B
BARUNSWAY
Waste Heat Recovery ⚡ Power & Thermal Energy Calculator
Live calculation ready.
PH Recovered Heat
— kW
From preheater gas
AQC Recovered Heat
— kW
From cooler air
Total Recoverable
— kW
PH + AQC thermal energy
Boiler Duty
— kW
After η boiler
Steam Generated
— TPH
Equivalent steam
Turbine Output
— MW
Shaft power
Gross Power
— MW
After generator
Net WHR Power
— MW
After aux
Specific Power
— kWh/t
Per tonne clinker
Overall Efficiency
— %
Net/Total heat
Heat Rec. Ratio
— %
Captured / available
Stack Loss
— kW
Exhaust to atmos
CO₂ Reduction
— t/yr
Grid displacement
Payback
— yr
Simple estimate
Carbon Credits
— USD/yr
At $15/t CO₂
Engineering Recommendations
- Enter parameters and press Calculate or Load Sample.
PH vs AQC Heat Recovery
Energy Balance
Monthly Generation Forecast
WHR System Performance Radar
Core Engineering Formulas
ṁ = V × ρ / 3600 (kg/s)
Q_recovered = ṁ × Cp × ΔT (kW)
Q_boiler = Q_total × η_boiler
Steam = Q_boiler / (Δh_steam − Δh_fw)
P_turbine = ṁ_st × Δh_turbine × η_turb
P_net = P_gross − P_aux (6‑12%)
Specific Power = kW_net / TPH_clinker
Industry Benchmarks
- Cement WHR capacity: 4‑15 MW
- Boiler efficiency: 72‑84%
- Turbine efficiency: 80‑88%
- Specific power: 12‑30 kWh/t
- Overall WHR efficiency: 16‑26%
- CO₂ avoidance: 30,000‑80,000 t/yr
Educational Notes
WHR captures waste heat from PH exhaust and AQC cooler air. Steam Rankine cycles operate at higher temperatures, ORC cycles use organic fluids for moderate temperatures. Hybrid systems maximize recovery across the temperature range. To improve performance, lower outlet temperatures, reduce auxiliary loads, and maintain high component efficiencies.