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Since eight engine units out of the 14 engine units at ACE Power Embilipitiya (Pvt) Ltd are already equipped with 750kW thermal oil boilers and only the other six engines have no existing WHR method, it has obviously been decided by the plant management that a new proper WHR system should be assessed only for the remaining six engines. The main goal is to enhance the overall efficiency of fuel utilization through optimized waste heat recovery for electricity generation by a steam bottoming cycle, thus also minimizing the release of rejected heat to the environment. During normal full-load running conditions one Caterpillar 16CM32C engine emits heated exhaust gas at 300oC~320 oC with a volume flow rate of 40904 m3/h. It was estimated that the energy waste due to current practice is approximately 235388.9 MJ per 24 hrs of operation as thermal energy lost to the environment with the hot exhaust gas, which corresponds to a 2724.4 kW thermal load of rejected heat just by the exhaust gases per each engine unit. For the six engines that lack any heat recovery, the total potential for recoverable heat rate from exhaust gases would therefore sum up to roughly 16.35 MW. This study completely disregarded any possibilities for waste heat utilization from other available low-temperature waste heat streams from the engines (such as jacket water cooling and charge air cooling) due to the clearly expressed unwillingness of the ACE plant management to consider any feasible investment options other than high-temperature heat recovery from exhaust gas only. 2PDF Image | waste heat recovery steam power system for ACE Embilipitiya
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