New K Plant WHRPG System Goes to Germany

Jul. 09, 2010

Tokyo, July 09, 2010 - Kawasaki Plant Systems, Ltd. (K Plant) announced today that it was awarded a contract to supply a waste heat recovery power generation (WHRPG) system to be constructed at Suedbayerische Portland Zementwerk Gebr. Wiesboeck & Co. GmbH’s Rohrdorf Cement Plant. This is the first system of its kind in Europe and has a power generation capacity of about 6,800 kW. The plant is scheduled to be put into operation in April 2012.

The project will be implemented by a consortium consisting of K Plant and Germany’s largest electric machinery company, Siemens. K Plant will provide the overall plant design and engineering, waste heat recovery boilers, basic engineering for equipment to be procured by the client and technical advisory services for erection/commissioning. Siemens will provide the steam turbine and generator as well as electrical and instrumentation equipment based on plant engineering to be done by K Plant. Rohrdorf Cement Plant is responsible for building, steel construction, piping and connection with existing equipment. All possible heat sources at the plant were analyzed and evaluated in close cooperation with Rohrdorf Cement, and as a result, an innovative and very high efficiency WHRPG has been developed.

A cement plant WHRPG system is designed to recover waste heat from the calcining process with waste heat boilers and generate electricity via a steam turbine. This energy-saving system can utilize waste heat to generate electricity to meet about 30% of the in-house power consumption needs of a cement plant while reducing CO2 emissions by about 40,000 tons per year. The system has been installed at most large size cement plants in Japan.

Since its first installation of a 2,640 kW system at a Japanese cement manufacturer in the 1980’s, K Plant has been a global leader in supplying cement plant waste heat recovery power generation systems. K Plant has gained a wealth of experience after delivering more than 130 units to date with a total power generation capacity that comes to more than 1,600 MW on top of a total reduction in CO2 emissions that comes to more than 1,100 million tons per year. This recently awarded contract is a testimony to K Plant’s proven track record and technical capability.

Germany and the rest of Europe are turning their attention to energy saving and environmentally friendly systems as a way to cope with global warming and strict environmental regulations. Interest in installing WHRPG systems at cement plants is expected to grow rapidly. This project is being supported by Germany’s Federal Ministry for the Environment within the framework of its environmental innovation program.