Need of WHRS:

Electrical energy is a significant contributor to the cost of manufacture of cement. In its endeavour to remain competitive, the cement industry remains pre-occupied with figuring out measures to reduce energy consumption or the cost of energy. Since the unit cost of captive generation turns out to be well below that of grid power, most cement plants prefer to set-up a captive power plant. As an additional measure, several cement plants have invested in power generation based on the recovery of heat from kiln & cooler exhaust gases, which would otherwise have been vented to the atmosphere; so called Waste Heat Recovery Systems (WHRS).

Our Scope

In the project executed in JK Cement Mangrol, Indexel was responsible for completely designing and implementation of Distributed Control System (DCS)for WHRS which includes development of application software to control and monitor entire WHRS operation.

DCS System maximizes the WHRS efficiency and reliability through the automation, integration and optimization of the entire plant. The system handles approx 1500 I/Os of the entire plant.

The application developed in the project encompasses logic for:
  1. 2 types of boiler for the kiln
    1. PH Boiler: Horizontal Boiler with vertical tubes for uniform dust disposal
    2. AQC Boiler: Vertical Boiler with horizontal tubes
  2. Steam Turbine of 29MW rating.
  3. Boiler Feed water and Deaerator System.
  4. Condensate System
  5. ACC Fan System
  6. Water Treatment Plant
  7. Cooling Water System

The System was commissioned and synchronized with the grid in March 2020 and is working satisfactorily. Apart from the monetary benefits involved, WHRS is playing vital role in energy conservation, as JK do not need any additional fuels to generate electricity and hence directly help conserve fuels and reduce overall carbon emission.

In-case of any queries please contact us for further information or to work together on your modernization plans…..