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An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system

Yıl 2025, Cilt: 11 Sayı: 2, 291 - 300, 24.03.2025

Baji Katta Manjini Sambandam M. Premlatha Saravanan Chandrasekaran

Öz

Steel-making industries use preheated ladles to transfer molten steel from primary to secondary facilities. The preheating process removes moisture, reduces thermal shock, protects the refractory lining, and minimizes temperature drop, but it emits substantial heat through the flue gas. This study introduces a novel, low-cost heat exchanger designed specifically for waste heat recovery in ladle preheating systems, contributing to a circular economy and substantial carbon dioxide reduction. We designed and analyzed a shell-tube heat exchanger using the Kern method and performed experiments and numerical analyses for thermal behavior with commercial ANSYS 19.0. We assessed waste heat utilization through an experimental setup, leveraging insights from computational fluid dynamics modeling and mathematical modeling. We reduced liquefied natural gas consumption from 224 kg/hr to 197 kg/hr. This method saved energy, cutting consumption from 5855 Gcal/yr to 5149 Gcal/yr and lowering carbon dioxide emissions from 1372 TCO2/yr to 1207 TCO2/yr. Our findings suggest that a waste heat recovery system effectively reduces greenhouse gas emissions and offers a practical, cost-effective way to recover energy from the ladle preheating system.

