Thermodynamics, economy and environment analyses and optimization of series, parallel, dual-loop Kalina cycles for double-source heat recovery in cement industry
This research aims to investigate the heat recovery of both suspension preheater flue gas and clinker cooler hot air in cement industry. Three thermodynamic cycles including series Kalina Cycle (S-KC)、parallel Kalina Cycle (P-KC) and dual-loop Kalina Cycle (DL-KC) are introduced for converting dual-...
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| Published in | PloS one Vol. 20; no. 2; p. e0315972 |
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| Main Authors | , , , |
| Format | Journal Article |
| Language | English |
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United States
Public Library of Science
21.02.2025
Public Library of Science (PLoS) |
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| Abstract | This research aims to investigate the heat recovery of both suspension preheater flue gas and clinker cooler hot air in cement industry. Three thermodynamic cycles including series Kalina Cycle (S-KC)、parallel Kalina Cycle (P-KC) and dual-loop Kalina Cycle (DL-KC) are introduced for converting dual-source heat resources into power to enhance the system efficiency for cement production process. Firstly, the multi-layer comprehensive evaluation models are established for the three thermodynamic cycles. Then, the parametric studies are implemented to estimate the influences of six key parameters on the system’s thermodynamic-economic-environmental performances. Meanwhile, optimization investigations consisting of thermodynamic optimal design (TOD), thermodynamic and economic optimal design (TEOD), and thermodynamic, economic and environmental optimal design (TEEOD) are considered, and the performances of systems and components are compared under three optimal design scenarios. The results prove that, for S-KC, P-KC and DL-KC, the higher net power output ( W net ) can be gained with decreasing condenser outlet temperature and regenerator temperature difference, and increasing evaporator temperature difference and superheat degree, the lower electricity production cost ( EPC ) can be acquired with decreasing condenser outlet temperature, evaporator temperature difference and regenerator temperature difference, while the less environment impact load ( EIL ) can be attained with decreasing condenser outlet temperature, regenerator temperature difference and basic ammonia concentration, and increasing superheat degree. In addition, under TOD, TEOD and TEEOD scenarios, DL-KC is the best selection from the thermodynamic, economic and environmental perspectives, with the corresponding W net of 7166 kW, 6904 kW and 6838 kW, the EPC of 0.00476 $/kWh, 0.00369 $/kWh and 0.00362$/kWh, the EIL of 0.0597 mPE China,90 /kWh, 0.0599 mPE China,90 /kW and 0.0593 mPE China,90 /kW. It also identifies that the evaporator unit is the key component contributing to exergy destruction and investment cost for three systems, while the pump has the maximum influence on environmental performance. |
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| AbstractList | This research aims to investigate the heat recovery of both suspension preheater flue gas and clinker cooler hot air in cement industry. Three thermodynamic cycles including series Kalina Cycle (S-KC)、parallel Kalina Cycle (P-KC) and dual-loop Kalina Cycle (DL-KC) are introduced for converting dual-source heat resources into power to enhance the system efficiency for cement production process. Firstly, the multi-layer comprehensive evaluation models are established for the three thermodynamic cycles. Then, the parametric studies are implemented to estimate the influences of six key parameters on the system's thermodynamic-economic-environmental performances. Meanwhile, optimization investigations consisting of thermodynamic optimal design (TOD), thermodynamic and economic optimal design (TEOD), and thermodynamic, economic and environmental optimal design (TEEOD) are considered, and the performances of systems and components are compared under three optimal design scenarios. The results prove that, for S-KC, P-KC and DL-KC, the higher net power output (Wnet) can be gained with decreasing condenser outlet temperature and regenerator temperature difference, and increasing evaporator temperature difference and superheat degree, the lower electricity production cost (EPC) can be acquired with decreasing condenser outlet temperature, evaporator temperature difference and regenerator temperature difference, while the less environment impact load (EIL) can be attained with decreasing condenser outlet temperature, regenerator temperature difference and basic ammonia concentration, and increasing superheat degree. In addition, under TOD, TEOD and TEEOD scenarios, DL-KC is the best selection from the thermodynamic, economic and environmental perspectives, with the corresponding Wnet of 7166 kW, 6904 kW and 6838 kW, the EPC of 0.00476 $/kWh, 0.00369 $/kWh and 0.00362$/kWh, the EIL of 0.0597 mPEChina,90/kWh, 0.0599 mPEChina,90/kW and 0.0593 mPEChina,90/kW. It also identifies that the evaporator unit is the key component contributing to exergy destruction and investment cost for three systems, while the pump has the maximum influence on environmental performance. This research aims to investigate the heat recovery of both suspension preheater flue gas and clinker cooler hot air in cement industry. Three thermodynamic cycles including series Kalina Cycle (S-KC)、parallel