IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v185y2019icp730-743.html
   My bibliography  Save this article

Modelling and simulation of steel reheating processes under oxy-fuel combustion conditions – Technical and environmental perspectives

Author

Listed:
  • Hu, Yukun
  • Tan, CK
  • Niska, John
  • Chowdhury, Jahedul Islam
  • Balta-Ozkan, Nazmiye
  • Varga, Liz
  • Roach, Paul Alun
  • Wang, Chunsheng

Abstract

This paper investigates the impact of flameless oxy-fuel combustion on the thermal performance of a pilot-scale steel reheating furnace. A comprehensive mathematical model, based on the zone method of radiation analysis, was developed, which takes into account the non-grey behaviour of the furnace atmosphere under oxy-fuel combustion conditions. The model was subsequently used to simulate the temperature profile of an instrumented slab used in the experiment. The results showed that the predicted slab temperature profile along the furnace is in good agreement with measurement. However the model over predicted the absolute slab temperatures due to the influence of formation of oxide scales on the slab surface, which was not taken into account in the current model. When compared to air-fuel combustion simulation, the results of oxy-fuel combustion also indicated a marked improvement in the furnace specific fuel consumption (approximately 16%). This was mainly due to the enhanced radiative properties of the furnace atmosphere and reduced exhaust energy losses as the result of less dilution effect from nitrogen. This resulted in reduction in the overall heating time by approximately 14 min. Furthermore, if the economics of carbon capture is taken into consideration, theoretically, the energy consumption per kilogram of CO2 captured can be reduced from 3.5 to 4.2 MJ kg−1 to 0.96 MJ kg−1. In conclusion, the current studies support the view that oxy-fuel combustion retrofitting to reheating furnaces is a promising option, both from a technical and from an environmental point of view.

