to October of As the head of waste heat recovery power generation R&D group and heating service & ventilation group in TCDRI, he took charge of the fulfillment of the technical innovation for 1 st generation technology & equipment of high temperature waste heat recovery power generation for long kiln, which had been developed to be the 2 nd generation technology & equipment. - As the head and technical principal of national brainstorm team on National Science & Technology Development Program of 8 th Five-year for WHR power generation (including 11 members from 4 organs) organized by the State Building Materials Bureau in 1989, prepared the report for project approval of National Science & Technology Development Program of 8 th Five-year for WHR power generation <The Research and Development for the Technology & Equipment of Low Temperature Waste Heat Recovery Power Generation for Cement Kiln>, putting forward that the development for the technology & equipment of low temperature waste heat recovery power generation for cement kiln in China shall follow the technical strategy in two steps to tally with the characteristics of China, i.e. the first step: research and develop <The Technology & Equipment of Low Temperature Waste Heat Recovery Power Generation with Additional Fuel Boiler for Cement Kiln>, and the second step: further research and develop <The Technology & Equipment of Pure Low Temperature Waste Heat Recovery Power Generation for Cement Kiln> basing on success of <The Technology & Equipment of Low Temperature Waste Heat Recovery Power Generation with Additional Fuel Boiler for Cement Kiln>. - Further educated in Engineering Thermal Physics Department of Tianjin University during January and December of 1991, majoring <The Principle of Steam Turbine and Thermal Power Plant Engineering>. - Further educated in MAX company in City of Philadelphia, USA during February and May of 1994 on Automation System for Power Plant. - Appointed to be the director of Waste Heat Recovery Power Generation Department in TCDRI basing on the national brainstorm team on National Science & Technology Development Program of 8 th Five-year for WHR power generation organized by the State Building Materials Bureau in

11 - Promoted to be senior engineer and awarded the honor of China s Youth Academic Pioneer by State Building Materials Bureau in He has completed the technical negotiation with NEDO (a Japanese company) and plant design for the project using complete set of Japanese equipment (as gift) to set up a 6480kW pure low temperature WHR power plant for Ningguo Cement Company s new type of dry cement kiln with clinker output of 4000TPD. - In November of 1996, he completed the brainstorm project of technology and equipment developing for combined power generation with WHR and additional fuel boiler and having been awarded the national prize for excellent achievement of key R&D project, and as a great honor, he was interviewed by the highest leaders of Party and State in person, such as Chairman Jiang Zemin etc. - In 1997, he held and gave lectures for national advanced study class of waste heat recovery power generation for cement kiln in three semesters for the State Building Materials Bureau and gave lectures for French Engineer School. - GM of Tianjin Nengda Technical Development Co. Ltd (affiliated to TCDRI) in August of 1998, which was the original of SINOMA. - He held and finalized the 1 st Generation Technical Solution of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Kiln during December of 1999 and May of 2001, to establish the foundation for the development of pure low temperature waste heat recovery power generation technology for cement kiln in China. - In May of 2001, he resigned his job in TCDRI and set up a cooperative company namely Hangzhou Qianchao Engineering Technology Co., Ltd. In title of chairman and general manager. - During May of 2001 and October of 2005, one by one, he held the completion for: R & D for the technology and equipment of high temperature two-stage waste heat recovery power generation for long kiln, technical innovation and R & D to increase the output and decrease the consumption for long kiln, technical development of new type of dry cement clinker production line for two-stage preheater and precalciner kiln equipped with medium & low temperature waste heat recovery power plant, the design and manufacturing technology of the 3 rd generation preheater waste heat recovery boiler (natural cycle SP boiler) and the 3 rd generation clinker cooler waste heat recovery boiler (natural cycle steam and hot water AQC boiler); and the thermodynamic system technology of low-temperature two-stage supplementary waste heat recovery boiler for cement kiln which is used Biofuels as the fuel, and the completion of the design and commissioning of low temperature waste heat recovery power plants with additional fuel boiler for 9 lines of cement kilns, which accelerates the experience for improving waste heat recovery power generation technology of new type of dry kiln to establish the technical

