International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 2, Issue- 7, July-2014

BF GAS UTILIZATION AND POWER GENERATION IN STEEL

PLANT USING TRT
1
S.SHANTHI PRIYA, 2R.G.PATIL
1,2
Basaveshwara Engineering College,Bagalkot,Karnataka
E-mail: [email protected], [email protected]

Abstract- This paper describes power generation simulation results using MATLAB. The output power depends on various
parameters such as turbine inlet pressure, turbine outlet pressure, temperature and flow rate of BF gas. The results are
compared and optimal value for which the turbine has to be operated are determined.

Keywords- TRT (Top gas pressure recovery turbine), BF gas, MATLAB/Simulink, Software.

I. INTRODUCTION 2000˚C, depending upon the blast temperature. Since

CO2 is unstable in the presence of carbon above
The increasing price of fossil fuels, the increasing 1000˚C,CO is produced according to
need for the power supply reliability and increasing CO2+CO=2CO.The tuyere gas therefore, consists
demand for energy-efficient technologies are tending only CO and nitrogen, their contents being about 25
to favor the application of small power generation and 40 percent respectively when dry blast is used.
solutions. Cogeneration produces a given amount of This hot reducing gas rises through the active coke
electricity and heat. In iron and steel works, bed to the bosh, belly and shaft and iron oxides.
byproduct gas – blast furnace gas (BFG) is widely Composition of BF gas is CO(22- 28 %), CO2 (18-
flared and vented to the atmosphere without 28%) ,H2 (3-8% ), N2 (40-45%)
utilization. On account of this, it is an important task
for the iron and steel works to sufficiently and TRT (Top gas pressure recovery turbine):
effectively utilize BFG so as to reduce waste gases Blast furnace top gas pressure recovery turbine unit is
emissions and save energy. On the other hand, the an energy recovery machine train, and its function is
power generated through combusting waste gases will to guide gas into turbine by residual pressure of blast
replace the major quantity of electricity that could furnace top gas, then gas works due to expanding and
have been generated by greenhouse gases (GHG) the generator is driven to generate power. The TRT-
intensive fossil fuel power plant, thus GHG emission unit can recover 25-30% energy of the blast furnace
reductions could be achieved. Aside from exploring requirement. At the same time, when it is running
renewable energy alternatives, available energy normally, it can act as pressure reducing valve unit.
resources must be utilized to their maximum The TRT can control blast furnace top pressure
potential. sensitively and the scope of fluctuation is small. So it
plays an active role that can make blast furnace
Blast Furnace gas: running normally and increasing production.
BF gas leaves the furnace at a temp of 150 - 250°C
and at a pressure equal to the top gas pressure of the The TRT utilizes the pressure energy of BF gas
furnace. BF gas also has a huge dust content which which is the by-product of the blast furnace. The
needs to be removed before it can be put to use. The cleaned gas is fed to top gas recovery turbine. In TRT
primary cleaning system at all blast furnaces is a dry the top gas kinetic energy converted to mechanical
system where about 75% of the dust is removed. This energy which is then converted to electric energy to
is typically a dust catcher. This dust is called Flue generate power through generator.
Dust and is typically recycled through sinter plants or The outlet pressure from the TRT is sent to the gas
rotary hearth furnace BF gas also has calorific value holder from where it is distributed to the different
of about 700 – 800 Kcal/ Nm³. This calorific value is consumers at constant pressure. If TRT not installed,
quite low compared to coke oven gas CV of 1850 pressure energy of gas goes as waste and we could
Kcal/Nm³. Due to low CV; BF gas does not have self lose substantial amount of power which can be
supporting flame. However in view of its quantity generated at very low generation cost. There are two
and the fact that it is available at high pressure, BF types of TRT Wet and Dry type .The dry type TRT
gas is the ideal fuel for reheating furnaces and power can generate more power than wet type TRT.
houses in BF. It is also necessarily used for heating
the stoves which heat the cold blast for the BF. The
hot blast of air entering the furnace through the
tuyeres burns the coke carbon to CO2. The intense
heat produced gives a flame temperature of 1800

BF Gas Utilization And Power Generation In Steel Plant Using TRT

79
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 2, Issue- 7, July-2014

T= Efficiency of turbine (85%);

G= Efficiency of generator (97%).

