Three different sources for the Waste heat recovery project with orc technology awarded to CTP Italy

Figure: Secil-Outão Cement plant

After the first two successful WHR projects in Turkey, CTP Team brings energy saving to Secil-Outão Cement plant

August 2020 – CTP Team Italy signed a turnkey EPC contract with Secil Group for a new Waste Heat Recovery System for Outão Cement factory, Portugal. The project consists of several new developments to provide a highly customized solution to feed a double-loop system (thermal oil + Organic), to recover waste heat and produce electricity from three different sources: kiln pre-heater and clinker cooler of the existing 4000 TPD cement unit N°9 and a new solar field, that SECIL will install nearby the production line.

The new heat exchangers by CTP will recover up to 29MW of waste heat to feed a new ORC equipped with a state-of-the-art axial turbine of 7,2MW by Turboden. The new WHR is expected to generate approximately 50 million of kWh per year, covering more than 30% of the current plant’s electricity needs. The first kW generation is scheduled for the second half of 2022.From an environment point of view, the new WHR system alone will drastically reduce the carbon footprint of cement plant by a total of 14.000 ton per year of equivalent CO2. In addition, the system provided by CTP is totally water free, without any need to treat residual waters from the process.

The WHR system is fully automatic and drastically reduces the need of physical presence of operators during the daily operation. Thanks to this specific advantage of organic cycles and to the total absence of water treatments in the process, the OPEX is reduced lower by 75% respect in comparison to an equivalent WHR based on traditional Steam Rankine cycle and with the added advantage that the plant can run autonomously from remote even in problematic situations like those that we are living in these days.

The WHR Project is part of the major R&D Clean Cement Line Project (CCL Project) that Group SECIL is undertaking at its Outão cement plant in Portugal. The CCL Project, aims to bring the Outão cement plant to the forefront of energy efficiency and lowest CO2 emissions among the European cement producers, and CCL Project is partly funded by the Portugal 2020 Government incentives program.

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The new solution engineered by CTP Team easily integrates different heat sources to produce electricity:
➕ AQC boiler (on clinker cooler)
➕ PH Boiler (on kiln preheater)
☀ new solar field
This project is concrete step towards the path of carbon neutrality and energy transition targets of our client Secil Group supported by CTP Team, Italy.

Energy Transition and solar energy field
WHR systems play an active role in the energy transition from high carbon to low carbon energy and in reaching the target of Zero Emissions.
In the Portuguese project we will integrate the energy from a solar field with the heat coming from the cement process (Kiln and PH). The heat flow coming from the solar field is in the range of 2,100 kWt, and shows how WHR systems developed by CTP can easily integrate different heat sources and produce electricity.
The solar field is connected in parallel to the preheater boiler. Respect to the previous WHR systems installed by CTP, this solution allows to reduce the amount of circulating oil. This case show how the WHR system is flexible.
The energy contribution of the solar field will allow to further increase the amount of zero-carbon energy that will be used in the cement plant.
When the WHR is running, we expect to produce 53.4 million kwh per year, without the use of fossil fuel, without CO2 emissions, without the use of water and integrating the energy coming from the solar field.
In general, the most suitable configuration is chosen case-by-case in order to find the most efficient solution.

Office CTP Team Italy
Ctp Team headquarter is located in the north of Italy in Kilometro Rosso Innovation district, one of the leading private hub for innovation in Europe.