Imagination at work

Energy recovery solutions for I&S industryMagnus MORTBERGMay, 2017

GE Proprietary Information—Class III (Confidential) Export Controlled—U.S. Government approval is required prior to export from the U.S., re-export from a third country,

or release to a foreign national wherever located.

Long tradition and experience in Air QualityControl Systems

1920

1974

19881999

2000

• 1920: AB Svenska Fläktfabrikenestablished in Jönköping

• Manufacturing of fans, duct work, ventilation systems, etc.

• No. of employees: 20• Share capital of SEK 175,000 (€

19,000)

1942 Start selling ESP worldwide

Fläktfabrikens first workshop

at the old hospital mill in

Jönköping, Sweden.

1983 Opening of the Technical Center in Växjö

Large fans were

delivered at an

early stage of

the history

The heritage from ASEA, STAL and AB Svenska Fläktfabriken (Fläkt) have later been transferred through ABB to GE today.

1986 Acquires Peabody Process Systems (USA) for WFGD technology

1981 Delivers first SDA to Igelsta, Sweden

1957 Start of the Växjöactivities

2015

1996 Acquires Daneco (Italy) for WFGD technology

Our AQCS portfolio

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Electrostatic Precipitator

(Particulate)Fabric Filters

(Particulate)

Dry Flue Gas Desulfurization

(SOx and multi-pollutant)

Volatile Organic Compounds

(VOC)

Selective Catalytic Reduction

(NOx)Spray Dryer Evaporator

(Zero Liquid Discharge)

R&D for Best-in-Class Technology

In-house pilot of absorption system

Extensive analytical laboratory services

• World’s largest in house AQCS

lab/test facility used to:

• Develop new products,

• Advance existing products

• Utilises pilot scale models to

reproduce real process

conditions

• Apply CFD models to evaluate &

optimize product

• Awarded 120+ patents for

advancing technologies

• Employing 70+ professional in the

lab

EAF energy recovery opportunities

Biggest sources of energy losses:

• Off gas is typically 200-400 kW/ton of steel

• Cooling water system 60-70 kW/ton of steel

The energy leaving the furnace can be as high as 115 MW (instantaneous).

The biggest issue is that the heat content in the offgas is quite cyclical so that energy recovery is quite difficult

Waste Heat Boilers are common and well-proven.

Application to EAF for power generation is complicated because the steam turbine cannot be ramped up and down according to the changes in offgas flowrate and heat content.

Application to transient operation for steam and

heat generation can be done with minimum plant modifications

Waste Heat Recovery for Industrial Raw Gas

GE has extensive experience with shell-and tube design for waste heat gas for other industries

Filter with integrated HEXfor aluminium industry

Waste heat recovery from converter

Type: Heat recovery system from 150 ton/h converter

Scope of work: Basic and detail engineering of a new water cooled duct with a heat recovery system to provide hot water to the nearby town

Water flow rate: 3700 m³/hInlet temperature: 125 °COutlet temperature: 100 °CExchanged heat: 110 MWthEnough to heat approx 3000 houses

Elkem Bluestar ThamshavnSilicon Metal High Pressure Steam 1985

Furnace: 70 MWel

Off gas: 81 MWth

Turbine: 20 MWel

Recovery: 28%el

District heating

Finnfjord – FeSi /Norway, 1990 + 1997

Two HEX: 7.5 m Ø4.5 m

Gas temp.: 350 to 550C

Heat load: 12/15 MW.

HEX –Demonstration plants Aluminium

Dubai – pilot

finish Feb. 2009

Minitube

HEX

MHEX, EHEX 2009 – Primary Alu. Prod.

IHEX 2010Integrated in filter

Prototypes ME

2007

Alba IHEX

1997

AHEX 2011

Why Heat Recovery?

Recover Energy

• Revenue source if sold

• Savings in energy use/electricity consumption

• Possible positive influence on process e.g.

– Dioxin de novo synthesis is at a max around 250-400C

– Rapid cooling of flue gas with HEX is likely to have positive effect on dioxinemissions

GE has developed and installed a pilot for heat

recovery of EAF Flue gas

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Use of energy

Conversion always mean energy loss

Use of thermal energy

• District heating/District cooling

• Boiler feed water preheating

• Steam production

• Preheating/drying of raw materials

• Desalination

• Electricity production is possible using

• Steam turbine

• ORC – Organic Rankine Cycle

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GE Heat Exchanger

• Based on Shell and Tube

technology

• Gas on the inside of straight

tubes, water on the outside

• Gas flow parallel to tubes with

minimal scaling due to impact.

• Straight tubes easy to clean

• Efficient heat transfer with counter

flow gas/water

• Patents filed

Flue gas

Water

Heat exchanger installation on site

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Figure 2. Schematic layout of EAF AQCS equipment (left) and schematic layout with heat exchanger concept (right).

Heat Exchanger Installation on Site

Slip Stream HEX Pilot Installation

(HEX + fan + duct + dampers)

• 10 000 Nm3/h (design)

• 60 m3/h water (max)

• Tg = 100-700°C

• Max energy transferred

• From Gas: 1.4 MW

• In water: 1 MW

• Significant smoothing of theenergy contained in water

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Demonstration HEX for EAF flue gas

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Inlet and outlet T of HEX

Energy in FG and water

Inlet Temp: up to 1250°C, Flow: 10.000 Nm³/h, energy recovered ~1MW

Operational Experience

Dust build-ups will affectperformance

HEX cleaned during regularmaintenance stops

Adhered dust analysed for mitigation guidelines

Pilot Rebuilt with cleaningmechanism

Ongoing test show satisfactoryresults

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Options for electricity production

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Steam Turbine with generator set

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ORC – Organic Rankine Cycle

Uses organic fluid with lowboiling temperature to produceelectric power from e.g. waste heat

Pilot installation at aluminium smelter in Norway

Power production and efficiencydepends on numerous variables

• Temp Hot source

• Temp cooling water

• Fluid selection

• 5-15% conversion efficiency24

Conclusions

• GE has long experience in supplying Energy

recovery systems for challenging environments

• Multiple possibilities to use recovered energy

• Slip stream pilot installed in EAF primary cooling in

operation for 2 years

• Recovered up to 1400 kWth energy

• Dust adhesion encountered and resolved

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