Making More Efficient Use of Blast-Furnace Gas at Russian Metallurgical Plants

Рыжков, А. Ф.; Levin, E. I.; Filippov, P. S.; Abaimov, N. A.; Gordeev, S. I.

doi:10.1007/s11015-016-0247-1

Cited by 8 publications

(5 citation statements)

References 2 publications

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“…Ryzhkov et al [54] studied the efficiency of operating a combined-cycle power plant (CCP) on BFG at Russian metallurgical plants. The goal was to be able to burn BFG without enhancement with higher CV fuel gases such as COG and natural gas or using special flame stabilising measures [54]. The results from calculations performed using a specialised software package were presented.…”

Section: Ryzhkov Et Al [54]mentioning

confidence: 99%

“…2,5 -8 MJ/Nm 3 , system upgrades are required. These include upgrades on the fuel delivery system, combustion chamber and the air compressor due to changes in fuel gas pressure and air volume [54].…”

Section: Ryzhkov Et Al [54]mentioning

confidence: 99%

“…The required upgrades will need a capital investment of almost $US 600 million (approximately R 8,9 billion) 18 . A payback period of 3.6 years was estimated [54]. The usage of BFG in high temperature applications requires enhancement with higher CV gases.…”

Section: Ryzhkov Et Al [54]mentioning

confidence: 99%

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Improving By-product Gas Utilisation in Steel Milling Operations

Mampuru

2019

SSRN Journal

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Iron and steel manufacturing are energy-intensive processes. Rising energy and operational costs have placed South African steel manufacturers under financial strain, while they struggle to remain afloat within an extremely competitive global market. Declining production and export figures, as well as increasing imports, have adversely affected the sustainability and profitability of the local market. It is, therefore, imperative for local manufacturers to implement operational change strategies without additional capital investment requirements in order to save energy and reduce costs.Hot-rolling processes of steel milling operations use reheating furnaces to elevate the temperature of the steel to a state of plastic deformation prior to rolling. The reheating furnaces combust fuel gases such as by-product gases or natural gas for thermal energy. They consume 70 % of the energy of the hot-rolling processes. By-product gases are combustible carriers of energy. Coke oven gas (COG) carries 18 % of the energy input of the coke production process. The energy content of COG was found to be competitive with natural gas and compatible for high-energy requirement applications, such as in reheating furnaces.The challenge arises in that the calorific value (CV) of COG fluctuates over time. These fluctuations prove problematic during the control of COG combustion processes as the air-fuel ratio needs to be adjusted accordingly. Furnace operators typically rely on a trial-and-error method for air-fuel ratio adjustments in response to the fluctuating calorific value of coke oven gas (CV of COG). This causes furnace temperature instabilities, energy inefficiencies and production losses. Additionally, COG has a high impurity content inherent from the coal. These impurities clog CV of COG analysing equipment.Several alternative tools are available to estimate the unavailable CV of COG; however, these tools do not account for the fluctuating nature of COG and only provide static estimated values.Based on these challenges, a need was identified to facilitate more stable operations of the furnace. The aim of this study entails the development of a new methodology to adjust the Improving by-product gas utilisation in steel milling operations ii air-fuel ratio according to the incoming CV of COG and the current furnace operating conditions. The historic behaviour of the furnace is used in the control strategy.To address the recurring events where CV of COG data is unavailable, a novel methodology is developed for a time-continuous estimation of CV of COG for stable process applications.A seven-step methodology was developed whereby an appropriate method can be selected for the determination of CV of COG, based on the available data and measuring equipment.Three methods are presented, with varying accuracy and consistency.Pilot studies were undertaken on a billet mill reheating furnace in order to validate the air-fuel ratio adjustment methodology. The results verified that the air-fuel adjustments were within 94 % -98 % accurate, res...

