Objective
Get an energy saving for a total of 475 TOE per year for a production of 25000 tons of metal, through an improvement of thermic efficiency of cupola. The aim is to obtain this saving for a reasonable cost in regard of production capacity. It is possible to get superheated blast through plasma torch, but in regard of the much more expensive cost such an investment can only be profitable of an yearly production of over 40000 tons.
Reduction of melting cost. The increase of thermic efficiency of cupola will authorize a partial replacement of foundry coke with blast furnace coke (less expensive), more important rate of scrap in charges and lower utilization of oxygen.
ESTIMATED ENERGY SAVING
TYPE OF ENERGY TOTAL YEARLY SAVINGS
1st case 2nd case
100% foundry coke 50% foundry coke
50% blast furnace coke
Coke 1 175 000 1 500 000
Electricity 525 000 525 000
Oxygen 402 500 402 500
Metal charges 1 350 000 1 350 000
Silicium 487 500 487 500
--------- ---------
TOTAL SAVING 1 915 000 2 240 000
This calculation is based on a production of 25000 tons/year with following unit costs :
Foundry coke : 1398.00 FF/t - blast coke : 1099.00 FF/t
kWh : 0.35 FF - Oxygen : 1.15 FF - Scrap : 850.00 FF/t
Silicium : 6500.00 FF/t.
The heating of the blast is realized in two steps. In first step, we get 500 deg. C through recuperation of the sensible and latent heat from cupola gas. This gas normally contains 10 to 15 % Co which represents a latent thermical energy of about one third of the one from the consumed coke. The gas is collected under the cupola charge opening and is conveyed into a combustion chamber where it is burned and grows to about 750 deg. C. This gas is mixed with combustion air to get blast at 500 deg. C. The combusted gas, then colder, goes through a cylonic separator where largest particles carried over are separated from the gas. At the issue of the recuperator the blast is divided in two different flows separately superheated from 500 deg. C to 800 deg. C by the way of two electrical boxes of resistance of 550 kW each. Each flow supplies a row of tuyeres from which the blast can be separately adjustable in volume and temperature.
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Coordinator
70303 LUXEUIL LES BAINS
France
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