Energies, Vol. 14, Pages 8099: Modeling of Energy Consumption and Reduction of Pollutant Emissions in a Walking Beam Furnace Using the Expert Method—Case Study (Energies)

This paper presents an algorithm for modeling electricity and natural gas consumption in a walking furnace with the use of artificial intelligence and simulation methods, depending on the length of the rolling campaign and the established rolling program. This algorithm is the basis for the development of a proposal for a set of minimum requirements characterizing the Best Available Techniques (BAT) for beam furnaces intended for hot rolling, taking into account the requirements set out in national regulations and the recommendations described in the BREF reference documents. This information should be taken into account when drawing up an application for an integrated permit, as well as when setting emission limit values. Based on the constructed algorithm, it was shown that depending on their type and technical specification, the analyzed projects will offer measurable economic benefits in the form of reducing the amount of energy consumed by 1,076,400 kWh during the implementation of 50 rolling campaigns to reduce gas by 14,625 GJ and environmental benefits in the form of reduction of pollutant emissions into the atmosphere 80–360 g/Mg. The constructed algorithm was validated in the Dosimis-3 program, based on a discrete event-driven simulation. Thanks to this representation of the model, its user can interactively participate in changes that take place in the model and thus evaluate its behavior. The model, verified in real conditions, can be the basic source of information for making effective operational technological decisions related to the preparation of production at the rolling mill as part of planning and long-term activities.