Aug 10, 2012
Smelter engineering firm introduces cogeneration technologyBack
Cogeneration|Eskom|Eti Krom|Gas|Metix|SMS Siemag|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|Waste Energy|Cogeneration|Klaus Schmale|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
Other Electricity News
The use of biofuels, as a renewable-energy source, presents the potential for numerous environmental, energy security and efficiency benefits to the South African economy, says law firm ENSafrica senior associate environmental law division senior associate Andrew...
Recent Research Reports
Steel 2014: A review of South Africa's steel sector (PDF Report)
Creamer Media’s Steel 2014 report provides an overview of the global steel industry and particularly of South Africa’s steel sector over the past year, including details of production and consumption, as well as the country's primary carbon steel and stainless...
Projects in Progress 2014 - First Edition (PDF Report)
This publication contains insight into progress at the delayed Medupi and Kusile coal-fired projects, in Mpumalanga and Limpopo respectively, as well as at the Ingula pumped-storage scheme, which is under construction on the border between the Free State and...
Automotive 2014: A review of South Africa's automotive sector (PDF Report)
The report provides insight into the business environment, the key participants in the sector, local construction demand, geographic diversification, competition within the sector, corporate activity, skills, safety, environmental considerations and the challenges...
Construction 2014: A review of South Africa's construction sector (PDF Report)
Construction data released during 2013 hints at a halt to the decline in the industry during the last few years, with some commentators averring that the industry could be poised for recovery. However, others have urged caution, noting that the prospects for a...
Electricity 2014: A Review of South Africa's Electricity Sector (PDF Report)
This report provides an overview of the state of electricity generation and transmission in South Africa and examines electricity planning, investment in generation capacity, electricity tariffs, the role of independent power producers and demand-focused initiatives,...
Defence 2013: A review of South Africa's defence industry (PDF Report)
Creamer Media’s 2013 Defence Report examines South Africa’s defence industry, with particular focus on the key players in the sector, the innovations that have come out of the defence sector, local and export demand, South Africa’s controversial...
This Week's Magazine
The Electronic Systems Laboratory (ESL) of the Department of Electrical and Electronic Engineering at Stellenbosch University is strongly reaffirming its position as one of South Africa’s leading centres for satellite technology and expertise. It is currently...
The world’s lowest-cost diesel-electric locomotive is not made in China, but in Pretoria, at RRL Grindrod Locomotives’ newly upgraded 30 000 m2 plant. The company’s locomotive pricing is “more competitive than any other original-equipment manufacturer (OEM)...
The South African Defence Review 2012, released to the public at the end of last month (despite the year given in its title) recommends the creation of the post of Chief Defence Scientist. This official would be responsible for the management of defence technology...
AltX-listed engineering technology company Ansys has been awarded an R188-million contract by Transnet to supply integrated dashboard display systems to the freight rail utility’s locomotives. Black-owned and controlled Ansys developed the bespoke integrated system...
South Africa’s sole nuclear power station Koeberg, which is located in the Western Cape, breached a major operations milestone on April 4, which marked the thirtieth anniversary of Unit 1 having been connected to the grid. Eskom, which operates the two-unit plant,...