Cogeneration Waste Heat Recovery at a Coke Calcining Facility

PSE Inc. recently completed the design, construction and start-up of a cogeneration plant in which waste heat in the high temperature flue gases of three existing coke calcining kilns is recovered to produce process steam and electrical energy. The heat previously exhausted to the atmosphere is now converted to steam by waste heat recovery boilers. Eighty percent of the steam produced is metered for sale to a major oil refinery, while the remainder passes through a steam turbine generator and is used for deaeration and feedwater heating. The electricity produced is used for the plant auxiliaries and sold to the local utility. Many design concepts were incorporated into the plant which provided for high plant availability, reliability and energy efficiency. This paper will show how these concepts were implemented and incorporated into the detailed design of the plant while making cogeneration a cost effective way to save conventional fuels. Operating data since plant start-up will also be presented