Waste heat recovery power plants in the cement industry

In an effort to reduce their reliance on coal, lower emissions, and increase energy efficiency further, many cement producers are turning to alternative fuels. Cement waste heat recovery and recycling that energy into production efforts is a cost-effective and more environmentally friendly strategy, as it lowers waste and reduces reliance on fossil fuels.

With GE steam turbines, cement manufacturers can recover heat from the kiln exhaust released during the manufacturing process and then generate electricity from that waste heat. This heat is typically produced by pre-heater waste gas and air-quenching waste gas.

Steam produced from these two waste gases during the cement waste heat recovery process powers the steam turbine, creating an electrical power source for the plant. Because the cement plant is using waste in this way, it can reduce its dependence on costly fuel sources and grid power.

GE’s portfolio of gas and steam turbines for the cement industry

GE offers a variety of gas and steam turbines for the cement industry for power production as well as waste heat recovery. Learn more about each to determine which turbine is right for you.

6B.03 gas turbine

The rugged, reliable 6B.03 heavy-duty gas turbine is a popular choice for refineries, natural gas liquefaction power, CHP applications and industrial power.

Its ability to operate in island mode makes the 6B an excellent solution for remote installations and extreme operating conditions far from the grid. And with more than 1,200 units installed since 1978, it has a record of dependability. The turbine can ramp to 20 MW in less than five seconds and accommodate non-standard fuels in cogeneration and industrial power generation operations. It features a 44 MW simple cycle output and greater than 51% combined cycle efficiency. Its standardized architecture and pre-assembled packaging allow for a delivery cycle of 10 months from contract signature to commercial operation.

LM2500 aeroderivative gas turbine

The LM2500 is the most reliable aeroderivative gas turbine in the world, featuring reliability consistently above 99.8%.

Recommended for combined cycle, onshore and offshore power generation, mechanical drive, and cogeneration, the LM2500 power plants feature 21-34 MW simple cycle output, up to 38.5% efficiency and accommodate a wide variety of fuels. It also comes with optional clutch-less synchronous condensing.

LM6000 aeroderivative gas turbine

The LM6000 allows you to operate on a wide variety of fuels—including natural gas, LPG (propane and butane), isopentane, ethanol, diesel, and Coke Oven gas.

This allows you to quickly switch between fuels to save money, all without stopping or a reduction in power. It has a 45-58 MW net power output and up to 41.3% net efficiency. Its start time for a simple cycle is less than 5 minutes, and its ramp rate is 50 MW/minute. The LM6000 offers 99%+ start and operational reliability, alongside 98% availability. Its fast start allows operators to differentiate their dispatch capability, and its dual-fuel capabilities provide fuel flexibility and help customers meet emissions limits.

200 series steam turbine

The STF-D200 and STF-A200 steam turbines are available with internally and externally controlled extractions to remove steam at any point along the steam path at the desired flow and pressure conditions.

Our LP moisture removal features enable reliable operation and improve LP section efficiency, and a self-synchronizing clutch improves operational flexibility in a single-shaft configuration.

600 series steam turbine

GE’s 600 series combined-cycle steam turbines help deliver high performance, reliability and availability for today’s 50 Hz and 60 Hz applications.

The STF-A650 is a two-casing machine with a combined IP-LP section and a separate HP section, providing high performance in a compact footprint, while the STF D-series turbines help deliver the reliability and availability needed in today’s demanding energy environment.

Customer stories

GE’s Advanced Gas Path (AGP) solution strengthens cement power production

In a historic deal that marked the first time GE’s Advanced Gas Path (AGP) solution is strengthening power generation productivity for the cement industry globally, Saudi Cement upgraded three GE 6B gas turbines at its Hofuf plant to increase capacity by 25 megawatts and efficiency by up to 3.3% per turbine.

increase in combined output

25 MW 

increased capacity

"

"Power supply is both a key input and one of the major costs in our manufacturing process. Reliable, efficient electricity supply is thus essential to the continuous operations of our facility as well as our competitiveness. GE’s Advanced Gas Path upgrade solution will allow us to improve efficiencies and become more self-sufficient in power production."

Mohammed AlGarni

CEO of Saudi Cement

The AGP upgrade allows Saudi Cement to become more self-sufficient in power production, achieve greater cost efficiencies by significantly saving fuel and enable the company to better serve the industry’s supply chain in alignment with the Saudi National Transformation Program’s goal to improve fuel utilization in electricity generation to 40% by 2020.

Learn more about an Advanced Gas Path upgrade for your cement plant