THE VALUE OF ENERGY & RESOURCE - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session6B...

Restricted © Primetals Technologies 2017 All rights reserved. primetals.com

THE VALUE OF ENERGY

& RESOURCETOWARDS AN EFFICIENT FUTURE STEELMAKING

Dr. Alexander Fleischanderl

Restricted © Primetals Technologies 2017 All rights reserved.

The Value of Energy and Resource

Content

1. Introduction

a. Economy Facts & Figures

b. Scrap market situation

2. Raw Material Flexibility

3. Resource EfficiencyEffective By-Product Management

4. Energy Efficiency Waste Heat Recovery Potential

5. Emission ControlContribution to low Capex and Opex


Economic Figures for the Steel Industry

Population, GDP, Material Extraction, Society’s Well Being

Source: Angus Maddison

https://wachstumimwandel.at/wp-content/uploads/Schandl_Vienna-Lecture-1.pdf

https://wachstumimwandel.at/wp-content/uploads/Schandl_Vienna-Lecture-1.pdf


Cost Structure Steelmaking

Comparison of Regions

Alan Grimmond, McLellan and Partners Ltd,

OECD STEEL COMMITTEE – 13 May 2011


Scrap Market

Impact on World Scrap Prices

Scrap availability expected to grow

Scrap price expected to decrease in Asia/China

• 2017 about 180mio to of scrap processed in Chinese steel plants –

expected to increase!

• Lifecycle of infrastructure 20-30 years

• Cars and consumer goods 10-15 years

• Regulations that force smaller EAF and IF to close down will increase scrap

availability further

Small IF and EAF with total capacity 120mt

per year closed 2016/2017!

Scrap in China act. ~ 80 US$/t cheaper

compared to Hot Metal• Average scrap ratio in China 2016: 10.8%

• Target 2017 according 13rd planning: >11%

• Target scrap ratio for 2020: >20%

• Pressure on integrated steel producers to

increase scrap rate further

• Scrap recycling system needs to be improved

to assure quality


Raw Material Flexibility - Jet Technology

Introduction - Motivation

• Available energy in LD converter limits maximum possible scrap / HBI rate

• Typical values ~ 20%, depending on hot metal composition and temperature

• For higher rates of solid charges additional energy source required

• Carbon injection => Jet Process

• Electric energy => EAF

• Jet process directly uses chemical energy to melt scrap / HBI

=> thus no conversion losses resulting in highest efficiency

• Coal is injected via converter bottom and post combusted with hot

blast from top, easy adaption to changing scrap or HBI rates

• Hot Blast blown from top ensures excellent mixing and therefore,

high post combustion and heat transfer to the bath

• Normal operation mode allows up to 50% scrap or HBI, with hot

heel operation even up 100%

(1) Benefit from low scrap and/or HBI price

(2) Benefit from low up-grade capital

expenditure

(3) Benefit from substantial yield

improvement of 2%

(4) Benefit from reduced CO2 emissions


Raw Material Flexibility - Jet Process

Bottom blowing converter with hot blast from top

Hot blast generation with pebble heater

• Energy storage and heat exchange with efficiency η > 90%

• Gas fired during tapping and charging time

Additional energy input

• Chemical heat through carbon injection

• Latent heat of hot blast

Higher efficiency

• High post combustion rate up to 60% (vs.11-12% LD/BOF)

• Heat transfer from off gas to bath up to 90%

• Efficient usage of chemical energy of coal injected

Flexible scrap and HBI rates

• Rates from 0% up to 100% of scrap or HBI possible

• For 100% hot heel operation required


Raw Material Flexibility - Jet Technology / POSCO

Flexibility in Operation

Source: Increased Scrap Rate at the BOF

Process by the Application of Hot Air Post

Combustion – PS-BOP Project

The 6 th China-Korea Joint Symposium on

Advanced Steel Technology, Nanjing, China,

October 9-10, 2014


By-Product Management

Slag Valorization – DSG Granulation & Waste Heat Recovery

voestalpine BF#AStart-Up May 2017

Dry Slag granulation a

development that has been in the

pipeline for many years

Current initiative is backed by the

drive to recover energy

Prototype plant built at voestalpine

Linz BF#A

Potential to recover ~20 MWth or

~6 MWel from a BF slag flow of 1

to/min

Production of a dry valuable slag

product is key (>98% glass)

No water consumption for the

granulation process obviously

No odor problems with sulphur

Dry product handling – no drying

required


Major Results from Pilot Trials:

