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Design and Development of an Alternative System of Recycling Exhaust Gas of a Direct Iron Reduction Furnace based on the Criterion of Minimum Destruction of Exergy and Water Usage

Golkar, Babak | 2016

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 48744 (46)
  4. University: Sharif University of Technology
  5. Department: Energy Engineering
  6. Advisor(s): Sobouhi, Yadollah; Ashjari, Mohammad Ali
  7. Abstract:
  8. Enormous amounts of water and energy are lost by scrubber utilization for furnace exhaust gas washing during direct iron reduction process. Hence, the aim of the current research is design and construction of a system which could be employed instead of scrubber within direct iron reduction process considering the equipment size constraints.To this end, the substitute system was manufactured after dimensional analysis and simulation of lab model compared to the prototype regarding the implementation limitations. The model has been tested in different operating conditions and empirical relations have been extracted for general analysis of direct iron reduction process. The case study here is Esfahan’s Mobarakeh Steel Company which produces 102 tons/day of Sponge Iron.The assessments represent that 40% water economization and 14 MW heat recovery from furnace exhaust gas can be achieved as results of the substitute system utilization at the economic optimal point. The recovered heat, then, was supposed to be used toward reformer fuel consumption reduction which led to 640 m3 and 1386 m3 decline in natural gas and reformer process gas consumptions, respectively. Getting the substitute system operated, exergy destruction rate within scrubber and reformer decreased by 17%. It also saves 0.75 Mm3 of water, 945 MWh of power, 5.6 Mm3 of natural gas and 16.4 Mm3 of process gas per annum. The economized process gas could be used as Methanol provider with high added value. From environmental standpoint, 17400 tons/year of CO2 emission decrement is the output of fuel less consumption. It is worth noticing that the results are related for each 102 tons sponge iron manufacturing unit and the company is currently using 5 units.The Internal Rate of Return (IRR) for the proposed plan is estimated to be 50-68% and the payback period to be 2.5-3 years
  9. Keywords:
  10. Scrubbers ; Direct Reduction Process ; Cyclone-Recuperator Exchenger ; Heat Recovery Section ; Water Conservation ; Direct Iron Reduction

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