6
x 10 Output Power verses Input pressure at different Flow rates
15

14

13

12

11

Output Pow er in M W
10

8
Q=2,00,000
7 Q=3,50,000
Q=5,00,000
6

Fig.1.TRT (Top gas recovery turbine) 4

275 280 285 290 295 300 305 310 315
Input Pressure ( P1)

Fig.2.Inlet pressure verses output power at different flow rates

II. POWER RECOVERED BY TRT:
Power increases with increase in inlet power. As
Twenty five to fifty percent (25~30%) of the power pressure increases in steps of 5Kpa power increases
consumed by the blast furnace blower can be
by 0.08 MW at Q=2,00,000 Nm3/hr ,0.14 MW at
recovered, which is economically remarkable. The
Q=3,50,000 Nm3/hr and 0.2MW at 5,00,000 Nm3 /hr.
power required to produce 1 Tonne of Hot Metal
At same inlet pressure power increases by 3.6 MW
(THM) is 150 KWhr. The daily average production is
when flow rate is increased by 1,50,000 Nm3/hr.
8000THM. 6
Output Power verses Inlet pressure at different outlet pressure
x 10
Hence power consumed in daily production is given 10

as:8000 THM/day = 150 x 8000 9.8

= 1200000 KWhr 9.6

= 1200 MWhr 9.4

By installing the TRT unit, the power consumed thus

O u tpu t P o w e r in M W

9.2

can be recovered about 25-30%.It is shown as 9

follows: 8.8

TRT capacity = 12.4 MW 8.6 P2=108.3

= 12.4 x 24 MWhr 8.4

P2=107.3

= 297.6 MWhr of power can be 8.2

P2=106.3

produced using TRT.

8
Therefore, the energy recovered through TRT = 297.6 275 280 285 290 295
Inlet Pressure ( P1)
300 305 310 315

x 100 = 24.8 ≅25 % Fig.3.Inlet pressure verses output power at different outlet
1200 pressure
Power increases with increase in inlet power. As
III. RESULTS pressure increases in steps of 5Kpa power increases
by 0.13 MW. when outlet pressure is increased by 1
OUTPUT POWER CALCULATION OF TRT: Kpa power decreases by 0.08 MW.
6 Inlet pressure verses Output Power at different temperatures
Parameters considered for estimating the TRT power 11
x 10

output:
•BF Gas volume flow 10.5

•BF Gas pressure at the furnace top 10

•Pressure drop across the GCP 9.5

O u tp u t P o w e r

•Temperature of BF Gas after the GCP 9

•BF Gas pressure as desired after the TRT

8.5
•Efficiency of top recovery expansion turbine T=323 K

•Efficiency of Generator 8
T=338 K

T=353 K
7.5

(n-1/n)
P = Q x D x Cp x T1 x {1 – (p2/p1) }x Tx G 7
275 280 285 290 295 300 305 310 315

Where: Inlet pressure P1

Q = Flow rate in Nm3/sec; Fig.4.Inlet pressure verses output power at different

D = Density of BF Gas in kg/m3; temperature
Cp = Specific heat at constant pressure in kJ/kg K;
T1 = TRT Inlet temperature in K; Power increases with increase in inlet power. As
p1 = TRT inlet pressure in bar; pressure increases in steps of 5Kpa power increases
p2 = TRT outlet pressure in bar; by 0.13 MW at T=323 ,0.14 MW at T=338,and 0.15
n = Exponent of adiabatic expansion; MW at T=353. At same inlet pressure power

BF Gas Utilization And Power Generation In Steel Plant Using TRT

80
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 2, Issue- 7, July-2014

increases by 0.39 MW when Temperature is Power increases with increases in temperature. As

increased by 15K. temperature increases by 5K power increases by
7.3
x 10
6
Output power vers es Outlet pres sure at different temperatures
0.07MW at Q=2, 00,000 Nm3/hr, 0.13 MW at Q=3,
50,000 Nm3/hr and 0.2MW at 5, 00,000 Nm3 /hr. At
T= 323K
7.2
T= 338K

T=353K
7.1

7 same temperature power increases by 3.6 MW when

flow rate is increased by 1, 50,000 Nm3/hr.
Output Power in MW

6.9

6.8
6
x 10 Temperature vers es OutPut Power at different Inlet press ure
10
6.7

9.5
6.6

6.5 9

6.4
8.5

OutPut Power in MW
6.3
106 106.5 107 107.5 108 108.5 109 109.5 110 8
Outlet Press ure (P2)

7.5

Fig.5.Outlet pressure verses output power at different

7 P!= 277.3

temperature P1=292.3
P1=307.3
6.5

Power decreases with increase in outlet pressure. As 315 320 325 330 335
Temperature in K
340 345 350 355

outlet pressure increases in steps of 0.5Kpa power Fig.9.Temperature verses output power at different inlet
decreases by 0.04 MW. Power increases by 0.31 MW pressure
for increase in temperature by 15K.
x 10
6
Outlet pres sure verses Output Power at different flow rates
Power increases with increases in temperature. As
14
temperature increases by 5K power increases by 0.12
12
MW. power increases by 0.35 MW for 15 Kpa
10
increase in inlet pressure.
Output Power

