With Waste Heat Recovery as a viable alternative for the power needs of cement plants, Triveni Turbines presents case studies to support their findings on the role of thermal renewable fuels in aiding the cement sector inch closer to its goal of a sustainable future.
The cement industry is an energy-intensive industry. On an average, the energy cost is around 40 per cent of the cost of production for cement manufacturing. The heat generated in cement processes is generally lost up to 30 to 40 per cent. Cement plants in India have Captive Power Plants (CPP), which are fired using fossil fuel (coal). These are in operation for several decades. Nowadays, the CPPs installed in cement plants use heat through Waste Heat Recovery (WHR) to generate power. Typically 20 to 30 per cent of the power requirement for cement plants can be fulfilled using waste heat for power generation. Globally, WHR based plants installed in the cement industry are based on three processes, namely
Steam Rankine Cycle System (SRC)
Organic Rankine Cycle System (ORC)
Kalina Based System
The function of the WHR is to recover the heat from the hot stream using Heat Recovery Steam Generators (HRSG) or Waste Heat Recovery Boiler (WHRB) to generate superheated steam. It can be used in the process (for co-generation) or to drive a steam turbine (combined cycle). The WHR based power plants installed in cement processing plants use the heat generated through rotary kiln preheater (PH) and after quenching cooler (AQC) exhaust hot gases for power generation. In India, the customer prefers SRC for WHR power generation in Cement Plants. Technically, in SRC, the exhaust gases from the rotary kiln pass through PH and go to the PH boiler. Similarly, mid-tapping from AQC gives hot gases to the AQC boiler. One cement kiln line requires 2 PH boilers and 1 AQC boiler. Based on the heat source, these boilers generate low-pressure steam of 12 ata to 18 ata at a temperature of 350 to 450 degree Celsius. and Low Pressure (LP)steam 2 ata to 3 ata pressure and temperature of 175 to 195 degree Celsius. WHR-based power plants also exist in the sectors like sponge iron, steel and chemicals, which came into existence from the year 2000 onwards in the Indian market. Initially in India, the major cement manufacturers installed cement WHR plants made in China while over the last decade or so, Indian boiler and Turbine OEMs offered products indigenously designed and manufactured catering to the market dynamics, demand requirements and providing sustained long-term aftermarket services.
Cement WHR Triveni Turbines is associated with cement WHR for many years now and has executed numerous prestigious projects with leading cement manufacturers in India and abroad. The requirement for cement WHR depends on the cement kiln capacity, heat utilisation, and plant efficiency. Triveni is currently in the process of installing many cement WHR projects and is also working on multiple projects that are either in the enquiry or in the order finalisation stage. Triveni has developed efficient injection condensing turbines that use medium pressure steam as turbine inlet and low pressure as injection steam. With the addition of 7th generation turbine blades developed by Triveni, power generation output is more for input steam parameters or gas parameters.
Salient features of Triveni’s steam turbines in the cement industry are as follows:
Integral Lube Oil tank: Triveni offers an Integral Lube Oil tank for Power House Layout and civil cost optimisations of TG House. The benefits include a reduction in the civil cost of the project.
Mechanical Run Test (MRT): Live steam mechanical run test at Triveni’s manufacturing facility for the steam turbines. The Turbine is tested with live steam from boilers at Bengaluru works with job-mounted turbo supervisory systems, Woodward governor, and gearbox.
In-house Manufacturing: Turbine components like blades, rotors, and casing are manufactured and assembled at Triveni’s facility.
Vacuum Tunnel: High-speed balancing of turbine rotor on ‘Schenk’ Vacuum Tunnel
Gear Box (Triveni Power Transmission) assembly is done along with the Turbine on the same base plate and converts into a single product. A separate foundation of the gearbox is not required.
Inlet Valve: Triveni supplies a customised inlet governing valve is designed in-house to overcome the varied load fluctuations in the cement industry
Injection Control Valve: Triveni supplies a specially designed globe control valve to maintain the minimum differential pressure to avoid the energy loss which results in the indirect losses in the final output.