Anahtar Kelimeler

CFD Green Energy Heat Exchanger Sustainability Waste Heat Recovery

Kaynakça

  • [1] Ministry of Steel, Government of India. Energy and Environment Management in Iron & Steel sector. Available at: https://steel.gov.in/en/energy-environment-management-steel-sector. Accessed February 21, 2025.
  • [2] Hamad FA, Egelle E, Gooneratne S, Russell P. Investigation of the effect of aspect ratio on heat transfer from a heated vertical wall to phase change material in a rectangular enclosure. Therm Sci Eng Prog 2023;42:101865. [CrossRef]
  • [3] Edenhofer O, Stern N. Towards a Global Green Recovery: Recommendations for Immediate G20 Action. Berlin: Report for the German Foreign Office; 2000.
  • [4] Fisher BS, Nakicenovic N, Alfsen K, Corfee Morlot J, de la Chesnaye F, Hourcade JC. Issues related to mitigation in the long-term context. In: Metz B, Davidson OR, Bosch PR, Dave R, Meyer LA, eds. Climate Change 2007: Mitigation. Contribution of Working Group III to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change. Cambridge: Cambridge University Press; 2007.
  • [5] European Commission. Communication from the Commission Energy Efficiency: Delivering the 20% Target 2008; 2010.
  • [6] Bernstein L, Roy J, Delhotal KC, Harnisch J, Matsuhashi R, Price L. Industry. In: Metz B, Davidson OR, Bosch PR, Dave R, Meyer LA, editors. Climate Change 2007: Mitigation. Contribution of Working Group III to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change. Cambridge and New York: Cambridge University Press; 2007.
  • [7] Song-Zhen T, Ya-Ling H, Fei-Long W, Qin-Xin Z, Yang Y. On-site experimental study on fouling and heat transfer characteristics of flue gas heat exchanger for waste heat recovery. Fuel 2021;296:120532. [CrossRef]
  • [8] Chan D, Yang K, Lee JD, Hong GB. The case study of furnace uses and energy conservation in the iron and steel industry. Energy 2010;35:1665–1670. [CrossRef]
  • [9] Worrell E, Laitner JA, Ruth M, Finman H. Productivity benefits of industrial energy efficiency measures. Energy 2003;28:1081–1098. [CrossRef]
  • [10] Jafari M, Khan MI, Al-Ghamdi SG, Artur J. Waste heat recovery in iron and steel industry using organic Rankine cycles. Chem Eng J 2023;477:146925. [CrossRef]
  • [11] Li G, Liu J, Jiang G, Liu H. Numerical simulation of temperature field and thermal stress field in the new type of ladle with the nanometer adiabatic material. Adv Mech Eng 2015;7:1–13. [CrossRef]
  • [12] Jouhara H, Khordehgah N, Almahmoud S, Delpech B, Chauhan A, Tassou SA. Waste heat recovery technologies and applications. Therm Sci Eng Prog 2018;6:268–289. [CrossRef]
  • [13] Prasad AK, Anand K. Design & analysis of shell & tube type heat exchanger. Int J Eng Res Technol 2020;09:524–539.
  • [14] Verma D, Shukla AA. Design of shell and tube type heat exchanger using CFD tools. Int J Innov Res Sci Technol 2017;3:39–43.
  • [15] Smith J, Brown A, Clark M. Improving energy efficiency in steel-making: a case study on waste heat recovery. J Ind Energy 2018;45:123–135.
  • [16] Johnson L, Liu H. Application of shell-and-tube heat exchangers in ladle preheating systems: a performance analysis. Int J Heat Mass Transf 2020;152:104–117.
  • [17] Nguyen T, Lee C, Patel R. High-temperature waste heat recovery systems: performance and efficiency evaluations. Energy Rep 2021;7:1234–1246.
  • [18] Amanowicz Ł, Wojtkowiak J. Validation of CFD model for simulation of multi-pipe earth-to-air heat exchangers (EAHEs) flow performance. Therm Sci Eng Prog 2018;5:44–49. [CrossRef]
  • [19] NPTEL – Chemical Engineering Design – II Module #1. Process Design of Heat Exchanger: Types of Heat Exchanger, Process Design of Shell and Tube Heat Exchanger, Condenser and Reboilers. Available at: https://archive.nptel.ac.in/content/storage2/courses/103103027/pdf/mod1.pdf. Accessed February 21, 2025.
  • [20] Shukla A, Kumar P, Tiwari DR. Design Procedure of Shell and Tube Heat Exchanger. Int J Eng Res Technol 2015;3:116–119.
  • [21] Thompson S, Si M. Strategic analysis of energy efficiency projects: case study of a steel mill in Manitoba. Renew Sustain Energy Rev 2014;40:814–819. [CrossRef]
  • [22] International Energy Agency. Direct Air Capture: A Key Technology for Net Zero. Available at: https://www.iea.org/events/direct-air-capture-a-key-technology-for-net-zero. Accessed February 21, 2025.
  • [23] ANSYS Inc. ANSYS Fluent Theory Guide. 14th ed. Canonsburg, Pennsylvania: ANSYS; 2011.
  • [24] Zhou GY, Xiao J, Zhu L, Wang J, Tu ST. A numerical study on the shell-side turbulent heat transfer enhancement of shell-and-tube heat exchanger with trefoil hole baffles. Energy Procedia 2015;75:3174–3179. [CrossRef]
  • [25] Kansal S, Fateh MS. Design and performance evaluation of shell and tube heat exchanger using CFD simulation. Int J Eng Res Technol 2014;3:1163–1166.
  • [26] Moosavi A, Ljung AL, Lundström TS. A comparative study on thermo-fluid characteristics of free and wall-bounded cross-flow heat exchangers. Therm Sci Eng Prog 2023;40:101746. [CrossRef]
  • [27] Wilcox DC. Turbulence Modelling for CFD. 2nd ed. California: DCW Industries Inc.; 1998.
  • [28] Woolley E, Luo Y, Simeone A. Industrial waste heat recovery: A systematic approach. Sustain Energy Technol Assess 2018;29:50–59. [CrossRef]
  • [29] Inayat A. Current progress of process integration for waste heat recovery in steel and iron industries. Fuel 2023;338:127237. [CrossRef]
  • [30] Kothandaraman CP, Subramanian S. Heat and Mass Transfer Data Book. 8th ed. UK: New Academic Science; 2013.
  • [31] Steel Tubes India. Available at: https://www.steeltubesindia.net/sa-213-t11-tube
  • [32] Sunden B. High-Temperature Heat Exchangers (HTHE) Boiler. CHE 2005–29. Available at: https://dc.engconfintl.org/cgi/viewcontent.cgi?article=1024&context=heatexchangerfall2005. Accessed February 21, 2025.
  • [33] Lawler JCW, Heffner KA, Clark MSMD. Design and optimization of a shell and tube heat exchanger using a genetic algorithm. Chem Eng Res Des 2005;83:179–188.
  • [34] Al-Shammari MAA, Ahmed HA, Zhao SS. A review on waste heat recovery technologies for industrial processes. Renew Sustain Energy Rev 2016;59:1461–1475.
  • [35] Chiu LJL, Thomas AT, Smith BR. Energy efficiency in industrial systems: A review of research and implementation. Energy 2017;123:247–263.
  • [36] Harris RH, Thompson FT, Chen CC. Development and optimization of a ladle preheating system for steelmaking. Steel Res Int 2018;89:170–182.
  • [37] Wang YW, Wu HW, Zhao ZZ. Numerical simulation of fluid flow and heat transfer in shell-and-tube heat exchangers. Int J Heat Mass Transf 2019;129:708–720.
  • [38] Johnson KJ, Williams TR, Brown AB. Applications of computational fluid dynamics in heat exchanger design and optimization. Comput Fluids 2022;237:105836.
  • [39] Liu SL, Patel MP, Wang NS. Techniques and strategies for reducing carbon emissions in industrial processes. J Clean Prod 2020;267:121678.
  • [40] Brown DM, Smith EF, Anderson JR. Energy savings and environmental benefits of waste heat recovery systems in industrial applications. Appl Energy 2021;293:116539.

