Aug 10, 2012
Smelter engineering firm introduces cogeneration technologyBack
Engineering|CoAL|Cogeneration|Environment|Eskom|Eti Krom|Generator|Metix|SMS Siemag|SMS-Siemag|System|Systems|Waste|Turkey|Chemical Energy|Cogeneration|Electrical Energy|Electricity|Energy|Energy Crunch|Energy Recovery|Ferrochrome Producer|Furnaces Industry Energy-recovery Systems|Given Energy|High Energy Prices|Integrated Energy System|Natural Gas|Oil|Power-saving Solutions|Process Gas|Recovery Solution|Service|Solutions|Systems|Waste Energy|Cogeneration|Klaus Schmale|Power|Waste|Colorado
© Reuse this
Metix has developed power-saving solutions that enable cogeneration and that are suitable for the local market.
Cogeneration is characterised by the simultaneous production of electricity and heat from a single fuel source, such as natural gas, biogas, biomass, coal, oil or waste heat.
“Combined heat and power (CHP) is an integrated energy system, which can be modified, depending on the requirements of the end-user,” says Metix deputy sales director Klaus Schmale.
Owing to their higher efficiency, CHP systems use less fuel to produce a given energy output.
Within the ferroalloy production sector, different types of submerged arc furnaces (SAFs) are applicable: open, semiclosed and closed. The last two are suited for energy recovery.
Within the semiclosed type furnace, carbon monoxide (CO) and hydrogen (H2) are generated but directly burned completely owing to sufficient false air, which enters the furnace through the doors and presribed openings.
Therefore, huge amounts of fully combusted offgas with a high amount of sensible heat is generated – on average it reaches temperatures of about 650 ºC.
The offgas of closed type furnaces is even hotter (up to 1 800 ºC) and contains large amounts of chemical energy in terms of CO and H2. The low calorific-value (LCV) is usually one-third of the LCV of natural gases.
Metix plans to generate power with a process gas-fired boiler combined with a turbine and a generator unit.
“The boilers burn LCV process gas in a combustion chamber. Our standardised boiler is a two-pass boiler. The first pass is the combustion chamber and the heat exchangers (superheater, evaporators and economisers) are located in the second pass.
“The thumb rule for efficiency is 33% and the superheated steam runs the turbine island to produce steam. Boilers using up to 360 t/h of steam at 540 ºC can typically produce 20 MW to 160 MW of electrical energy,” states Schmale.
Metix says Turkey-based ferrochrome producer Eti Krom has ordered this type of energy- recovery solution from Metix for use in two semiclosed ferrochrome SAFs. Each furnace is equipped with one waste-heat boiler.
The system is expected to start up early in 2013 and will produce steam, which will be used in a steam turbine with an attached power- generation unit to produce 5 MW of electrical energy.
With this system, Eti Krom expects an amortisation period of less than three and a half years.
“Up to 40% of the energy spent during smelting in a furnace leaves with the offgas. These offgases are always hot and are mostly bursting with energy; Metix offers energy-recovery systems for steelmaking, as well as for ferroalloy production, which will save up to 55% of the waste energy,” says Schmale.
The waste energy of an operating plant, which is not normally used but heats up the environment instead, can save other energy sources and, in turn, reduce energy costs.
Using the waste heat of process gas also reduces carbon dioxide emissions, which further reduces the amortisation period for Eti Krom.
“A directly controllable and constant price gives you an advantage, compared with using electricity from the grid and from a power supplier that is increasing its prices,” says Schmale.
As a service supplier, Metix will also provide training for internal and external plants using its CHP technology.
The company also plans to approach State-owned power utility Eskom to present the features of the technology and to discuss how it can help overcome the shortfall in electrical energy.
Metix hopes that Eskom will support the introduction of the energy-recovery system as part of its range of energy-saving initiatives.
Edited by: Chanel de Bruyn© Reuse this Comment Guidelines (150 word limit)
Other Electricity News
Recent Research Reports
Liquid Fuels 2014 - A review of South Africa's Liquid Fuels sector (PDF Report)
Creamer Media’s Liquid Fuels 2014 Report examines these issues, focusing on the business environment, oil and gas exploration, the country’s feedstock supplies, the development of South Africa’s biofuels industry, fuel pricing, competition in the sector, the...
Water 2014: A review of South Africa's water sector (PDF Report)
Creamer Media’s Water 2014 report considers the aforementioned issues, not only in the South African context, but also in the African and global context, and examines the issues of water and sanitation, water quality and the demand for water, among others.
Defence 2014: A review of South Africa's defence industry (PDF Report)
Creamer Media’s Defence 2014 report examines South Africa’s defence industry, with particular focus on the key participants in the sector, the innovations that have come out of the sector, local and export demand, South Africa’s controversial multibillion-rand...
Road and Rail 2014: A review of South Africa's road and rail infrastructure (PDF report)
Creamer Media’s Road and Rail 2014 report examines South Africa’s road and rail transport system, with particular focus on the size and state of the country’s road and rail network, the funding and maintenance of these respective networks, and the push to move road...
Real Economy Year Book 2014 (PDF Report)
This edition drills down into the performance and outlook for a variety of sectors, including automotive, construction, electricity, transport, steel, water, coal, gold, iron-ore and platinum.
Real Economy Insight: Automotive 2014 (PDF Report)
This four-page brief covers key developments in the automotive industry over the past 12 months, including an overview of South Africa’s automotive market, trade figures, production and the policies influencing the sector.
This Week's Magazine
South Africa remains an important manufacturing and export platform for Ford Motor Company, says executive chairperson Bill Ford. However, he adds that other countries on the continent are “becoming interesting”, and that the US carmaker is casting its net wider for...
Germany’s Max-Planck-Society (MPG) and the Max-Planck-Institute for Radio Astronomy (MPlfR) are investing €11-million (about R150-million) into South Africa’s MeerKAT radio telescope array programme. The money will be used to design, build and install S-band radio...
Infrastructure spend in sub-Saharan Africa will grow from $70-billion in 2013 to $180-billion by 2025, says PwC capital projects and infrastructure Africa leader Jonathan Cawood. This is one of the findings of PwC’s Capital Projects & Infrastructure report on East...
Private-owned defence and aerospace manufacturer Paramount Group and the Ichikowitz Family Foundation unveiled its Anti-Poaching Skills and K9 Training Academy in Magaliesburg last month.
The inclusion of Bluetooth to provide sub-three meter accuracy and heightened functionality for users is one of the ways to change existing wireless networks into engagement networks. An engagement network differs from common wireless networks in that it enables the...