Suggested Citation

  • Hu, Yukun & Tan, CK & Niska, John & Chowdhury, Jahedul Islam & Balta-Ozkan, Nazmiye & Varga, Liz & Roach, Paul Alun & Wang, Chunsheng, 2019. "Modelling and simulation of steel reheating processes under oxy-fuel combustion conditions – Technical and environmental perspectives," Energy, Elsevier, vol. 185(C), pages 730-743.
    • Handle: RePEc:eee:energy:v:185:y:2019:i:c:p:730-743
    DOI: 10.1016/j.energy.2019.07.054
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544219313817
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2019.07.054?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Oliveira, Flávio A.D. & Carvalho, João A. & Sobrinho, Pedro M. & de Castro, André, 2014. "Analysis of oxy-fuel combustion as an alternative to combustion with air in metal reheating furnaces," Energy, Elsevier, vol. 78(C), pages 290-297.
    2. Hu, Yukun & Tan, CK & Broughton, Jonathan & Roach, Paul Alun, 2016. "Development of a first-principles hybrid model for large-scale reheating furnaces," Applied Energy, Elsevier, vol. 173(C), pages 555-566.
    3. Hu, Yukun & Wang, Jihong & Tan, CK & Sun, Chenggong & Liu, Hao, 2018. "Coupling detailed radiation model with process simulation in Aspen Plus: A case study on fluidized bed combustor," Applied Energy, Elsevier, vol. 227(C), pages 168-179.
    4. Chen, Demin & Lu, Biao & Dai, FangQin & Chen, Guang & Zhang, Xihe, 2018. "Bottleneck of slab thermal efficiency in reheating furnace based on energy apportionment model," Energy, Elsevier, vol. 150(C), pages 1058-1069.
    5. Chowdhury, Jahedul Islam & Hu, Yukun & Haltas, Ismail & Balta-Ozkan, Nazmiye & Matthew, George Jr. & Varga, Liz, 2018. "Reducing industrial energy demand in the UK: A review of energy efficiency technologies and energy saving potential in selected sectors," Renewable and Sustainable Energy Reviews, Elsevier, vol. 94(C), pages 1153-1178.
    6. Eketorp, Sven, 1987. "Energy considerations of classical and new iron- and steel-making technology," Energy, Elsevier, vol. 12(10), pages 1153-1168.
    7. Hu, Yukun & Yan, Jinyue, 2012. "Characterization of flue gas in oxy-coal combustion processes for CO2 capture," Applied Energy, Elsevier, vol. 90(1), pages 113-121.
    8. Jóźwiak, Piotr & Hercog, Jarosław & Kiedrzyńska, Aleksandra & Badyda, Krzysztof, 2019. "CFD analysis of natural gas substitution with syngas in the industrial furnaces," Energy, Elsevier, vol. 179(C), pages 593-602.
    9. Lixin Tang & Huizhi Ren & Yang Yang, 2015. "Reheat furnace scheduling with energy consideration," International Journal of Production Research, Taylor & Francis Journals, vol. 53(6), pages 1642-1660, March.
    10. Li, Kangkang & Leigh, Wardhaugh & Feron, Paul & Yu, Hai & Tade, Moses, 2016. "Systematic study of aqueous monoethanolamine (MEA)-based CO2 capture process: Techno-economic assessment of the MEA process and its improvements," Applied Energy, Elsevier, vol. 165(C), pages 648-659.
    11. Bo Gao & Chunsheng Wang & Yukun Hu & C. K. Tan & Paul Alun Roach & Liz Varga, 2018. "Function Value-Based Multi-Objective Optimisation of Reheating Furnace Operations Using Hooke-Jeeves Algorithm," Energies, MDPI, vol. 11(9), pages 1-18, September.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Schmitz, N. & Sankowski, L. & Kaiser, F. & Schwotzer, C. & Echterhof, T. & Pfeifer, H., 2021. "Towards CO2-neutral process heat generation for continuous reheating furnaces in steel hot rolling mills – A case study," Energy, Elsevier, vol. 224(C).
    2. Wachter, Philipp & Gaber, Christian & Demuth, Martin & Hochenauer, Christoph, 2020. "Experimental investigation of tri-reforming on a stationary, recuperative TCR-reformer applied to an oxy-fuel combustion of natural gas, using a Ni-catalyst," Energy, Elsevier, vol. 212(C).
    3. Liu, Yiwei & Wang, Jin & Min, Chunhua & Xie, Gongnan & Sundén, Bengt, 2020. "Performance of fuel-air combustion in a reheating furnace at different flowrate and inlet conditions," Energy, Elsevier, vol. 206(C).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Chen, Demin & Lu, Biao & Dai, FangQin & Chen, Guang & Zhang, Xihe, 2018. "Bottleneck of slab thermal efficiency in reheating furnace based on energy apportionment model," Energy, Elsevier, vol. 150(C), pages 1058-1069.
    2. Oh, Se-Young & Binns, Michael & Cho, Habin & Kim, Jin-Kuk, 2016. "Energy minimization of MEA-based CO2 capture process," Applied Energy, Elsevier, vol. 169(C), pages 353-362.
