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STATEMENT OF WORK

Project Title:

Development and Field Trial of an Advanced Indirect Heating System for Metal Heat Treating Applications

Contractor:

Ohio Department of Development
77 South High Street, 26th Floor
Columbus, OH 43215
(614) 466-7429

Program Area:

Industrial Technologies

Partners:

Ohio Department of Development, Office of Energy Efficiency

University of Texas at Austin

Gas Technology Institute (GTI) Sustaining Membership Program

Akron Steel Treating Company

North American Manufacturing Company

Energy Solutions Center

Project Description:

The project will optimize the design of an advanced indirect heating system for the steel industry with respect to efficiency improvement, lower emissions, radiant tube temperature uniformity and lower internal tube temperatures. The work will progress through concept evaluations, modeling and engineering of the selected concept, fabrication of a prototype unit and laboratory test of that unit, and finally fabrication and field-testing of an alpha prototype unit in an Ohio heat treating facility.

Management Plan (Approach):

The unique nature of STAC requires that projects be supported by multiple State entities, and to the extent necessary any other entity. As indicated in the STAC Agreement, it is the Contractor’s responsibility to coordinate the execution of work under the Contract, incorporated by reference hereto. Contractor, in conjunction with the other State entities, and to the extent necessary any other entity, shall conduct the project in accordance with the Management Plan (approach) described below.

Task 1: Optimization and Finalization of the AIHS (NAMCO, GTI and UTX-Austin)

On the basis of previous development work at GTI and numerical modeling by UTX-Austin, engineer and fabricate a pre-prototype AIHS; install in GTI's full-scale heat treat furnace; and test and evaluate for radiant tube temperature uniformity, burner efficiency, NO_x, and CO emissions, and longevity potential (lower internal tube temperature).  Based on test results, make further modifications and retest as necessary until design is optimized and finalized.

North American Manufacturing Co. will fabricate the prototype AIHS (RASERT and recuperator), and consult with GTI during this phase and collaborate on evaluating the internal design of the elements.  Akron Steel Treating Company will periodically consult with GTI based on testing results.

GTI will be responsible for preparing and submitting periodic project status reports that include Work Planned, Work Completed, and Spending versus Actual Budget reconciliations.

A Go/No Go meeting will be held with the project team at the completion of this work phase.

Task 2: Field Trial (NAMCO, GTI, and Akron Steel Treating Company)

Thoroughly evaluate host site to determine field trial specifications.  Conduct a baseline test, i.e., install on-site instrumentation package to record pertinent technical data.  Fabricate appropriate amount of alpha prototype AIH Systems (estimated as four to six).  Remove existing radiant tubes and retrofit with AIH Systems.  Monitor heat treating operation and accumulate necessary data.  Evaluate results and prepare a final draft technical report.

NAMCO will fabricate the AIH Systems.  GTI will be responsible for evaluating the field trial specifications with support from NAMCO and guidance from Akron Steel Treating Company.  GTI will accumulate base line information on the heat treat furnace that will include the air emissions (NO_x, CO and CO₂) and will include fuel usage information.

Akron Steel Treating will remove existing SERTs and will retrofit the furnace with the AIH Systems.  NAMCO and GTI will assist in shaking down the AIH Systems and the start up of the furnace.  Once the furnace is on line, GTI will utilize the field instrumentation package that was used in the baseline test to monitor performance, emissions and other pertinent information as was done during the baseline test period.

GTI will be responsible for preparing and submitting periodic project status reports that include Work Planned, Work Completed, and Spending versus Actual Budget reconciliations.  GTI, with Akron Steel Treating Company's review and assistance, will reduce and analyze all data and prepare a Final Technical Report with conclusions and recommendations.

Project Tasks, Status, and Deliverables

The Project Lead, NYSERDA, shall be responsible for compiling all deliverables and submitting them to NASEO with a description of how the various deliverables for that task relate to the work performed on that task.

Last Updated: 10/31/06