The testing and data collection at the demonstration site was delayed due to COVID-19. The Thermjet burners were installed August 2021. Immediately after installation and refractory curing, the project team started collecting data in different furnace operating regimes. Data collection is expected to take 6 to 8 weeks and be completed in October. After data is collected, the Technical Readiness Transfer Plan and the Commercialization Plan will be prepared and included in the Final Report. The draft final report is expected in early November 2021.
This project demonstrates a Radiative Recuperator with Secondary Emitters (RRSE) technology on an aluminum melter to reduce natural gas use. This advanced technology will preheat the combustion air with heat from the exhaust gas. Ultra-low NOx burners will be installed and operated with air preheated to as high as 1200 degrees Fahrenheit in the RRSE. Further natural gas savings are anticipated by using the exhaust gas leaving the RRSE to preheat scrap on its way to the furnace.
This technology could reduce natural gas use and costs. Up to 10% of industrial natural gas furnaces can benefit from this technology. For these furnaces, average gas savings are estimated at 25%. Assuming 10% market penetration, each year there is potential to annually save 2 billion cubic feet (2 trillion Btu) of gas, or about $10 million (based on $5 per million Btu for gas).
Key Project Members
Bedrosian & Associates
California Die Casting, Inc.
Southern California Gas Company (SoCalGas)