Energy Efficiency in the Steel Industry

Transcription

1 Energy Lunch OV Efficiency IJmond in the Steel industry Tata Steel Slide 1 Energy Efficiency in the Steel Industry Thursday June 18, 2015 Gerard Jägers Programme Manager Energy Efficiency Tata Steel Together we make the difference Together we make the difference

2 Tata Steel Slide 2 The values of the Tata Group Integrity Fair, honest and transparent Responsibility Personal leadership in health- and safety Devotion and ownership Understanding Care, respect and sincerely concern Excellence Highest norms, first time right Share, learn and improve continously Unity, the community is not just another stakeholder in business but is in fact the very purpose of its existence Improve the quality of life of the communities we serve through leadership in sectors of national economic significance Jamsetji Tata, founder Tata Group Cooperation in the interest of the customer 2

3 Tata Steel Slide 3 Tata Group 100 bln US dollar turnover thousand employees ICT Automotive & Engineering Products Materials Services Energy Chemistry Retail

4 Tata Steel Slide 4 the heart in IJmuiden part of the high tech manufacturing industry High tech integrated steel company fte s, incl. 350 researchers (total R&D TSE 600 fte), 7,2 million ton steel in 2014 and ambition for 8 million ton steel Excellent geographic position Long history of industrial symbiosis (blast furnace slag, blast furnace gas delivery) Much attention for the environment From 2004 to million invested. Next 5 years 1 billion.

5 Tata Steel Slide 5 High quality and high energy intensive processes give opportunities to reduce the overall energy consumption Raw materials - Pig iron - Steelmaking - Casting - Rolling - Coating

6 Tata Steel Slide 6 Carbon is used both for reduction of iron ore and for the required energy Ideal reaction: 2 Fe 2 O 3 + 3C + energy => 4Fe + 3CO 2 Blast furnace process: xfe 2 O 3 + yc + zo 2 => afe + bco 2 + cco Carbon Feedstock Process quality largely determines CO 2 emission CO 2 as a result of the reduction cannot be limited

7 Tata Steel Slide 7 IJmuiden spends around 150 PJ on energy and produces around 11 million tons of CO 2 Consumption of reduction agent plus energy in IJmuiden represents approximately 4 % of Dutch consumption Coal as reductant 41 PJ Reduction 41 PJ Breeze/cokes export, 0 PJ Tar/BTX, 5 PJ Works arising gasses export 27 PJ Coal as energy 84 PJ Oil, 0 PJ Natural Gas, 11 PJ Steam, 0 PJ Electricity, 14 PJ Electricity via oxygen plant, 7 PJ Works arising gasses internal use 27 PJ Breeze as energy, 5 PJ Coal as energy 20 PJ Miscellaneous energy 32 PJ Source: MoniCA, Group Environment, Hans Kiesewetter

8 Tata Steel Slide 8 The Trias Energetica shows the way towards energy efficiency improvement in the steel industry 1 Reduce unnecessary energy consumption, by good heat insulation, innovative design, hot connect, start-stop management; 2 3 For the remaining energy requirement use sustainable energy, such as wind, solar, biomass or geothermal energy; When renewable energy is not sufficient, make use of efficient fossil sources, for example, low- CO 2 power of an incinerator.

9 Tata Steel Slide 9 The EE project structure promotes successful implementation of the most realistic improvement measures Assessment 0 Data gathering Analysis Idea development Measure development Implementation 2 weeks 4 weeks 4 weeks 4 weeks Current A B C D Aimed -X% A B C D Gather data on Consumption Processes Analyze Consumption Process Potential Brainstorms to generate ideas Prioritize ideas and develop measures Evaluate and get approval for measures Plan implementation Implement all approved measures Continuous improvement

10 Tata Steel Slide 10 To achieve lasting impact, management infrastructure and behavioural change are as important as technical measures The way physical assets and resources are configured and operated to create value and minimize losses Technical system Management infrastructure Mindset & behaviour The formal structures, processes, and systems through which the operating system is managed to deliver the business objectives The way people think, feel, and behave in the workplace, both individually and collectively

11 Tata Steel Slide 11 In the Analysis phase, the theoretical limits for the major utilities and process steps are determined Performance level Target state within 24 months and payback <2 years Theoretical limit State after bottom-up design future state (Continuous Improvement) Theoretical limit calculation Higher aspiration level Free from influence of existing bottom-up ideas Identification of loss areas with higher energy savings potential Fosters thinking about process energy efficiency and opportunities Current state Time

12 Tata Steel Slide 12 Development of the energy input shows progress and opportunities Electricity Natural Gas Coal = 100 Per ton of liquid steel Electricity without own generation

13 Tata Steel Slide 13 Over the last 25 years the energy efficiency at Tata Steel in IJmuiden has improved with more than 30% % MJA1 Benchmark MEE Set targets Actual World class In 2014 an energy reduction of 2.2% has been achieved The total energy reduction in 2013 and 2014 is 4.6 % and already bigger than the target of 3.9 % energy savings in the EEP ( ). High Strength Steels (HSS) in cars give an extra saving of 2.8 % in 2014 Energy saved in 2014 (incl. HSS) is the yearly use of natural gas in households.