12 foundation for the development of the technology & equipment of the 2 nd generation of pure low temperature waste heat recovery power generation for new type of dry kiln. - During May of 2005 and July of 2007, he led the completion of R&D for the 2 nd technology and equipment of pure low temperature waste heat recovery power generation for cement kiln, and developed a number of detailed technical measures (6 practical new type patents and 3 patent technologies). - In October of 2005, set up Dalian East Energy Engineering Co., Ltd. (which becomes Dalian East New Energy Development Co., Ltd.) as one of the founders, in title of Chief Engineer. - He has been leading the R&D of 3 rd generation technology of pure low temperature waste heat recovery power generation for cement kiln since He has been leading the completion of 14 kinds of waste heat recovery power generation system technology, R&D for 32 kinds of waste heat recovery power generation equipments, 53 waste heat recovery power projects for cement plant, the design and technical revamping for 9 new production lines, and the start-up & commissioning of waste heat recovery power plants for 25 cement plants. - He has published 29 pieces of technical paper in the field of waste heat recovery on the academic publication at the level of provincial, ministerial and higher, and been awarded the prize of first class for excellent paper at state level

13 3. The 1st Generation Technology of pure low-temperature WHR power generation for Cement kilns 3.1 Definition and Feature (1) Definition: it is the technology that transfers the waste heat of the flue gas coming from both the pre-heater and the clinker cooler at rear and front of the kiln respectively, which is of new type of dry cement kiln (hereinafter referred as cement kiln in short), into power energy by using steam of 0.69MPa ~ 1.27MPa 280 ~ 330 without impairing the production output & quality of cement clinker, lowering the cement kiln operation rate, changing cement production technology process & machines, nor increasing the consumption of power energy and heat on clinker as the premise. (2) Features: The 1st Generation Technology for pure low-temperature WHR power generation for cement kilns also features as two points or more as follows besides the above mentioned definition: The cooler has only one flue gas exhaustion outlet for power generation; The temperature of the primary steam admission to the turbine is not adjustable but varies along with the temperature fluctuation of the flue gas from the cement kiln; The feed water systems for respective AQC boiler and SP boiler are of serial systems; Deaeration system by boiler feed water uses extra consumption of chemicals or power energy. 3.2 Key Points of the Technology and Construction of Thermodynamic System (1) Key Points of the Technology Set up a waste heat recovery boiler for the suspending preheater at rear of the cement kiln (hereinafter referred as SP boiler in short) served by recovery of the hot air exhausted from the suspending preheater, and extract the total flue gas exhausted from the clinker cooler at front of the cement kiln as two segments from the clinker cooler (see Diagram 1), wherein, an extraction outlet is opened at the middle part of the clinker cooler to serve extracting flue gas below 400 for clinker cooler waste heat recovery boiler (hereinafter referred as AQC boiler in short),

14 meanwhile, another extraction outlet is set up to serve extracting flue gas below 120 which is exhausted to the atmosphere directly. Equip a steam turbine and power generation system for the steam generated by WHR boiler; the parameters of the primary steam by power generation plant is 0.69~1.27MPa 280~330 and the actual power generation capacity basing on per tonnage of clinker is 3140kJ/kg clinker 28~35kwh (2) Construction of Thermodynamic System a) The thermodynamic power system mode for the 1st Generation Technology of WHR power generation for cement kiln consists of the following three kinds: Mono pressure pure low temperature WHR power generation technology without secondary steam. (See diagram 1.) b) Combined flash evaporation pure low temperature WHR power generation technology with secondary steam. (See diagram 2.) c) Multi-pressure pure low temperature WHR power generation technology with secondary steam. (See diagram 3.) Diagram 1 Basic construction for mono-pressure without secondary steam pure low temperature WHR power generation thermodynamic system

