R&D tasks financed by support of applications

1. Development of boiler family for burning of briquette produced of agricultural byproducts

In the framework of the Operative Program of the New Széchenyi Plan the GOP-1.3.1-11/A-2011-0074 project targeted the utilisation of firing wood, wood industrial, paper industrial and agricultural byproducts in using gasification processes to achieve thermal utilisation. The innovation work is focused on the development of a thermogenerator family operating on the principle of gasification. In the phase of realisation a wet facility of 25 kW and an air facility of 100 kW capacity will be manufactured. Task of trial phase of this activity will be the pilot running of the appliance in using firing wood and briquetted industrial wastes, as well as the evaluation of the service experiences and feeding back the gained results to the development process.

The range of thermogenerator of 25-150 kW makes possible the perfect burning of cellu-lose based solid fuels. The utilisation of the generated thermal energy takes place in the integrated heat exchanger units. From the point of view of heat utilisation one can define two basic types of design. The version of hot water has been targeted for utility requirements. The other goal of the R+D+I to develop a hot air generator for industrial purposes. In designing this facility enables us to apply the same basic unit for specific purposes aligning this way the heat exchanger to the related conditions. The realised prototype in the framework of this project possessing this mentioned feature.

2. Investigation and working out of design aspects of high efficiency recuperator which can be applied by utilisation of alternative gases too.

Grantee: TÜKI Research and Development Inc. for Combustion Technology

Amount of granted sum from the Research and Technological Innovation Fund is 39.104.268 HUF.
The R&D task has been worked out by the TÜKI Inc. and the Gas Institute as part of the "REPLACING" project of the EUREKA forum of Brussels in co-operation with the Gas Institute NASU of Ukraine. Support of the program took place in the framework supporting the Hungarian partaking of the EUREKA Program EUREKA Hu 12-1-2012-0003 designated contract. The international project is focused for the application of special heat exchangers and firing equipment by producing gaseous alternative fuels, as well as to the application of low calorific value/LCV/ gases for high temperature technologies, putting stress on development of preheating and heat recovery facilities. The realisation targets the substitution of natural gas by LCV gases, in order to decrease the environment burden. The TÜKI's task in this project is to enlarge the application possibilities of non conventional fuels using the recuperators developed by the Ukrainian partner for LCV gases focused. During the working out of RD project TÜKI Inc. manufactured on the basis of Ukrainian partner 2 pcs. of max. 100 kW heating capacity recuperators. TÜKI Inc. designed and fabricated the trial furnace needed to the tests as well as the relevant energy supply and operating units of 200 kW firing capacity. The facility enabled us to investigate the chief parameters of the heat exchanger in the temperature range of 700-1000 °C.

The tests were carried out in three phases at the Heat Treating Workshop of the Billet-Mill of ISD DUNAFERR.

1. The measurement of the flow resistance of the equipment was investigated in using a cold testing facility resp. the testing device was installed at a bell-type furnace applying operational circumstances.
2. The TÜKI Inc. carried out semi-service trials at the test furnace applying blast furnace gas of 5,8 MJ/m3 - chamber gas mixture /LCV gas/.
3. The recuperators have been tried out at the bell-type furnace in using preheated air and hot operational conditions.

On the basis of the carried out trials it can be stated, that due to the favourable features of the new design the new recuperator can be run with efficient heat exchange parameters as well as with low flow resistance.

The achieved measured data making possible to determine the optimum concepts of design and calculation of pressure losses for concrete installation targets, resp. to determine the maximal heat exchange factor and minimal heat exchange surface temperature by fuels differing from natural gas in composition and volume flow ratios.
The new type heat exchangers taking into account the features of the LCV gases are ensuring to fire industrial waste gases, biogases and gaseous secondary energy carriers the developed heating power could be used for wider application range of heating technologies enabling us to spare higher amount of natural gas.
The experimental work was followed by theoretical studies. The TÜKI Inc. worked out the computation processes needed to the evaluation of the recuperator. The model makes possible to compare the" traditional" bundle type recuperators with the new type ones. The evaluation takes place on the basis of comparison of identical flow volumes and input temperatures in relation to the heat transfer /air preheating temperatures/.

Publications showing the working out of the process of project.

1. Application of new type recuperator for low type calorific value gases (Engineering and Economical Bulletin of the ISD DUNAFERR of 2013 IV. Quarterly No.)

