ENGINEERING SOLUTION
Waste Gas to Power & Process Energy
Turning Pyrolysis, Flare and Process Gases into Electricity, Steam & Cooling
The Opportunity
Pyrolysis plants, sinter plants and several industrial processes generate waste gases, off-gases and flare gases that are often burned, flared or otherwise rejected due to limited utilisation options.
These gases can contain significant chemical energy.
DK Engineers can develop waste-gas-to-power solutions that utilise suitable waste or flare gases as fuel for a Gas Turbine (GT), converting otherwise wasted energy into useful electricity.
Our Engineering Concept
- Waste / Flare Gas
- Gas Cleaning & Conditioning
- Gas Turbine + Generator
- Electrical Power
At the same time, the high-temperature GT exhaust is recovered through a Heat Recovery Steam Generator (HRSG) or suitable heat-recovery system.
The recovered heat can be utilised to produce:
This creates an integrated Waste Gas → Power → Heat/Cooling energy-recovery system.
Maximising Energy from Waste Gas
The concept can be particularly attractive where the waste gas is:
- Continuously available
- Available at sufficient pressure
- Having adequate calorific value
- Currently being flared or combusted without energy recovery
- Produced as a by-product of an industrial process
Potential applications include:
- Pyrolysis plants
- Sinter and metallurgical processes
- Steel plants
- Chemical and process industries
- Refineries and oil & gas facilities
- Biomass and waste-processing plants
- Other industrial processes generating combustible off-gases
Combined Heat & Power from Waste Gas
The key advantage is that the system can utilise both the chemical energy in the waste gas and the thermal energy in the GT exhaust.
- Waste Gas
- Gas Turbine
- Electricity
- High-Temperature Exhaust
- HRSG / Heat Recovery System
- Steam or Chilled Water
- Industrial Utility
This can significantly improve the overall energy utilisation of the available waste gas compared with simply flaring or combusting it without energy recovery.
DK Engineers' Role
DK Engineers can support the project from waste-gas assessment through power and utility-system integration, including:
- Waste-gas composition and calorific-value assessment
- Gas flow and pressure evaluation
- Gas cleaning and conditioning requirements
- Gas turbine selection
- Fuel-gas system engineering
- GT-generator integration
- HRSG / heat-recovery system engineering
- Steam-generation system
- Chilled-water generation concept
- Electrical integration
- Piping and utility integration
- Instrumentation and control
- Safety and operating philosophy
- Techno-economic feasibility
- Vendor coordination and project engineering support
From Waste Gas to Useful Energy
What is currently treated as a waste stream or flare gas can potentially become a valuable source of:
The optimum configuration depends on the gas composition, flow, pressure, temperature, operating profile and the site's electrical and thermal/cooling requirements.
Recover the Gas. Generate the Power. Utilise the Heat.