Solutions

COMPLETE TURNKEY SOLUTIONS     REFERENCES       TECHNOLOGY

Cement

Cement plants form the backbone of global economic activity and prosperity and are an integral part of our daily lives. In fact, cement is the second most consumed product worldwide after drinking water. Although cement plays a central role in modern society, the cement industry has also become a significant environmental problem.

The cement industry alone is responsible for around 8% of global CO₂ emissions and has the highest emissions per dollar of revenue. Business as usual is therefore no longer a viable option in the long term. Sustainable and economical solutions are needed to reduce emissions and increase energy efficiency.

By integrating waste heat recovery (WHR) systems into cement plants, manufacturers can increase electrical efficiency and significantly reduce emissions caused by electrical energy consumption. Modular ORC systems enable the efficient use of waste heat and contribute to reducing Scope 2 emissions and energy costs.

Thanks to their high adaptability, modular ORC systems ensure optimal performance under changing operating conditions. They offer immediate savings, improve competitiveness and mitigate long-term risks in a changing cement industry.

 

 

Complete Turnkey Solutions

Orcan Energy supplies turnkey waste heat recovery (WHR) solutions for the cement industry, covering the entire project scope – from planning and design to execution, commissioning and annual maintenance. CAPEX-free financing options are available on request, making energy efficiency both accessible and low-cost. Thanks to its modular design, the WHR system can be easily adapted to changing conditions, such as changes in fuel composition or process changes such as the integration of CCUS.

The integration into the clinker cooler and preheater can be carried out either simultaneously or in separate phases. High quality is ensured through the use of standard components, which are mainly sourced from reliable European suppliers. Each ORC module is assembled and tested in Germany before being shipped to the installation site. This proven approach minimises on-site work and enables quick and easy installation as well as reliable, fully autonomous operation. No on-site personnel are required, and maintenance is limited to a single annual service by Orcan Energy. Together, these features enable an exceptionally short project lead time – from order to first power production.

 

References

Wittekind

Wittekind Zement operates six Orcan Energy eP 150.200 Efficiency PACKs at its plant in Germany. These modules not only generate green electricity from waste heat, but also reduce the power consumption of the existing cooler, resulting in additional energy cost savings.

‘We have set ourselves the clear goal of reducing our own carbon footprint. However, the energy efficiency measures taken must not at any time be at the expense of a smooth production process,’ says Lars Richter, plant engineer at Wittekind Zement.

The project fully met Wittekind Cement's objectives: the carbon footprint was reduced and operations were not disrupted.

CEMEX

CEMEX has installed six eP 150.200 Efficiency PACKs at its plant in Rüdersdorf, Germany. The solution uses previously unused waste heat from the clinker cooler to generate a total of up to 8,150 MWh of electricity per year. At the same time, it reduces the plant's CO₂ emissions by around 3,500 tonnes per year.

"We opted for a solution with a short payback period and a significant impact on reducing CO₂ emissions. We also looked for alternatives for generating clean electricity. Given the space restrictions this solution has the best MWh/m² ratio, enabling us to produce the highest amount of clean electricity within this range," said Stefan Schmorleiz, plant manager and managing director of CEMEX Zement GmbH.

Dyckerhoff

After only six months of construction, a turnkey waste heat recovery solution from Orcan Energy was commissioned at Dyckerhoff's cement factory in Geseke. This includes an Efficiency PACK, which converts previously unused hot air from the clinker cooler into green electricity via an ORC system. The plant, which includes a 50-tonne heat exchanger and is expected to generate over 1,000,000 kWh of electricity annually, reduces both energy costs and CO₂ emissions by around 900 tonnes per year.

‘The effective use of waste heat to generate electricity not only reduces energy costs at the Geseke site, but also enables a reduction in greenhouse gas emissions,’ says Dyckerhoff's production manager Ralf Schmees.

Technologie

The unused waste heat from the clinker cooler or preheater is transferred to an intermediate circuit (water or thermal oil) by means of a heat exchanger. This closed intermediate circuit then transports the heat to the efficiency PACKs. An ORC cycle operates inside the efficiency PACK:

An ORC cycle operates inside the efficiency PACK: the evaporator transfers the waste heat to the efficiency PACK. This heats the pressurised working medium, which is then fed as superheated steam to the expansion machine. The steam drives the expansion engine and thus the generator, which produces electricity. The gaseous working medium is liquefied in the condenser, releasing residual heat into the ambient air. The now liquid working medium is brought to high pressure in the pump. This closes the cycle and starts it all over again.

Contact

Our experts will be happy to help you generate affordable, carbon-neutral electricity from your waste heat:

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Orcan Energy AG
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81379 München