1 2 3 Current Status of Waste Heat Recovery in Steel Industry Analysis of the Current Situation of WHR for an iron & steel plant in China Study and Ap
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1 Systematic high efficiency waste heat utilization technique and application Shanghai Service Co., Ltd. Cao, Xian-chang May 23, 2018
2 1 2 3 Current Status of Waste Heat Recovery in Steel Industry Analysis of the Current Situation of WHR for an iron & steel plant in China Study and Application on Waste Heat Recovery Technologies in Steel Industry Shanghai Service Co., Ltd.
3 1 Current Status of WHR in Steel Industry Waste Heat is clean, green energy Waste heat recovery ratio is low in iron & steel industry Product s sensible heat 50.04% Product's sensible heat recovery ratio Exhaust gas's sensible heat 14.92% Cooling water's sensible heat 1.90% Slag s sensible heat 1.59% Waste heat in iron & steel industry 25.80% High temperature Waste heat 44.40% Mid temperature Waste heat 30.20% Low temperature Waste heat Abt 1% Slag's sensible heat Product's sensible heat Cooling water's sensible heat Exhaust gas's sensible heat Waste heat accounts for about 30% of the total energy consumption in iron & steel enterprises of china. For more than 500 solid heat, 100 liquid heat, and 200 gas heat, we should do our best to recover. * From Professor Wen Yuqing of the Chinese Society for Metals. Shanghai Service Co., Ltd.
4 1 Current Status of WHR in Steel Industry Development of WHR technologies is very importnant for Iron-steel industry energy's conservation and emission reduction Key technology 共性技术 Research on common key technology of waste heat recovery and utilization New WHR technology and process should be researched with the whole iron-steel process System optimization 系统优化 New process 新型工艺 Research on system energy recovery and gradient utilization Research on new process of system energy saving and emission reduction Shanghai Service Co., Ltd.
5 1 Current Status of WHR in Steel Industry How much heat recovery rate can be achieved in iron and steel industry in ? 25.8% % 2015? If the waste heat recovery rate is increased from 35% to 65%, the comprehensive energy consumption per ton steel will be reduced by 100 kgce (2.93GJ) * From Professor Cai Jiuju of Northeastern University Shanghai Service Co., Ltd.
6 1 2 3 Current Status of Waste Heat Recovery in Steel Industry Analysis of the Current Situation of WHR for an Iron & Steel Plant in China Study and Application on Waste Heat Recovery Technologies in Steel Industry Shanghai Service Co., Ltd.
7 2 Analysis of the Current Situation of WHR for an Iron & Steel Plant Main WHR technologies have already been applied COG recovery 回收焦炉煤气 steam 干熄焦 and (CDQ) electricity 回收蒸汽 电力 recovery by CDQ Coal Iron ore Coke oven Sinter plant TRT 余压发电回收高炉煤气 BFG recovery(bfg) Blast furnace Hot blast stove Leader in the iron & steel technology Steam 回收蒸汽 recovery LDG 回收转炉煤气 recovery technology (LDG) Corporate Steam model and LDG for common Steam recovery development recovery of staff and the Corporation Hot blast stove waste 热风炉余热回收 heat recovery to preheat 预热空气 煤气 air and gas Waste heat recovery 主排废气预热空气 from main exhaust gas Steam recovery from the 环冷气余热回收蒸汽 sinter ore heat in cooler HTAC 钢包蓄热式燃烧技术 technologies in ladle Driver of green industry Steam recovery 汽化冷却装置回收蒸汽 in evaporation cooling device HTAC 蓄热式燃烧技术 combustion technology Converter EAF Continuous caster Hot strip mill Hot delivery 板坯热送热装 and loading of slabs Cold tandem mill Steam 余热锅炉回收蒸汽 recovery in waste heat boiler Hot 换热器回收热水 热量 water recovery in heat exchanger Shanghai Service Co., Ltd.