2.Development of Calculation Technique and of Design Procedure for Advanced Radiative Recuperator in Frame of EUREKA Program. (Int he process of publishing in a Ukrainian journal).

3. Application of New Type recuperator for Low Calorific Value Gases (VIII. International Scientific Conference on Refractories, Furnaces and Thermal Insulations, Novy Smokovec, 2014.04.08-10, Szlovákia)

4. Разработка и исследование новой Высокоэффективной конструкции Рекуператора типа ррд для печей Машиностроения (xvii международная конференция Теплотехника и энергетика B металлургии, НМетАУ, г. Днепропетровск, Украина, 7 – 9 октября 2014 г).

3. Development of heavy duty and good workability steel products in the steel industry taking into account the demands of automobile industry and environmental requirements.

Code number of the project: GINOP-8.1.1-16

Overall cost of the project 899,6 million HUF.
The 90% /809million HUF/ will be ensured through a Credit program for the supporting of activity R&D of the related GINOP Companies. The own contribution of the Research and Development Company TÜKI Inc. is 10% /89,9 million HUF/.

The working out of the R&D tasks will take place in close -co-operation through TÜKI Inc. and DUNAFERR Inc.

In the framework of the project we are intending to realise the manufacturing of basic materials too primarily for the vehicle industry in using upgraded type of steel quality applying new milling process conception.
In the range of heavy duty fine grade /HSLA/ steel type new products will be manufactured, where the production is featured by well approachable basic and auxiliary materials, providing in this way easy design possibilities, allowing improved product quality, making possible to reach enhanced competition conditions for the company. The highly influencing factor by the micro alloyed steel from the point of view of mechanical and microstructure is the niobium. From the point of view of acquisition of this alloying element is of crucial importance. Taking into account these mentioned tendencies, we are targeting in this scheduled research program, that by the four microalloyed steel quality the amount of niobium should be decreased in accordance with the prescribed mechanical properties specified by the related standards.
As a second target of this scheduled research program wide malleable steel strips will be developed enabling us to apply it for complex cold working activities. In order to increase the workability conditions titan and boron microalloys are generally used, but all the phases of the metallographical processes, their working mechanism resp. the conditions of the optimal applicability of this technology by the ISD DUNAFERR production lines are not yet known. During the research trials metal workability boundary diagrams have been made. With help of these diagrams the range of workability without breaking and brittle danger possibility can be safely determined. Possessing these data new qualities meeting the demands of customers resp. new manufacturing technologies will be realised.
The R&D&I task line extends to the modernisation of process technologies of new steel types. This contributes not only enhanced product quality conditions but also improved power engineering efficiency and decreased harmful emissions.
In the phase of steelmaking phase depending on the metallurgical treatment, production organisation conditions, state of ladle, the melt will be cooled after charging from the converter. The rate of this process is varying, at the same time there is no possibility for temperature correction and heat supply toward the melt. The steel charge manufactured in converter takes place with too much overheating technology. As a result of the higher tapping temperature lower productivity and higher energy utilisation will be achieved.
The different ladle heat-state uncertainity can be handled by the help of mathematical model. In order to accomplishe this the wall temperature field should be measured continuously, in this way the accumulated heat quantity can be calculated on the basis of the heat transfer model will be reduced the uncertainty due to the changing heat-state, which made the necessary the rate of overheating of the charge. As a result of the application of the model the temperature of the model can be reduced, achieving better purity of steel providing in this way more appropriate mechanical properties.

The cast ingots are heated in pusher type furnaces of continuous service resp. in using walking beam furnaces to reach the required temperature for the hot milling processes.
The operational parameters of the furnaces are determined by the temperature of the firing chamber and steel stock. In the framework of the project a new combustion technology model will be launched which is based on the algorithm of per zone calculation versus the presently applied process based on the heat balance of each zone.
The local temperature and components of the flue gas will be measured by a laser type device measuring and analysing so ensuring in this way the more accuracy of ingot temperature monitoring. The new fuel engineering technology significantly improves the mechanical quality of the ready made products, the uniformity of quality and decreases the development of scale.
The realisation of this R&D&I program ensures better final product quality and production technology efficiency as well as improved specific energy consumption and lower harmful emissivity can be predicted.