Yıl 2025, Cilt: 11 Sayı: 2, 291 - 300, 24.03.2025

Baji Katta Manjini Sambandam M. Premlatha Saravanan Chandrasekaran

Öz

Kaynakça

  • [1] Ministry of Steel, Government of India. Energy and Environment Management in Iron & Steel sector. Available at: https://steel.gov.in/en/energy-environment-management-steel-sector. Accessed February 21, 2025.
  • [2] Hamad FA, Egelle E, Gooneratne S, Russell P. Investigation of the effect of aspect ratio on heat transfer from a heated vertical wall to phase change material in a rectangular enclosure. Therm Sci Eng Prog 2023;42:101865. [CrossRef]
  • [3] Edenhofer O, Stern N. Towards a Global Green Recovery: Recommendations for Immediate G20 Action. Berlin: Report for the German Foreign Office; 2000.
  • [4] Fisher BS, Nakicenovic N, Alfsen K, Corfee Morlot J, de la Chesnaye F, Hourcade JC. Issues related to mitigation in the long-term context. In: Metz B, Davidson OR, Bosch PR, Dave R, Meyer LA, eds. Climate Change 2007: Mitigation. Contribution of Working Group III to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change. Cambridge: Cambridge University Press; 2007.
  • [5] European Commission. Communication from the Commission Energy Efficiency: Delivering the 20% Target 2008; 2010.
  • [6] Bernstein L, Roy J, Delhotal KC, Harnisch J, Matsuhashi R, Price L. Industry. In: Metz B, Davidson OR, Bosch PR, Dave R, Meyer LA, editors. Climate Change 2007: Mitigation. Contribution of Working Group III to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change. Cambridge and New York: Cambridge University Press; 2007.
  • [7] Song-Zhen T, Ya-Ling H, Fei-Long W, Qin-Xin Z, Yang Y. On-site experimental study on fouling and heat transfer characteristics of flue gas heat exchanger for waste heat recovery. Fuel 2021;296:120532. [CrossRef]
  • [8] Chan D, Yang K, Lee JD, Hong GB. The case study of furnace uses and energy conservation in the iron and steel industry. Energy 2010;35:1665–1670. [CrossRef]
  • [9] Worrell E, Laitner JA, Ruth M, Finman H. Productivity benefits of industrial energy efficiency measures. Energy 2003;28:1081–1098. [CrossRef]
  • [10] Jafari M, Khan MI, Al-Ghamdi SG, Artur J. Waste heat recovery in iron and steel industry using organic Rankine cycles. Chem Eng J 2023;477:146925. [CrossRef]
  • [11] Li G, Liu J, Jiang G, Liu H. Numerical simulation of temperature field and thermal stress field in the new type of ladle with the nanometer adiabatic material. Adv Mech Eng 2015;7:1–13. [CrossRef]
  • [12] Jouhara H, Khordehgah N, Almahmoud S, Delpech B, Chauhan A, Tassou SA. Waste heat recovery technologies and applications. Therm Sci Eng Prog 2018;6:268–289. [CrossRef]
  • [13] Prasad AK, Anand K. Design & analysis of shell & tube type heat exchanger. Int J Eng Res Technol 2020;09:524–539.
  • [14] Verma D, Shukla AA. Design of shell and tube type heat exchanger using CFD tools. Int J Innov Res Sci Technol 2017;3:39–43.
  • [15] Smith J, Brown A, Clark M. Improving energy efficiency in steel-making: a case study on waste heat recovery. J Ind Energy 2018;45:123–135.
  • [16] Johnson L, Liu H. Application of shell-and-tube heat exchangers in ladle preheating systems: a performance analysis. Int J Heat Mass Transf 2020;152:104–117.
  • [17] Nguyen T, Lee C, Patel R. High-temperature waste heat recovery systems: performance and efficiency evaluations. Energy Rep 2021;7:1234–1246.
  • [18] Amanowicz Ł, Wojtkowiak J. Validation of CFD model for simulation of multi-pipe earth-to-air heat exchangers (EAHEs) flow performance. Therm Sci Eng Prog 2018;5:44–49. [CrossRef]
