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Energy efficiency assessment by process heating assessment and survey tool (PHAST) and feasibility analysis of waste heat recovery in the reheat furnace at a steel company

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  • Si, Minxing
  • Thompson, Shirley
  • Calder, Kurtis

Abstract

The steel industry is one of the most energy intensive industries, contributing greenhouse gas (GHG) emissions. This research analyzes the feasibility of waste heat recovery and assesses energy efficiency at a steel company, Gerdau Ameristeel in Selkirk, Manitoba. The process heating assessment and survey tool (PHAST) determined that the overall efficiency in the reheat furnace is 60%. Flue gas losses are the biggest energy losses in the reheat furnace, accounting for 29.5% of the total energy losses during full production. Heat losses from wall, hearth and roof are also significant, being 7,139,170 kJ/h during full production. To reduce energy inefficiencies, it is recommended that billets be preheated to 315 °C in the reheat furnace. This requires 1.48 h to capture waste heat with a preheating section length of 1691.64 cm. The annual energy savings are estimated to be $215,086.12 requiring a 3.03 years payback period. This study was the first to determine the required size of a preheating box and the rate of heat transfer through billets in the preheating section.

Suggested Citation

  • Si, Minxing & Thompson, Shirley & Calder, Kurtis, 2011. "Energy efficiency assessment by process heating assessment and survey tool (PHAST) and feasibility analysis of waste heat recovery in the reheat furnace at a steel company," Renewable and Sustainable Energy Reviews, Elsevier, vol. 15(6), pages 2904-2908, August.
    • Handle: RePEc:eee:rensus:v:15:y:2011:i:6:p:2904-2908
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    References listed on IDEAS

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    Cited by:

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    2. 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.
    3. Ibrahim, Thamir K. & Mohammed, Mohammed Kamil & Awad, Omar I. & Abdalla, Ahmed N. & Basrawi, Firdaus & Mohammed, Marwah N. & Najafi, G. & Mamat, Rizalman, 2018. "A comprehensive review on the exergy analysis of combined cycle power plants," Renewable and Sustainable Energy Reviews, Elsevier, vol. 90(C), pages 835-850.
    4. Dal Magro, Fabio & Jimenez-Arreola, Manuel & Romagnoli, Alessandro, 2017. "Improving energy recovery efficiency by retrofitting a PCM-based technology to an ORC system operating under thermal power fluctuations," Applied Energy, Elsevier, vol. 208(C), pages 972-985.
    5. Sun, Wenqiang & Zhang, Fengyuan, 2016. "Design and thermodynamic analysis of a flash power system driven by process heat of continuous casting grade steel billet," Energy, Elsevier, vol. 116(P1), pages 94-101.

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