Kalina Cycle (P-KC) and dual-loop Kalina Cycle (DL-KC) are introduced for converting dual-source heat resources into power to enhance the system efficiency for cement production process. Firstly, the multi-layer comprehensive evaluation models are established for the three thermodynamic cycles. Then, the parametric studies are implemented to estimate the influences of six key parameters on the system’s thermodynamic-economic-environmental performances. Meanwhile, optimization investigations consisting of thermodynamic optimal design (TOD), thermodynamic and economic optimal design (TEOD), and thermodynamic, economic and environmental optimal design (TEEOD) are considered, and the performances of systems and components are compared under three optimal design scenarios. The results prove that, for S-KC, P-KC and DL-KC, the higher net power output ( W net ) can be gained with decreasing condenser outlet temperature and regenerator temperature difference, and increasing evaporator temperature difference and superheat degree, the lower electricity production cost ( EPC ) can be acquired with decreasing condenser outlet temperature, evaporator temperature difference and regenerator temperature difference, while the less environment impact load ( EIL ) can be attained with decreasing condenser outlet temperature, regenerator temperature difference and basic ammonia concentration, and increasing superheat degree. In addition, under TOD, TEOD and TEEOD scenarios, DL-KC is the best selection from the thermodynamic, economic and environmental perspectives, with the corresponding W net of 7166 kW, 6904 kW and 6838 kW, the EPC of 0.00476 $/kWh, 0.00369 $/kWh and 0.00362$/kWh, the EIL of 0.0597 mPE China,90 /kWh, 0.0599 mPE China,90 /kW and 0.0593 mPE China,90 /kW. It also identifies that the evaporator unit is the key component contributing to exergy destruction and investment cost for three systems, while the pump has the maximum influence on environmental performance. This research aims to investigate the heat recovery of both suspension preheater flue gas and clinker cooler hot air in cement industry. Three thermodynamic cycles including series Kalina Cycle (S-KC)、parallel Kalina Cycle (P-KC) and dual-loop Kalina Cycle (DL-KC) are introduced for converting dual-source heat resources into power to enhance the system efficiency for cement production process. Firstly, the multi-layer comprehensive evaluation models are established for the three thermodynamic cycles. Then, the parametric studies are implemented to estimate the influences of six key parameters on the system's thermodynamic-economic-environmental performances. Meanwhile, optimization investigations consisting of thermodynamic optimal design (TOD), thermodynamic and economic optimal design (TEOD), and thermodynamic, economic and environmental optimal design (TEEOD) are considered, and the performances of systems and components are compared under three optimal design scenarios. The results prove that, for S-KC, P-KC and DL-KC, the higher net power output (Wnet) can be gained with decreasing condenser outlet temperature and regenerator temperature difference, and increasing evaporator temperature difference and superheat degree, the lower electricity production cost (EPC) can be acquired with decreasing condenser outlet temperature, evaporator temperature difference and regenerator temperature difference, while the less environment impact load (EIL) can be attained with decreasing condenser outlet temperature, regenerator temperature difference and basic ammonia concentration, and increasing superheat degree. In addition, under TOD, TEOD and TEEOD scenarios, DL-KC is the best selection from the thermodynamic, economic and environmental perspectives, with the corresponding Wnet of 7166 kW, 6904 kW and 6838 kW, the EPC of 0.00476 $/kWh, 0.00369 $/kWh and 0.00362$/kWh, the EIL of 0.0597 mPEChina,90/kWh, 0.0599 mPEChina,90/kW and 0.0593 mPEChina,90/kW. It also identifies that the evaporator unit is the key component contributing to exergy destruction and investment cost for three systems, while the pump has the maximum influence on environmental performance.This research aims to investigate the heat recovery of both suspension preheater flue gas and clinker cooler hot air in cement industry. Three thermodynamic cycles including series Kalina Cycle (S-KC)、parallel Kalina Cycle (P-KC) and dual-loop Kalina Cycle (DL-KC) are introduced for converting dual-source heat resources into power to enhance the system efficiency for cement production process. Firstly, the multi-layer comprehensive evaluation models are established for the three thermodynamic cycles. Then, the parametric studies are implemented to estimate the influences of six key parameters on the system's thermodynamic-economic-environmental performances. Meanwhile, optimization investigations consisting of thermodynamic optimal design (TOD), thermodynamic and economic optimal design (TEOD), and thermodynamic, economic and environmental optimal design (TEEOD) are considered, and the performances of systems and components are compared under three optimal design scenarios. The results prove that, for S-KC, P-KC and DL-KC, the higher net power output (Wnet) can be gained with decreasing condenser outlet temperature and regenerator temperature difference, and increasing evaporator temperature difference and superheat degree, the lower electricity production cost (EPC) can be acquired with decreasing condenser outlet temperature, evaporator temperature difference and