15 Diagram 2 Basic Construction for combined flasher with secondary pure low temperature WHR power generation thermodynamic system Diagram 3 Basic construction for dual-pressure with secondary pure low temperature WHR power generation thermodynamic system

16 3.3 Features of the Technology Abovementioned three modes have no substantial difference but share the common features as: Extract the total flue gas exhausted by the clinker cooler from the cooler as two segments, where a flue gas exhaustion outlet is opened in the middle part of the cooler to extract flue gas below 400 to produce steam & hot water through AQC boiler which is used for WHR power generation conversion through a set of steam turbine & generator, and another flue gas exhaustion outlet is set up at the rear of the cooler to extract flue gas below 120, which is emitted into the atmosphere directly. The waste heat of the flue gas exhausted from the preheater is used for producing steam through SP boiler. The steam generated by SP boiler and the steam & hot water generated by AQC boiler respectively mix before converting into power energy through a set of steam turbine & generator. The temperature of the flue gas exhausted from SP boiler is not adjustable meanwhile meet the maximum drying temperature for raw meal & fuel demanded by the cement production, i.e. the flue gas from the preheater is used for drying the raw & fuel material to meet cement production primarily and the residual waste heat of the flue gas is used for power generation. As the most important characteristic, the parameters of the primary steam for power generation totally vary at range of 0.69~1.27MPa-280~330. The differences among the three modes are shown as: (1) while the AQC is producing the low pressure & low temperature steam at 0.69~1.27MPa-280~330, it is reproducing either saturate low pressure & low temperature steam at 0.1~0.5MPa-saturated~160 or hot water at 105~180 ; (2) Steam turbine is used as the type of either with or without secondary steam; (3) Due to the same flue gas parameter, the power generation capacity will be 100% if based on the first mode, about 101.5%~102% if based on the second mode and about 102~103% if based on the third mode; (4) The first mode is not affected by the relative location between the steam turbine house and the cooler. The second mode (i.e. combined flash evaporation with secondary steam) is proper for the case that the steam turbine house locates far away from the cooler. The third mode is proper for the case that the (dual-pressure with secondary steam) steam turbine house locates closely to the cooler. 3.4 Power Generation Capacity by Theoretical Calculation

17 The 1st Generation Technology of WHR power generation fills the gap in China's cement industry, and laid the foundation and accumulated valuable experience for China to develop this technology. However, due to the limitations of technical condition, comparing to new type of dry kiln, the level of the 1st Generation Technology of WHR power generation is equivalent to the level of new type of dry kiln at the beginning of last 90s with certain problems existing among any following aspects such as investment, power generation capacity, operational stability, the lifetime of BTG, or operational adjustability. Whereas the 1st Generation Technology of WHR power generation is no good use of clinker cooler exhaustion temperature, system has only been in the production of low-temperature & low pressure steam, therefore, the waste heat has not been recovered in cascade as per the temperature distribution so as to make the thermodynamic power generation efficiency of the circulation system much too low and the waste heat is not able to reach its rated power generation capacity. Regarding the WHR power generation capacity for cement kiln with a 5-stage preheater, under the conditions such as, the flue gas temperature is not higher than 330 at SP, and the required flue gas temperature is more than 170 to meet drying the raw material and to meet the required flue gas parameter for coal mill drying, without impacting the cement clinker output and operational rate, increasing the consumption of heat and power on finished production of cement clinker, changing the drying heat supply for raw material to produce cement, nor changing the cement production process or plant, theoretically, the WHR power generation capacity basing on per tonnage of clinker output has no way to be over 3140kj/kg-28~35kwh (for the cement kiln with actual clinker output of 2750t/d, heat consumption less than 3140kj/kg or the flue gas temperature at the outlet of the preheater lower than 330, and the drying temperature for raw material higher than 170, the maximum power generation output by theoretical calculation is 4000KW or 8000KW for the cement kiln with clinker output of 5500t/d)

