42 Month Pitagoras Meeting Waste heat recovery pilot plant ... · PITAGORAS 18th Month Meeting...

Waste heat recovery pilot plant for power and

heat production at the steel mill of ORI MARTIN

Andrea Panizza - ORI Martin Spa

April 2017, Ostrava

“sustainable urban Planning with Innovative and low energy Thermal And power Generation frOm Residual And renewable Sources”

42th Month Pitagoras Meeting

O.R.I. MARTIN Acciaieria e Ferriera di Brescia S.p.A.

ORI MARTIN Red Hot Passion for Steel

ORI Martin at a glance

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• ORI Martin Group (www.orimartin.it)

– ORI Martin (Brescia, Italy) – meltshop and rolling mill

– Ori Martin (Ceprano, Italy) – Rolling Mill

– Trafilati Martin (Cologne, Italy) – Drawing and peeling

– Meccanica Trafilati Martin (Cologne, Italy) – Deep drilling

– Siderurgica Latina Martin (Ceprano, Italy) – Drawing

• More than 200 special steel grades:

– Fastener grades

– Spring grades

– Quenching and tempering steel

– High and Medium carbon grades

– Welding grades

– Tool grades

• 644kt of crude steel in 2015

• >40% export

• 357 M€ turnover in 2015

• 700 permanent employees

(Sources: ORI Martin website, SOLE 24 ORE)

http://www.orimartin.it/

http://www.google.it/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&ved=0CAcQjRw&url=http://www.expometals.net/en-gb/raw-materials/online-stand-ori-martin-spa&ei=4p1AVcfaJIungwTkmYGoAg&bvm=bv.91665533,d.eXY&psig=AFQjCNFsbIvcqKomdYwy141IrTFM2wo_Pg&ust=1430384383013483

PITAGORAS 18th Month Meeting 20-21 April 2015 - Stuttgart : ORI Martin waste heat recovery pilot plant

District heating network of Brescia – key figures

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District heating network of Brescia – key figures

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i-RECOVERY SYSTEM


Heat recovery at ORI Martin: general scheme

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SYSTEM Electricity during summer time (April-October) : around 1800 KWel

District Heating during winter time (October-April) : 10MWth


PFD – Process flow diagram

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Layout of the Pitagoras Brescia demonstration plant

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Project technical data

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Waste Heat Boiler

Heat Recovery Potential: 9,1 MWth

Heat Recovery Capacity: 52.000 MWh/year

Minimum working pressure/temperature 16,0 bar(g) @ 204,3 °C

Maximum working pressure/temperature 26,0 bar(g) @ 223,9 °C

Pressure design, PS 30,0 bar(g)

District heating station, A2A

Nominal thermal power 10,0 MWth

Steam flow rate 18,0 t/h

Working pressure 10,0 bar(g)

ORC Turbine

Nominal thermal power input 10,4 MWth

Nominal electrical power produced (gross) 1,88 MWe

Nominal electrical power distributed (net) 1,82 MWe


Project technical data

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Steam accumulator

Buffering capacity 6,0 MWht

Volume 150 m3

Admissible maximum pressure 30,0 bar(g)

Feed water tank

Capacity 20,0 m3/h

Volume 30 m3

Admissible maximum pressure 6,0 bar(g)


Waste Heat Recovery Unit

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Waste Heat Recovery Unit

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Main Features

4 Evaporators and 1 economizer

Natural draft (no circulation pumps)

Nominal Volume flow: 100.000 – 150.000 Nm³/h

Inlet waste gas temperature: 500 - 750 °C

Boiler working pressure: 16 - 26 bar (g)

Steam temperature: 204 - 228 °C

Steam generation max: 30 t/h

Integration at ORI Martin

Installed parallel to existing quenching tower

In case of problems possible to switch to old system

without downtime

Off gas way is controlled by a cut-off damper

upstream the waste heat boiler

Flow rate controlled by second damper downstream

the boiler

Flow rate measured by Venturi meter

Booster installed downstream the boiler


Steam accumulator and feed water pumps

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Steam Drum, Steam Accumulator and Emergency Condenser

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The drum and the accumulator store the energy and

release steam with the flow required by the steam user:

