Code: PRJ-ACT
10MW Waste Heat Recovery Plant
Rabai Kaloleni, Kilifi County
Scale
KSh 500,000,000
Status
Ongoing
The 10MW Waste Heat Recovery project at National Cement's Rabai Kaloleni facility in Kilifi County is a landmark sustainable energy project in Kenya's cement industry. Civicrete is providing design and construction supervision for the civil and structural elements of this plant, which captures waste heat from the cement manufacturing process to generate electricity — significantly reducing the plant's reliance on grid power. The project involves highly specialised structural engineering for dynamic machinery foundations, high-temperature process pipework structures, and the boiler building, all designed to withstand the unique thermal and vibration loads of power generation equipment.
High-Temperature Structural Effects
Boiler structures and steam pipework supports must account for differential thermal expansion. Expansion joints and sliding bearing details were incorporated to manage movement without inducing secondary stresses.
Steam Turbine Foundation Design
The steam turbine and generator foundation required detailed dynamic analysis to isolate machinery vibrations from the main structure and meet OEM installation tolerances within ±2 mm.
Coastal Environment
Rabai's proximity to the coast demands XS2/XS3 concrete durability design with GGBS cement replacement, epoxy-coated reinforcement in splash zones, and protective coatings on all structural steel.
Site Investigation
Ground investigation and laboratory testing at Rabai Kaloleni
Equipment Layout Review
Structural coordination with OEM equipment supplier drawings
Foundation Design
Steam turbine, boiler, and cooling tower foundation structural calculations
Steel Structure Design
Boiler house framing, walkways, pipework supports, and stairways
Construction Supervision
Site inspections, concrete quality control, and steel erection oversight
Dynamic Verification
Post-installation vibration monitoring and comparison with design predictions
Commissioning Support
Structural sign-off for plant operational testing
