Vol 6, No 6 (2015) > Mechanical Engineering >

Optimization of Organic Rankine Cycle Waste Heat Recovery for Power Generation in a Cement Plant via Response Surface Methodology

Hendi Riyanto, Sigit Yoewono Martowibowo



A cement plant that produces 8,300 tons per day
releases 265,000 Nm3/h of flue gas at 360°C from its Suspension
Preheater (SP) and 400,000 Nm3/h of hot air at 310°C from its air
quenching cooler (AQC). It is imperative to recover the waste heat emitted by
the plant for power generation, i.e., Waste Heat Recovery Power Generation
(WHRPG). This paper aims to optimize waste heat recovery from the cement plant
using Response Surface Methodology (RSM), for which an Organic Rankine Cycle
(ORC) is applied for electric power generation. The working fluid of an ORC
power generation system was selected among candidates of organic working fluids
(i.e., isobutane, isopentane, benzene, and toluene) by using the Technique for
Order of Preference by Similarity to Ideal Solution (TOPSIS), a Multi-Criteria
Decision Analysis (MCDA) method. The ORC power generation system configuration
and the corresponding operating conditions employing the selected working fluid
(i.e., pressures and temperatures) are optimized by applying RSM. Based on
TOPSIS evaluation and considering factors of health, safety, environment
impacts, cost, and power generated, isopentane was selected as the working
fluid for the ORC WHRPG, which was configured to consist of a boiler, two
expansion turbines, a reheater, and a recuperator. Implementation of RSM
attained optimum operating conditions of high pressure turbine, low pressure
turbine, and condenser at 11.3 bar-a saturated vapor, 4.3 bar-a and 184°C, and
1.8 bar-a, respectively. Finally, the gross electric power generated of 5.7 MW
at 12.5 percent of energy conversion efficiency is generated by the pertinent

Keywords: Cement plant; Optimization; RSM; ORC; TOPSIS; WHRPG

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