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WHR Project with ORC awarded to CTP Italy

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World Cement,

CTP Team Italy recently 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 customised 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 29 MW of waste heat to feed a new ORC equipped with a state-of-the-art axial turbine of 7.2 MW by Turboden. The new WHR is expected to generate approximately 50 million 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 tpy 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 cycles and with the added advantage that the plant can run autonomously from remote.

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 programme.

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