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Please use this identifier to cite or link to this item: http://repository.iitr.ac.in/handle/123456789/2466
Title: Recovery and utilization of waste heat in a coal based sponge iron process
Authors: Kumar V.
Khanam, Shabina
Published in: Chemical Engineering and Processing: Process Intensification
Abstract: The present work is an attempt to conserve energy in coal based sponge iron industry incorporating certain design modifications without disturbing the process technology. A typical sponge iron plant has been investigated to find out the potential areas where energy is being wasted. To recover heat from these areas two design modifications, Case-1 and Case-2, are proposed. Case-1 accounts for preheating of air using waste gas exiting from ESP. However, for Case-2 initially water is heated using hot sponge iron exiting rotary kiln and further hot water is used to preheat air. To compute coal demand of modified designs a model is developed based on heat of reactions, feed preheating, sensible and radiation losses, etc. Preheating of air up to 170. °C for Case-1 reduces coal consumption by 8.7%. Consequently, waste gas generation reduces by 16.7%. Thus, for Case-1 profit is Rs 9.6. million/year. However, for Case-2 preheating of air to 80. °C before entering the kiln reduces coal and water consumption by 7.2% and 96.3%. Consequently, cooling tower capacity is reduced by 37.2%. Due to 27.8% less profit for Case-1 in comparison to Case-2 Case-1 offers higher payback period than that of Case-2. Thus, Case-2 is selected as best proposed design. © 2012 Elsevier B.V.
Citation: Chemical Engineering and Processing: Process Intensification (2012), 56(): 19-28
URI: https://doi.org/10.1016/j.cep.2012.03.002
http://repository.iitr.ac.in/handle/123456789/2466
Issue Date: 2012
Keywords: Design modifications
Heat integration
Payback period
Sponge iron plant
ISSN: 2552701
Author Scopus IDs: 57200713984
23025264900
Author Affiliations: Kumar, V., Department of Chemical Engineering, National Institute of Technology, Rourkela-769008, Orissa, India
Khanam, S., Department of Chemical Engineering, National Institute of Technology, Rourkela-769008, Orissa, India
Corresponding Author: Khanam, S.; Department of Chemical Engineering, National Institute of Technology, Rourkela-769008, Orissa, India; email: skhanam@nitrkl.ac.in
Appears in Collections:Journal Publications [CH]

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