18 4. The 2nd Generation Technology of pure low-temperature WHR power generation for cement kilns 4.1 Definition and Feature (1) Definition: it is the technology that transfers the waste heat of the flue gas coming from both the pre-heater and the clinker cooler at rear and front of the kiln respectively, which is of new type of dry cement kiln (hereinafter referred as cement kiln in short), into power energy by using steam of 1.27MPa~ 3.43MPa 340 ~435 without impairing the production output & quality of cement clinker, lowering the cement kiln operation rate, changing cement production technology process & machines, nor increasing the consumption of power energy and heat on clinker as the premise. (2) Features: The 2nd Generation Technology for pure low-temperature WHR power generation also features as two points or more as follow besides the above mentioned definition: The cooler has two flue gas extraction outlets or more for power generation (patent of Dalian East New Energy Development Co., Ltd.); An independent superheater is set up near AQC, through which the temperature of the primary steam admission to the turbine is adjustable but does not follow the temperature fluctuation of the flue gas from the kiln (patent of Dalian East New Energy Development Co., Ltd.); An independent superheater is set up inside C1 (the last stage of preheater) to improve the operational rate & stability of the power plant (patent of Dalian East New Energy Development Co., Ltd.); The water feed systems for respective AQC boiler and SP boiler are of parallel systems which do not affect mutually but with respective independence (patent of Dalian East New Energy Development Co., Ltd.); Deaeration system by boiler feed water uses low-temperature waste heat below 145 without the consumption of extra chemicals or power energy (patent of Dalian East New Energy Development Co., Ltd.); An adjusting unit is equipped at the outlet of the SP boiler to adjust the outlet flue gas temperature to meet the various drying temperature requirement for

19 various humidity in different seasons (patent of Dalian East New Energy Development Co., Ltd.); The cooling air from the clinker cooler is of circulation (patent of Dalian East New Energy Development Co., Ltd.). 4.2 Key Points of the Technology and Construction of Thermodynamic System (1) Key Points of the Technology Set up a suspension preheater boiler to recover the hot air emitted from the suspension preheater at rear of the kiln and the flue gas emitted from the clinker cooler through changing the emission method as three segments from the clinker cooler, wherein, a flue gas extraction outlet is opened in the front-middle part of the cooler to extract a small quantity of flue gas below 500 separately to serve an independent clinker cooler flue gas waste heat superheater (hereinafter as ASH superheater); a flue gas extraction outlet is opened in the middle part of the cooler to recover the flue gas below 360 emitted from the clinker cooler to serve a hot air quick cooler boiler (hereinafter as AQC boiler); and another flue gas exhaustion outlet is set up at the rear of the cooler to extract flue gas below 120, which is emitted into the atmosphere directly. equip a steam turbine with secondary steam for the waste heat boiler and the waste heat superheater; the parameters of the primary steam for power generation system is 1.27~3.43MPa 340~435, the parameters of the secondary steam are 0~0.2 MPa saturated~160 and the power generation capacity is 3140kJ/kg clinker output 38~45kwh/t clinker output. (2) Construction of Thermodynamic System The prevailing thermodynamic power system mode for the 2nd Generation Technology of WHR power generation for cement kiln consists of the following two kinds: The first mode is of basic configuration system, for whose construction, see Diagram 4. The second mode is of adjustable configuration system, for whose construction, see Diagram

20 Diagram 4 Basic configuration mode for 2 nd generation technology of WHR power generation thermodynamic system Diagram 5 Adjustable configuration mode for 2 nd generation technology of WHR power generation thermodynamic system

