Natural Gas Integrated Pressure Regulating System for Steel Mill Burner in India

1. Project Background

As the steel industry in India develops at a rapid pace, many steel mills are replacing conventional fuel coal and heavy oil with cleaner natural gas for heating purposes in their furnaces. Natural gas, the superior choice in terms of efficiency, emission, and heat stability, provides a superior combustion over the traditional alternatives. The Project required a stable and precise natural gas pressure supply to feed a burner system for a steel reheating furnace. The supply pressure to the upstream pipeline was 1 MPa, whereas the burner system required an average pressure of 0.03 MPa stable to function.

The client required a compact but reliable integrated solution for safe and efficient utilization of gas. Our solution is a compact natural gas integrated pressure reducing station incorporating gas filtration and protection.

2. Customer Pain Points & Challenges

• Large Pressure Reduction Requirement
  The system required pressure reduction from 1 MPa to 0.03 MPa, which demands highly reliable multi-stage pressure regulation to ensure safe burner operation.
• Stable Gas Supply for Burner Combustion
  Industrial burners require a steady and exact gas pressure. If there are pressure fluctuations with industrial burners, they can produce unreliable, inferior, or dangerous performance.
• Limited Installation Space
  The gas supply area within the steel works had very restricted space available, so a very compact, but integrated gas plant was required, using a high-pressure header supplying downstream processes.
• Reliable Industrial Operation
  The Steel Works produces steel on a 24/7 basis and as such requires equipment that is highly reliable and low maintenance.

3. Our Customized Solution

This integrated natural gas pressure reducing station was designed from scratch to meet the requirements of the project. The station is a skid-mounted, integrated natural gas pressure regulating assembly for industrial burner applications.

• Integrated Skid-Mounted Design
  Comprised of gas filters, pressure regulators, safety shut-off valves, pressure gauges, and control components, the unit is skid-mounted for ease of installation and removal. Modular design reduces installation work on-site and facilitates system commissioning.
• Multi-Stage Pressure Regulation
  A stable pressure reduction from 1 MPa down to 0.03 MPa was achieved with a two-stage precision pressure regulator.
• High-Efficiency Gas Filtration
  Inlet high-capacity natural gas filters remove contaminants such as dust and other particles from pipeline gas to protect commercial gas furnaces, regulators, and burner assemblies from damage.
• Comprehensive Safety Protection
  Our system is equipped with overpressure protection devices and safety shut-off valves to stop gas supply in the event of abnormal pressure and automatically prevent any damage to the burner system in the steel mill.

4. Core Advantages of our Integrated Gas Pressure Regulating System
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• Compact and Space-Saving Design
  The combined package is designed to provide an integrated skid-mounted unit to minimize floor space requirements in industrial facilities simplifying installation.
• High-Pressure Control Accuracy
  Constant outlet pressure of 0.03 MPa is maintained in the system for constant burner combustion.
• Industrial-Grade Reliability
  All components are intended for continuous year-round operation in heavy industrial environments such as steel mills.
• Easy Operation and Maintenance
  The EPP pump has been designed with a modular configuration, enabling easy inspection and maintenance without affecting normal operation.

5. Equipment Operating Condition

After installation and commissioning, the fully integrated natural gas pressure reducing station is in safe and reliable operation. The system maintains constant pressure at the outlet, smooth gas flow, and stable furnace burner operation. It maintains constant outlet pressure at 0.03 MPa while upstream pressure is unstable.

The skid-mounted technology employed for the EAFOnline asset notably reduced installation and commissioning time enabling the new system to rapidly be integrated into the Steelworks’ production pathway.

6. Customer Benefits & ROI

• Improved Furnace Heating Efficiency
  A stable and consistent supply of Natural Gas ensures proper burner operation, as well as improved efficiency in reheating steel.
• Reduced Installation and Construction Cost
  Integrated pre-assembled building construction significantly reduced the amount of on-site installation work, and therefore lowered the construction costs for the project by more than 50%.
• Lower Maintenance and Operation Cost
  High-quality filters, regulators, and associated parts provide long life and low maintenance.
• Cleaner and More Efficient Energy Use
  The conversion to natural gas not only offers emissions reductions and improved environmental performance, but also increased efficiency in the steel making process.

Typical Application Scenarios:

It is widely used by:

• Other industrial gas supply systems – coking plants, breweries, chemical works, glass manufacturing plants, atomic power stations, blast furnaces, etc.
• Industrial boilers and heating furnaces
• Ceramic and glass manufacturing plants
• Food processing heating systems
• Industrial park gas supply stations
• Natural gas distribution for industrial end-users