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Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 1 European IPPC Bureau Review process for the Iron and Steel Industry BREF Rainer Remus European IPPC Bureau Sustainable Production and Consumption Unit Joint Research Centre – Institute for Prospective Technological Studies 20 July 2011

Transcript of jrc_sunum_5_

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Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 1

European IPPC Bureau

Review process

for the Iron and Steel Industry BREF

Rainer Remus

European IPPC Bureau

Sustainable Production and Consumption Unit

Joint Research Centre – Institute for Prospective Technological Studies

20 July 2011

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European IPPC Bureau

Review process for the IS BREF

The original Iron and Steel BREF was adopted in

December 2001 and was one of the first BREFs in a

series of 33 documents. Consequently it was

foreseen as one of the first BREFs to be reviewed.

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European IPPC Bureau

Milestones in the review process for the IS BREF

October 2005 Activation of the TWG for the review of the Iron and Steel

BREF and submission of TWG wishes

September 2006 TWG kick off meeting

February 2008 First draft of the review of the Iron and Steel BREF (1250

comments received)

July 2009 Second draft of the review of the Iron and Steel BREF (1385

comments received)

January 2010 Third draft of the review of the Iron and Steel BREF

February 2010 Final TWG meeting

April 2010 Fourth draft of the review of the Iron and Steel BREF

October 2010 Fifth draft of the review of the Iron and Steel BREF

June 2011 Final draft of the review of the Iron and Steel BREF

September 2011 Forum opinion on the full BREF including BAT conclusions

November 2011 Adoption of the BAT conclusions by the Committee

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European IPPC Bureau

Scope of the IS BREF

This document addresses the industrial activities specified

in Annex I to the IED, namely:

• Activity 1.3: coke production

• Activity 2.1: metal ore (including sulphide ore) roasting and

sintering

• Activity 2.2: production of pig iron or steel including

continuous casting, with a capacity exceeding 2.5 tonnes

per hour

• The document also covers some activities that may be

directly associated to these activities on the same site, i.e.

pelletisation plants.

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European IPPC Bureau

The two main IS production routes

Electric Arc Furnace scrap Casting/

Rolling/

Finishing

1

2

ores

fluxes

coal

Sinter Plant

Pelletis.

Plant

Coking Plant

Blast Furnace

hot blast

reductant injection

Basic Ox. Steelmak.

pig iron

Slag Processing

Casting/ Rolling/ Finishing

oxygen

Steel products

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European IPPC Bureau

The share of the two main IS production routes

In 2006 in the EU-27:

• 60 % of the steel production was based on the blast furnace/basic oxygen

furnace route (123 Mio. tonnes)

• 40 % was based on the EAF route (83 Mio. tonnes)

Turkish steel industry:

• 2nd largest producer of steel in Europe (approx. 26 Mio. tonnes)

• 10th most important steel-producing country globally

• 28 % blast furnace/basic oxygen furnace route

• 72 % EAF route (EAF mills)

• Largest scrap consumer in Europe (25.3 million tonnes) in 2010

• World’s largest importer of scrap metal

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European IPPC Bureau

The structure of the IS BREF

• Preface

• Scope

• Chapter 1: General information (Production, economics and key

environmental issues)

• Chapter 2: horizontal issues (horizontal matters which do not relate to one

steel process only)

• Chapter 3 to 8 provide information on particular iron and steel processes

(sinter plants, pelletisation, coke ovens, blast furnaces, basic oxygen

steelmaking and casting, electric arc steelmaking and casting), including

information on applied processes and techniques, current emission and

consumption levels and techniques to consider in the determination of

BAT. The latter consists of a catalogue of environmental techniques and

forms the heart of the BREF.

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European IPPC Bureau

The structure of the IS BREF

• In Chapter 9 are the BAT conclusions as defined in Article 3(12) of the

Directive for Chapter 2 to 8.

• Chapter 10 provides information on alternative iron making techniques that

are already being applied.

• Chapter 11 presents information on 'emerging techniques'

• Chapter 12 provides the concluding remarks and recommendations for

future work

• Chapter 13 are the annexes.

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European IPPC Bureau

The key environmental issues in IS Production

The key environmental issues are:

• the reduction of emissions to air and water

• efficient energy and raw material usage

• minimisation, recovery and the recycling of process residues

• effective environmental and energy management systems.

• nuisance by noise emissions.

The key polluting substances emitted to air are dust, nitrogen oxides

and sulphur dioxide. Carbon oxides, polyaromatic hydrocarbons,

polychlorinated dibenzo-p-dioxins and dibenzofurans, total organic

carbon, metals, hydrogen chloride and hydrogen fluoride are

emitted as well.

