Waste Heat Recovery Systems

Waste Heat Recovery Systems (WHR) utilize the heat in industrial waste gases for the generation of electrical power. WHR Systems are common in cement and lime plants and other pyroprocess industries where Rotary Kilns are used and the price and reliability of grid power supply make the investment economically feasible.

In developing the concepts for the WHR system, the challenge lies in determining the optimum quantity of waste heat available for power generation and in integrating the WHR system with the cement process. PEC Consulting can assist the client to perform a Feasibility Study to assess the optimum size and configuration of the WHR system and the viability of the project. The study will provide recommendations for an efficient and economical system based on several factors such as the thermal capacity of exhaust gases, size and type of heat exchanger, and desired parameters of the cogeneration system operating conditions.

In some cogeneration systems, the exhaust gas from power generator sets using diesel oil or furnace oil is used as a source of heat for the WHR plant.


    • Reduction of electrical power demand from the grid and consequently of the plant’s operating costs.
    • Reliable electrical power supply from waste gases from the kiln and cooler.
    • Reduction of the carbon footprint by conserving the use of fossil fuels and thus helping the environment.

What We Do

    • Assess the realistic quantity of heat that can be recovered taking into account variations in the drying requirements of raw materials and fuel throughout the year. This analysis results in optimum sizing of the WHR system.
    • Determine the energy recovery process to be utilized: The steam Rankine cycle uses water as the thermodynamic medium and is commonly used for generating power from high temperature sources. Depending on the temperature and other situational factors, some plants use the Organic Rankine cycle for generating power, using an organic compound as the thermodynamic medium.
    • Optimize the layout of the boilers and power generation system considering plant footprint space constraints.
    • Provide an effective integration of the WHR equipment with the existing cement plant or industrial facility.
    • Provide our clients with an assessment of the power potential, a financial analysis with capital and operating cost estimates, and an economic analysis to assess the viability of the project.
    • Technical Feasibility Studies of WHR Systems for Cement Plants.
    • Technical Feasibility Studies of WHR Systems for Lime Plants.

Learn more about WHR; click on the following publication:

Waste Heat Recovery for Power Generation

To download a list or Energy Efficiency/Process Studies, including WHR projects, please click here.

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