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Analisis Estrategico de Proyectos de EE
Analisis Estrategico de Proyectos de EE
art ic l e i nf o
a b s t r a c t
Article history:
Received 4 March 2012
Received in revised form
25 March 2014
Accepted 19 July 2014
Available online 23 August 2014
An analysis of energy efciency opportunities at a steel mill were undertaken using two energy
modeling tools, the RETScreen Clean Energy Project Analysis Software (RETScreen) and the Process Heat
Assessment and Survey Tool (PHAST). A number of energy efciency opportunities were found to be
feasible in this analysis at Gerdau North America Long Steel-Manitoba Mill. The waste heat recovery
opportunities included: (1) preheating combustion air in the ladle preheater, with an estimated energy
savings of 22,000 GJ/yr and a payback period of 10 months; and, (2) preheating billets with an estimated
energy savings of 60,323 GJ/yr and a payback period of three years. Changing natural gas space heaters
to more energy efcient and safer models was both socially and economically benecial, although having
a longer payback period of 4.5 years. Oxy-fuel combustion was not deemed feasible as oxygen costs
negated any natural gas savings and the productivity gains were not considered applicable. The strategic
analysis showed that environmental, economic and productivity benets were larger than the smaller
concerns of: production interruption, the economic barriers of capital costs, as well as the risks posed by
a downturn in the economy or by outsourcing.
& 2014 Elsevier Ltd. All rights reserved.
Keywords:
Energy efciency
Steel mini-mill
Steel
RETScreen Clean Energy Project Analysis
Software (RETScreen)
Process Heat Assessment and Survey Tool
(PHAST)
Contents
1.
2.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.
Determined the energy savings from preheating billets with waste heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.
Calculated the energy savings from ladle preheater waste recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.
Replacing natural gas heaters with direct red heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.
Oxy-fuel combustion impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.
Recovering waste heat to preheat billets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.
Recovering waste heat to preheat combustion air in the ladle preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.
Replacing natural gas heaters with direct red heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.
Estimating fuel use potential by oxy-fuel combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.
Strategic analysis for SWOT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1. Introduction
Corresponding author.
E-mail address: s.thompson@umanitoba.ca (S. Thompson).
http://dx.doi.org/10.1016/j.rser.2014.07.140
1364-0321/& 2014 Elsevier Ltd. All rights reserved.
815
Waste Heat
Scrap
Eccentric
Bottom
Furnace
Ladle Furnace
Ladle
Natural Gas
18.4 million m3
Electricity
253 million kWh
Tundish
Casting
Rolling
Reheat
Furnace
Finished
Products
GHG Emissions
Billets
Waste Heat
2. Method
An energy audit was carried out for four key areas for energy
optimization at Gerdau considering: (1) preheating billets using
816
Fans
Gas collection
Hot gases
Burners
Hot gases
Reheat furnace
Preheating section
Billets
Billets
waste heat (Fig. 2); (2) recovering waste heat to preheat combustion air; (3) replacing direct-red natural gas heaters; and (4)
applying oxy-fuel to the reheat furnace. During this audit data
collected included oxygen (% dry) in the ladle preheater, ue gas
and combustion temperature in the ladle preheater, oxygen in
combustion air in the reheat furnace and ue gas and combustion
air temperature in the reheat furnace.
Table 1
Production data for the waste heat recovery to
preheat billets.
Items
Value
94.5
50%
8016
56.4%
where:
M 324,235,991 kg (average annual production at Gerdau from
20052010)
Cp 0.12 kcal/kg 1C (specic heat in carbon steel)
T 312.3 1C.
Applied the change in temperature and a $7.8/GJ fuel rate, which is
the average rate at Gerdau from 20052010, in RETScreen's method
one, Energy Efciency: heat recovery [17]. See Table 1 for data inputted
into RETScreen. Energy savings potential, CO2 emission reduction and
payback period were determined by RETScreen.
2.2. Calculated the energy savings from ladle preheater waste
recovery
For PHAST to calculate energy consumption (GJ/h) inputs
included 15 MM Btu/h as ring capacity in the ladle preheater at
Gerdau [22], a ue gas temperature of 871 1C and ambient
temperature of 20 1C. See Fig. 4 for other inputs to PHAST to
compare the current ladle preheater to one modied to include a
recuperator. Energy savings were determined using Eq. (2) (step 1)
for 8016 operating h/yr at a fuel rate of $8.2/MM Btu. Eq. (3) for
simple payback (step 2) was calculated considering the cost to
install and purchase a recuperator of $144,017 [22]. Eq. (4) was
applied to calculate the CO2 emission reductions.
