Modeling of Energy Consumption and Reduction of Pollutant Emissions in a Walking Beam Furnace Using the Expert Method—Case Study

Abstract

This paper presents an algorithm for modeling electricity and natural gas consumption in a walking furnace with the use of artificial intelligence and simulation methods, depending on the length of the rolling campaign and the established rolling program. This algorithm is the basis for the development of a proposal for a set of minimum requirements characterizing the Best Available Techniques (BAT) for beam furnaces intended for hot rolling, taking into account the requirements set out in national regulations and the recommendations described in the BREF reference documents. This information should be taken into account when drawing up an application for an integrated permit, as well as when setting emission limit values. Based on the constructed algorithm, it was shown that depending on their type and technical specification, the analyzed projects will offer measurable economic benefits in the form of reducing the amount of energy consumed by 1,076,400 kWh during the implementation of 50 rolling campaigns to reduce gas by 14,625 GJ and environmental benefits in the form of reduction of pollutant emissions into the atmosphere 80–360 g/Mg. The constructed algorithm was validated in the Dosimis-3 program, based on a discrete event-driven simulation. Thanks to this representation of the model, its user can interactively participate in changes that take place in the model and thus evaluate its behavior. The model, verified in real conditions, can be the basic source of information for making effective operational technological decisions related to the preparation of production at the rolling mill as part of planning and long-term activities.

Assessment of the Impact of Wear of the Working Surface of Rolls on the Reduction of Energy and Environmental Demand for the Production of Flat Products: Methodological Approach

“…During this period, there were times when low-alloy steels were rolled and times when they were not rolled, but the rolling conditions used did not change significantly. As a measure of the degree of utilization of the roll, the Q index used in metallurgy was adopted, determined from the following formula [ 7 , 38 ]: Q = Z / U where Z is the amount of rolled steel, Mg, and U is the reduction in roll weight due to rolling and calibrations, kg.…”

“…If you measure the height of the top and bottom vertices on the surface of the roll with respect to the zero position, you obtain key information about the technical condition of the roll under test, defined by its non-roundness N ( α ) [ 7 , 38 ]: where N ( α ) is the roundness of the roll, E ( α ) is the height of the top peak of the roll and Q ( α ) is the height of the bottom peak of the roll.…”

“…In the literature, there are many works [ 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 ] on the potential of using RES technologies in the global energy mix, while apart from [ 7 ], there is little research on reducing CO 2 emissions into the atmosphere by plants with a diversified production method, i.e., metallurgy. In Poland, the steel industry is responsible for 14% of total CO 2 emissions.…”

“…Therefore, solutions should be sought to optimize existing technologies that will help reduce CO 2 emissions, and thus reduce emission allowances payments to production plants. These issues are described in detail in the paper: “Modeling of Energy Consumption and Reduction of Pollutant Emissions in a Walking Beam Furnace Using the Expert Method—Case Study” [ 7 ].…”

Assessment of the Possibility of Using Various Types of Renewable Energy Sources Installations in Single-Family Buildings as Part of Saving Final Energy Consumption in Polish Conditions

“…Building energy quality, determined by the parameters thermal insulation of building partitions and the quality of energy systems, determined by the partial efficiency of carrier production, accumulation, transport, and regulation, has a significant impact on the size of devices and installations using renewable energy sources. The analysis of the profitability of using various renewable energy installations in single-family housing is presented in the works [14,15].…”