Cement Manufacturers Association (CMA)

16 Rawan Cement Works WHRS generation enhancement project Shriprakash Gupta, Sr General Manager - Department Head Captive Power Plant, Operation & Maintenance, Rawan Cement Works, UltraTech Cement Limited, Chhattisgarh Rawan Cement works unit was installed with 15MW waste heat recovery unit and later due to cement plant volume enhancement found heat loss at cooler hot gases and also loss in efficiency of steam boiler & turbine. Evaluated the gaps and successfully modified the WHRS and enhanced power generation by 4.0 MW. Modification Details 1. Line-1 clinker cooler boiler exit temperature considered as 280 0 C and the same is being used for slag drying which are of excess heat is given. Reduced hot gas temperature to 165 0 C by addition of New Economizer and increased Super heater area in the boiler with upgraded alloy steel tubes to withstand high temperatures. Also cooler replacement with Hot air recirculation system increased inlet gas volume and temperature which in turn improved steam generation and steam temperature. 2. Line -2 clinker cooler heat load increased by installation of hot air recirculation system and thereby exit hot gases volume & temperature increased. Replaced boiler super heater coil with upgraded alloy steel tubes to with stand high temperatures & also added additional super-heated coils for better heat transfer area and reduced boiler exit temperature to 90 0 C. Also steam generated from Pre-heater heat recovery boiler circulated through cooler heat recovery boiler and increased TG inlet steam temp from 302°C to 400°C 3. Existing steam turbine of capacity 15MW replaced with new, higher capacity & efficiency turbine, generator with 20.4 MW. Modified turbine & generator deck foundation along with new piping & supports and recommissioned along with related electrical & instrumentation system. 4. Installed Two new air-cooled condenser