21 4.3 Features of the Technology Regarding both the waste heat recovery method for the flue gas from the clinker cooler and the construction of the thermodynamic system by the 2nd Generation Technology of pure low temperature WHR power generation for cement kiln, the new generation technology not only inherits the technology features of the predecessor but also specifies itself by other characteristics as follow, The cooler works in a multi-stage way of extracting the flue gas to create the conditions for providing relative high temperature & high pressure primary steam parameters for the power plant and realizing the recovery of waste heat in cascade as per the flue gas temperature; Install a separate clinker cooler flue gas superheater to create conditions for adjusting and controlling the steam parameters (such as temperature, pressure); The power plant uses the relative high temperature and high pressure primary steam parameters as 1.27~3.43MPa 340~435 to ensure the improvement of the WHR power generation capacity; The turbine uses the way of multi-stage mixed steam feed (i.e. with secondary steam mode), and AQC boiler uses the relative high pressure steam segment as 1.47~3.43MPa, low pressure steam segment as 0.15~0.5MPa and 100~120 hot water segment arrangement of heating surface to provide the measures for changing the low pressure and low temperature steam & hot water of 0.15~0.5MPa generated by flue gas waste heat below 190 into power energy and using 100~120 hot water to serve feed water & deaeration by flue gas waste heat below 145 ; The water feed systems for respective AQC boiler and SP boiler are of independent system which creates the conditions for the operation of both boilers without mutual influence; Deaeration system by boiler feed water uses low-temperature waste heat below 145 without the consumption of extra chemicals or power energy. An adjusting unit is equipped at the outlet of the SP boiler to adjust the outlet flue gas temperature to follow the various drying temperature requirement for cement production so as to provide the measures of converting the waste heat into the power energy to the utmost. 4.4 The Achievement by the 2 nd Generation Technology of Pure Low Temperature Waste Heat Recovery Power Generation for Cement Kiln

22 For the 2nd Generation Technology of pure low temperature power for cement kiln, comparing with the existing problems by the 1st Generation Technology of WHR power generation, in case of without impacting the heat consumption of cement clinker, meeting the required minimum temperature of 170 for drying raw meal & fuel, without changing cement production process and equipments, nor impacting the cement kiln operation, the achievement by the 2nd generation technology of pure low temperature waste heat recovery power generation for cement kiln is as follow: (1) The waste heat is able to generate either sub-medium pressure or medium pressure steam of saturated-overheat 450, low pressure and low temperature steam of 01.~ 05MPa saturated-180, and hot water of 85~110 at the same time; (2) The thermodynamic circulation system is able to use sub-medium pressure and medium temperature parameters, to improve the thermodynamic circulation system efficiency, and to realize the principle of heat utilization in cascade as per the fluctuation of temperature meanwhile making full use of the waste heat as per various flue gas temperature from the cement kiln; (3) The 2nd Generation Technology of pure low temperature power generation for cement kiln thermodynamic circulation system, circulation parameters and flue gas extraction method coverts the flue gas waste heat from cement kiln by its quality into the power energy to the maximum extent so that the WHR power generation capacity is improved highly than the 1st Generation Technology pure low temperature power generation for cement kiln to reach 3140KJ/Kg---38~45kWh/t in actual. Comparing with the 1st Generation Technology of pure low temperature WHR power generation, the WHR power generation capacity per ton of clinker is improved 12.%~31.25% at the premise of the constant heat consumption of clinker; (4) It solves the problem that the primary steam temperature of the 1st Generation Technology of pure low temperature power generation is not adjustable so as to impact the lifetime of the steam turbine; (5) Employing primary steam with quite high pressure and temperature creates the conditions for the steam turbine operation with smooth parameters of primary steam pressure and temperature in a large various range (When the primary steam pressure and temperature are designed as 2.29MPa-370, the actual operational various range is able to reach 1.27~2.47MPa, 325 ~400 ); yet the actual permissible various range of the turbine primary steam pressure and temperature for the 1st Generation Technology of the pure low temperature power generation is much smaller (When the primary steam pressure and temperature are designed as 0.689MPa-317, the actual operational various range is able to reach 0.49~0.98MPa, 292 ~330 only). Therefore, meanwhile being able to improve the WHR power generation capacity, the 2nd Generation Technology of pure low temperature power

