Aug 10, 2012
Smelter engineering firm introduces cogeneration technologyBack
Engineering|CoAL|Cogeneration|Environment|Eskom|Eti Krom|Generator|Metix|SMS Siemag|SMS-Siemag|System|Systems|Training|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 Foundries, Forges and Die-Casting News
Recent Research Reports
Steel 2015: A review of South Africa's steel sector (PDF Report)
Creamer Media’s Steel 2015 report provides an overview of the key developments in 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...
Projects in Progress 2015 - First Edition (PDF Report)
In fact, this edition of Creamer Media’s Projects in Progress 2015 supplement tracks developments taking place under the Renewable Energy Independent Power Producer Procurement Programme, which has had four bidding rounds. It appears to remain a shining light on the...
Electricity 2015: A review of South Africa's electricity sector (PDF Report)
Creamer Media’s Electricity 2015 report provides an overview of State-owned power utility Eskom and independent power producers, as well as electricity planning, transmission, distribution and the theft thereof, besides other issues.
Construction 2015: A review of South Africa’s construction sector (PDF Report)
Creamer Media’s Construction 2015 Report examines South Africa’s construction industry over the past 12 months. The report provides insight into the business environment; the key participants in the sector; local construction demand; geographic diversification;...
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.
This Week's Magazine
Forest products group Sappi has confirmed the selection of its 25 MW biomass-to-power project, to be erected at its Ngodwana mill, in Mpumalanga, as a preferred bidder under the South African government’s Renewable Energy Independent Power Producer Procurement...
Information and communications technology (ICT) distributor DCC is making Windows- and Android-operating systems tablets available through retailers and education equipment suppliers to provide school children with affordable, high-performance education tools. The...
Another cement manufacturer is set to enter the Ugandan market, raising hopes that prices will come down and spur growth in the construction industry. National Cement, a Kenyan manufacturer, has unveiled plans to invest $195-million in a new manufacturing plant in...
With growth rates exceeding that in the developed world – at an average of between 4% and 5% between 2002 and 2014 – African countries provide investors with ample reason to tap into booming consumer demand says Manufacturing Circle executive director Coenraad...
The South African Chamber of Commerce and Industry’s (Sacci’s) Business Confidence Index (BCI) decreased by 3.7 index points month-on-month to 89.1 in March.
Next ArticleSteel producer orders two furnaces