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CASE STUDY NO. 1 ORMAT's WASTE HEAT RECOVERY POWER PLANT AT A CEMENT PLANT IN LENGFURT, GERMANY On 23 July 1999, at the Lengfurt plant of Heidelberger Zement AG, east of Würtzburg, Bavaria, an Organic Rankine Cycle-facility (ORC) waste heat recovery power plant began operation. The ORC facility at Lengfurt is the world’s first to be installed at a cement plant. Heidelberger Zement built the pilot project. Thirty percent of the project’s cost was provided as a grant from the German Federal Ministry for Environment and the Bavarian State, in recognition of the innovative technology and environmental acceptability of the facility. The Heidelberger Technology Center was responsible for the implementation of the project. In total, the facility generates approximately 1.3 MW. After deduction of the facility’s internal power demand about 1.1 MW is supplied to the plant’s electric power network, thus providing a significant percentage of the plant’s electric power consumption. The ORC facility’s principle of operation is fairly simple. Significant amounts of low to moderate temperature waste heat is generated during the cement clinker manufacturing process. The heat emitted during the cooling of the clinker is captured and then converted into electric power. ORMAT's power generation module accommodates the hourly temperature fluctuations in the clinker cooler air flow, without any effect on the operation of the cement plant itself. Operating fully automatically and remotely monitored via a modem, ORMAT's power generation equipment is expected to displace approximately 45,000 tons of fuel over its expected lifetime, and so avoids the emission of some 120,000 tons of CO2. Summary of Operating Experience During the First TwoYears With the completion of the first two years of plant operation the following significant features evidencing the system’s success are noted: 1. The implementation of the ORC facility ( which has proved to be an effective operating system in the renewable / geothermal market ) into the cement manufacturing process was justified, and proved to be extremely successful. 2. On line availability, similar to that of geothermal power plants of above 98%, was achieved. 3. Empirical data have shown that the system was still performing well at off- design conditions, in fact capable of generating approximately 17% more power than defined under the design point operating conditions.PDF Image | Organisations in Different Renewables
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