Objective The aim is to saving energy by generating hot gases required for a calciming processes in a revolving tubular Kiln on the basis of a power-heat cogeneration plant: a gas turbine will supply the basic load of hot gases and cogenerate electricity. Up to now hot gases have been supplied by firing natural gas. Energy saving expected is 691 TOE/year.The demonstration phase for the entire project was sheduled for the period between 1 Jan 89 and 30 June 89.However, due to unexpected corrosion problems leading to permanent pollution of the finished product, the demonstration phase had to be interrupted on 15 April 89.During the entire operating period, which comprised the period between 2 May 88 and 25 November 88 (with the gas turbine alone) and between 26 November 88 and 15 April 89 (gas turbine + surface burner), 5,664 MWh of electric power were produced, and 50,514 MWh of natural gas were consumed.The project has not proved to be full economical, because at no time has the total exhaust-gas volume of the gas turbine been utilized in, or by, the rotary-kiln system.While it was necessary to carry on our production, we were unable to optimize the system control. It is to be expected, however, that almost the complete exhaust-gas volume could be utilized in, or by, the rotary-kiln plant.At the Benckiser-Knapsack plant, in Ladenburg (D), the mean demand of hot gas required for calcinating processes in revolving tubular Kilns is 8.4 kg/s, at the average temperature of 750 deg.C and were obtained, until now, by burning natural gas.In the project hot gases will be generated in combination with a cogeneration of thermal and electric energy. A gas turbine is used for this pourpose and the exhaust from this gas turbine supply the necessary basic load of hot gases.The selected type of gas turbines generates 7.7 kg/s of hot gas at a temperature of 505 deg.C and produces 1040 kw of electric power.The fishtail burners, which are integrated directly into the exhaust duct of the gas turbine, will heat the hot gases to the required temperature.These burners as well as gas turbine burn natural gas and the residual oxygen in the exhaust from the gas turbine (approx. 15 - 16%) is used as combustion air.Since the hot gas demand is greater than the quantities of exhaust obtained from the gas turbine, and additional portion is supplied adding mixed air which can be furnished from an existing waste heat recovery system.The new hot gas generating system will be installed in parallel with existing hot gas generating plant. The projected system , compared to the actual separate hot gas and power generation, results in energy saving of 1340 kw, equivalent at 6000 operating hour/year to 8040 Mwh/y, i.e. 691 TOE/y. Programme(s) ENG-ENDEMO C - Programme (EEC) of demonstration projects and industrial pilot projects (EEC) in the energy field, 1985-1989 Topic(s) 3.4 - INDUSTRY Call for proposal Data not available Funding Scheme DEM - Demonstration contracts Coordinator BK LADENBURG GMBH EU contribution No data Address DR. ALBERT REINMANN STRASSE 22 6802 Ladenburg - Neckar Germany See on map Total cost No data