23 generation is much better than the 1st Generation Technology on the aspects of operational rate & reliability of the power generation system, and adaptability for the fluctuation of the cement kiln production due to the permissible operational various range of the primary steam parameters by the 2nd Generation Technology of WHR power generation much larger than that by the 1st Generation; (6) It solves the problems such as the mutual influence because of the serial connection between AQC boiler and SP boiler, difficult controlling water feed system, and unstable service of the system etc.; (7) Due to the adjustable unit set up at SP boiler to govern the temperature of the outlet flue gas from the SP boiler, without control the existing gas duct damper on the cement line, the temperature of the outlet flue gas from the SP boiler can be along with the various temperature required by drying raw meal & fuel for cement production as well as convert the waste heat into the power energy to the utmost. (8) Serving the feed water & deaeration system in a thermal way of low temperature waste heat of below 145,it has no longer the consumption of extra chemical dose or power energy as wells improve the stability for feed water and the continuity of the boiler operation with the requirement on the oxygen content in the feed water. Above mentioned points have been already proven by the WHR power plants put into production

24 5. Technical Specifications for the 2nd & 1st Generation Technology of Pure Low Temperature Waste Heat Recovery Power Generation for Cement Kiln with Typical Clinker Output 5.1 Typical Technical Specifications for the 2 nd Generation Technology of Pure Low Temperature Waste Heat Recovery Power Generation for Cement Kiln Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 1300tpd (by the 2nd Generation Technology) Description Value Parameters of hot air from PH 75000~105000Nm³/h 320~350 Parameters of flue gas from clinker cooler 56000~85000Nm³/h 260~290 Actual clinker output 1000~1500tpd Designed power capacity 2.0~3.0MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.5~7.2% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

25 Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 2000tpd (by the 2nd Generation Technology) Description Value Parameters of hot air from PH ~163000Nm³/h 320~340 Parameters of flue gas from clinker cooler 88000~133000Nm³/h 270~290 Actual clinker output 1600~2400tpd Designed power capacity 3.6~5.0MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.5~7.2% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 2500tpd (by the 2nd Generation Technology) Description Value Parameters of hot air from PH ~190000Nm³/h 320~340 Parameters of flue gas from clinker cooler ~155000Nm³/h 270~290 Actual clinker output 2500~2800tpd Designed power capacity 5.0~6.0MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.3~7.0% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

26 Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 3200tpd (by the 2nd Generation Technology) Description Value Parameters of hot air from PH ~233000Nm³/h 310~340 Parameters of flue gas from clinker cooler ~192000Nm³/h 270~290 Actual clinker output 3200~3700tpd Designed power capacity 6.0~7.5MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.3~7.0% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 4000tpd (by the 2nd Generation Technology) Description Value Parameters of hot air from PH ~322000Nm³/h 310~330 Parameters of flue gas from clinker cooler ~262000Nm³/h 280~300 Actual clinker output 4000~4800tpd Designed power capacity 8.0~10.5MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.0~6.8% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

27 Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 5000tpd (by the 2nd Generation Technology) Description Value Parameters of hot air from PH ~380000Nm³/h 310~330 Parameters of flue gas from clinker cooler ~312000Nm³/h 280~300 Actual clinker output 5000~5800tpd Designed power capacity 9.0~12MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 5.8~6.5% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

28 5.2 Technical Specifications for the 1 st Generation Technology of Pure Low Temperature Waste Heat Recovery Power Generation for Cement Kiln with Typical Clinker Output Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 1300tpd (by the 1st Generation Technology) Description Value Parameters of hot air from PH 75000~105000Nm³/h 320~350 Parameters of flue gas from 56000~85000Nm³/h 260~290 clinker cooler Actual clinker output 1000~1500tpd Designed power capacity 1.5~2.5MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.5~7.2% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