8 2 Analysis of the Current Situation of WHR for an Iron & Steel Plant Recycling of waste heat resources for an iron & steel plant buy energy 1296 Coal 1163 Oil 2 NG km 3 Electric power 25 GHW Coke 45 Sintering Coking Secondhand energy recovery 1403(WHR165) Leader in the iron & steel technology Blast furnace Steelmaking Corporate model for common development of staff and the Corporation Driver of green industry Auxiliary system 1 For example : total waste heat is about 3540 ktce, recovered 1650 ktce, recover ratio is 46.6% in waste heat is 216 kgce/t, recoverd 101 kgce/t, un-recoverd 115 kgce/t. 3 Waste heat is 276 kgec/t, if included waste heat of cooling water under 80 or heat dissipation in progress ( e.g. motor). Steel rolling 136 units:10 k tce Steam, power etc. sell energy energy consume 1160 Waste heat 189 major form of let out liquid gas solid Shanghai Service Co., Ltd.
9 2 Analysis of the Current Situation of WHR for an Iron & Steel Plant The proportation for waste heat recovery of each process un-recoverd waste heat (10k tce ) recoverd waste heat (10k tce ) waste heat recovery ratio (%) Coking Sintering Iron making Steel making Steel rolling Auxiliary system Shanghai Service Co., Ltd.
10 2 Analysis of the Current Situation of WHR for an Iron & Steel Plant Problems to be solved 1 A huge gap between basic theory and practice of Energy gradient utilization, and systems thinking less. e.g. The different waste heat resources in coking process and sintering process etc. 2 Some technical problems have not been solved in the field of high temperature waste heat e.g. Raw coke oven gas sensible heat, slag sensible heat, etc. 3 A lot of low temperature waste heat due to poor investment returns have not been recovered e.g. Huge amount of flue gas waste heat below 200, condensate water etc. Shanghai Service Co., Ltd.
11 1 2 3 Current Status of Waste Heat Recovery in Steel Industry Analysis of the Current Situation of WHR for an Iron & Steel Plant in China Study and Application on Waste Heat Recovery Technologies in Steel Industry Shanghai Service Co., Ltd.
12 3 Study and Application on WHR Technologies in Steel Industry S1 Reuse ReplaceCorporate model for Upgrading common Conversion development of staff and the Corporation measures Hold equipment state High efficient combustion(oxygen enrichment etc) Heat reservation Air-fuel ratio control Preheat air Preheat gas RRUC System optimization method: with the local environment conditions, Matched the temperature, Gradient utilization Four steps measures Replace fuel for producting steam Replace steam for heating air Replace steam for heating water Replace electric power for drive measures Low quality energy for higher quality use Driver of green industry Heat pump technology Steam jet Gas reheat Cogeneration measures Utilizing waste heat for refrigeration Differential pressure power generation Shanghai Service Co., Ltd.
13 3 Study and Application on WHR Technologies in Steel Industry S2 Technology bottleneck Technology developmen t tendency Research and development key technologies for high temperature WHR Leader in the iron & steel technology Corporate model for common development of staff and the Corporation Sintering Coking Blast furnace sinter cooler air leak high failure rate of cooling process parameter of waste heat fluctuate wildly low efficiency of waste heat Primetals POSCO CITIC HIC, NEU coking & carbon deposit Driver corrosion of green leak industry alternating thermal stress high temperature, combustible Japan, Germany, Russia Baosteel, WISCO, Jinan Steel etc. big gross sensible heat of melting slag flush slag consume great water low quality of waste heat PW, CSIRO NCU of Science and Technology, Baosteel etc. Shanghai Service Co., Ltd.
14 3 Study and Application on WHR Technologies in Steel Industry S3 Research and development key technologies for low temperature WHR Leader in the iron & steel technology waste heat potential analysis refrigerate technology thermoelectric technology key technologies Effective anticorrosion technology ORC technology heat store and transport technology In view of the common problems of waste heat recovery and utilization, the technology of waste heat recovery with different grade, different impurity and intermittent fluctuation, as well as the waste heat utilization technology of power generation, heating, refrigeration and cogeneration is studied. Shanghai Service Co., Ltd.