regenerator temperature difference, while the less environment impact load (EIL) can be attained with decreasing condenser outlet temperature, regenerator temperature difference and basic ammonia concentration, and increasing superheat degree. In addition, under TOD, TEOD and TEEOD scenarios, DL-KC is the best selection from the thermodynamic, economic and environmental perspectives, with the corresponding Wnet of 7166 kW, 6904 kW and 6838 kW, the EPC of 0.00476 $/kWh, 0.00369 $/kWh and 0.00362$/kWh, the EIL of 0.0597 mPEChina,90/kWh, 0.0599 mPEChina,90/kW and 0.0593 mPEChina,90/kW. It also identifies that the evaporator unit is the key component contributing to exergy destruction and investment cost for three systems, while the pump has the maximum influence on environmental performance. This research aims to investigate the heat recovery of both suspension preheater flue gas and clinker cooler hot air in cement industry. Three thermodynamic cycles including series Kalina Cycle (S-KC), parallel Kalina Cycle (P-KC) and dual-loop Kalina Cycle (DL-KC) are introduced for converting dual-source heat resources into power to enhance the system efficiency for cement production process. Firstly, the multi-layer comprehensive evaluation models are established for the three thermodynamic cycles. Then, the parametric studies are implemented to estimate the influences of six key parameters on the system's thermodynamic-economic-environmental performances. Meanwhile, optimization investigations consisting of thermodynamic optimal design (TOD), thermodynamic and economic optimal design (TEOD), and thermodynamic, economic and environmental optimal design (TEEOD) are considered, and the performances of systems and components are compared under three optimal design scenarios. The results prove that, for S-KC, P-KC and DL-KC, the higher net power output (W.sub.net) can be gained with decreasing condenser outlet temperature and regenerator temperature difference, and increasing evaporator temperature difference and superheat degree, the lower electricity production cost (EPC) can be acquired with decreasing condenser outlet temperature, evaporator temperature difference and regenerator temperature difference, while the less environment impact load (EIL) can be attained with decreasing condenser outlet temperature, regenerator temperature difference and basic ammonia concentration, and increasing superheat degree. In addition, under TOD, TEOD and TEEOD scenarios, DL-KC is the best selection from the thermodynamic, economic and environmental perspectives, with the corresponding W.sub.net of 7166 kW, 6904 kW and 6838 kW, the EPC of 0.00476 $/kWh, 0.00369 $/kWh and 0.00362$/kWh, the EIL of 0.0597 mPE.sub.China,90 /kWh, 0.0599 mPE.sub.China,90 /kW and 0.0593 mPE.sub.China,90 /kW. It also identifies that the evaporator unit is the key component contributing to exergy destruction and investment cost for three systems, while the pump has the maximum influence on environmental performance. |
| Audience | Academic |
| Author | Ning, Shengwang Xu, Yongjun Wang, Yali Qiu, Yongliang |
| Author_xml | – sequence: 1 givenname: Yali orcidid: 0000-0002-8414-5762 surname: Wang fullname: Wang, Yali – sequence: 2 givenname: Yongjun surname: Xu fullname: Xu, Yongjun – sequence: 3 givenname: Yongliang surname: Qiu fullname: Qiu, Yongliang – sequence: 4 givenname: Shengwang surname: Ning fullname: Ning, Shengwang |
| BackLink | https://www.ncbi.nlm.nih.gov/pubmed/39982869$$D View this record in MEDLINE/PubMed |
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| Copyright | Copyright: © 2025 Wang et al. This is an open access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited. COPYRIGHT 2025 Public Library of Science 2025 Wang et al. This is an open access article distributed under the terms of the Creative Commons Attribution License: http://creativecommons.org/licenses/by/4.0/ (the “License”), which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited. Notwithstanding the ProQuest Terms and Conditions, you may use this content in accordance with the terms of the License. 2025 Wang et al. This is an open access article distributed under the terms of the Creative Commons Attribution License: http://creativecommons.org/licenses/by/4.0/ (the “License”), which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited. Notwithstanding the ProQuest Terms and Conditions, you may use this content in accordance with the terms of the License. |
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| SubjectTerms | Ammonia Analysis Capacitors Cement Cement industry Cement plants Clinker Coal-fired power plants Construction Industry - economics Construction Industry - methods Construction Materials Design Design optimization Economics Electric power generation Electricity Energy consumption Energy efficiency Energy use Environmental aspects Environmental performance Evaporation Evaporators Exergy Flue gas Gases Heat Heat recovery Heat recovery systems Heating equipment Hot Temperature Impact loads Industrial plant emissions Investigations Kalina cycle Methods Models, Theoretical Multilayers Optimization Payback periods Production costs Production processes Regenerators Temperature Temperature gradients Thermodynamic cycles Thermodynamics |
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| Title | Thermodynamics, economy and environment analyses and optimization of series, parallel, dual-loop Kalina cycles for double-source heat recovery in cement industry |
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