| Summary: | This paper deals with the energy audit and heat recovery system
modeling and design
,
taking
a cement factory in Ethiopia
as a case study. The system is a dry type rotary kiln
equipped with
a
sixth stage cyclone type
preheater
, pre
-
calciner and grate cooler. The kiln
has a capacity of 3
,
000 tons/day. The energy auditing has been performed based on the
data collected from control volume of the kiln system for
a
ten
-
month
period
. The result
shows that 25.23% of the total heat input is released to the environment through the
preheater
and an
other 15.58% through the cooler exhausts. The west heat recovery system
(WHRS) can produce a gross power of 5.26 MW as long as the kiln is
i
n
operation
. The
generated power can cover all the electrical
energy
consumption of the kiln system
whether there is
a power supply from the grid or not. Therefore, the company can save
up
to
536,222.10 USD per year due to the production of clinker using
their
own power source
and avoiding the loss
sustained
by the company due to power interruption from the grid
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