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TA 6M: Waste Heat Recovery Considerations for the Iron and Steel Industry The iron and steel industry was the fifth largest energy-consuming U.S. manufacturing sector in 2010 (following chemicals; petroleum refining; forest products; and food and beverage), consuming 1,460 TBtu of the 19,200 TBtu of manufacturing total primary energy use.37,38 The R&D considerations most relevant to the iron and steel industry include: Secondary heat recovery devices that can supplement and enhance performance of the currently used systems, and are capable of recovering part (less than 50%, in most cases) of the waste heat available. Recovery of waste heat or increasing the value of available heat from blast furnace gas (removal of moisture). Recovery of waste heat in hot products such as hot slabs, rolled steel shapes downstream of the rolling mill, heat treated steel processed in furnaces, and coke discharged from coke oven batteries. In some cases, the technologies exist but are too difficult to implement due to space requirements in existing operations, cost, or lack of use of the low-grade heat produced after heat recovery. Further examination in partnership with industry would improve understanding of these opportunities. Recovery and use of waste heat from highly contaminated hot gases such as hot coke oven gas from the ovens. No technology exists or is commercially used in similar cases. Energy recovery through cleaning and recycling steam heat from degasifying systems used for liquid steel refining. Recovery or utilization of convective and radiant heat from furnace walls or openings, or from hot products such as hot steel shapes after rolling. Use of low-grade heat in the form of cooling water used in casters or in rolling operations. Considerations for Steel Mini-mills (EAF Furnaces and Rolling Mill) WHR related R&D considerations specific to EAF steel plants include: Heat recovery from EAF exhaust gases. Options could include hot gas clean-up, controlled combustion of combustibles to manage reaction temperatures while avoiding melting of steel oxides and other solid contaminants, and heat recovery from highly contaminated (e.g., particulate and condensable oil vapors) gases. Heat recovery from surfaces of hot ladles. The heat loss from hot ladles takes place through radiation and convective heat transfer to the surrounding environment. Heat recovery from cooling water used in the continuous casting process and reheat furnace cooling (e.g., walking beam furnaces or thin-slab reheating roller hearth furnaces). Secondary heat recovery from reheat furnaces downstream of conventional heat recuperators to recover additional heat. One option is preheating the product entering the furnace. Issues to be addressed include the location of the heat source and heat use, available space, and the infrastructure or logistics of transporting heat to the desired location. Heat recovery from hot cooled products. This could be medium- or low-grade heat. Considerations for the Aluminum Industry The aluminum industry was the tenth largest energy-consuming U.S. manufacturing sector in 2010 (following chemicals; petroleum refining; forest products; food and beverage; iron and steel; plastics; fabricated metals; transportation equipment; and computer, electronics, and electrical equipment), consuming 456 TBtu of the 19,200 TBtu of manufacturing total primary energy use.39,40 To enable the aluminum industry to more effectively adopt WHR technologies, the following R&D issues need to be addressed: 31 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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