    3. Ünal, Berat Berkan & Onaygil, Sermin & Acuner, Ebru & Cin, Rabia, 2022. "Application of energy efficiency obligation scheme for electricity distribution companies in Turkey," Energy Policy, Elsevier, vol. 163(C).
    4. Solomon Aforkoghene Aromada & Nils Henrik Eldrup & Fredrik Normann & Lars Erik Øi, 2020. "Techno-Economic Assessment of Different Heat Exchangers for CO 2 Capture," Energies, MDPI, vol. 13(23), pages 1-27, November.
    5. Hajo Terbrack & Thorsten Claus & Frank Herrmann, 2021. "Energy-Oriented Production Planning in Industry: A Systematic Literature Review and Classification Scheme," Sustainability, MDPI, vol. 13(23), pages 1-32, December.
    6. Gupta, Sapna & Adams, Joseph J. & Wilson, Jamie R. & Eddings, Eric G. & Mahapatra, Manoj K. & Singh, Prabhakar, 2016. "Performance and post-test characterization of an OTM system in an experimental coal gasifier," Applied Energy, Elsevier, vol. 165(C), pages 72-80.
    7. Zhang, Minkai & Guo, Yincheng, 2013. "Rate based modeling of absorption and regeneration for CO2 capture by aqueous ammonia solution," Applied Energy, Elsevier, vol. 111(C), pages 142-152.
    8. David D. J. Antia, 2023. "Conversion of Waste Synthesis Gas to Desalination Catalyst at Ambient Temperatures," Waste, MDPI, vol. 1(2), pages 1-29, May.
    9. Ren, Siyue & Feng, Xiao & Wang, Yufei, 2021. "Emergy evaluation of the integrated gasification combined cycle power generation systems with a carbon capture system," Renewable and Sustainable Energy Reviews, Elsevier, vol. 147(C).
    10. Li, Shiyuan & Xu, Mingxin & Jia, Lufei & Tan, Li & Lu, Qinggang, 2016. "Influence of operating parameters on N2O emission in O2/CO2 combustion with high oxygen concentration in circulating fluidized bed," Applied Energy, Elsevier, vol. 173(C), pages 197-209.
    11. Álvarez, L. & Gharebaghi, M. & Jones, J.M. & Pourkashanian, M. & Williams, A. & Riaza, J. & Pevida, C. & Pis, J.J. & Rubiera, F., 2013. "CFD modeling of oxy-coal combustion: Prediction of burnout, volatile and NO precursors release," Applied Energy, Elsevier, vol. 104(C), pages 653-665.
    12. Tu, Te & Yang, Xing & Cui, Qiufang & Shang, Yu & Yan, Shuiping, 2022. "CO2 regeneration energy requirement of carbon capture process with an enhanced waste heat recovery from stripped gas by advanced transport membrane condenser," Applied Energy, Elsevier, vol. 323(C).
    13. Mansir, Ibrahim B. & Ben-Mansour, Rached & Habib, Mohamed A., 2018. "Oxy-fuel combustion in a two-pass oxygen transport reactor for fire tube boiler application," Applied Energy, Elsevier, vol. 229(C), pages 828-840.
    14. Xie, Heping & Wu, Yifan & Liu, Tao & Wang, Fuhuan & Chen, Bin & Liang, Bin, 2020. "Low-energy-consumption electrochemical CO2 capture driven by biomimetic phenazine derivatives redox medium," Applied Energy, Elsevier, vol. 259(C).
    15. Tang, YuTing & Ma, XiaoQian & Lai, ZhiYi & Chen, Yong, 2013. "Energy analysis and environmental impacts of a MSW oxy-fuel incineration power plant in China," Energy Policy, Elsevier, vol. 60(C), pages 132-141.
    16. Jiao, Liguo & Li, Jian & Yan, Beibei & Chen, Guanyi & Ahmed, Sarwaich, 2022. "Microwave torrefaction integrated with gasification: Energy and exergy analyses based on Aspen Plus modeling," Applied Energy, Elsevier, vol. 319(C).
    17. Chauvy, Remi & Dubois, Lionel & Lybaert, Paul & Thomas, Diane & De Weireld, Guy, 2020. "Production of synthetic natural gas from industrial carbon dioxide," Applied Energy, Elsevier, vol. 260(C).
    18. Hu, Yukun & Wang, Jihong & Tan, CK & Sun, Chenggong & Liu, Hao, 2018. "Coupling detailed radiation model with process simulation in Aspen Plus: A case study on fluidized bed combustor," Applied Energy, Elsevier, vol. 227(C), pages 168-179.
    19. Bo Gao & Chunsheng Wang & Yukun Hu & C. K. Tan & Paul Alun Roach & Liz Varga, 2018. "Function Value-Based Multi-Objective Optimisation of Reheating Furnace Operations Using Hooke-Jeeves Algorithm," Energies, MDPI, vol. 11(9), pages 1-18, September.
    20. Lin, Boqiang & Chen, Yu, 2020. "Transportation infrastructure and efficient energy services: A perspective of China's manufacturing industry," Energy Economics, Elsevier, vol. 89(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:185:y:2019:i:c:p:730-743. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.