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from these dirty gaseous streams are available, yet implementation has been limited due to high capital investment costs.60 This study investigated waste heat losses in both integrated steel mills and minimills. In integrated steel mills, which account for about 54% of U.S. raw steel production in 1999,61 processes analyzed included coke making, blast furnace ironmaking, and basic oxygen furnace steelmaking. In the minimill, exhaust gases from electric arc furnaces were analyzed. Waste heat from these processes total about 79 TBtu/yr based on a reference temperature of 77°F [25°C] (Table 12). Table 12 Unrecovered Waste Heat and Work Potential from Selected Process Exhaust Gases in the Iron and Steel Industry Source Energy Assumed Average Consumption Exhaust Temperature Waste Heat 77°F [25°C] Ref TBtu/yr 15.8 11.2 5.3 10.6 3.2 27.1 5.8 0.2 79.1 Waste Heat 300°F [150°C] Ref TBtu/yr 13.9 10.0 1.9 26.0 5.4 0.1 57.3 Carnot Work TBtu/yr °F Coke Oven 65.5 °C 980 200 430 250 130 1,700 1,200 204 Coke Oven Gas Coke Oven Waste Gas Blast Furnace Blast Furnace Gas Blast Stove Exhaust no Recovery with Recovery Basic Oxygen Furnace Electric Arc Furnace no Recovery with Recovery Total 642.3 1,800 392 200 0.8 12.1 0.4 4.1 0.19 1.0 0.4 4.6 0.3 0.8 0.8 23.0 0.8 4.6 0.4 0.1 36.2 482 34.1 266 49.7 3,100 57.7 2,200 13.3 400 828.6 49.2 Note: Sources and assumptions in Appendix A: Documentation of Waste Heat Estimates 4.3.1 Integrated Steel Mills 4.3.1.1 Coke Oven Producing coke, an essential fuel for blast furnace operation, is a key step in the ironmaking process. Coke is produced in coke ovens, where coal is heated in an oxygenlimited environment. There are two methods for producing coke: the byproduct process and the nonrecovery process. In the byproduct process, chemical byproducts (tar, ammonia, and light oils) in the coke oven gas are recovered, while the remaining coke oven gas is cleaned and recycled within the steel plant. In the nonrecovery process, all the coke oven gas is burned in the process. The most common type of process is still the byproduct process, which is the focus of our discussion here. Byproduct cokemaking process (Figure 22) has two sites of sensible heat loss: a) coke oven gas that is cooled in the gas cleaning process and b) waste gas exiting the coke oven. The coke making process employs several coke oven chambers separated by heating flues. Recycled coke oven gas (COG), and sometimes other gases such as blast furnace gas, are used as the fuel source in the heating flue and supply heat to the oven chamber where coal pyrolysis takes place. As coal is pyrolyzed in the oven chamber, gas and moisture (accounting for about 811 mass % of charged coal) are driven off and exit through the 37 Efficiency Potential TBtu/yrPDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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