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D APPENDIX D: TECHNOLOGY SOLUTIONS FOR ENERGY RECOVERY Cooling and Storage (Food) Refrigeration in the food sector is a large energy consumer and is mainly used for freezing or cooling of meat, fruit, vegetables, as well as for frozen products. Refrigeration in industry is mostly done by means of compression cooling and in some cases by absorption cooling. Electricity use for refrigeration in the food and beverages industry is estimated at 11.1 TWh, mainly used by compressors. Many options exist to improve performance of industrial refrigeration systems. System optimization and control strategies combined show a large potential for energy efficiency improvement of up to 30 percent. Opportunities include system design, component design, adjustable speed drives, process control systems, adsorption heat pumps, gas- engine-driven adsorption cooling, new working fluids (e.g. ammonia, CO2) and alternative approaches (e.g. thermal storage). Many of these opportunities already exist; insertion is what is needed to realize up to 40% efficiency savings. 5.0 Steel Gas and Heat Recovery at Basic Oxygen Furnace The iron and steel industry is one of the largest U.S. industrial energy consumers. The U.S. iron and steel industry is made up of integrated steel mills that produce pig iron from raw materials (iron ore, coke) using a blast furnace and steel using a basic oxygen furnace (BOF) and electric arc furnace steel mills that produce steel from scrap steel, pig iron, or direct reduced iron (DRI) using an electric arc furnace. In 1994, 2,180 TBtu (about 11% of manufacturing primary energy use) was consumed in the production of about 100 Mton of crude steel products. Within steelmaking, the largest energy use is required to reduce iron ore in the integrated mills to re-melt steel scrap in electric arc furnace mills. Primary steel is produced using the BOF. In the BOF process liquid pig iron, scrap and limestone are mixed. Oxygen is injected to reduce the carbon content of the hot metal from about 5% to less than 2%. Steel contains less than 2% carbon. The BOF process replaced the last open hearth furnace in the U.S. by 1992 due to its greater productivity and lower capital costs. Fuel and electricity consumption in the BOF is estimated at 18TBtu and 1.7TWh, respectively, in 1994. Energy intensity for this process step in 1994 was 0.30 MBtu/short ton fuel and 27 kWh/short ton steel. In the U.S., no BOF gas seems to be recovered at this time. According to the EPA, the BOF-process is an important source of CO emissions, emitting 617,000 tons in 1992, or equivalent to 21 lb/short ton liquid steel. Carbon in the hot metal reacts to carbon monoxide, which is emitted as BOF gas. The BOF gas has a heating value of 7.4 and 9.1 MJ/Nm3. By reducing the amount of air entering over the converter, the CO is not converted to CO2. The BOF gas can be recovered and used as fuel gas in the steel plant or for steam and power production. The hot off-gases must be cooled before gas cleanup, and the heat can be recovered by generating steam and hot water. BOF gas combined with sensible heat recovery is the 131PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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