Aug 10, 2012
Smelter engineering firm introduces cogeneration technologyBack
Engineering|CoAL|Cogeneration|Eskom|Eti Krom|Gas|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|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
Updated 2 hours 37 minutes ago A consortium led by two Kenyan firms won a government tender to build a 1 000-MW, coal-fired power plant, company officials said on Tuesday, part of moves to satisfy rising demand for energy in East Africa's biggest economy. Kenya suffers from regular blackouts due...
Updated 3 hours ago Regional interconnections and oil discoveries are expected to drive the transmission and distribution industry’s (T&D’s) growth in East Africa, the second-fastest growing region in Africa, global growth consulting firm Frost & Sullivan said on Tuesday. The...
Updated 4 hours ago Small, 100 MW nuclear power plants could be the answer to Africa’s electricity generation challenges, Nuclear Africa CEO Dr Kelvin Kemm said on Tuesday, stating that he believed in 100 years’ time, the world would mostly be run on nuclear power. “I believe...
Updated 2 hours 33 minutes ago Despite various challenges related to the extraction of shale oil and gas, as countries grow accustomed to the idea, the use of shale as a form of energy will be more widely pursued, international oil and gas market analyst Michael Lynch said on Tuesday. Speaking at...
Updated 2 hours 36 minutes ago A consortium led by two Kenyan firms won a government tender to build a 1 000-MW, coal-fired power plant, company officials said on Tuesday, part of moves to satisfy rising demand for energy in East Africa's biggest economy. Kenya suffers from regular blackouts due...
Updated 2 hours 42 minutes ago The announcement of the successful bidder for the construction of Durban’s long-awaited passenger cruise terminal was imminent, Transnet National Ports Authority (TNPA) CEO Tau Morwe told delegates at the African Ports Evolution Conference in Durban on Tuesday. ...
Recent Research Reports
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...
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.
Real Economy Insight: Construction 2014 (PDF Report)
This five-page brief covers key developments in the construction industry over the past 12 months. It provides an overview of the sector and includes details of employment in the sector, infrastructure and municipal spending, as well as insight into companies’...
Real Economy Insight: Electricity 2014 (PDF Report)
This five-page brief covers key developments in the electricity industry over the past 12 months, including details of State-owned power utility Eskom’s generation activities, funding and tariffs, independent power producers and prospects for the sector.
Real Economy Insight: Road and Rail 2014 (PDF Report)
This six-page brief covers key developments in the road and rail industries over the past 12 months, including details of South Africa’s road and rail network and prospects for both sectors.
This Week's Magazine
South African State-owned defence industrial group Denel has announced its fourth consecutive year of profits. The group's results for the financial year 2013/2014 were recently announced at its head office in Centurion, south of Pretoria. Revenues grew by 17%, net...
There is little opportunity for JSE-listed infrastructure company Group Five to grow shareholder value in the domestic market, says CEO Mike Upton. He says value can still be found in the private sector, in the renewable and industrial power sector, as well as in...
The National Association of Automobile Manufacturers of South Africa (Naamsa) has announced the event dates of the 2015 Johannesburg International Motor Show (JIMS). The event will take place from October 14 to October 25, 2015, at the Johannesburg Expo Centre, Nasrec.
UK engineering support services provider Babcock is set to deliver the largest order of global truck manufacturer DAF’s truck tractors in Southern Africa to bulk carrier road-based logistics company Ngululu Bulk Carriers (NBC), with 133 trucks to be delivered in...
Digital radio communications in the African local government space can open up the world, but have many challenges to overcome, notes integration and migration of legacy radio communications infrastructure with digital mobile radio company Emcom Wireless head of...