Waste Heat Recovery and Utilization for Power Generation at Maple Leaf Cement Factory Limited, Iskanderabad, Pakistan

Description

Iskanderabad, District Mianwali, Punjab Province, Pakistan

Waste Heat Recovery and Utilization for Power Generation at Maple Leaf Cement Factory Limited, Iskanderabad, Pakistan

Maple Leaf Cement Factory Limited (MLCFL) is a cement producer in Pakistan having installed production capacities in two phases. Phase I of the cement plant had five kilns with a combined clinker production capacity of 1600 TPD while Phase II had two kilns of 4000 TPD and 6700 TPD. The kilns run on fossil fuels i.e. coal, heavy fuel oil (HFO), natural gas and diesel. The cement plant meets its electricity requirement from the grid and fossil fuel (HFO and natural gas) based captive power plant comprising of four Niigata engines (4 x 5.96 MW) and one Wartsila engine (16.4 MW). Waste heat is available from the clinker production process and from the exhaust of the Wartsila engine. Prior to the implementation of the project activity, most of the waste heat from clinker production process was vented to the atmosphere with a small portion recovered to pre-heat the incoming raw materials. All the waste heat from the Wartsila engine was vented to the atmosphere without any utilization. The project activity involves the installation of a Waste Heat Recovery (WHR) system to generate electricity comprising of five Heat Recovery Steam Generators (HRSGs) with an installed steam generating capacity of 70.4 TPH and one steam turbine of 16.5 MW, which was fully commissioned in February 2011. The electricity generated by the project displaces grid electricity. Since grid electricity in Pakistan is primarily fossil fuel based, the project activity results in displacement of the electricity which would otherwise be generated by power plants connected to the grid. In the absence of the project activity, the pre-project situation would continue. The project activity has resulted into 281,193 tCO2e emission reduction during the current monitoring period.

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