  • [19] NPTEL – Chemical Engineering Design – II Module #1. Process Design of Heat Exchanger: Types of Heat Exchanger, Process Design of Shell and Tube Heat Exchanger, Condenser and Reboilers. Available at: https://archive.nptel.ac.in/content/storage2/courses/103103027/pdf/mod1.pdf. Accessed February 21, 2025.
  • [20] Shukla A, Kumar P, Tiwari DR. Design Procedure of Shell and Tube Heat Exchanger. Int J Eng Res Technol 2015;3:116–119.
  • [21] Thompson S, Si M. Strategic analysis of energy efficiency projects: case study of a steel mill in Manitoba. Renew Sustain Energy Rev 2014;40:814–819. [CrossRef]
  • [22] International Energy Agency. Direct Air Capture: A Key Technology for Net Zero. Available at: https://www.iea.org/events/direct-air-capture-a-key-technology-for-net-zero. Accessed February 21, 2025.
  • [23] ANSYS Inc. ANSYS Fluent Theory Guide. 14th ed. Canonsburg, Pennsylvania: ANSYS; 2011.
  • [24] Zhou GY, Xiao J, Zhu L, Wang J, Tu ST. A numerical study on the shell-side turbulent heat transfer enhancement of shell-and-tube heat exchanger with trefoil hole baffles. Energy Procedia 2015;75:3174–3179. [CrossRef]
  • [25] Kansal S, Fateh MS. Design and performance evaluation of shell and tube heat exchanger using CFD simulation. Int J Eng Res Technol 2014;3:1163–1166.
  • [26] Moosavi A, Ljung AL, Lundström TS. A comparative study on thermo-fluid characteristics of free and wall-bounded cross-flow heat exchangers. Therm Sci Eng Prog 2023;40:101746. [CrossRef]
  • [27] Wilcox DC. Turbulence Modelling for CFD. 2nd ed. California: DCW Industries Inc.; 1998.
  • [28] Woolley E, Luo Y, Simeone A. Industrial waste heat recovery: A systematic approach. Sustain Energy Technol Assess 2018;29:50–59. [CrossRef]
  • [29] Inayat A. Current progress of process integration for waste heat recovery in steel and iron industries. Fuel 2023;338:127237. [CrossRef]
  • [30] Kothandaraman CP, Subramanian S. Heat and Mass Transfer Data Book. 8th ed. UK: New Academic Science; 2013.
  • [31] Steel Tubes India. Available at: https://www.steeltubesindia.net/sa-213-t11-tube
  • [32] Sunden B. High-Temperature Heat Exchangers (HTHE) Boiler. CHE 2005–29. Available at: https://dc.engconfintl.org/cgi/viewcontent.cgi?article=1024&context=heatexchangerfall2005. Accessed February 21, 2025.
  • [33] Lawler JCW, Heffner KA, Clark MSMD. Design and optimization of a shell and tube heat exchanger using a genetic algorithm. Chem Eng Res Des 2005;83:179–188.
  • [34] Al-Shammari MAA, Ahmed HA, Zhao SS. A review on waste heat recovery technologies for industrial processes. Renew Sustain Energy Rev 2016;59:1461–1475.
  • [35] Chiu LJL, Thomas AT, Smith BR. Energy efficiency in industrial systems: A review of research and implementation. Energy 2017;123:247–263.
  • [36] Harris RH, Thompson FT, Chen CC. Development and optimization of a ladle preheating system for steelmaking. Steel Res Int 2018;89:170–182.
  • [37] Wang YW, Wu HW, Zhao ZZ. Numerical simulation of fluid flow and heat transfer in shell-and-tube heat exchangers. Int J Heat Mass Transf 2019;129:708–720.
  • [38] Johnson KJ, Williams TR, Brown AB. Applications of computational fluid dynamics in heat exchanger design and optimization. Comput Fluids 2022;237:105836.
  • [39] Liu SL, Patel MP, Wang NS. Techniques and strategies for reducing carbon emissions in industrial processes. J Clean Prod 2020;267:121678.
  • [40] Brown DM, Smith EF, Anderson JR. Energy savings and environmental benefits of waste heat recovery systems in industrial applications. Appl Energy 2021;293:116539.
Toplam 40 adet kaynakça vardır.

