Closed-loop cooling circuits
Water-cooled components in melting and recycling systems should remain in use for as long as possible and be maintenance-free. One of the keys to success is a well-functioning cooling system that is specially adapted to the system. The systems we plan are preferably designed as closed-loop cooling circuits in order to ensure optimum monitoring (leakages, temperatures, flow rates, etc.) and control.
Utilize waste heat.
Furthermore, closed-loop cooling circuits with dry coolers have the advantage over evaporative coolers of not falling under the requirements of the 42nd BImSchV. The waste heat generated in the units can also be decoupled and reused in our closed-loop cooling circuits. Our many years of expertise and our in-depth understanding of the core thermal engineering processes in our customers' plants ensure that all interventions for waste heat recovery in existing systems are carried out without negative consequences for production.
You can find a recent publication by us on the subject of waste heat recovery in the publications of the VIK Verband der Industriellen Energie- und Kraftwirtschaft e.V. from 03/23, for example. The article is available for free download here:
Promoting ecology.
Together with selected partners from the energy industry and energy technology, we develop holistic waste heat recovery concepts for you on request, which include technical feasibility, ecological and macroeconomic considerations, funding management and all other criteria necessary for an investment decision. Would you like to check whether your cooling water circuits also have potential for extracting waste heat? Are you unsure why your cooling system regularly overheats? Do not hesitate to contact us.
The six KSK quality criteria in the cooling systems.
Clearly arranged
Can't find your way around the pump station of your electric arc furnace? Even a glance at the operating instructions doesn't help? At this point you may also be thinking: What operating instructions? Even if it's sometimes just something as simple as the documentation: clear and understandable layouts, diagrams and instructions - including for waste heat recovery - can make work much easier at the end of the day, can't they?
Functional
A modern cooling circuit (with waste heat recovery) should be able to do more than just cool. Much more! Does your current cooling circuit only detect a leak in the electric arc furnace when you can already see a plume of steam? Is the flow temperature in your hot gas duct controlled by climate change and not by you at the control panel in the pump station? Then we should have a chat.
Innovative
Every unit to be cooled is different, every customer has their own ideas. It goes without saying that every cooling circuit we design is therefore unique. We always remain true to our basic design, but whether we should integrate a diesel pump or a city water pipe for emergency cooling is up to you. Just like the decision as to whether you want to integrate waste heat recovery or not. And even if there is less space available for your new pump station: We will find a solution.
Perfect fit
Safe cooling of the circulation water heated in the cooling circuit must be guaranteed at all times. But why not use as much of this waste heat as possible for other purposes? With the innovative waste heat recovery solutions of our versatile cooling systems, you can easily meet the constantly growing challenges in energy management. Waste heat recovery is just one of them.
Maintenance-friendly
No long distances to the control room or the system to check measured values or set the cooling circuit to maintenance mode - in a KSK pump station (with or without waste heat recovery) you will find everything in one place: control cabinets with control panel, pump technology, sensors, water treatment, leakage monitoring and much more. It goes without saying that we ensure that all purchased parts installed are absolutely suitable for use in steelworks. This means that once the pump station has been commissioned, you can concentrate fully on your day-to-day business. Because unlike suppliers, colleagues and customers, our cooling circuit always does what it is supposed to do all by itself: cooling reliably around the clock.
Economical
Well-designed process engineering cooling systems (with or without waste heat recovery), combined with a deep understanding of the components to be cooled, ensure that we dimension pumps, recoolers and the like in an economically sensible way. We can also rely on a strong network of partners and suppliers with whom we have been working for years to put together the purchased components in our cooling circuits. You don't know in which building you should install the new pump station? Then ask about our KSK Plug & Play container solution, including waste heat recovery on request. We pre-install the entire pump technology, control cabinets with control panel and even the dry cooler in a transportable container, all you have to do is connect cables and water pipes on your premises. As a result, you save on both investment and operating costs, making the new cooling circuit a complete success for maintenance, operation and purchasing!
Further content on the topic of waste heat recovery
Waste heat recovery refers to the use of heat that is generated as a by-product of an industrial process. This unused heat can be used efficiently in many different ways in various industries and companies. Effective waste heat recovery not only makes economic sense, but also helps to conserve resources and reduce environmental pollution.
What contribution can waste heat recovery in the German steel industry potentially make to achieving the EU climate targets?
Waste heat recovery in the German steel industry can make a significant contribution to achieving the climate targets of the European Union (EU). The EU has set itself the target of reducing greenhouse gas emissions by at least 40% by 2030 compared to 1990 levels. Increasing waste heat recovery in the steel industry can help to achieve this target. It is estimated that waste heat recovery in the German steel industry can make a quantitative contribution of up to 10% to achieving the EU's climate targets due to legal requirements and technical improvements - at least according to publicly available statistics and analyses.
What does waste heat recovery mean in the steel industry?
Waste heat recovery is a process in which the waste heat generated during the production of steel is used to generate energy. Waste heat is generated during the production of steel by heating pig iron, steel or scrap. This waste heat can be reused in the form of heat, steam or compressed air for various processes in the steel industry. For example, it can be used to heat rooms, operate machines or generate electricity.
