Today, industries face tremendous pressure to find innovative solutions that enhance efficiency and reduce environmental impact. The cement industry, known for its high energy consumption, has long sought ways to optimize power usage and reduce emissions. One of the most promising advancements in this area is waste heat recovery, a process that captures and repurposes the heat generated during cement manufacturing to produce electricity. 

This breakthrough is transforming the way the cement industry approaches sustainability. However, while the concept of waste heat recovery is widely known, the real challenge lies in implementing efficient and reliable systems that deliver long-term benefits. 

“That’s precisely what Triveni Turbines has been doing for decades: leading the way in steam turbine technology to help cement plants and other industries achieve their energy efficiency goals. Through our custom-designed steam turbines, we have mastered the art of transforming waste heat into a powerful source of sustainable power generation.” 

The Role of Waste Heat Recovery in Cement Production 

Cement manufacturing is an energy-intensive process that generates significant amounts of waste heat. Traditionally, this heat was lost to the environment, contributing to inefficiency and environmental degradation. Waste Heat Recovery (WHR) systems are designed to capture this excess heat and convert it into usable power, reducing a plant’s reliance on external energy sources. 

By leveraging waste heat, cement producers can lower their carbon footprint, decrease operational costs, and improve overall energy efficiency. This aligns with the worldwide shift towards sustainable and green technology, positioning the cement industry as a key player in the energy transition. 

Triveni Turbines’ Expertise in the Cement Industry 

We at Triveni Turbines have been providing high-efficiency steam turbines for the sub-100MW market, catering to industries like sugar, distillery, cement, steel, pharmaceuticals, and many more. In the cement sector, we have a proven track record of delivering customized steam turbine solutions that meet the specific operational demands of waste heat recovery. For over 50 years, Triveni Turbines has installed over 6,000 steam turbines in more than 80 countries, with a total capacity exceeding 16 GW. 

Case Study 

One of the most notable examples of our steam turbine generators for WHR applications can be found in a cement plant in Satna, Madhya Pradesh. The plant annually produces 7 million tons per annum (MTPA) and requires an upgrade in its power generation capabilities. The existing turbine, supplied by an overseas OEM, was no longer able to meet the plant’s needs due to low efficiency and performance. 

Triveni Turbines provided a high-efficiency 22 MWe steam turbine generator (STG) by replacing the existing 14 MWe steam turbine generator that boosted the plant’s power generation by 7 MW and enhanced energy efficiency. We designed the new turbine to operate with high-pressure steam at 10.50 ata and 295°C, as well as medium-pressure injection steam at 2 ata and 190°C. This innovative solution led to reduced coal consumption, lower power generation costs, and a significant decrease in the plant’s carbon footprint. 

The STG set was installed on the same foundations and within the same housing as the existing STG, utilizing the same hardware components. The entire installation and commissioning process, including the dismantling and removal of the existing STG set, was handled by our qualified in-house team of engineers. 

Benefits of our Steam Turbines for the Cement Industry WHR 

The success of Triveni Turbines in WHR applications stems from our ability to address the real-world challenges faced by cement producers. Rather than simply focusing on the technical features, we emphasize the benefits that steam turbines bring to customers, such as: 

1. Energy Optimization 

Triveni Turbines’ high-efficiency steam turbines significantly optimize energy use by converting waste heat into usable power, reducing the plant’s dependency on the grid. This not only lowers energy costs but also improves the plant’s overall power generation capacity. 

2. Cost-effective Power Generation 

With our ability to maximize energy recovery, we provide cost-effective power generation solutions. By reducing the need for additional fuel, such as coal, cement plants can minimize operational expenses, leading to higher profitability. 

3. Environmental Impact 

Triveni Turbines is committed to promoting sustainable power generation solutions. By enabling cement plants to convert waste heat into power, we help reduce greenhouse gas emissions and lower the plant’s carbon footprint. This is particularly important as the cement industry strives to adopt green technology and align with global efforts to combat climate change. 

4. Customized Solutions 

We ensure that our steam turbines are customized to the specific requirements of each plant. Our expertise in replacement solutions also makes sure that existing systems can be upgraded without significant disruptions. 

5. Aftermarket Services 

Triveni Turbines’ commitment to customer success does not end with installation. We offer a comprehensive suite of aftermarket services, including 24/7 customer support and regular maintenance to ensure optimal turbine performance. This proactive approach to service minimizes downtime and extends the lifecycle of the turbine. 

Driving Success in Waste Heat Recovery 

Waste Heat Recovery in the cement industry represents an opportunity to reduce energy costs, enhance efficiency, and lower emissions. With Triveni Turbines at the forefront, cement producers can harness the latest steam turbine technology to achieve their sustainability goals. By delivering tailored power generation solutions that meet the unique needs of each manufacturing industry, we will continue to set benchmarks in the waste heat recovery market. 

With a proven track record and extensive expertise in the cement industry, we are positioned as a leader in delivering efficient power generation solutions. Our focus on sustainable technologies further strengthens our role in driving sustainable power generation solutions across the industrial sector.