Waste Heat Recovery Systems

Waste Heat Recovery (WHR) systems are revolutionizing the steel industry by addressing critical challenges faced by producers and manufacturers. As energy costs rise and environmental regulations become tighter, the need for efficient energy recovery becomes increasingly paramount. WHR systems by Primetals Technologies capture and convert waste heat from different sources, transforming it into valuable energy resources, thereby enhancing plant efficiency and reducing emissions.

Waste Heat Recovery Systems

Waste Heat Recovery Systems developed by Primetals Technologies are designed to maximize energy recovery from sinter plants, ironmaking, and steelmaking processes, including COREX plants, FINEX plants, MIDREX direct reduction plants, HYFOR, LD converters (BOF), AOD converters, and Smelter. These systems are tailored to the metallurgical aggregates and local conditions, offering options such as feeding steam into on-site networks, generating additional electricity, or using heat for district heating. They integrate seamlessly with existing operations, providing an efficient solution for energy management.

Sinter Cooler Waste Heat Recovery

In sintering plants, energy is recovered by capturing hot exhaust air from the either conventional sinter cooler systems of shaft-based systems. The heat is used to generate steam or hot water in a waste heat boiler system or, optionally, to produce electricity in a modular power block. When combined with a dedusting system, the cleaned hot air further reduces dust emissions from the sinter plant.

Cooling Stack: Efficient Energy Recovery for Converter Steelmaking

Recovering energy from converter off-gas is challenging due to extreme operating conditions, including high dust loads, high temperatures, and the batch nature of the process. The Cooling Stack offers an innovative solution for energy recovery in LD converter (BOF), AOD converter, and Smelter Applications.

As the first section of the BOF waste gas cleaning system, the Cooling Stack connects to the LD converter (BOF) and controls gas recovery by regulating partial combustion through an adjustable skirt. Waste gas flows through the stationary stack and is redirected to the dry or wet waste gas cleaning plant (DDS or WDS) via a deflection bend.

Most modern LD converter (BOF) cooling stacks are used for steam generation—or hot water production. Heat is transferred from off-gas to cooling water, producing steam that is stored in an accumulator for stable feed into the plant’s steam network.

Key Features and Benefits

• Precise control: A hood-pressure measurement device and a gas analysis system optimize performance.
• Easy inspection: An inspection cover allows operators to clean or repair the stack without stopping production.
• Simplified revamps: The innovative construction enables quick and efficient upgrades.
• Integrated dedusting: Evaporation-cooler spraying nozzles help the cooling stack function as part of the converter’s primary dedusting system.
• This advanced design not only improves energy efficiency but also enhances operational reliability and environmental compliance.

Benefits of Waste Heat Recovery Systems (WHR)

• Enhance efficiency: increase plant efficiency by recirculating hot air back to the sinter cooler, optimizing the sinter process
• Reduce emissions: achieve compliance with emission standards and significantly reduce dust and CO₂ emissions, contributing to a cleaner environment
• Lower costs: decrease operating costs through the production of steam and electrical power
• Flexible integration: tailor-made solutions for steam generation and energy utilization, ensuring adaptability to specific plant needs
• Sustainable operations: contribute to resource conservation and environmental sustainability, aligning with global green initiatives