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This case study illustrates the use of chilled water on a joint steel mill and petrochemical plant.
Company Information
Anshan Steel Company
State Owned
Anshan, Liaoning Province
North-East China
Background
The Liaoning province has been home to a large industrial
revolution over the last century. There are numerous coal mines,
oil refineries, petrochemical plants and steel mills operating
on a large scale in this area.
Anshan steel is the largest steel producer in China, with over 100,000 employees on site. The factory produces many basic steel products as well as incorporating a petrochemical plant for coking production and others. The petrochemical plant employs 3,000 people.
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| Fig. 1 Panoramic View of the Steel Works and Petrochemical Plant |
The Problem
Poor heat exchange in the coking plant and other areas leads to inefficient production of processed materials and excess gases plus large volumes of water utilisation.
The Solution
To ensure heat exchange within the petrochemical division is optimized cold water is needed. For most of the year the ambient temperature of the circulation water is too high. Therefore an additional process is needed to control the temperature of water.
Prior to Wap-Flaro absorption chilling was commissioned to achieve these results. After installation running costs proved too high because of chemical additives needed (lithium bromide) and volumes of water required.
A New Approach
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It was decided that WF would be the most economical solution to this problem. In October 2001 WF was commissioned on site.
In this case the steel works have fed 2 process water lines
to the WF plant. One line cools down general process water for the
petrochemical facilities and the other line is used for cooling
liquefied ammonia also within the petrochemical works. |
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| Fig. 2 Picture shows the whole plant |
The benefits of operating WF over other methods include:
- Use of very low-pressure waste steam
- Very little additional water usage
- Very low power consumption, as there are no moving parts, only small integral pumps required
- No chemical additives needed only steam and water
Operational Data
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Required/Available |
Result |
Wap-Flaro Capacity |
2,000,000 kcal |
2,002,000 kcal |
Chilled Water Capacity |
250m³/h |
210m³/h |
Temperature Reduction |
8°C |
12°C |
Steam Pressure |
2.5 - 3 bar |
4.9 bar |
Steam Input |
Saturated -
130°C |
Overheated -
192°C |
Steam Consumption |
6,229kg/h |
5,000kg/h |
Ambient Temperature 20°C
Conclusions
WF has succeeded in reducing circulation water temperature to optimum levels for production efficiency. This achievement will ensure greater efficiency and volume of production as well as a much more efficient water usage system.
Customer Evaluation
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Miss Wang Ho-Jen
Wap-Flaro Plant Manager for Anshan Steel
Physics and Engineering Graduate of Shenyang University |
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"We use 10 m³/h of water to cool down the liquefied ammonia and 200 m³/h to cool down process water for the coking plant mainly.
"The temperature of the ammonia is very high, between 70 and 80°c. We can now cool this to 40-50°c using the heat exchangers in the (WF) factory.
"We can also cool down process water to 8°c using other heat exchangers within the (WF) plant.
"Cold water production in the plant has been normally over 200 m³/h.
"Working pressure of the steam is approximately 3 bar from the source, maybe a little bit less by the time it reaches our plant.
"We have been running the plant continuously since it was commissioned in October last year.so far we are very pleased with the results we have been receiving."
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