Study of the waste heat recovery from kilns of Tartous cement factory

In this research we carried out a study on the thermal furnace in Tartous Cement Plant, it is a cylinder with a diameter of 4.6 m and a length of 69 m, and lined with 10 cm thickness of manganese bricks as a aim of thermal insulation. The temperature inside the furnace grades from 800 Co at the beginning the oven reaches 1400 Co at the end, which is relatively high heat. Although there is a liner for thermal insulation, this does not prevent thermal leakage to the outer surface of the furnace, where the values ​​of lost and leaked temperatures to the outer medium across the oven surface varies between (130-350 Co). Therefore, the idea of ​​the research is to design a heat exchanger to recover part of the waste heat and use it in thermal applications. For this reason, a laboratory model has been designed for the oven with a length of 1 m and a diameter of 27 cm with thermal conditions that correspond to the production process, and a model of heat exchanger has been applied with copper tubes of different diameters (0.86,1.36 and 1.86cm) and tested at different flow speeds (0.015-0.52 m/sec). The best yield for the exchanger was 1.36 cm in diameter and water flow velocity was 0.0354 m/sec. This ensures a thermal energy recovery 10121.4998 [kw], equivalent to burning 8246.8368 tonfuel/year, this amount can be used to steam 782161.88 m3w/year, the rate of heat recovery is 72.088%, and the rate of fuel recovery is 5.72697%.