Modelling and Analysis of Enhanced Power Generation by Recovering Waste Heat from Fallujah White Cement Factory for Clean Energy Sustainability

Improving energy efficiency and lowering negative environmental impact through waste heat recovery (WHR) is a critical step toward sustainable cement manufacturing. This study analyzes advanced cogeneration systems for recovering waste heat from the Fallujah White Cement Plant in Iraq. The novelty of this work lies in its direct application and comparative thermodynamic analysis of three distinct cogeneration cycles—the Organic Rankine Cycle, the Single-Flash Steam Cycle, and the Dual-Pressure Steam Cycle—within the Iraqi cement industry, a context that has not been widely studied. The main objective is to evaluate and compare these models to determine the most effective approach for enhancing energy and exergy efficiencies. The methodology involved detailed thermodynamic and exergy analyses of each system, supported by mathematical modelling and simulation using data from plant operations. The results reveal that the Dual-Pressure Steam Cycle emerged as the most effective system, delivering 13.76 MW of net power with a thermal efficiency of 32.8% and an exergy efficiency of 51%. This significantly outperformed the baseline Organic Rankine Cycle (8.18 MW, 18.8% thermal efficiency, 30.7% exergy efficiency). These findings confirm that multi-pressure steam cycles offer a robust and practical solution for the Fallujah plant. This application provides a clear, high-impact pathway to enhance national industrial energy efficiency, significantly reduce CO2 emissions, and promote clean energy sustainability in Iraq. Future work should consider economic feasibility and potential integration with renewable energy sources to further enhance sustainability.