Cement grade slag granulate

o > 98% glass content

o Evenly sized granulate (1–3 mm)

o Dry slag product properties

High off-gas temperature

(~ 600 ºC)

CFD Model validated up-scale

Absolutely no sticking


Slag Valorization – DSG Granulation & Waste Heat Recovery


Fines Recycling Plant

Feed material pellet fines, sludge, HBI chips and fines, misc.

dust

Annual

Capacity

approx. 160.000 t/a

Design

Capacity

24.6 t/h (briquettes)

Binder system inorganic binder

Briquette size approx. 5 ccm

Start-Up of

Plant

01.2017

Acceptance 10.02.2017


Ferrous Oxides Recycling for DR Plants / US Texas

http://www.google.ae/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiO5Y35-4HQAhXJCBoKHV7pCxIQjRwIBw&url=http://www.voestalpine.com/texas/en/&psig=AFQjCNFVM69f0o4NuNN89R9rbnFNy3qkQw&ust=1477897646776042

http://www.google.ae/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiO5Y35-4HQAhXJCBoKHV7pCxIQjRwIBw&url=http://www.voestalpine.com/texas/en/&psig=AFQjCNFVM69f0o4NuNN89R9rbnFNy3qkQw&ust=1477897646776042


Modular Waste Heat

Recovery System

Tailor-made Solutions

About 30% of the Energy

Input leaves with the Off-

Gas

Energy Efficiency

Waste Heat Recovery for EAF Waste Gas – Arvedi Italy


Energy Efficiency

Waste Heat Recovery from EAF Waste Gas – Arvedi Italy

EAF WHR – Arvedi / Italy

Key Performance Indicators Arvedi:

Steam production ≥ 17 t/h

Annual steam production ≥ 122.000 to

Savings in natural gas (CH4) ≥ 8.200.000 Nm³

CO2 savings per year ≥ 20.500 to


Energy Efficiency

Waste Heat Recovery from Sinter Cooler Waste Gas


Actual status: Circular Coolers Innovation: Shaft Cooler

Energy Efficiency

Waste Heat Recovery from Sinter Cooler Waste Gas


Emission Control

Energy Saving Assistant/ eService

Potential to reduce power consumption by more than 20%

Increased reliability

Just in Time Warehousing


Emission Control

PRIMZERON Fabric Filter

Standard Bag-filter Design PRIMZERON Filter Design


Austria / Foundry: 260.000 Am³/h

Germany / EAF: 1.300.000 Am³/h

Emission Control

PRIMZERON Fabric Filter

Absolute Emission Tight: < 2mg/Nm³

Lowest Sound Emissions: Reduction level of 57dB

Minimum Pressure Loss: Lowest ever achieved levels

Maximum Flexibility: Modular Construction

Robust and Weather Resistant: Massive, no corrosion, explosion proof

Shortest fabrication and Erection: Premanufactured concrete panels


Conclusion

The Value of Energy – Towards an Efficient Steelmaking

1. Modern steelmaking production processes are close to theoretical minimum for energy and carbon intensity

2. 60% reduction in energy consumption sine 1960. Less than 20 GJ/mt for average world crude steel production

3. Main challenge remains the immense cost pressure on production cost dominated by raw material and energy cost

4. Raw material flexibility, yield improvement, energy efficiency and carbon footprint are the key levers to stay/become competitive

a. Increased and flexible Scrap / HBI rates for BOF steelmaking (modular system)

b. Waste heat recovery from steel production & slag processing, waste gases still not fully tapped

c. Valorization of by-products (maximize market price, replacement of primary raw materials

5. Mid-term transformations expected to happen

a. Scrap Pre-heating for EAFs (i.e Quantum) – 30% less energy intensive

b. Direct rolling (i.e. Winlink and ESP) – 40% less energy intensive

c. I4.0 – Fully automated plants (i.e robotic systems)

d. TPOpt – rule based guidance for steel grade quality control

e. Carbon-2-Fuel and chemicals

f. Hydrogen Metallurgy

6. Intelligent Gas Cleaning

a. New low cost approach for high performance bag filters

b. Energy Saving Assistant for de-dusting systems (I4.0)

c. eSevice, eDocumentation, etc

THE VALUE OF ENERGY & RESOURCE - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session6B...

Documents

Transcript of THE VALUE OF ENERGY & RESOURCE - Home - SEAISIseaisi.org/seaisi2017/file/file/full-paper/Session6B...