Best practices on steam turbine design solution Large cement companies are primarily considering WHR power plants for their Greenfield projects. Dependency on the Chinese turbines has now declined in the Indian market as the Indian OEM’s adapted to injection condensing turbines technology with a dominant leadership. Triveni has a firm reference of injection condensing turbines supplied to cement WHR plants across India. Specific design consideration is vital in the injection and admission zone. The rotor designed by Triveni has the higher stability to offset the excitation due to fluctuating injection steam loads. To meet customer requirements for various mid-pressure and low-pressure steam combinations, an injection condensing turbine was developed by Triveni and is successfully working in the Indian Cement Industry. Design and engineering teams carried out Computational Fluid Dynamic (CFD) analysis and creep-fatigue analysis to address this issue. This design philosophy is a value-addition for Triveni for its robust and efficient cement WHR solution.
Environmental concerns and the solutions offered According to industry sources, cement manufacturing accounts for an estimated 4 to 8 per cent of the world’s carbon dioxide (CO2) emission, making it a significant contributor to global warming. Increasing the energy efficiency of cement plants by replacing fossil fuels with thermal renewable fuels (such as waste heat) and capturing and storing the CO2 to contain greenhouse gas (GHG) emissions are some of the solutions common to the cement industry and other industrial sectors.
WHR power potential There is a vast potential for power generation from waste heat across the world. The installation of cement WHR based power plants in China is over 80 per cent, much ahead of India. Similarly, Europe, the USA, and Latin America plan to implement WHR in their cement plants. It is observed that waste heat recovery-based power plants are emerging as an excellent value addition to the existing captive power plants. Other than reducing energy costs significantly, it can also be a reliable source of power.
Case studies of Triveni a. Waste Heat Recovery based Power plant in Madhya Pradesh, India Driven by Triveni 1*22.5 MWe Injection Condensing steam turbines with an inlet steam parameter of 12 Bar and 425 degree Celsius with 0.2 Bar Exhaust
Customer challenge The steam flow in this project was from multiple sources (i.e., multiple boilers). Steam generation depends on the waste heat generated from hot gas temperature from the preheating process and AQC process. There is a variation in the steam inlet at Medium Pressure (MP) and Low Pressure (LP) side and load variation in load or power output.
Solution The steam turbine we proposed is an Injection condensing turbine that receives MP steam as an inlet and LP steam as an injection in the middle steam path. The steam collected was from 4 No’s of Preheater (PH) boilers and 2 No’s of After Quenching Cooler (AQC) Boilers from the two cement kilns of 7,000 TPD and 8,000 TPD capacity. The steam turbine generator (STG) is suitable for an air-cooled condenser with a new generation blade design and reaction stages. Despite various challenges, the commissioning of the Turbine was executed with quick delivery of eight months, which set a benchmark for Triveni in the cement industry.
Benefits The company does not have a captive power plant installed, and this WHR plant has offered many benefits. The waste gas generated at around 400 degree Celsius is cooled to 130 degree Celsius, thus safeguarding the environment and simultaneously utilising the waste heat to generate almost free power. b. Waste Heat Recovery based Power plant installed overseas Driven by Triveni 1*30 MWe Bleed condensing steam turbines with an inlet steam pressure of 65 Bar and 505 degree Celsius with 0.1 Bar Exhaust pressure
Customer challenge The customer proposed installing a power plant and expanding the company’s manufacturing capacity and was on the lookout for a steam turbine solution provider. The customer wanted to generate the necessary power by banking on their captive power capacities and to ensure a steady supply for critical processes.
Solution Triveni offered the best solution to meet the plant efficiency by utilising the waste heat recovered from the existing blast furnace for power generation.
Benefits The company entrusted Triveni’s expertise in manufacturing robust and highly reliable products. It awarded us with the supply contract of a steam turbine that benefits from improving the plant’s energy efficiency, reducing the energy cost, and transmitting surplus electricity to the grid. To complement the above new product portfolio, Triveni’s refurbishment arm Triveni REFURB steps up to provide an aftermarket solution for the complete range of rotating equipment across the globe. From steam turbines, compressors to the gas turbine range, we have adapted ourselves to ensure that customers find a one stop solution. Over a period of time, the existing turbines degrade thereby reducing the efficiency of the turbines by consuming more steam. The Triveni REFURB team provides solutions to enhance the efficiency of turbines of ‘Any make, Any age’ by only replacing the critical components of the turbine i.e., rotor, guide blade carriers and bearings, which ensures the efficiency is restored and thereby reducing the carbon footprint. Triveni REFURB converts the existing turbine into injection mode turbine. The turbines are then re-engineered to allow additional steam to be injected into the turbine and improve the efficiency of the plant. a. Conversion of Bleed Condensing Turbine to Injection Condensing A Chinese Turbine 1*25MWe Bleed Condensing Turbine with 84 Bar 515 degree Celsius inlet conditions and 0.176 Bar Exhaust pressure
Customer challenge A major cement Industry customer wanted to convert their existing Chinese make turbine from a 3 bleed condensing to injection condensing turbine. The pressure at the inlet was reduced to 13 Bar 425 degree Celsius as against 84 bar 515 degree Celsius. The injection parameters are 2.25 Bar 185 degree Celsius.