Table 2
Preheating combustion air in the ladle preheater.
Items
Value
2.75
8016
22,000
$171,600
$144,017
0.8
1081
Cp
Sa
817
Table 3
Energy saving calculation of replacing direct-red
natural gas heaters.
Item
Value
2
2880
$44,928
$200,000
4.5
282
Gas collection
header
Hot gases
was applied.
Burners
Lalde side
Bp P i P b P p
Preheated air
Recuperator
Ambient air
3. Results
Hot gases
Hot flue gases
Fig. 4. The proposed scheme of preheating combustion air in the ladle preheater.
Source: Adapted from U.S. Department of Energy [20].
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Table 4
Energy saving estimates for oxyfuel combustion at Gerdau
Manitoba Mill.
Item
Value
25.8%
8016
195,430
$1,524,354
15,029
30,058
$ 158.9
$ 4,776,216
$ (3,251,862)
9576
Table 5
Estimated benets to productivity from oxyfuel combustion at Gerdau Manitoba Mill.
Item
Value
324,236
162,118
550
8%
$7,133,192
Table 6
Environment and economic benets of energy efciency projects at Gerdau Manitoba Mill.
Project name
CO2 reduction
(ton/yr)
Fuel saving
(GJ/yr)
Annual saving/cost
($/yr)
Payback
period (yr)
Feasibility
(Y/N)
2999
1081
282
9576
60,323
22,000
5760
159,430
$
$
$
$
$ 1,250,000
$ 144,017
$ 200,000
3.0
0.8
4.5
Y
Y
Y
N
a
b
470,519
171,600
44,928
(3,251,862)
low point, having dropped 50% since 2008 [31] the economic
rationale for energy efciency is reduced. The energy price of
natural gas now is much lower than $7.8/GJ, which is Gerdau's
average price over six years, from 2005 to 2010.
The other threat is outsourcing to a developing country and
moving the steel mill. In developing countries labor costs are
lower and environmental regulations are less stringent. If a
company has a plan to outsource their manufacturing to developing countries as a mid-term strategy, energy efciency projects
that generally have a three to ve year payback are not considered
desirable.
4. Conclusion
This study showed that energy efciency projects can have
good nancial returns and short payback periods. Thus energy
efciency projects make good business sense now and even better
business sense in the future with trends for escalating fossil fuel
prices. After an energy audit and strategic analysis of energy
efciency at Gerdau, the following projects are considered feasible: (1) recovering waste heat to preheat billets, with an estimated
60,323 GJ/yr energy savings and a 3 year payback period, (2) using
waste heat to preheat combustion air in the ladle preheat with an
estimated 22,000 GJ/yr energy savings and a 10 month payback
period, and 3) replacing direct-red natural gas heaters with an
estimated 5760 GJ/yr energy savings. Oxy-fuel combustion is not
deemed feasible as the high oxygen costs negate any natural gas
savings and the productivity gains were not considered applicable
in this case.
This case study demonstrates that energy efciency projects have
many benets. These positive impacts include: (1) reducing emissions
and environmental impacts, (2) decreasing fuel use, (3) providing
savings annually after a short payback period, and (4) increasing
productivity. Although production downtime, during the installation
of energy efciency equipment, and capital costs pose economic
barriers to implementing energy efciency projects, government and
utility incentive programs are available to help reduce the nancial
burden. Since environmental regulation and steel production are
increasing the only big threat is outsourcing to developing countries,
which in the case of Gerdau is unlikely due to its unique product lines.
Acknowledgments
The authors would like to thank for their support: Kurtis Calder
and Ryan Billingham from Gerdau, as well as Tom Naylor from
Manitoba Hydro. The authors also would like to thank Manitoba
Hydro, which funded this project.
References
[1] Edenhofer O, Stern N. Towards a global green recovery: recommendations for
immediate G20 action. Berlin: Report for the German Foreign Ofce; 2000.
[2] Fisher BS, Nakicenovic N, Alfsen K, Corfee Morlot J, de la Chesnaye F, Hourcade JC,
et al. Issues related to mitigation in the long term context. In: Metz B, Davidson OR,
Bosch PR, Dave R, Meyer LA, editors. Climate change 2007: mitigation. Contribution
of working group III to the fourth assessment report of the intergovernmental
panel on climate change. Cambridge: Cambridge University Press; 2007.
[3] European Commission. Communication from the commission energy efciency:
delivering the 20% target, 2008. Retrieved July 1, 2010, from: http://www.ec.
europa.eu/energy/strategies/2008/doc/2008_11_ser2/energy_efciency_commu
nication_en.pdf.
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