When heat recovery system produces more steam

than required, there in an increase of the pressure

and temperature inside the system

In case the steam consumption is higher than the

steam generation, the result is a drop in pressure

inside the system. As a pressure drop occurs, the

water starts boiling immediately and flash steam is

generated. The rate at which the water flashes to

steam is a function of the storage pressure, and

corresponds to the rate required by the system


Steam Drum, Steam Accumulator and Emergency Condenser

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The emergency condenser allow the

system to not to go in over-pressure,

condensing the steam when the pressure in

the system is going too high

It starts working when the pressure in the

boiler is more then 26 bar(g)

The steam from the medium pressure

collector (16 bar(g)) flows into the

emergency condenser, condenses and the

water is pumped into the Feed Water Tank


High pressure and Medium pressure collectors

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High Pressure Collector: 16 – 25 bar(g)

Max working pressure: 30 bar(g)

Medium Pressure Collector: 16 bar(g)

Max working pressure: 18 bar(g)


HMI Monitoring

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Off-gas HMI

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Boiler HMI

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Accumulator HMI

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Collectors HMI

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Exchange unit with A2A Heat District Heating

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Exchange unit with A2A Heat District Heating

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In the heat exchange section of the i-Recovery system:

Steam is condensed in two parallel exchangers, and

energy is transferred from steam to hot water for local

district heating

Condensate is pumped to feed water tank (closed loop)

Expected annual thermal energy generation:

26.500 MWhth/year

ORI Martin is the first steel industry to supply waste energy


ORC module

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ORC module

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Heat from the I-Recovery steam is transferred

to the organic fluid inside the turbine through

heat exchangers

Water condensate from the heat exchanger is

fed back to feed water tank in a closed loop

Nominal power output: 1,82 Mwel

The electric energy produced will be available

for internal use

Expected annual electricity generation:

4.200 MWhel/year


ORC module

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Electricity generation during summertime for plant self-consumption

The ORC unit is composed by:

• Evaporator

• Turbine + Generator

• Regenerator

• Condenser

• Circulating pump

• LT and HT Preheaters

• Post-cooler

ORC internal fluid: silicone oil (MM).

Average cycle efficiency: 18%.


ORC Turbo Generator main data

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During the past season we have done some tests for different cases; all these cases were related

to different thermal loads of the cycle


ORC Turbo Generator test

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The graph is related to the design test of the ORC cycle that we have done in July

The red line is the thermal power [Kw] taken by the ORC cycle

The blue line is the steam flow [ton/h] from the i-Recovery to the ORC cycle


Status of demonstrator works

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Detail engineering: completed

Installation: completed

Start-up and first demonstration period of the waste heat recovery system

(and DH heat injection): from January till 15th April 2016

Start-up and first demonstration period of the ORC system: from 15th April

2016 to 15th October 2016

General optimizations: present until the end of the year


Some Technical data

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Average steam production: 11 ton/h

Average accumulator pressure: 24 bar(g)

Average thermal power to a2a DH: 6 MWth

Average thermal power to ORC cycle: 5,5 MWth

Average net electric power from ORC cycle: 1 MWel


What we have done in the last months

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Optimization of the hot temperature of the boiler inlet exhausted gas thanks to

revamping works of the duct and the quenching tower

Reduction of the ambient air infiltration into the duct

Optimization of the steam-exchange between i-Recovery and a2a DH

Optimization of the steam-exchange between i-Recovery and ORC cycle

More reliable PLC - supervisor system with implementation of new alarms

Easier alarms consultation and recognition by our operators

Internal training


Work to be done in the next months

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Continuous optimization of the steam-exchange between i-Recovery and

ORC/a2a

Optimization of the steam production in combination with the scrap mix

charged

Reduction of the steam flow into the emergency condenser

Reduction and optimization of the water flow into the ORC cycle condenser

Internal training

PITAGORAS 18th Month Meeting 20-21 April 2015 - Stuttgart : ORI Martin waste heat recovery pilot plant 34

The research leading to these results has received funding from the

European Union Seventh Framework Programme FP7/2007-2013 under

grant agreement n° ENER / FP7EN / 314596 / PITAGORAS. This

publication reflects only the author’s views and the Union is not liable for

any use that may be made of the information contained therein.

Thanks for your attention!

Andrea Panizza

ORI Martin Spa

Via Cosimo Canovetti 13

25168 Brescia

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