Field trial system for metal processing plant

Use of the waste heat from a pusher furnace

Another ORC system was erected on the premises of Badische Stahlwerke and is intended to work as the fourth pilot plant for the field testing programme. Our ground-breaking technology further improved the recovery of waste heat at the company's natural gas-fired pusher furnace. The thermal exhaust gas energy available downstream from the pusher furnace's recuperator is exploited for electricity production thanks to the use of our efficient ORC module. In addition to generating electrical energy, the company plans to utilise the waste heat from the ORC process to operate an absorption chiller.

The ethanol evaporator built into our ORC system was modified to take into account the high degree of availability the system must ensure, given the discontinuous heat supply of the pusher furnace.

Since the exhaust gas can reach very high temperatures up to 600°C, a fresh air blower was installed to reduce the flue gas temperature, optimising cost and availability of the system components.

To be able to maintain the internal pressure defined for the pusher furnace by the customer, an induced draught fan was incorporated into the flue gas path of the ORC heat exchanger. Since the pressure is regulated by the controller built into the ORC system, there was no need to modify the company's existing furnace control system.

Owing to the spatial constraints on the premises, the ORC container had to be set up at a distance of 50 metres and at a height of 8 metres relative to the ORC heat exchanger. 

Use of the waste heat from a pusher furnace

Another ORC system was erected on the premises of Badische Stahlwerke and is intended to work as the fourth pilot plant for the field testing programme. Our ground-breaking technology further improved the recovery of waste heat at the company's natural gas-fired pusher furnace. The thermal exhaust gas energy available downstream from the pusher furnace's recuperator is exploited for electricity production thanks to the use of our efficient ORC module. In addition to generating electrical energy, the company plans to utilise the waste heat from the ORC process to operate an absorption chiller.

The ethanol evaporator built into our ORC system was modified to take into account the high degree of availability the system must ensure, given the discontinuous heat supply of the pusher furnace.

Since the exhaust gas can reach very high temperatures up to 600°C, a fresh air blower was installed to reduce the flue gas temperature, optimising cost and availability of the system components.

To be able to maintain the internal pressure defined for the pusher furnace by the customer, an induced draught fan was incorporated into the flue gas path of the ORC heat exchanger. Since the pressure is regulated by the controller built into the ORC system, there was no need to modify the company's existing furnace control system.

Owing to the spatial constraints on the premises, the ORC container had to be set up at a distance of 50 metres and at a height of 8 metres relative to the ORC heat exchanger.