tenova recovery technology · pdf fileit boasts an engineering team with extensive experience...
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TENOVA i RECOVERY® TECHNOLOGY
TENOVA. INNOVATIVE SOLUTIONS FOR METALS AND MINING
Saving Energy with Steam, for a Combination of Heat Recovery and Environmental Sustainability
Tenova is a worldwide partner for innovative, reliable and sustainable solutions in the metals and mining industries. Building upon decades of experience, Tenova develops solutions that help mining and metals companies reduce costs, save energy, limit environmental impact and improve working conditions for their employees. Tenova believes in on-the-job passion, and actively seek out professionals who truly love what they do. Their contributions to the business have helped make Tenova the industry-leading company it is today, and their passion is the driver behind the company business approach. This approach can be summed up in four key pillars: Innovation, Reliability, Sustainability and Safety.
i RECOVERY® TECHNOLOGY
i Recovery® technology is a heat recovery cooling system for different industrial furnaces, among others the electric arc furnaces (EAF), submerged arc furnaces (SAF), basic oxygen furnaces (BOF), walking beam furnaces and pusher type furnaces.The difference between i Recovery® technology and conventional cooling systems is that energy losses in the waste gas are now recovered as steam. 30% of the primary energy input of a typical EAF is lost in the off gas: i Recovery® technology allows recovering 35-70% of these losses, bringing back 10-25% of the primary energy input.
The technology is based on the following process:
Pressurized water at the boiling point is pumped towards the cooled waste gas duct. The pressure can be set in a wide range between 5-55 bar depending on the steam usage
The off gas heat is exploited by the process of evaporation, cooling down the waste gas in the same way as conventional cooling.
A mix of steam and water is flowing back to the steam drum where steam gets spilled for different purposes.
Tenova i Recovery® is part of the i Steel technologies portfolio, the Tenova program for increasing the furnace process efficiency. Belong to the i Steel portfolio also:
i EAF™, an innovative automation system, based on continuous, real time process measurements and online process models, developed for the dynamic control and optimization of the EAF.
i BOF®, a breakthrough technology designed to reduce GHG emissions while improving yield, productivity and scrapmelting capability and cutting operating costs.
Tenova center of excellence specialized in heat recovery equipment for the energy intensive industries is located in Essen (Germany). It boasts an engineering team with extensive experience in heat recovery steam generation and develops its turnkey projects with the aim of increasing energy efficiency and reducing environmental impact, a feature that strengthens Tenova’s positioning as a player committed to environmental sustainability and energy recovery.
SAVING ENERGY WITH STEAM TYPICAL EAF ENERGY BALANCE
Energy efficiency is a topic that gets more and more importance to all potential customers in the steel and non-ferrous metal industry. 25-30% of the energy input in industrial furnaces is lost in waste gas and cooling water. The Tenova i Recovery® technology brings back up to 70% of the energy that would be lost. Hot cooling is a well established technology in use from many years for reheating furnaces and converters. The combination of heat recovery system with sophisticated control technology and a wide range of tools for steam buffering, applied to electric arc furnaces and submerged arc furnaces is the innovation that Tenova is bringing into the market.The heat recovery systems installed by Tenova have successfully demonstrated their ability to ‘re-generate’ energy from waste gas and reduce environmental impact, while assuring low operating costs for the customers.
** Considering complete combustion of C
Up to 70% off gas energy losses can be recovered. Reduced water consumption respect to open cooling towers.
Reduced duct corrosion, pipes deposit and elimination of sulphuric acid condensation.
Reduced thermal stress in the off-gas ducts and in the skids.
Longer life time and less maintenance. High flexibility in the characteristics of produced steam (temperature and pressure).
Applicable for nearly all kind of furnaces.
MAIN BENEFITS
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455
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Electrical losses
Energy in liquid steel and slag
Energy in off gas and dust
Radiation, convenction and other losses
Watercooling
Electric energyCombustionof natural gas(burned), chargedcoal, oil andelectrodes
Metallic chargeoxidation**(oxigen lancing)
4
TECHNOLOGICAL FEATURES
The mix of steam and
water arrives at the steam
drum where water and
steam get separated.
The steam that is taken
out from the steam drum
can be used for a wide
variety of purposes.
The feed water tank
replaces the demand
of steam consuming
processes.
A Ruth steam buffer
homogenizes the steam
output during power-off
time.
The feed water tank
replaces the demand
of steam consuming
processes.
5
Water gets pumped at
temperatures bar pressures
between 150°C/5 bar and
270°C/55 bar.
An additional heat transfer
surface and dust removal
optimizes the off gas
cooling duct (optional).
HEATING /COOLING Building and plant heating Operation of absorption refrigerators
PROCESS STEAM Vacuum steel degassing DRI production Steel pickling Material or air preheating for other processes
Oxygen production Compressor operation
STEAM
POWER GENERATION Steam turbines ORC turbines
STEAM SALES Local district heating and public services
Industrial usages (tires, paper, chemical)
Public services like sewage sludge drying or swimming halls Power stations
USE OF STEAM
Tenova SpAVia Gerenzano, 5821053 Castellanza (VA) - ItalyT +39 0331 444111F +39 0331 [email protected]
Tenova Metals Deutschland GmbHAm Lichtbogen, 2945141 Essen - GermanyT +49 211 1891 729F +49 211 1891 [email protected]
Tenova Goodfellow Inc.6711, Mississauga Road, Suite 200L5N 2W3 Mississauga, ON - CanadaT +1 905 567 3030F +1 905 567 [email protected]
Tenova Inc.Cherrington Corporate Center100 Corporate Center Drive15108-3185 Coraopolis, PA - USAT +1 412 262 2240F +1 412 262 [email protected]
Tenova East Europe LLCUl. Gruzinskij val, dom 10, stroenie 4123557 Moscow - RussiaT +7 495 995 95 07F +7 495 995 95 [email protected]
Tenova Industrial Technologies (Beijing) Co., Ltd.Room 802-806, 8th Floor,T5 Building, Han’s PlazaNo. 2 Yard, RonghuaSouth Road, YiZhuangBeijing Economic & TechnologyDevelopment Zone100176 Beijing - ChinaT +86 10 8447 5656F +86 10 8447 [email protected]
Tenova India Pvt Ltd I Think Techno Campus, A Wing, 5th floor Pokhran Road no 2, Behind TCS, Thane (West) 400607 MumbaiT +91 22 6104 5700F +91 22 6104 [email protected]
Tenova Vietnam Co Ltd.6th floor, Empire Tower,26-28 Ham Nghi street,Dist 1, HCMC - VietnamT +84 8 39111 388F +84 8 39111 [email protected]
www.tenova.com