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European IPPC Bureau

IS production from ores: Sinter plants

1

ores

fluxes

coal

Sinter Plant

Pelletis. Plant

Coking Plant

Blast Furnace

hot blast

reductant injection

Basic Ox. Steelmak.

pig iron

Slag

Processing

Casting/ Rolling/

Finishing

oxygen

Steel products

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European IPPC Bureau

Sinter strand

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European IPPC Bureau

Reduction of particulates in sinter plants • Sinter plants are the major source for dust, heavy metal and dioxin

emissions in IS production from ores

• Waste gases from sinter plants are characterized by:

• high fine particles

• high specific dust resistivity due to high alkaline content

• high concentrations of dioxins, mercury, SO2, HF and HCl

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European IPPC Bureau

Technique Type Achieved emission levels [mg/Nm3]

Averaging period

Fabric Filter

Fabric Filter 1 – 15 DAV

<3 DAV

<2 DAV

<0.5 AAV

<10 n/a

Eletrostatic precipitator (ESP)

ESP 36 AAV

ESP 25 - 65 AAV

MEEP1) – ESP 25 – 56 DAV

ESCS2) – ESP 20 -37 n/a

Energy pulse superimposition3) – ESP 43 – 77 AV

ESCS2) – ESP 40 n/a

Most ESP 50 - 140 n/a

1) Moving electrodes electrostatic precipitator 2) Electrostatic space cleaner super 3) Energy puls superimposing

DAV = Daily average

AAV = Annual average

n/a = not reported

Dust abatement in sinter plants by advanced ESP and fabric filter

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European IPPC Bureau

Control of dust, PDCC/F, HCl, HF and SOx emissions by

prededusting-additive injection-final dedusting

Additives

required:

pre - dedusting

Option:

• return to

sinter strand

• treatment

• disposal

sinter strand

waste gas suction

mixing drum

• Disposal

• treatment

• return to

sinter strand

Cyclone

ESP

Bag filter

required:

filter internal

dust return

optional: pre - dedusting

Option:

• return to sinter strand

• treatment • disposal

sinter strand

waste gas suction

mixing drum

• Disposal • Return to sinter strand

Cyclone

ESP

Cyclone

ESP Bag filter

required:

filter internal dust return

Additive

injection Stack

Lim

e

(HC

l, HF, p

reco

atin

g)

Ca

rbo

n a

dd

itive

(PC

DD

/F)

Wate

r, lime

(SO

2 )

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European IPPC Bureau

Performance for dust from Jan – Oct 2008

(daily mean values)

0

1

2

3

4

5

6

01/0

1/20

08

15/0

1/20

08

29/0

1/20

08

12/0

2/20

08

26/0

2/20

08

11/0

3/20

08

25/0

3/20

08

08/0

4/20

08

22/0

4/20

08

06/0

5/20

08

20/0

5/20

08

03/0

6/20

08

17/0

6/20

08

01/0

7/20

08

15/0

7/20

08

29/0

7/20

08

12/0

8/20

08

26/0

8/20

08

09/0

9/20

08

23/0

9/20

08

07/1

0/20

08

21/1

0/20

08

du

st

co

nc. in

th

e t

reate

d w

aste

gas i

n [

mg

/m3]

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European IPPC Bureau

Sinter strand primary dust emissions with ESP

Dust emissions from sinter strands

0

10

20

30

40

50

60

70

80

90

0 2 4 6 8 10

Installations

Diu

st [

mg

/Nm

3]

AAV

5th percentile

DAV

95th percentile

BAT-AEL

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European IPPC Bureau

PCDD/F emissions with ESP and additive injection from sinter

strand

Dioxin emissions from sinter strand

0

0,1

0,2

0,3

0,4

0,5

0,6

0 1 2 3 4 5 6

Installations

PC

DD

/F [

ng

I-T

EQ

/Nm

3]

BAT-AEL

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European IPPC Bureau

Upper

BAT-AEL

Sinter strand primary dust emissions with fabric filter

Lower

BAT-AEL

Dust emissions from 5 sinter strands with fabric filter

0

2

4

6

8

10

12

14

16

0 1 2 3 4 5 6

Installations

Du

st

[mg

/Nm

3]

DAV

95th percentile

Upper

BAT-

AEL

Lower

BAT-

AEL

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European IPPC Bureau

Dioxin emissions from sinter strand

0

0,05

0,1

0,15

0,2

0,25

0 1 2 3 4 5 6

Installations

PC

DD

/F [

ng

I-T

EQ

/Nm

3]

PCDD/F emissions with fabric filter and additive injection from Sinter strand

BAT-AEL

Dioxin emissions with fabric filter and additive injection from 5 sinter

strands

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European IPPC Bureau

BAT conclusion for dust emissions from the sinter plant

20. BAT for primary emissions from sinter plants is to reduce dust emissions from the

sinter strand waste gas by means of a bag filter.

BAT for primary emissions for existing plants is to reduce dust emissions from the

sinter strand waste gas by using advanced electrostatic precipitators when bag filters

are not applicable.

The BAT-associated emission level for dust is <1 – 15 mg/Nm3 for the bag filter and <20

– 40 mg/Nm3 for the advanced electrostatic precipitator (which should be designed and

operated to achieve these values), both determined as a daily mean value.

