Feasibility study for reheat furnace upgrade

In 2012, Russula was selected by Gerdau, to conduct an energy saving feasibility study to increase the furnace capacity from 80 ton/hr to 120 ton/hr or the maximum possible capacity at the lowest possible investment cost, without significant modifications to the current furnace layout.

Project Execution

At the time of the study, the furnace used a mixture of BFG – Blast Furnace Gas and fuel, which enriches the gas supply to the burner flames. The study evaluated the advantages and disadvantages of substituting fuel with natural gas or LPG, Liquid Propane Gas. In addition the study considered the possibility to increase the supply of the Blast Furnace Gas.

• Determine maximum possible furnace capacity increase without major modification.
• Analyze current Blast Furnace Gas operation with fuel.
• Determine feasibility to increase Blast Furnace Gas volume.
• Evaluate substituting fuel with natural gas or LPG.
• Analyze the possibility to use the existing burner.
• Lower energy costs – quantify energy savings with all options.
• Benefit analysis report.

Results

With this feasibility study Russula provided the right information for the Gerdau Divinopolis plant to decide the future steps, minimizing investments and maximizing returns. Rising energy costs have driven many companies to contract ESCO – Energy Service Companies – to perform technical studies leading to the design and implementation of energy savings projects. Russula is pleased to fit the role of an energy saving technical consultant for steel producing companies.