6
x 10 Output power verses Temperature at different outlet press ure
8 8.1

6
7.9

7.8
4
Q=2, 00, 000
OutPut Power in MW

7.7
Q=3, 50, 000
Q=5, 00, 000
2 7.6

106 106.5 107 107.5 108 108.5 109 109.5 110 7.5
Outlet press ure P2
P2=106.3
7.4 P2=107.3
P2=108.3

Fig.6.Outlet pressure verses output power at different flow 7.3

rates 7.2

7.1
315 320 325 330 335 340 345 350 355
Temperature in K

Power decreases with increase in outlet pressure. As Fig.10.Temperature verses output power at different inlet
pressure increases in steps of 0.5 Kpa power output pressure
decreases by 0.02 MW at Q=2,00,000 Nm3/hr ,0.04
MW at Q=3,50,000 Nm3/hr and 0.05MW at 5,00,000 Power increases with increases in temperature. As
Nm3 /hr.The power increases by 3.7 MW as flow rate temperature increases by 5K power increases by 0.11
is increased by 1,50,000 Nm3/hr. MW
6
x 10 output power verses flow rate at different temperatures
12
6
x 10 Output power verses Output pressure at different Inlet pressure
11 11

10
10. 5
9

8
10
OutPut power in MW

9. 5 6
Output P ower in MW

5
9
4 T=323 K
T=338 K
T=353 K
3
8. 5

8 1
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6
Flow rate (Q) 5
x 10

7. 5

Fig.11.Flow rate verses output power at different temperatures

7
106 106.5 107 107.5 108 108.5 109 109.5 110
Output pressure P2

Fig.7.Outlet pressure verses output power at different inlet Power increases with increases in Flow rate. As Flow
pressures rate increases by 50,000 Nm3/hr power increases by
0.9MW. Power increases with increases in Flow rate.
Power decreases with increase in outlet pressure. As Flow rate increases by 50,000 Nm3/hr power
power increases by 0.04 MW as outlet pressure increases by 0.9MW.
increases in steps of 0.5 Kpa. 12
x 10
6
Output power vers es flow rat e at different Outlet press ure

6
x 10 Output power verses temperat ure at different flow rates
11

14
10

12
9
Output Power in MW

10 8
Output power in MW

7
8

6
P2=106. 3
6
P2=107. 3
P2=108. 3
5

4 Q= 2, 00,000
Q= 3, 50,000
4
Q= 5, 00,000 2 2.5 3 3.5 4 4.5 5
Flow rat e (Q) 5
x 10
2
315 320 325 330 335 340 345 350 355
Temperature in K

Fig.12.Flow rate verses output power at different outlet

Fig.8. Temperature verses output power at different flow rates pressure

BF Gas Utilization And Power Generation In Steel Plant Using TRT

81
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 2, Issue- 7, July-2014

Power increases with increases in Flow rate. As Flow maximum power generation .The furnace top
rate increases by 50,000 Nm3/hr power increases by pressure fluctuation is the main reason for variation
1.23MW of TRT inlet pressure. So the fine tuning and trouble
14
x 10
6
Output power vers es flow rate at different Inlet pressure
free operation of Blast Furnace is required to generate
13

12
constant BF top pressure.As per design a constant
11 TRT outlet pressure of 0.125 bar max, is also
OutPut Power in MW

10

9
necessary to achieve maximum power output of
8
P1=277.3
12.4MW from the TRT. Flow rate of BF gas should
be maintained at 5,00,000 Nm3/hr.
P1=292.3
7 P1=307.3

4
1 1.5 2 2.5 3 3.5
Flow rate (Q)
4 4.5 5 5.5
5
x 10
6
REFERENCES
Fig.13.Flow rate verses output power at different inlet pressure
[1] Yang Wei-hua, Xu Tao, Li Wei, Chen Guang, Jia Li-yue,
Guo Yue-jiao “Waste Gases Utilization and Power
Power increases with increases in Flow rate. As Flow Generation in Iron and Steel Works” 2009 Third
rate increases by 50,000 Nm3/hr power increases by International Symposium on Intelligent Information
1.2MW. Technology Application
Workshops.IEEEDOI10.1109/IITAW.2009.17.
CONCLUSION [2] M. Modesto a,*, S.A. Nebra b “Exergoeconomic analysis
of the power generation system using blast furnace and coke
A consistent and constant TRT inlet BF gas pressure oven gas in a Brazilian steel mill” 2009 Elsevier Ltd.
of 2.2 bar is to be maintained to achieve maximum
[3] Xiao Ding, Hongyuan Li “Environmental Benefit from
power output of 12.4MW. Fluctuation of BF gas inlet Blast Furnace Gas Recycling in the Integrated
pressure adversely effects the power generation. Steelworks”2011 International Conference on Computer
Therefore to achieve 100% PLF, the inlet BF gas Distributed Control and Intelligent Environmental
pressure of the TRT has to be constant to obtain Monitoring.



BF Gas Utilization And Power Generation In Steel Plant Using TRT

82