Industrial reheating furnaces: A review of energy efficiency assessments, waste heat recovery potentials, heating process characteristics and perspectives for steel industry

Zhao, Jianlin; Ma, Ling; Zayed, Mohamed E.; Elsheikh, Ammar H.; Li, Wenjia; Qi, Yan; Wang, Jiachen

doi:10.1016/j.psep.2021.01.045

Cited by 82 publications

(33 citation statements)

References 113 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…The burner as shown Fig. 7 is the main component used for combustion, the burner functions to regulate the mixture of air and fuel gas continuously [10].…”

Section: Burnermentioning

confidence: 99%

Performance Analysis of Reheating Furnace on Billet Heating Production of Reinforced Iron

Setiawan¹,

Arsana²,

Soeryanto³

2022

Proceedings of the International Joint Conference on Science and Engineering 2022 (IJCSE 2022)

View full text Add to dashboard Cite

Hanil Jaya Steel company is engaged in reinforcing steel fins with various deformed and according to the Indonesian National Standard (SNI). The product produced by this company is Reinforced Iron or commonly known as Esser Concrete. One of the most important processes in the manufacturing stage of reinforcing steel is the Furnace Billet Reheating process to be processed into reinforcing steel. This study aims to analyze the performance of the reheating furnace on billet production of reinforcing iron in the Rolling Mill III area of PT. Hanil Jaya Steel. This study uses the observation method. This research results that RHF heating is carried out to change the material properties, and carry out the machining process (heat treatment). The type of furnace used at PT. Hanil Jaya Steel is a pusher type, the furnace is used to heat billets measuring 150 × 150 × 6000 mm with temperatures reaching 1100 ºC -1250 ºC. The nominal capacity of the furnace used is 30 tons/hour. The fuel used in the reheating furnace is natural gas from PGN. The process of making reinforced concrete steel, reheating furnace process is the initial process that must be carried out to change the billet into a material that is easily shaped into reinforcing steel according to SNI standards. Heating process billet is carried out by inserting billets one by one into the RHF with a temperature of up to 1100 ºC for 2 h. With this process the billet changes, which is useful for the next process, namely the rolling process.

show abstract

“…The burner as shown Fig. 7 is the main component used for combustion, the burner functions to regulate the mixture of air and fuel gas continuously [10].…”

Section: Burnermentioning

confidence: 99%

Performance Analysis of Reheating Furnace on Billet Heating Production of Reinforced Iron

Setiawan¹,

Arsana²,

Soeryanto³

2022

Proceedings of the International Joint Conference on Science and Engineering 2022 (IJCSE 2022)

View full text Add to dashboard Cite

show abstract

“…Reheating furnaces are used in the steel industry for reheating and heat treatment of semi-finished products (e.g., billets, slabs) before they can undergo forming/plastic deformation processes, e.g., hot rolling in a mill. The reheating process is a critical process that consumes large amounts of energy in terms of fuel, incurring considerable costs and directly affecting product quality [4,5].…”

Section: Introductionmentioning

confidence: 99%

Multi-Mode Model Predictive Control Approach for Steel Billets Reheating Furnaces

Zanoli

Pepe

Orlietti³

2023

Sensors

View full text Add to dashboard Cite

In this paper, a unified level 2 Advanced Process Control system for steel billets reheating furnaces is proposed. The system is capable of managing all process conditions that can occur in different types of furnaces, e.g., walking beam and pusher type. A multi-mode Model Predictive Control approach is proposed together with a virtual sensor and a control mode selector. The virtual sensor provides billet tracking, together with updated process and billet information; the control mode selector module defines online the best control mode to be applied. The control mode selector uses a tailored activation matrix and, in each control mode, a different subset of controlled variables and specifications are considered. All furnace conditions (production, planned/unplanned shutdowns/downtimes, and restarts) are managed and optimized. The reliability of the proposed approach is proven by the different installations in various European steel industries. Significant energy efficiency and process control results were obtained after the commissioning of the designed system on the real plants, replacing operators’ manual conduction and/or previous level 2 systems control.

show abstract

Section: Introductionmentioning

confidence: 99%

“…Currently, there are multiple waste energy recovery technologies applied in I&S enterprise, such as coke dry quenching (CDQ), [ 27 ] sintering flue gas waste heat recovery, [ 28 ] hot rolling flue gas waste heat recovery, [ 1 ] etc. Nevertheless, the steam produced is always surplus in I&S enterprise.…”

Section: Introductionmentioning

confidence: 99%

“…The energy consumption of iron and steel (I&S) industry accounts for approximately 18% of global industry, and greenhouse gas emissions account for 7% of the total. [1,2] A large amount of energy waste occurs in the I&S production processes, hence improving energy utilization efficiency is a top priority for I&S enterprise. [3][4][5][6][7] Steam system is one of the most important energy systems in I&S industry, and its energy consumption accounts for 10% of the energy consumption of I&S production.…”

mentioning

confidence: 99%

See 1 more Smart Citation

Energy Optimization Based on Steam System Analysis and Waste Energy Recovery for Iron and Steel Industry

et al. 2022

View full text Add to dashboard Cite

To solve the unreasonable energy distribution and excessive energy waste in the steam system of iron and steel (I&S) industry, a mixed integer linear programming model based on the theory of exergy and energy level is developed in this study to optimize the steam system. After optimization, the utilization potential of waste energy is found. Then, several waste energy recovery technologies are compared according to their application results. The results show that the exergy efficiency of steam system is 74.065%. After optimization, the exergy efficiency of steam system is increased by 10.568%, the energy input of the I&S enterprise is reduced by 84.30 MJ t−1‐CS−1, and waste energy potential is found at hot rolling, sintering, and converter. Herein, flue gas waste heat from hot rolling and sintering is recovered using series two‐stage Organic Rankine Cycle with cyclopentane as the working fluid, and steam waste energy from converter is recovered using saturated steam power generation. These waste energy technologies increase the electricity generation of I&S enterprise by 15.25 kWh t−1‐CS−1. Overall, combining the optimization model with the use of waste energy recovery technologies is necessary and effective for I&S enterprise to increase their energy efficiency.

show abstract

Industrial reheating furnaces: A review of energy efficiency assessments, waste heat recovery potentials, heating process characteristics and perspectives for steel industry

Cited by 82 publications

References 113 publications

Performance Analysis of Reheating Furnace on Billet Heating Production of Reinforced Iron

Performance Analysis of Reheating Furnace on Billet Heating Production of Reinforced Iron

Multi-Mode Model Predictive Control Approach for Steel Billets Reheating Furnaces

Energy Optimization Based on Steam System Analysis and Waste Energy Recovery for Iron and Steel Industry

Contact Info

Product

Resources

About