14 Tata Steel Slide 14 The Direct Sheet Plant (DSP) is more energy efficient than the conventional root Caster Slab thickness: 70 mm Casting speed 5-6 m/min Integrates process of casting and hot rolling Significant energy savings 7 stands rolling mill Exit thickness 1-3 mm Carrousel coiling after continuous rolling Tunnel furnace Homogenises the slab temperature Ultra fast cooling

15 Tata Steel Slide 15 Hisarna Hisarna trialproject Flagship of European staal research ( ULCOS ) Iron ore sinter cokes Blast furnace Topics A significant new process: concept of direct use of raw materials Iron ore being melted in a cyclone Fine coals being directly injected into the smelter coals Liquid iron The use of pure Oxygen results in a Nitrogen free processgas Combination with CCS easy to enable Direct use of coal and oreno coking and agglomeration HIsarna HIsarna-technologie delivers 20% less CO 2 -emission, with CCS 80% technology available as off 2020 on industrial level

16 Tata Steel Slide 16 New topics are picked up now Demand response, smart grids Water & Symbiosis Solar, PV Waste heat recovery Lighting and darkness policy H 2 from Coke Oven Gas

17 Tata Steel Slide 17 Residual heat The heatloop of steel is comparable with a heavy stage in the Tour de France with peaks and valleys Col de Cokeplant 1000 C Col de hoogoven 2200 C Col de Blast furnace 2200 C Col de Hot Strip Mill 1200 C Col de Steelplant 1500 C Raw materials Iron Steel Strip mill

18 Tata Steel Slide 18 One third of the available residual heat is used for own purpose, which leads to mayor CO 2 -reduction 100% 35% 10% 55% Total Re-use Available Hard to capture 1 Source: Residual heat projects CORUS (Kiesewetter & Hoeben) 1 With current means of technology and sufficient economic value

19 Tata Steel Slide 19 For many energy efficiency measures automation and instrumentation are crucial Start stop management Monitoring and control Control of moisture content at ore stocks Control of continuous annealing lines. Compressed air Modelling of processes Optimisation of streams of works arising gasses Optimisation of control of arc control of the ladle furnaces Better capture of works arising gas in steelplant Automatic switching of street lighting Variable speed drives Automated width adjustment

20 Tata Steel Slide 20 Matching pump operation and capacity to the process requirement Switching off pumps of the water treatment plant when possible based on temperature and flow needed Stop the descaling pumps fully in stead of bypass them during no demand Reduce the pressure in spraying pumps from 11 to 5 bar when no cast is in progress Example from DSP Wave

21 Tata Steel Slide 21 Hydraulic pumps can be switched off as a measure of Start Stop Management Electricity consumption Ampere Current 47 Idle load Pomp 1 Pomp 2 Pomp 3 Pomp 4 Pomp 5 Pomp 6 Pomp 7 Pomp 8 Possible 5 11 Work load pumps can do the work of 8 3 pumps can be permanently dismantled extra pumps can be switched off when standstill Pomp 1 Pomp 2 Pomp 3 Pomp 4 Pomp 5 Pomp 6 Pomp 7 Pomp 8 Example from DSP Wave

22 Tata Steel Slide 22 Control of excess air at COG by energy flow and air demand metering COG variation over time (samples, online Wobbe) , , , , ,5 Steekmonsters KF1GKDC015 S1 KJ/M3 Meting bij slakkenhuis HG1GKQS001 F1 MJ/M

23 Tata Steel Slide 23 Compressed air dashboard Trends geven duidelijk ontwikkeling weer

24 CO % Oxy-gas Energy Efficiency in the Steel industry Tata Steel Slide 24 BOS gas recovery steel plant Early gas recovery Quicker start of process suppressed combustion, formation of inert plug Improved control Faster and more precise measurement and control system for pressure/flow and skirt position Gas distribution Additionally recovered gas is used through existing system to generate more heat and power Flare Gasholder Time (minutes) Flare

25 Tata Steel Slide 25 Together we make the difference