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A coke plant transforms coal into coke, using a pyrolysis process. The coke produced has the physical and mechanical characteristics needed by a steel furnace. The heating of the coke ovens is provided by the combustion of process gas (coke oven gas, steel furnace gas or natural gas). A large quantity of thermal energy resulting from the combustion of the gas escapes through the exhaust. The coking plant under study emits around 150 000 Nm3/h of flue gas at a temperature of 150°C. The flow rate is relatively stable and the coking plant is never stopped. Another particularity of the exhaust is the high sulphur content (level of H2S sometimes reaches 3g/Nm3). This element is corrosive for piping and heat exchanger. Due to the high sulphur content, it is not possible to cool the exhausts below 110°C. Thus, the potential recoverable thermal energy is around 2,5MW6. Project sizing Analysis of the data showed an ORC potential of 250kWe by recovering the heat of the exhaust gases through an intermediate loop (pressurized water between 90 and 120°C). For this temperature and power, 2 Clean Cycle units of 125kWe gross (produced by Calnetix, recently purchased by General Electric) would fit. The gross efficiency of such a module for this heat source would reach 10% with a cooling loop at 25/35 °C (using a cooling tower). Auxiliary’ electrical consumption represents around 50kWe (20% of the gross power): 30kWe for the ORC modules circulating pump, 15kWe for the cooling loop (pump and cooling towers) and 5kWe for heat transfer loop circulating pump. Thus we expect a net production of 200kWe. 6 Calorific capacity of exhausts is evaluated at 1,45kJ/°C/Nm3 Average daily exhaust flow rate (30 day period)PDF Image | Waste heat recovery projects using ORC
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