29 Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 2000tpd (by the 1st Generation Technology) Description Value Parameters of hot air from PH ~163000Nm³/h 320~340 Parameters of flue gas from 88000~133000Nm³/h 270~290 clinker cooler Actual clinker output 1600~2400tpd Designed power capacity 3.0~3.6MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.5~7.2% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 2000tpd (by the 1st Generation Technology) Description Value Parameters of hot air from PH ~190000Nm³/h 320~340 Parameters of flue gas from ~155000Nm³/h 270~290 clinker cooler Actual clinker output 2500~2800tpd Designed power capacity 3.6~4.5MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.3~7.0% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

30 Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 2500tpd (by the 1st Generation Technology) Description Value Parameters of hot air from PH ~233000Nm³/h 310~340 Parameters of flue gas from ~192000Nm³/h 270~290 clinker cooler Actual clinker output 3200~3700tpd Designed power capacity 5.0~6.0MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.3~7.0% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 3200tpd (by the 1st Generation Technology) Description Value Parameters of hot air from PH ~233000Nm³/h 310~340 Parameters of flue gas from ~192000Nm³/h 270~290 clinker cooler Actual clinker output 3200~3700tpd Designed power capacity 5.0~6.0MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.3~7.0% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

31 Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 4000tpd (by the 1st Generation Technology) Description Value Parameters of hot air from PH ~322000Nm³/h 310~330 Parameters of flue gas from ~262000Nm³/h 280~300 clinker cooler Actual clinker output 4000~4800tpd Designed power capacity 5.4~6.5MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 6.0~6.8% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator Technical Specifications of Pure Low Temperature Waste Heat Recovery Power Generation for New Type of Dry Cement Kiln with Typical Clinker Output of 5000tpd (by the 1st Generation Technology) Description Value Parameters of hot air from PH ~380000Nm³/h 310~330 Parameters of flue gas from ~312000Nm³/h 280~300 clinker cooler Actual clinker output 5000~5800tpd Designed power capacity 7.5~10MW Operational rate of the power As 97.5% of the operational rate of cement plant kiln Power self-consumption by the power plant 5.8~6.5% Posts and staff 17(persons) AQC boiler, superheater Main SP boiler, equipment superheater Steam turbine Generator

32 6. The Technology of Low Temperature Waste Heat Recovery Power Generation with Additional Fuel Boiler for Cement Kiln 6.1 Features of the Technology An HRSG-SP recovering the waste heat from the C flue gas exhausted from SP; An HRSG-AQC recovering the waste heat from the C hot air attracted from AQC; An additional fuel boiler served by gangue, trash or biogas adjusts the the parameters of the steam and hot water coming from AQC & SP boiler until meeting the admission for the turbine. 6.2 The Construction of the Thermodynamic System Diagram 6 the Mode of the Construction of Low Temperature Waste Heat Recovery Power Generation Thermodynamic System with Additional Fuel Boiler for Cement Kiln

33 6.3 Installed Power Generation Capacity for Power Plant Basing on the resource and supply capacity of gangue, trash or biogas, the installed power generation capacity for low temperature waste heat recovery power plant with additional fuel boiler for cement kiln can be determined as less than 80% of total consuming power for the whole cement plant. In this case, energizing from the cement plant to grid inversely will be avoided. In case of the confirmed waste heat from the cement kiln, the capacity of the additional fuel boiler is determined by the installed power generation capacity

34 7. Patent Technology of Dalian East New Energy Development Co., Ltd. 7.1 Practical New Pattern 1- Preheater C2 Waste Heat Recovery Power Generation System (Technology for steam superheater built-in preheater C2). 7.2 Practical New Pattern 2- Clinker Cooler Waste Heat Recovery Power Generation System (Technology for multi-stage waste heat extraction from the clinker cooler). 7.3 Practical New Pattern 3- Clinker Cooler Circulation Air (Technology for circulation air used by clinker cooler). 7.4 Practical New Pattern 4- Multi-stage Waste Heat Extraction from the Clinker Cooler System (2) (Technology for improving multi-stage waste heat extraction from the clinker cooler). 7.5 Practical New Pattern 5- An Independent Steam Superheater System for Clinker Cooler. 7.6 Practical New Pattern 6- Adjusting Unit for the Temperature of Outlet Hot Air from SP boiler (Technology for low pressure steam segment built in SP boiler)