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Section: Ryzhkov Et Al [54]mentioning

confidence: 99%

Section: Ryzhkov Et Al [54]mentioning

confidence: 99%

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Improving By-product Gas Utilisation in Steel Milling Operations

Mampuru

2019

SSRN Journal

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“…Campos [3] compared the efficiency of combined cycle and Rankine cycle in BFG utilization, showing that the combined cycle has higher power generation efficiency. Ryzhkov [4] discussed the worldwide practice of operating combined cycle power plants on BFG to date, and the principles of upgrading a standard gas turbine power plant to a combustion BFG were studied.…”

Section: Introductionmentioning

confidence: 99%

Energy and Exergy Analysis on a Blast Furnace Gas-Driven Cascade Power Cycle

et al. 2022

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Blast furnace gas is the major combustible by-product produced in the steel industry, where iron ore is reduced by coke into iron. Direct combustion of blast furnace gas after simple treatment for power generation is a common utilization method nowadays. However, this method suffers from low efficiency and high carbon intensity. The use of gas-steam combined cycle is an excellent method to improve the efficiency of blast furnace gas for power generation. However, there is a problem of insufficient utilization of low product heat, and the addition of CCS system can further reduce the power efficiency. To solve these issues, a new blast furnace gas power generation system with a Brayton cycle with supercritical CO2 and a Rankine cycle with transcritical CO2 is proposed in this work. The new system is then thermodynamically simulated by Aspen Plus, after the sub-modules are validated. The effects of molar ratio of steam to carbon, selexol/CO2 mass ratio, compression ratio, turbine import temperature and turbine inlet pressure on the system are investigated. A comparison is also performed between the new combined cycle system and the traditional combined cycle power generation system. The results show that in the new power generation system, net power efficiency of 53.29%, carbon capture efficiency of 95.78% and sulfur capture rate of 94.46% can be achieved, which is significantly better than the performance of the conventional combined cycle.

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“…The majority of the thermoelectric power plants installed in steel plants operate only in the Rankine cycle. Ryzhkov, et al, (2016) present 42 thermoelectric power plants operating in combined cycle and utilizing BFG or a mix of steelwork gases as fuel for the gas turbines. However, the power plant analysed in this study is the first of its kind located in the Southern hemisphere and in tropical humid climate conditions.…”

Section: Introductionmentioning

confidence: 99%

A technical-economic analysis of turbine inlet air cooling for a heavy duty gas turbine operating with blast-furnace gas

Costa¹,

Silva²,

Campos

et al. 2021

RSD

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The study was developed inside an integrated steel mill, located in Rio de Janeiro city, aiming to analyse the technical-economic feasibility of installing a new inlet air refrigeration system for the gas turbines. The technologies applied for such purpose are named Turbine Inlet Air Cooling (TIAC) technologies. The power plant utilizes High Fogging and Evaporative Cooling methods for reducing the compressor’s inlet air temperature, however, the ambient climate condition hampers the turbine’s power output when considering its design operation values. Hence, this study was proposed to analyse the installation of an additional cooling system. The abovementioned power plant has two heavy-duty gas turbines and one steam turbine, connected in a combined cycle configuration. The cycle nominal power generation capacity is 450 MW with each of the gas turbines responsible for 90 MW. The gas turbines operate with steelwork gases, mainly blast furnace gas (BFG), and natural gas. The plant has its own weather station, which provided significant and precise data regarding the local climate conditions over the year of 2017. An in-house computer model was created to simulate the gas turbine power generation and fuel consumption considering both cases: with the proposed TIAC system and without it, allowing the evaluation of the power output increase due to the new refrigeration system. The results point out for improvements of 4.22% on the power output, corresponding to the electricity demand of approximately 32960 Brazilian homes per month or yearly earnings of 3.92 million USD.

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Making More Efficient Use of Blast-Furnace Gas at Russian Metallurgical Plants

Cited by 8 publications

References 2 publications

Improving By-product Gas Utilisation in Steel Milling Operations

Improving By-product Gas Utilisation in Steel Milling Operations

Energy and Exergy Analysis on a Blast Furnace Gas-Driven Cascade Power Cycle

A technical-economic analysis of turbine inlet air cooling for a heavy duty gas turbine operating with blast-furnace gas

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