In Germany, waste heat recovery is already widespread in the steel industry. Many companies use the waste heat generated during steel production to increase their energy efficiency and reduce their carbon footprint. However, many companies are also encouraged to further expand waste heat recovery in their operations due to legal requirements and technical improvements.
Are there guidelines for waste heat recovery?
The legal requirements include EU directives aimed at increasing energy efficiency in the steel industry and reducing CO2 emissions. For example, the European Commission has adopted the Energy Efficiency Directive (EED), which obliges companies to reduce energy consumption in their operations and expand waste heat recovery.
There are also specific directives aimed at promoting waste heat recovery in the steel industry, such as the Energy Efficiency Directive for the Steel Industry (EESI). These directives are part of the EU's Energy Efficiency Action Plan and are intended to encourage the steel industry to make more efficient use of the waste heat generated during the production of steel.
In addition, companies are motivated to increase waste heat recovery in their plants through technical improvements and new techniques. There are various methods that can be used for waste heat recovery in the steel industry. One of these is the use of heat recovery systems - such as those from KSK - which make more efficient use of the waste heat generated during steel production. These systems can use the waste heat generated during the production of steel to operate building heating systems, to feed it into local and district heating networks or to generally increase energy efficiency. The use of waste heat from the steelworks to operate combined heat and power processes is also a popular method of using the waste heat generated during the production of steel more efficiently.
Overall, it can be said that waste heat recovery in the German steel industry can make a quantitative contribution of up to 10 % to achieving the EU's climate targets. Legal requirements and technical improvements are encouraging companies to further expand waste heat recovery in their plants. This enables companies to reduce their energy consumption and their carbon footprint, which in turn can contribute to achieving the EU's climate targets.
Definition of waste heat recovery
Waste heat recovery refers to the process by which the unused heat generated in a plant or process is recovered and used for other purposes. The aim of waste heat recovery is to make efficient use of the unused heat generated by industrial processes and thus increase energy efficiency.
Types of waste heat
The waste heat produced can have different temperatures and properties. It can be generated as process heat, exhaust air or as heat from technical systems. There are different types of waste heat, which are differentiated according to temperature level and technical possibility.
Energy agency and waste heat recovery
The Energy Agency is an important point of contact when it comes to supporting companies in the efficient use of waste heat. It offers expertise and advice on the technological possibilities of waste heat recovery and helps companies to examine and implement the potential of heat recovery.
Why is waste heat recovery important in companies?
Efficient use of waste heat
The efficient use of waste heat is important for companies as it helps to reduce energy costs and use the resources sustainably. By utilizing unused waste heat, energy consumption can be reduced and the environmental impact reduced.
Potential of heat recovery
Heat recovery has great potential for reducing energy consumption and energy costs in industrial processes. By recovering waste heat, companies can increase their energy efficiency and reduce their CO2 emissions at the same time.
Technological possibilities for waste heat recovery
Technological solutions for waste heat recovery include the use of heat pumps, heat storage systems and various heat recovery processes. These technologies offer a wide range of options for using heat energy efficiently and supplying it to your own business.
How can waste heat be used?
Use of waste heat for heating purposes
The unused waste heat can be used for heating purposes by feeding it into existing heating systems. This means that the thermal energy is used efficiently and can help to cover the company's heating requirements.
Power generation from waste heat
Waste heat can also be used to generate electricity by feeding it into ORC systems, steam turbines or other suitable systems. This allows the waste heat to be converted into electrical energy and used for the company's own operations.
Waste heat sources and their potential uses
Waste heat sources can arise in various processes and systems. It is important to identify the waste heat sources and examine their potential uses in order to make the most of the waste heat recovery potential.
Which areas benefit from waste heat recovery?
Industrial waste heat in various sectors
Industrial waste heat can be generated in various sectors, such as the manufacturing industry, the food industry or the chemical industry. By using waste heat efficiently, companies in these sectors can reduce their energy costs and increase their energy efficiency.
Waste heat recovery for cooling
Waste heat recovery for cooling offers the possibility of using waste heat to cool processes or products. By using appropriate technologies, waste heat can be used efficiently to generate cooling.
Waste heat recovery in energy-intensive companies
In energy-intensive companies, such as those in the metal or glass industry, the efficient use of waste heat can help to reduce energy costs and increase competitiveness. Waste heat recovery offers a wide range of opportunities to improve energy efficiency in such companies.
How can the efficiency of waste heat recovery be maximized?
Use of heat pumps for waste heat recovery
The use of heat pumps offers an efficient way of utilizing waste heat and raising it to a higher temperature level. By using heat pumps, waste heat can be used efficiently for a variety of purposes.
Technological solutions for recovering waste heat
Technological solutions for recovering waste heat, such as heat exchangers or steam generators, offer the possibility of recovering waste heat from processes and using it for your own heat and power supply.
Optimization of heat demand through waste heat recovery
Waste heat recovery can optimize the heat demand in your own company. The recovered waste heat can help to cover heating requirements and increase energy efficiency.
