An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system

Baji Katta; Manjini Sambandam; M. Premlatha; Saravanan Chandrasekaran

doi:10.14744/thermal.0000894

An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system

Abstract

Steel-making industries use preheated ladles to transfer molten steel from primary to secondary facilities. The preheating process removes moisture, reduces thermal shock, protects the refractory lining, and minimizes temperature drop, but it emits substantial heat through the flue gas. This study introduces a novel, low-cost heat exchanger designed specifically for waste heat recovery in ladle preheating systems, contributing to a circular economy and substantial carbon dioxide reduction. We designed and analyzed a shell-tube heat exchanger using the Kern method and performed experiments and numerical analyses for thermal behavior with commercial ANSYS 19.0. We assessed waste heat utilization through an experimental setup, leveraging insights from computational fluid dynamics modeling and mathematical modeling. We reduced liquefied natural gas consumption from 224 kg/hr to 197 kg/hr. This method saved energy, cutting consumption from 5855 Gcal/yr to 5149 Gcal/yr and lowering carbon dioxide emissions from 1372 TCO2/yr to 1207 TCO2/yr. Our findings suggest that a waste heat recovery system effectively reduces greenhouse gas emissions and offers a practical, cost-effective way to recover energy from the ladle preheating system.

Keywords

References

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Details

Primary Language

English

Subjects

Fluid Mechanics and Thermal Engineering (Other)

Journal Section

Research Article

Authors

Baji Katta ^* This is me
0009-0009-0734-5929
India

Manjini Sambandam This is me
0000-0002-7659-2327
India

M. Premlatha This is me
0000-0003-2445-3269
India

Saravanan Chandrasekaran This is me
0009-0000-2953-3597
India

Publication Date

March 24, 2025

Submission Date

May 14, 2024

Acceptance Date

September 11, 2024

Published in Issue

Year 2025 Volume: 11 Number: 2

DOI

https://doi.org/10.14744/thermal.0000894

IZ

https://izlik.org/JA45UD28CE

Cite

RIS / Bibtex

APA

Katta, B., Sambandam, M., Premlatha, M., & Chandrasekaran, S. (2025). An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering, 11(2), 291-300. https://doi.org/10.14744/thermal.0000894

AMA

1.Katta B, Sambandam M, Premlatha M, Chandrasekaran S. An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering. 2025;11(2):291-300. doi:10.14744/thermal.0000894

Chicago

Katta, Baji, Manjini Sambandam, M. Premlatha, and Saravanan Chandrasekaran. 2025. “An Experimental and Numerical Analysis on the Effective Utilization of Waste Heat from a Ladle Preheating System through a Heat Exchanger System”. Journal of Thermal Engineering 11 (2): 291-300. https://doi.org/10.14744/thermal.0000894.

EndNote

Katta B, Sambandam M, Premlatha M, Chandrasekaran S (March 1, 2025) An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering 11 2 291–300.

IEEE

[1]B. Katta, M. Sambandam, M. Premlatha, and S. Chandrasekaran, “An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system”, Journal of Thermal Engineering, vol. 11, no. 2, pp. 291–300, Mar. 2025, doi: 10.14744/thermal.0000894.

ISNAD

Katta, Baji - Sambandam, Manjini - Premlatha, M. - Chandrasekaran, Saravanan. “An Experimental and Numerical Analysis on the Effective Utilization of Waste Heat from a Ladle Preheating System through a Heat Exchanger System”. Journal of Thermal Engineering 11/2 (March 1, 2025): 291-300. https://doi.org/10.14744/thermal.0000894.

JAMA

1.Katta B, Sambandam M, Premlatha M, Chandrasekaran S. An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering. 2025;11:291–300.

MLA

Katta, Baji, et al. “An Experimental and Numerical Analysis on the Effective Utilization of Waste Heat from a Ladle Preheating System through a Heat Exchanger System”. Journal of Thermal Engineering, vol. 11, no. 2, Mar. 2025, pp. 291-00, doi:10.14744/thermal.0000894.

Vancouver

1.Baji Katta, Manjini Sambandam, M. Premlatha, Saravanan Chandrasekaran. An experimental and numerical analysis on the effective utilization of waste heat from a ladle preheating system through a heat exchanger system. Journal of Thermal Engineering. 2025 Mar. 1;11(2):291-300. doi:10.14744/thermal.0000894