Solution Due to the steep drop in inlet pressure the volumetric expansion was almost three times the original condition. We had proposed to modify the Inlet valve of the turbine and the first stage nozzles to accommodate this expansion. Two bleed ports were closed and the injection would be taken from the third bleed port. Complete re-engineering of the turbine was undertaken to adopt the upgraded steam flow path.
Benefits By keeping the existing casing and civil foundation, customers benefited by lower expenditure and improved efficiency. This would enable the customer to get a faster Return on Investment (within 2 years) and enhanced life of the turbine.
The cost of construction in India increased by 11% over the past year, primarily driven by a 25% rise in labour expenses, according to Colliers India. While prices of key materials like cement dropped by 15% and steel saw a marginal 1% decrease, the surge in labour costs stretched construction budgets across sectors.
“Labour, which constitutes over a quarter of construction costs, has seen significant inflation due to the demand for skilled workers and associated training and compliance costs,” said Badal Yagnik, CEO of Colliers India.
The residential segment experienced the sharpest cost escalation due to a growing focus on quality construction and demand for gated communities. Meanwhile, commercial and industrial real estate remained resilient, with 37 million square feet of office space and 22 million square feet of warehousing space completed in the first nine months of 2024.
“Despite rising costs, investments in automation and training are helping developers address manpower challenges and streamline project timelines,” said Vimal Nadar, senior director at Colliers India.
With labour costs continuing to influence overall construction expenses, developers are exploring strategies to optimize operations and mitigate rising costs.
Swiss Steel has announced plans to cut 800 jobs as part of a restructuring effort, triggered by weak demand in the global steel market. The company, a major player in the European steel industry, cited an ongoing slowdown in demand as the primary reason behind the workforce reduction. These job cuts are expected to impact various departments across its operations, including production and administrative functions.
The steel industry has been facing significant challenges due to reduced demand from key sectors such as construction and automotive manufacturing. Additionally, the broader economic slowdown in Europe, coupled with rising energy costs, has further strained the profitability of steel producers like Swiss Steel. In response to these conditions, the company has decided to streamline its operations to ensure long-term sustainability.
Swiss Steel’s decision to cut jobs is part of a broader trend in the steel industry, where companies are adjusting to volatile market conditions. The move is aimed at reducing operational costs and improving efficiency, but it highlights the continuing pressures faced by the manufacturing sector amid uncertain global economic conditions.
The layoffs are expected to occur across Swiss Steel’s production facilities and corporate offices, as the company focuses on consolidating its workforce. Despite these cuts, Swiss Steel plans to continue its efforts to innovate and adapt to market demands, with an emphasis on high-value, specialty steel products.
UltraTech Cement, the Aditya Birla Group’s flagship company, has announced plans to raise up to Rs 3,000 crore through the private placement of non-convertible debentures (NCDs) in one or more tranches. The move aims to strengthen the company’s financial position amid increasing competition in the cement sector.
UltraTech’s finance committee has approved the issuance of rupee-denominated, unsecured, redeemable, and listed NCDs. The company has experienced strong stock performance, with its share price rising 22% over the past year, boosting its market capitalization to approximately Rs 3.1 lakh crore.
For Q2 FY2025, UltraTech reported a 36% year-on-year (YoY) decline in net profit, dropping to Rs 825 crore, below analyst expectations. Revenue for the quarter also fell 2% YoY to Rs 15,635 crore, and EBITDA margins contracted by 300 basis points. Despite this, the company saw a 3% increase in domestic sales volume, supported by lower energy costs.
In a strategic move, UltraTech invested Rs 3,954 crore for a 32.7% equity stake in India Cements, further solidifying its position in South India. UltraTech holds an 11% market share in the region, while competitor Adani holds 6%. UltraTech also secured $500 million through a sustainability-linked loan, underscoring its focus on sustainable growth driven by infrastructure and housing demand.