15 3 Study and Application on WHR Technologies in Steel Industry A1 Multi energy coupling optimization of coking system and synergistic treatment of pollutants Combined with the research and development of key technologies of coking and energy saving and emission reduction, we optimized the recovery and utilization of waste heat resources in coke oven to improve system efficiency and reduce pollutant emissions. Support technology: CATHE technology High pressure boiler of dry quenching Low temp. waste heat ammonia evaporation technology High efficiency and low nitrogen combustion technology in coke oven Shanghai Service Co., Ltd.
16 3 Study and Application on WHR Technologies in Steel Industry A2 Four major characteristics Combination and mixture of various materials Multiple leakageproof structure Accurate part design Optimized thermodynamic system Sensible Heat Recovery of Raw Coke Oven Gas CATHE Four major advantages Coking resistant and high heat transfer efficiency Modular, easy-to install Easy-to-maintain and customizable Compact structure Little space occupation 135*10 4 t coke 7m Energy-saving and environmental enhancement 2 unites 示范规模 110 CATHE 示范效果 84 *10 3 t steam 8417 tce 6-9 kgce 21 *10 3 t CO 2 Coking resistant, high efficiency; corrosion resistant, long service life Shanghai Service Co., Ltd.
17 3 Study and Application on WHR Technologies in Steel Industry A3 有机朗肯循环发电机组 冷却机风罩 烧结矿料层 冷却机下风箱 自然风 # 烟囱 80 Organic Rankine cycle (ORC) power generation technology and its demonstration application 4# 烟囱 150 3# 烟囱 220 2# 烟囱 # 烟囱 450 水预热器 余热锅炉 烧结机点火 布袋除尘器 Conventional Optimization Increase proportion Heat efficiency 48.2% 62.9% 30.5% Exergy efficiency 50.1% 62.0% 23.8% Saving energy 20.8% ( tce) Economic returns 23.9% ( ) 烟囱 Heat resource Rated power generation capacity Low temp. gas 2500kW Power factor 0.8 Annual rated electric quantity kw h Shanghai Service Co., Ltd.
18 3 Study and Application on WHR Technologies in Steel Industry A4 Recovery technology of residual heat of Electric Arc Furnace Before the transformation: The flue gas of an EAF is discharged into the atmosphere through the induced draft fan after water cooling, settling room, water cooling and air cooling, resulting in energy waste. Technical programme: According to the layout conditions of the site, the horizontal heat recovery boiler is made. According to the dust characteristics of EAF, the appropriate soot blowing system is selected. A flue gas heat storage device and a steam storage system are adopted with fluctuation of waste heat. Waste heat system is fully automatic operation control. Transformation effect: Operation in May 2014, 129 thousand tons of steam per year. More than , Save 13 thousand tons of standard coal per year. Shanghai Service Co., Ltd.
19 3 Study and Application on WHR Technologies in Steel Industry A5 Recovery of waste heat from flue gas of Q318 retreating unit of silicon steel Before the transformation: The exhaust gas temperature of Q318 continuous annealing coating unit is between 350 and 700 degrees C, which is pumped to the chimney by two exhaust fans. At the same time, the unit's production line needs steam heating. Technical programme: The waste heat recovery system is added to produce 0.6MPa saturated steam. The system includes waste heat recovery device, control system, bypass system and so on. Transformation effect: Put into production in August thousand tons of steam per year. The economic benefit 2.8 million. Energy saving 2114 tce per year. Shanghai Service Co., Ltd.
20 Lower-Carbon, Better Future CAO, Xian-chang Ph.D Chief Engineer Thank you! QQ: Shanghai Service Co., Ltd.
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