Pobuzhie Ferronickel Plant

Cost-benefit analysis for OPT heat-exchanger unit in the tube rotary furnace for nickel ore melting (Ukraine), gas

Estimated data:

  • Nickel ore melting
  • Continuous furnace
  • Flue gas temperature is 326° С
  • Heated air temperature is 280° С
  • Flue gas volume is 95 000 Nm3/h
  • Heated air volume is 42 000 Nm3/h
  • Dust content is up to 150 g/m3
  • Unit purpose – gas saving
  • Number of the heat exchangers – 4 pcs.

Feasibility study for the heat exchanger application

Capital costs

Heat exchanger price, $ VAT excl.
596 550

Connections, construction and assembly operations, project design works, etc., $ VAT excl.
278 270

Total capital costs, $ VAT excl.
874 820

Day-to-day operation

Heat flow returned back to the furnace, KW
6 844

Saving, Gcal per hour
5,9

Gas volume in Nm3 required to produce 1 Gcal
125

Price of 1 Nm3 of gas VAT excl., $
0,5

Number of working hours per day
24

Number of working hours per day
30

Saving for air heating per month, $
248 525

Operating costs

Energy, $ VAT excl.
14 516

Repair of purchased equipment, $ VAT excl.
7 742

Прочие, $ без НДС
5 161

Total operating costs, $ VAT excl.
27 419

Payback period for the heat exchanger, months
4,0

Operating effect

  • Technical parameters met requirements of the specifications
  • Fuel (natural gas) consumption saving is 736 м3/ч for each furnace
Solution

готовый рекуператор

Weight is 25 000 kg
Heat power: 5 000 KW
Used for gas furnace blast preheating
Flue gas temperature: 350° С
5. Heated air temperature: 280° С

Reference

Severstal

Cost-benefit analysis of replacement of the existing low-performance heat exchanger by OPT heat exchanger in the metallurgic integrated plant, gas

Estimated data:

  • Metal rolling block
  • Continuous furnace
  • Connections shall be retained
  • Flue gas temperature is 900° С
  • Heated air temperature is 412° С
  • Heated air temperature after the current heat exchanger is 150 ℃
  • Flue gas volume is 19 100 Nm3/hour
  • Heated air volume is 17 500 Nm3/hour
  • Unit purpose – gas saving
  • Number of the heat exchangers – 1pcs

Feasibility study for the heat exchanger replacement

Capital costs

Heat exchanger price, rubles, VAT excl.
3 127 118,64

Connections, construction and assembly operations, project design works, etc., rubles, VAT excl.
0

Total capital costs, rubles, VAT excl.
3 127 118,64

Day-to-day operation

Heat flow returned back to the furnace, KW
1 697

Saving, Nm3 of gas per hour
185

Price of 1 Nm3 of gas VAT excl., rubles
4,5

Saving for air heating per month, rubles
599 400

Operating costs

Energy, rubles, VAT excl.
40 800

Repair of purchased equipment, rubles, VAT excl.
19 150

Other, rubles, VAT excl.

Total operating costs, rubles, VAT excl.
59 950

Payback period for the heat exchanger, months
6

Economic benefit from the heat exchanger operation during (10) year service life, rubles.
71 928 000

Operational effect

  • Technical parameters met requirements of the specifications
  • The existing system of air and flue gas ducts is retained
  • Fuel (natural gas) consumption savings is 185 Nm3/h
Solution

замена рекуператора

Weight is 5 880 kg
Heat power is: 2 669 KW
Used for air heating at burners
Flue gas temperature: 900° С
Heated air temperature: 412° С

Reference

JSC Rosneft

Cost benefit analysis for installation of OPT air heater in the oil and gas refinery

Estimated data:

  • ELOU-AVT-5 installation
  • Connections should be retained
  • Flue gas temperature is 350° С
  • Heated air temperature is 218° С
  • Unit purpose – gas saving, replacement of the broken down foreign air heater
  • Number of the heat exchangers – 1pcs.

Feasibility study for the air heater

Capital costs

Heat exchanger price, rubles, VAT excl.
13 474 576

Connections, construction and assembly operations, project design works, etc., rubles, VAT excl.
3 836 186

Total capital costs, rubles, VAT excl.
17 310 763

Day-to-day operation

Heat flow returned back to the furnace, KW
10 000

Saving, Nm3 of gas per hour
1 260

Price of 1 Nm3 of gas VAT excl., rubles
4

Saving for air heating per month, rubles
3 688 123

Operating costs

Energy, rubles, VAT excl.
54 000

Repair of purchased equipment, rubles, VAT excl.
43 277

Other, rubles, VAT excl.
14 426

Total operating costs, rubles, VAT excl.
111 703

Payback period for the heat exchanger, months
4,8

Economic benefit from the heat exchanger operation during (10) years service life, rubles.
429 170 485

Operational effect

  • Technical parameters met requirements of the specifications
  • The existing system of air and flue gas ducts is retained
Solution

Техникоэкономическое обоснование воздухоподогревателя

Weight: 24 000 kg
Heat power: 4 637 KW
Used for air preheating for burning
Flue gas temperature: 350° С
Heated air temperature: 218° С

Reference