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4.3.3 Waste Heat from Solid Streams In addition to waste heat losses from offgases, solid streams and cooling water are sources of additional sensible heat losses. Solid products and byproducts with significant waste heat losses include hot cokes, byproduct fuels (BF) slag, BOF slag, cast steel, and hot rolled steel. Waste heat losses from these systems were analyzed by de Beer, et. al.95 and are summarized in Table 15. Though the heat from solid streams are often more difficult to recover, the heat losses are high, totaling about 500 TBtu/yr. The sensible heat loss from coke can be partially recovered by coke dry quenching (CDQ) as an alternative to wet quenching. CDQ involves catching incandescent coke in a specially designed bucket, which is discharged into the CDQ vessel. An inert gas such as nitrogen passes over the coke and recovers its sensible heat. The hot gas is then passed through a waste heat boiler.96 Energy savings are approximately 0.7 to 1 million Btu/ton of coke. Retrofit costs of these systems are high ($70/ton of coke) and thus are seldom installed.97 There have also been attempts to recover heat from other solid flows via radiant heat boilers. This was unsuccessful for BF and BOF slag, but has been commercialized for recovering heat from cast steel in a few locations in Japan and Germany.98 Another option for reducing heat losses from cast steel is hot charging, in which slabs are charged to the reheating furnace while still hot. The feasibility of hot charging often depends on the distance between the caster and hot rolling mill. Hot charging is done at a few plants in the United States; however, it is usually applied only to a fraction of production (e.g., 1015%)99 due to logistical reasons, such as mismatched capacities in the caster and rolling mill.100 Hot charging can save about 0.5 million Btu/ton.101 Finally, sensible heat loss from hot rolled steel can be partially recovered by using watercooling. Since the final temperature of the cooling water is generally low (around 180°F or 80°C), it can be upgraded for other heating applications with a heat pump.102 Table 15 Unrecovered Sensible Heat Losses from Hot Solid Streams in Iron/Steel Production Waste Heat Source Max Temp a Sensible Heat (Btu/ton) a Applicable Steel Production (million tons /year) Recovery Technology a Stage of Development a Waste Heat (TBtu/yr) Hot Coke BF Slag BOF Slag Cast Steel Hot Rolled Steel 2000°F 0.21 [1100°C] 2400°F 0.34 [1300°C] 2700°F 0.02 [1500°C] 2900°F 1.20 [1600°C] 1700°F 4.76 [900°C] 56.47 b 56.47 b 56.47 b 104.58 c 104.58 c Dry coke quenching Radiant heat boiler(RHB) RHB RHB with heat pipes, slab cooler boiler, hot charging. Water spraying and heat pumps Commercial, not widely 12 used in US Prototype, R & D stopped 19 since end of 1980s Prototype, R & D stopped 1 since end of 1980s RHBs are commercial, 125 but not used in US. Hot charging is used for a small % of production. Commercial, not widely 497 used in US Total 497 a. adapted from de Beer, p. 189 b. based on steel production at integrated steel mills in the United States (USGS Mineral Yearbook, 2005) c. based on total steel production in the United States 42PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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