POWER GENERATION FROM WASTE HEAT

OF GAS IN IRON &STEEL PLANTS

POWER GENERATION FROM WASTE HEAT

OF GAS IN IRON &STEEL PLANTS
INTRODUCTION:-

Iron and steel industry is one of the most energy

intensive industries in the world.
The main units of the industry where iron making
takes place are
1) Blast furnace
2) Sinter plant
3) Coke oven battery
These units consume 39%, 12.5% and 11.9% of the
total electricity consumption.

POWER GENERATION FROM WASTE HEAT

OF GAS IN IRON &STEEL PLANTS
INTRODUCTION:-

These three units generate lot of heat which was

conventionally wasted.
In this paper, generation of power from this waste
heat gas is explained.

WASTE HEAT RECOVERY FROM BLAST

FURNACE
In blast furnace the end products
are usually Molten metal, slag
and blast furnace gas (BFG).
BFG has high pressure and
temperature.
The pressure of BFG is between
1.6 to 2.5 bar.
Dust catcher and wet or dry scrubbing are used to
remove fine particulates from the flue gas.
Flue gases from the blast furnace needs to be reduced
to 0.1 bar for the gas pipe network.

WASTE HEAT RECOVERY FROM BLAST

FURNACE
CONVENTIONAL METHOD:

The energy of BFG was wasted by pressure

reduction at septum valve.
Before it is supplied to other processes at low
pressure.

WASTE HEAT RECOVERY FROM BLAST

FURNACE
MODERN METHOD:

Top pressure recovery turbine (TRT) is installed

1)To reduce the pressure.
2)To generate power from this gas.
It is a gas turbine.
By using TRT
1)flue gas is not consumed.
2)No influence on the operation of the blast furnace.
A TRT unit could recover about 20% of electricity
consumed by blast furnace including air blower.

WASTE HEAT RECOVERY FROM BLAST

FURNACE

MODERN METHOD:

Note: Blast furnace of capacity greater than 1000m

should be equipped with TRT.
Typical TRT system is given below:
Blast furnace capacity: 3800 m
BFG flow through turbine: 550000 Nm/Hr
BFG pressure at turbine inlet : 2.2Kg/cm
BFG Temperature at turbine inlet: 50C
Rating of:14MW

WASTE HEAT RECOVERY FROM COKE

DRY COOLING PLANT
Coke is used as a fuel in the blast furnace.
Coke is produced from coke oven battery by heating
coking coal in an oxidation-free atmosphere.
Red hot coke(Temp around 1000C to 1100C) is
brought from the battery to the CDCP.
It is cooled by inert gas.
The inert gas picking heat from the hot coke, comes
out from the top at 800C.
Dust collector is used to remove dust & it pass
through WHRB.

WASTE HEAT RECOVERY FROM COKE

DRY COOLING PLANT

WASTE HEAT RECOVERY FROM COKE

DRY COOLING PLANT
The inert gas used to produce steam at about 40kg/cm2 pressure
and 440C.
The inert gas at WHRB exit is pressurized by blower &Corrected
by nitrogen gas then injected at bottom of CDCP chamber temp of
gas is around 170C.
The parameters of CDCP of Visakhapatnam steel plant
Temp. of hot coke: 950-1000C
Temp of cooled coke :200-250C
Coke production :700 ton
Steam gen rate :25 t/hr/boiler
Steam pressure 40 bar
Steam temp:440C
Rated power :14 MW

WASTE HEAT RECOVERY FROM SINTER

PLANT
Sinter is a method of fusing iron ore fines into large
particles suitable for charging into the blast furnace.
This technology was developed by in the early 20th
century.
Presently more than 70% hot metal in the world is
produced through the sinter& In India, approximately
50% .
Sintering involves the heating of iron ore fine with
flux and coke fines or coal to produce a semi melting
mass that solidifies into porous pieces of sinter with the
size and strength characteristics required for feeding
into blast furnace.

WASTE HEAT RECOVERY FROM SINTER

PLANT
CONVENTIONAL METHOD:

Initially the sinters are cooled by fans & transported

to blast furnace.
The temp reduced to
75C-80C.
The hot air escaped to
atmosphere.

WASTE HEAT RECOVERY FROM SINTER

PLANT
MODERN METHOD:

wind boxes are covered with hood and hot gas is

made to pass by ducts to a waste heat recovery boiler.
The boiler steam generally low pressure around
20kg/cm2.

WASTE HEAT RECOVERY FROM SINTER

PLANT
In India such power plant is first established at Visakhapatnam
Steel Plant
The salient features of the project are:

Sinter production: 5.256MT/sinter/year

Inlet gas temperature to boiler: 390C
Outlet Gas Temperature from the boiler: 190C
Steam pressure at super heater: 21Bar
Turbine inlet steam pressure: 18.5 Bar
Turbine inlet steam temperature: 324C
Steam flow to turbine: 110tph
Exhaust steam pressure: 0.1ata
Rating of generator: 20.6 MW

CONCLUSION
Production of electricity from waste heat gas does not require
any new fuel and hence cost of energy is less.
Further, Waste heat is not allowed to enter to the atmosphere,
which produces thermal pollution.
No fuel is burned and so, no or other greenhouse gasses are
generated. Also benefit of clean development mechanism can
be availed for such type of projects.