Ayrıntılar

Birincil Dil İngilizce
Konular Akışkan Mekaniği ve Termal Mühendislik (Diğer)
Bölüm Makaleler
Yazarlar

Baji Katta 0009-0009-0734-5929

Manjini Sambandam 0000-0002-7659-2327

M. Premlatha 0000-0003-2445-3269

Saravanan Chandrasekaran 0009-0000-2953-3597

Yayımlanma Tarihi 24 Mart 2025
Gönderilme Tarihi 14 Mayıs 2024
Kabul Tarihi 11 Eylül 2024
Yayımlandığı Sayı Yıl 2025 Cilt: 11 Sayı: 2

Kaynak Göster

APA Katta, B., Sambandam, M., Premlatha, M., Chandrasekaran, S. (2025). An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering, 11(2), 291-300. https://doi.org/10.14744/thermal.0000894
AMA Katta B, Sambandam M, Premlatha M, Chandrasekaran S. An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering. Mart 2025;11(2):291-300. doi:10.14744/thermal.0000894
Chicago Katta, Baji, Manjini Sambandam, M. Premlatha, ve Saravanan Chandrasekaran. “An Experimental and Numerical Analysis on the Effective Utilization of Waste Heat from a Ladle Preheating System through a Heat Exchanger System”. Journal of Thermal Engineering 11, sy. 2 (Mart 2025): 291-300. https://doi.org/10.14744/thermal.0000894.
EndNote Katta B, Sambandam M, Premlatha M, Chandrasekaran S (01 Mart 2025) An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering 11 2 291–300.
IEEE B. Katta, M. Sambandam, M. Premlatha, ve S. Chandrasekaran, “An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system”, Journal of Thermal Engineering, c. 11, sy. 2, ss. 291–300, 2025, doi: 10.14744/thermal.0000894.
ISNAD Katta, Baji vd. “An Experimental and Numerical Analysis on the Effective Utilization of Waste Heat from a Ladle Preheating System through a Heat Exchanger System”. Journal of Thermal Engineering 11/2 (Mart 2025), 291-300. https://doi.org/10.14744/thermal.0000894.
JAMA Katta B, Sambandam M, Premlatha M, Chandrasekaran S. An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering. 2025;11:291–300.
MLA Katta, Baji vd. “An Experimental and Numerical Analysis on the Effective Utilization of Waste Heat from a Ladle Preheating System through a Heat Exchanger System”. Journal of Thermal Engineering, c. 11, sy. 2, 2025, ss. 291-00, doi:10.14744/thermal.0000894.
Vancouver Katta B, Sambandam M, Premlatha M, Chandrasekaran S. An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering. 2025;11(2):291-300.
 Kapak Resmi İndir

IMPORTANT NOTE: JOURNAL SUBMISSION LINK http://eds.yildiz.edu.tr/journal-of-thermal-engineering