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Retrofit of steam power plants in a steel mill

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Abstract

This article presents a systematic methodology for the analysis and design of steam power plants in a typical steel mill. Therein most of the steam is produced by applying synthesis gas, a side-product from the coke processing plants. This offers the opportunity of energy integration with vicinal companies using fuel oil or natural gas for generating steam. Components of this work include the energy reallocation and the retrofitted design of steam systems. In this study, the current strategy of energy utilization for existing sites in a steel mill is first assessed. In this regard, the energy policy is adjusted in order to enhance the performance and reduce the costs of the steam power plants. Thereafter, the retrofit is taken into account to evaluate the potential energy for the integration. The problems are formulated as a mixed integer nonlinear program based on a superstructure approach. The results of an industrial case study show that the energy integration among plants is benefit, which provides incentive to promote the cooperation of neighboring companies in an eco-industrial park.

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Abbreviations

\( b \in \mathcal{B} \) :

Boilers

\( i \in \mathcal{I} \) :

Steam headers

\( j \in \mathcal{J} \) :

Shaft power demands

\( m \in \mathcal{M} \) :

Electric motors

\( t \in \mathcal{T} \) :

Steam turbines

\( u \in \mathcal{U} \) :

Fuels

C exp,s i :

Cost per unit mass of exported i level steam (NT$/kg)

C imp,s i :

Cost per unit mass of imported i level steam (NT$/kg)

C u :

Cost per unit mass fuel u (NT$/kg)

C cw :

Specific cost of cooling water (NT$/kW)

C w :

Cost per unit mass of demineralized water make up (NT$/kg)

C exp,e :

Specific cost of exported electricity (NT$/kWh)

C imp,e :

Specific cost of imported electricity (NT$/kWh)

F pd i :

Steam process demand at header i (kg/s)

F ps i :

Steam input from process entering header i (kg/s)

H imp,s i :

Enthalpy of imported i level steam (kJ/kg)

H ps i :

Enthalpy of steam supplied by processes and delivered at header i (kJ/kg)

H sat,l i :

Enthalpy of saturated water at steam header i level (kJ/kg)

H LHV u :

Enthalpy of low heating value for fuel u (kJ/kg)

H deaer :

Enthalpy of water leaving a deaerator (kJ/kg)

H c :

Enthalpy of returning condensate from processes (kJ/kg)

H w :

Enthalpy of demineralized water makeup (kJ/kg)

t hrs :

Total operating time (h)

W dem,s j :

Shaft power demand j (kW)

W dem,e :

Total electricity demand (kW)

Z bu :

Denoting boiler b uses fuel type u

Ω:

An arbitrary large number

\( \overline{\Upomega }_{b} ,\underline{\Upomega }_{b} \) :

Upper and lower bound of steam flow rate for boiler b (kg/s)

\( \overline{\Upomega }_{D} ,\underline{\Upomega }_{D} \) :

Upper and lower bound of steam flow rate for deaerator (kg/s)

\( \overline{\Upomega }_{t} ,\underline{\Upomega }_{t} \) :

Upper and lower bound of steam flow rate for steam turbine t (kg/s)

\( \overline{\Upgamma }_{t} ,\underline{\Upgamma }_{t} \) :

Upper and lower bound of power generation for steam turbine t (kW)

φ:

Fixed blowdown fraction for boilers

η b :

Efficiency for boiler b

η m :

Fixed efficiency for electric motors

f bd bi :

Blowdown water from boiler b at pressure i (kg/s)

f bfw b :

Boiler feedwater for boiler b (kg/s)

f bi :

Steam output from boiler b to steam header i (kg/s)

f bu :

Fuel u consumed in boiler b (kg/s)

f ii′t :

Steam flow rate from header i to header i′ through steam turbine t (kg/s)

f ii′ :

Steam flow rate from header i to header i′ (kg/s)

f i :

Steam flow rate from header i to deaerator (kg/s)

f ld i :

Desuperheating boiler feedwater injected into header i (kg/s)

f exp,s i :

Steam export flow rate from header i (kg/s)

f imp,s i :

Steam import flow rate into header i (kg/s)

f vent i :

Vented steam at header i (kg/s)

f c :

Condensate return (kg/s)

f w :

Demineralized water makeup (kg/s)

h bi :

Enthalpy of steam generated by boiler b entering header i (kJ/kg)

h ii′t :

Enthalpy of discharge by steam turbine t entering header i′ (kJ/kg)

h i :

Enthalpy of steam header i (kJ/kg)

q b :

Heat added to the water in boiler b (kW)

q t :

Cooling water use for condensing turbine t (kW)

w ii′t :

Power produced by steam turbine t (kW)

w mj :

Shaft power produced by electric motor m to shaft demand j (kW)

w tj :

Shaft power produced by steam turbine t to shaft demand j (kW)

w exp,e :

Electricity exported (kW)

w imp,e :

Electricity imported (kW)

z bi :

Denotes the existence of the connection between boiler b and header i

z b :

Denotes the presence of boiler b

z ii′t :

Denotes the existence of the connection of steam turbine t between i and i′ headers

z m :

Denotes the presence of electric motor m

z tj :

Denotes the existence of the connection between steam turbine t and shaft demand j

z t :

Denotes the presence of steam turbine t

z exp,e :

Denotes the presence of electricity export

z imp,e :

Denotes the presence of electricity import

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Acknowledgments

The financial support from National Science Council of ROC (NSC100-3113-E-002-0094 and NSC 101-3113-E-002-004) is gratefully appreciated.

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Authors and Affiliations

  1. Department of Chemical Engineering, National Taiwan University, Taipei, 10617, Taiwan, ROC

    Cheng-Liang Chen & Chih-Yao Lin

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  1. Cheng-Liang Chen
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Correspondence to Cheng-Liang Chen.

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Chen, CL., Lin, CY. Retrofit of steam power plants in a steel mill. Clean Techn Environ Policy 15, 753–763 (2013). https://doi.org/10.1007/s10098-012-0532-z

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