Application of a gas turbine for electricity generation
In metallurgical processes, large amounts of blast furnace gas energy are lost during pressure reduction. DB Energy designed a solution based on gas turbines, which made it possible to recover 211 GWh of energy annually and reduce CO2 emissions by more than 170,000 tons.
The challenge
In the metallurgical industry, blast furnace processes generate large amounts of high-pressure gas, which is typically used as fuel. However, before it can be utilized in installations, it must be cleaned and its pressure reduced. In most cases, this reduction is carried out using throttling systems, which results in the irreversible loss of the gas’s energy potential.
A client from the metallurgical sector asked us whether it was possible to harness this energy through the use of expansion turbines to generate electricity.
Our approach
The DB Energy team began with an analysis of the process parameters of blast furnace gas:
- pressure,
- temperature,
- chemical composition,
- volumes generated during production.
Particular attention was given to the issue of high alkali content, which, without proper purification, could cause severe corrosion of turbine components.
As part of the work, a feasibility study was prepared, including the selection of back-pressure turbines, the economic model of the investment, and an analysis of the impact on the plant’s energy balance.
Solution
The project included the installation of expansion gas turbines instead of conventional throttling systems. In this way, the kinetic energy of the blast furnace gas, previously lost during pressure reduction, was used to generate electricity in synchronous generators.
As a result, the company not only increased the efficiency of its own energy resource utilization, but also reduced the need to purchase part of its electricity from the grid, further improving its energy security and independence from market price fluctuations.
Results
The implementation of the investment enabled energy savings of 211 GWh per year, which translated into a reduction of CO2 emissions by more than 170,000 tons annually. The payback period for the investment was less than 7 years, which, for an installation of this scale, should be considered a highly favorable result.
Conclusions
The project carried out in the metallurgical plant shows that the installation of expansion gas turbines is an effective way to recover energy lost during pressure reduction in blast furnace processes. As a result, companies can not only reduce energy costs and CO2 emissions, but also improve energy security by using their own resources instead of grid electricity. However, the proper preparation of the concept – particularly in terms of gas purification and turbine corrosion protection – as well as consideration of process parameters in the economic model is crucial.
Nasze najnowsze realizacje, które Cię zainteresują
The largest LNG-powered cogeneration unit in southern Poland – Schumacher Packaging Myszków
The largest LNG-powered cogeneration unit in southern Poland is now operating at Schumacher Packaging in Myszków. Thanks to an investment of 21.8 million PLN, the facility has achieved nearly 80% energy independence, producing almost 9 MW of electricity and significant amounts of heat. The project, implemented by DB Energy, demonstrates how an energy audit can serve as a starting point for a comprehensive energy transformation of a factory – from modernization of existing heat sources, through energy recovery, to the implementation of advanced cogeneration.
Przejdź do artykułuHigher production and lower emissions – a chemical industry client on the path to net zero
At a chemical plant in southern China, we developed a 4-month strategy to reduce emissions by 70%, enabling increased production while lowering energy consumption and laying the groundwork for achieving net zero by 2035.
Przejdź do artykułuZero-emission in practice – emission reduction in pharmaceutical chemistry
Zero-emission in the chemical industry is not theory but concrete action. For a client in the pharmaceutical sector, we prepared a CO₂ reduction roadmap and implemented an incinerator modernization with heat recovery. The result? 12 GWh of thermal energy saved, a reduction of 2,172 tCO₂, and a quick payback period.
Przejdź do artykułu
Czekaj