35 8. Introduction about Power Generation Capacity & Associated Issues 8.1 About Designed Average Power Generation Capacity (attributed to the issue that cement plant owners seldom study in depth) Several Aspects Working on the Designed Average Power Generation Capacity of WHR for a Cement Plant: At the premise of all the definite parameters of the waste heat from cement kiln, such as flowrate & temperature of the hot air from the preheater outlet, flowrate & temperature of the flue gas for drying raw meal and the flowrate & temperature of the hot air from the clinker cooler, the designed average power generation capacity is also worked on by other aspects probably as follows besides the technical proposal for WHRPP for a cement plant as the main consideration, to calculate the designed average power generation capacity,: The lower the exhaust steam pressure from the turbine, the larger the designed average power generation capacity The higher the turbine internal high & low pressure steam admission efficiency factors (F1, F2 respectively), the efficiency factor of turbine mechanical, heat dissemination and self-consumption power loss (F3), and generator efficiency factor (F4), the larger the designed average power generation capacity The larger the efficiency factor of air duct heat dissemination, bypass air duct leakage, or steam & water pipe steam leakage & heat dissemination (F5), the larger the designed average power generation capacity Dalian East New Energy Development Co., Ltd. puts the abovementioned three aspects into the consideration on the calculation of designed average power generation capacity for cement kiln as follows to calculate the designed average power generation capacity for a WHRPP: The turbine steam exhaust pressure is considered as 0.007MPa, the temperature of the exhausted steam is considered as 39 and the required temperature of the cooling water is F1 is considered as 82%, F2 is considered as 80%, F3 is considered as 97.5%, F4 is considered as 97.5%, generally F5 is generally at the range of 91~93% for a kiln of 2,500TPD-level

36 output, and 93~95% for a kiln of 5,000TPD-level output respectively Other suppliers put the abovementioned three aspects into the consideration on the calculation of designed average power generation capacity for cement kiln as follows to calculate the designed average power generation capacity for a WHRPP: The turbine steam exhaust pressure is considered as MPa, the temperature of the exhausted steam is considered as 33.9 and the required temperature of the cooling water is 21. The problems will exist when the turbine steam exhaust pressure is considered as MPa: When the required the temperature of the cooling water is not higher than 21, the ambient daily average dry ball temperature has to be not higher than 20 subsequently. Unfortunately, the period with daily average temperature lower than 20 is very short, and what is more, the pressure of exhausted steam from the turbine in the actual operation is hardly able to meet MPa, therefore, the actual power generation capacity can in no way guarantee to meet the designed power generation capacity proposed by these suppliers F1 is considered as 85% or even higher, F2 is considered as 83% even higher, F3 is considered as 98.5% even higher, F4 is considered as 98.5% even higher, generally. The problems will exist when above four efficiency values (F1&2&3&4) are considered as F1=85% or even higher, F2=83% or even higher, F3=98.5% or even higher, F4=98.5% or even higher, which are provided by the manufacturers are to be met only under ideal operation condition and rated state, however, during the actual operation of the WHR power plant, either steam parameters, power capacity or cooling water operation condition vary too much to keep the installation in operation under ideal operation condition or rated state for a long term, so that the actual efficiency values will be lower than those provided by the manufacturers, i.e. their actual power generation capacity is not able to meet the calculated power generation capacity of design by these suppliers F5 is generally considered as 100%. The problems will exist when F5 is generally considered as 100%: In practice, since the valve of the flue gas duct is not possibly closed completely, it is impossible for flue gas duct or steam pipe to have zero heat dissemination or zero air (steam) leakage, F5 is never 100%, which means their actual power generation capacity will be far away to meet the designed & calculated power generation capacity by these suppliers