Bag Filter

Description: Bag filters used in sinter plants are usually applied downstream of an

existing electrostatic precipitator or cyclone but can also be operated as a standalone

device.

Applicability: For existing plants requirements such as space for a downstream

installation to the electrostatic precipitator can be relevant. Special regard should be

given to the age and the performance of the existing electrostatic precipitator.

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European IPPC Bureau

BAT conclusion for dioxin prevention and reduction in sinter plant off-gas

25. BAT for primary emissions from sinter strands is to reduce emissions of

polychlorinated dibenzodioxins/furans (PCDD/F) and polychlorinated biphenyls (PCB)

by using injection of adequate adsorption agents into the waste gas duct of the sinter

strand before dedusting with a bag filter or advanced electrostatic precipitators when

bag filters are not applicable.

The BAT- associated emissions level for polychlorinated dibenzodioxins/furans

(PCDD/F) is <0.05 – 0.2 ng I-TEQ/Nm3 for the bag filter and <0.2 – 0.4 ng-I-TEQ/Nm3

for the advanced electrostatic precipitator, both determined for a 6 – 8 hour random

sample under steady-state conditions.

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European IPPC Bureau

IS production from scrap: Electric Arc Furnace

Electric Arc Furnace scrap

Casting/

Rolling/

Finishing

2

Steel products

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European IPPC Bureau

Electric Arc Furnace

Charging the furnace

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European IPPC Bureau

Typical off-gas collection and treatment system in an EAF

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European IPPC Bureau

Overall view of the

activated lignite dosing

system

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European IPPC Bureau

Daily averages for dust from an EAF over three years

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European IPPC Bureau

Dust emissions from various EAF plants

Dust emissions from EAF

0

2

4

6

8

10

12

14

16

0 2 4 6 8 10 12 14 16 18

Installations

Diu

st

[mg

/Nm

3]

DAV

Min

Max

AAV

AAV 2004

AAV 2008

AAV 2003

BAT-AEL

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European IPPC Bureau

Dioxin emissions from various EAF plants

BAT-AEL

0

0,05

0,1

0,15

0,2

0,25

0 5 10 15 20 25

Installations

PC

DD

/F I

-TE

Q n

g/N

m3

lower range

upper range

DAV

BAT-AEL

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European IPPC Bureau

BAT conclusion for dust emissions from the electric arc furnace

89. BAT for the electric arc furnace (EAF) primary and secondary dedusting (including

scrap preheating, charging, melting, tapping, ladle furnace and secondary metallurgy)

is to achieve an efficient extraction of dust emissions from all emission sources by using

one of the techniques listed below and to use subsequent dedusting by means of a bag

filter:

I. a combination of direct off-gas extraction (4th or 2nd hole) and hood systems

II. direct gas extraction and doghouse systems

III. direct gas extraction and total building evacuation (low-capacity electric arc

furnaces (EAF) may not require direct gas extraction to achieve the same

extraction efficiency).

The overall average collection efficiency associated with BAT is >98 %.

The BAT-associated emission level for dust is <5 mg/Nm3, determined as a daily mean

value.

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European IPPC Bureau

BAT conclusion for dioxin emissions from the electric arc furnace

90. BAT for the electric arc furnace (EAF) primary and secondary dedusting (including

scrap preheating, charging, melting, tapping, ladle furnace and secondary metallurgy) is

to prevent and reduce polychlorinated dibenzodioxins/furans (PCDD/F) and

polychlorinated biphenyls (PCB) emissions by avoiding, as much as possible, raw

materials which contain PCDD/F and PCB or their precursors (see BAT 6 and 7) and

using one or a combination of the following techniques in conjunction with an

appropriate dust removal system:

I. appropriate post-combustion

Applicability of BAT I: In existing plants, circumstances like available space, given off-

gas duct system, etc. need to be taken into consideration for assessing the applicability.

II. appropriate rapid quenching

III. injection of adequate adsorption agents into the duct before dedusting.

The BAT-associated emission level for polychlorinated dibenzodioxins/furans (PCDD/F)

is <0.1 ng I-TEQ/Nm3, based on a 6 – 8 hour random sample during steady-state

conditions. In some cases, the BAT-associated emission level can be achieved with

primary measures only.

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European IPPC Bureau

Concluding remarks

• The BREF process followed a defined and demanding exchange information process.

• Lot of information and expertise of many stakeholders from industry, Member States and NGOs were included.

• This BREF can be considered as a good description of the current best available techniques and their associated emission levels in the iron and steel production.

• It will be used as the reference for setting permit conditions where the BAT-AELs should not be exceeded.

• The revised BAT Reference Document for Iron and Steel Production can be considered a driver towards improved environmental performance.

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European IPPC Bureau

All BREFs can be downloaded free of charge

from the EIPPCB website

http://eippcb.jrc.es/reference/

Thank you for your attention Rainer Remus

European IPPC Bureau

[email protected]

Tel.: +34 954 488 290

http://eippcb.jrc.es