Project Initiation and Reliance on Domestic Engineers.
Project Initiation and Reliance on Domestic Engineers The Bisotoun Steel Melt Company’s 12 MW Heat Recovery Power Plant, whose main contractor was a foreign European company, was left unfinished in 2019 (1398) due to problems arising from sanctions and the COVID-19 pandemic.
Despite extensive efforts and negotiations with the foreign contractor, a desirable outcome was not achieved; hence, the management of Shokri Industrial Group decided to continue the completion process of this project domestically, relying on the capability of Iranian engineers and utilizing the capacity of Iranian industries.
Moving Towards Green Industry and Reducing Energy Waste
The Bisotoun Steel Melt Heat Recovery Power Plant is considered one of the most important steps towards environmental protection and the reduction of industrial pollutants.
Heat Recovery in the Direct Reduction Process
n this project, the heat resulting from combustion in the direct reduction process, which was previously wasted through the chimney, is recovered and converted into electricity.
This action leads to a reduction in greenhouse gas emissions, an increase in energy efficiency, and the achievement of “Green Steel” goals.
How the Reduction Unit Works and the Heat Recovery Process
In the direct reduction unit of Bisotoun Steel Melt, raw materials including pellets, coal, and dolomite enter a horizontal kiln approximately 80 meters long.
Due to reduction reactions, sponge iron is produced. A portion of the energy from combustion (about 10 percent) was escaping as hot gases through the chimney, which is now the basis for electricity generation.
Generating Electricity from Wasted Energy
With the commissioning of the Heat Recovery Power Plant, this wasted energy is used to generate 12 MW of electricity.
The electricity generated, in addition to supplying a significant portion of the complex’s needs, can also be injected into the national grid and even adjacent areas in the future.
Technical Details and Electricity Generation Process
Boiler Structure and Conversion of Thermal Energy to Steam
The power plant is of the steam type with a boiler. Hot gases exiting the reduction unit at a temperature of about 1000 degrees Celsius cause water to vaporize in the boiler and produce steam.
The steam, after passing through various stages including the economizer, drum, superheater, and Down Comer, is guided to the turbine at a temperature of 485 degrees Celsius.
Electricity Generation by Turbine and Generator.
The turbine rotates at a speed of 6052 revolutions per minute and is connected to the generator via a gearbox.
In this process, the mechanical energy resulting from the turbine’s rotation is converted into electrical energy.
The power plant generator produces 12 MW of power at 11 kV voltage. This voltage is then increased to 20 kV via the main transformer and transferred to the power plant switchgear and, from there, to the complex’s 63/20 kV substation.
A branch to the 20 kV auxiliary transformer has also been allocated for the power plant’s internal consumption.
Project Implementation Structure and Progress Status
Main Sections of the Project
The power plant project is designed and implemented in seven main sections:
Civil Works
Mechanical
Electrical
Instrumentation
Chemical
Auxiliary Installations
Commissioning and Start-up
Percentage of Progress and Actions Taken
Currently, the project has 70 percent physical progress. The highest progress has been achieved in the construction and engineering sections, and the sections related to equipment, piping, and commissioning are underway.
Activities Conducted to Date
Performing detailed studies of the current status and identifying missing equipment
Collaborating with domestic consulting firms to update the technical design
Requesting quotes from active power plant companies to complete the remaining sections
Following up on obtaining related legal permits and certifications
Negotiating for the connection of the power plant to the national electricity grid
Developing the administrative and organizational chart of the power plant and determining the required personnel
A Project Serving the Environment and the Future of Energy
The Bisotoun Steel Melt Heat Recovery Power Plant project is an example of green economy and sustainable development in Iran’s steel industry.
This project, while reducing the consumption of fossil fuels and preventing energy waste, leads to a reduction in the emission of carbon dioxide and other polluting gases.
A Step Towards Industrial Self-Sufficiency
The completion of this project, relying on the capability of Iranian engineers, is a major step towards industrial self-sufficiency, environmental protection, and achieving green steel; an action that places Bisotoun Steel Melt and Shokri Industrial Group on the path of sustainable and responsible energy production.
