Beruflich Dokumente
Kultur Dokumente
furnace technology
Disclaimer:
This presentation does not engage CMI or EUnited or reflect their opinions. It may contain
material that is confidential and privileged. Any review, reliance or distribution by others
or forwarding without express permission is strictly prohibited. CMI and EUnited herewith
exclude any liability for third-party information recognizably contained in this
presentation. Third-party information does not necessarily reflect the opinion of CMI and
EUnited.
Objectives
n Present and appreciate technological status and trends
n Propose technical and other policy solutions to achieve energy savings
& lower environmental impact (example from steel industry).
n Using Case Studies from steel industry(CS):
n Short term:
n Improvement of energy efficiency of existing equipments:
implementation of Best Available Technologies (B.A.T.) for
revamping. (CS#1 to CS#3)
n Medium term:
Application of new developments (CS#4)
n Global approach (CS#5)
Medium/long term:
n R&D (CS#6)
n
Kyoto
protocol
Oil crisis
Computer
simulation
Metallurgy
developments
Oil at
100$/barrel,
Environmental
Pressure,
Electricity market
liberalisation
World
Crisis
1950
1960
Focus on
productivity
[Michel BOYER]
1970
First energy
savings
considerations
1980
1990
More flexible
furnaces
2000
2010
Energy savings
+
Environmental
pressure
Intensive
Cost cutting
+
Technology
breakthroughs
n But in all cases this was not the unique goal of the revampings
motivated by the necessity to adapt the furnaces operating conditions
to the new world context and justifying short payback:
n Flexibility increase,
n
(*) Productivity increase is no longer a driving force due to the foreseen long term overcapacity
In Europe.
[Michel BOYER]
Capacity increase,
Consumption savings.
n Solution:
n Implementation of regenerative burners,
n
Existing radiant tubes are unchanged to limit the modification time and to limit CAPEX.
n Results:
n The savings for maximum yearly output (450,000 tons per year) of the furnace are:
10.6 GWh or approx. 1,000 T.O.E. (Tons of Oil Equivalent)
1,300 tons of CO2 saved
24 tons of NOx avoided
Benchmark: Provided extensive study for each furnace, this technology could be applicable for :
n
105 furnaces for Continuous Galvanizing Lines (C.G.L.) in E.U. (from which only one under construction will
be fully equipped with regenerative burners)
n
65 furnaces for Continuous Annealing Lines (C.A.L.) in E.U. no one is equipped with regenerative burners
[Michel BOYER]
Conventional
NOx emissions
n Results:
n The savings for maximum yearly output of the furnace (90000 tons per year) are
the following:
8.1 GWh or ~800 T.O.E.
33,000 tons of CO2 saved
1 ton of NOx avoided
Benchmark: Provided extensive study for each furnace, this technology could be applicable for :
n
About 20 similar furnaces in E.U. not equipped with regenerative burners. (Not taken into account the
walking beam furnaces, annealing and tempering furnaces involved in tube manufacturing process where
same order of magnitude of savings can be also reached).
[Michel BOYER]
n Results:
n Line productivity was increased: approx. 7% in line average speed,
n Yearly consumption gain at maximum output are :
67 T.O.E. (Direct + impact on final product)
Benchmark: Provided extensive study for each furnace, this technology could be applicable for :
n
170 furnaces for Strip Processing Lines (C.G.L. & C.A.L.) in E.U. (1/3 have already old generations of
mathematical models which could be replaced as per explained in this C.S., 2/3 are not equipped with
mathematical models for which gains can be multiplied by 3 to 5 ).
[Michel BOYER]
Results:
n Out of 11 MW lost by the fumes of the furnaces, 6 are recovered to produce 1.2
MW of electricity
This would represent yearly:
Approx. 1,100 T.O.E.
2,500 tons of CO2 saved
550,000 of electricity produced (*)
(*)
Benchmark:
n
Installed capacity in E.U. represents approx. 200 times above figures if ORC is installed on all reheating fces.
[Michel BOYER]
For one industrial unit (process unit), one industrial plant or one industrial area
involving several plants.
n Such approach is under investigation for one industrial unit and involves already
several partners:
n Energy providers
n
Banks
[Michel BOYER]
Natural gas
heating
Conventional
Cooling gas
soaking
cooling
Hot waste gases : LOST
Hot rolls
Natural gas
preheat
heating
soaking
Cool 1
Cool 2
Cool 3
403C
Global approach
n Potential results:
450C
386C
330C
70C
Cold water : 20
132C
Water at 123C for plant or urban utilities
n For a 180.000 tons/year processing line, the following results on yearly energy
savings have been calculated:
Available water at 123C for plant or urban utilities :
20 GWh / year or 2000 T.O.E.
Saving on Natural gas :
8 GWh / year or 800 T.O.E
[Michel BOYER]
[Michel BOYER]
Energy providers
Equipment suppliers (for B.A.T. implementation)
Industrial Customers (for investment & best operating practices)
Investors
Political decision-makers at local, national & European level to support & give
incentives
Environmental & energy standardization committees
14th February 2010
Finished(2007-2010)
Industrialization process
n
Fluids diagrams
n
Mechanical design
n
Standards
n
Process control
Experiments at semi-industrial scale
Industrial commercialization
n Needs:
n Necessity to finance development action plan
n
[Michel BOYER]
to impact = SHORT
[Michel BOYER]