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blast furnace is in the form of sensible and chemical heat from the blast furnace gas (BFG), which is used as fuel at several locations within the plant. The BFG, as it is discharged from the top of the blast furnace, contains several contaminants including particulates, sulfur, and other compounds, and must be cleaned using a scrubber and then dehumidified. Following are the waste heat sources from blast furnaces: Hot BFG with a considerable amount of sensible heat: The gas contains particulates and condensable materials that need to be addressed if any type of sensible heat recovery is to be achieved. Moisture removal from the BFG itself with a heating value of approximately 90 Btu/cu ft: At this low heating value moisture content becomes an important consideration, as it will suppress “flame” temperature when used as a fuel. An innovative method of reducing or eliminating water vapor will improve the combustion characteristics of the gas. Recovery of heat from flared BFG when not in use: Recovery or conversion of this heat in a usable form such as independent electricity production, if economically justifiable, would save energy. Blast Furnace Stoves BF stoves are direct-fired regenerators used to preheat the blast air used in the BF. These stoves use BFG and coke oven gas (COG) with an injection of natural gas to achieve the required temperature in the stoves, and hence for the air. Following are the areas of waste heat, heat recovery, and performance improvement in BF stoves: Dehumidifying or drying BFG prior to its use in the stoves. Recovering heat from the stove’s exhaust gases at approximately 600°F (316°C); as these gases are relatively clean and free of particulates or other contaminants. Adding O2 in combustion air used for combustion of the blast furnace gas in the stoves to increase flame temperature and increase heat transfer as well as to reduce stove exhaust gas volume. This is an option for a possible replacement for natural gas mixing with the blast furnace gas to enhance its heating value. In either one of these cases the net result is improved heat transfer and delivery of hotter temperature for the blast air used in the blast furnace. The economics depend on the relative cost of natural gas versus oxygen. In most cases, availability of on-site O2 may favor use of O2. Power Plant (Boilers – Steam System) Boilers in an integrated steel plant normally use BFG and COG as fuel. The exhaust gas temperature for the boilers varies with the boiler’s age and the controls used. Temperatures could be fairly high (650°– 840°F or 340°–450°C) to average (700°F or 370°C), with O2 content varying from 3%–7.5%. The waste heat is in the form of clean, contamination-free gases and does not require further conditioning. The areas of waste heat and recovery from boilers and steam systems include the following: Using exhaust gases to preheat BFG and COG Using low-temperature power generation if economically justifiable Industrial Waste Heat Recovery Page 12PDF Image | Industrial Waste Heat Recovery: Potential
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