AGENDA. - Conclusions. - i EAF. - i Recovery. - Definition. - Implementation. - Results

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2 AGENDA - Introduction to a Holistic Approach - EAF Energy Balance & Efficiency - i STEEL Program provides basic platform & future expandability for additional savings - i EAF - Definition - Implementation - Results - i Recovery - Definition - Implementation - Results - Conclusions 2

3 Plant Wide Completely integrated Solution Equipment on Site Steel Making EAF Holistic approach. Dynamic Process Control and energy optimization for EAF operation focused on the reduction of conversion costs while increasing productivity and improving safety 3

4 EAF Energy Balance 4

5 EAF Energy Balance 5

6 Energy Efficiency If ~70% of EAF Energy Losses are in Off-Gas The 1 st objective must be to focus on the Off-Gas for Improving Energy Efficiency Holistic Approach EAF Energy improvements 6

7 Energy Efficiency A detail analysis of the off-gas Composition, Pressure, Temperature and Flow provides valuable information for an EAF optimization process. The EAF energy balance shows that the Off-gas represents ~70% of Energy Loses Optimizing using off-gas information will dramatically improve the EAF process providing: Reduction of the overall transformation cost, Reduction of maintenance cost Reduction capital investment Reduction of CO2 emissions 7

8 EAF Off Gas Energy EAF Off-Gas contains 2 forms of energy Chemical Energy uncombusted CO & H 2 Thermal Energy sensible heat Thermal Energy sensible heat also represents ~50% of off-gas energy EAF ~1600 C (2900 F) CO, CO 2, H 2, H 2 O, N 2, O 2 8

9 i STEEL Intelligent Steel Technologies How Can We Improve EAF Energy Efficiency? FIRST Maximize In-EAF Energy Efficiency SECOND Recover the Remaining Post-EAF Energy 9

10 i STEEL Tenova Goodfellow Launches Intelligent Steel Technology i STEEL Modular Breakthrough Technology designed to Reduce Operating Costs Increase Productivity & Yield Reduce Energy Consumption Reduce Emissions i STEEL Solution for an EAF i EAF Dynamic EAF Control #1 Energy Control #2 Melting Control #3 End Point Control Water Detection Module i RECOVERY Off-Gas Heat Recovery #1 Continuous Steam #2 Electricity Generation 10

11 i STEEL i EAF Intelligent Electrical Arc Furnace 11

12 i EAF Technology OBJECTIVE 1: To Maximize in-eaf Energy Utilization Efficiency to achieve the highest energy utilization efficiency inside EAF THREE PROGRESSIVE STEPS STEP 1: Optimize & Dynamically Control Chemical Energy (may include CFD Modeling) STEP 2: Determine real-time Mass & Energy Balance. Calculate NET ENERGY actually imparted to charge after losses = Chemical + Electrical - Losses Dynamic Optimization & Control based on Net Energy STEP 3: Dynamic Prediction of the End Point (C &T) } i EAF Intelligent Electrical Arc Furnace 12

13 i EAF Technology MODULE # 1 Optimization & Dynamic Control Of Chemical Energy Sensors: EFSOP Off gas composition Measurements: CO, CO2, H2, O2, H2O 13

14 i EAF Technology MODULE # 1 Optimization & Dynamic Control Of Chemical Energy CLC 14

15 i EAF Technology MODULE # 1 Optimization & Dynamic Control Of Chemical Energy Sensors: EFSOP Off gas composition Measurements: CO, CO2, H2, O2, H2O MODULE # 1 Optional Deliveries CFD Modeling: Fume System Improvements 15

16 i EAF Technology MODULE # 1 Optional Deliveries CFD Modeling: Fume System Improvements All equipment from furnace to the bag-house could be sliced to review chemistry, flow, temperature, pressure, turbulence, velocity, hot spots, etc Chemistry evaluation, equipment design and operational parameters, including heat transfer, overall performance and maintenance requirements are analyzed 16

17 i EAF Technology MODULE # 1 Optimization & Dynamic Control Of Chemical Energy Sensors: EFSOP Off gas composition Measurements: CO, CO2, H2, O2, H2O MODULE # 1 Optional Deliveries CFD Modeling: Fume System Improvements Water Detection System: Enhance of EAF Safety 17

18 i EAF Technology MODULE # 1 Optional Deliveries Water Detection System: Enhance of EAF Safety EFSOP Water Detection Technology ANALYZES BOTH H 2 & H 2 O VAPOR GAS SAMPLING PROBE, HEATED LINE & ANALYZER are designed to integrate specialized H 2 O sensor DYNAMIC FINGERPRINT SOFTWARE accounts for process variability & dynamically adjust to changing scrap quality 3 ALERT LEVELS Operators provided with Green, Amber & Red Alerts INSTANTANEOUS ALARM Smart-filtered 18

19 i EAF Technology MODULE # 1 Optimization & Dynamic Control Of Chemical Energy Sensors: EFSOP Off gas composition Measurements: CO, CO2, H2, O2, H2O MODULE # 1 Optional Deliveries CFD Modeling: Fume System Improvements Water Detection System: Enhance of EAF Safety MODULE # 2 Dynamic Control Of Melting Process MODULE # 3 Dynamic End Point Control Sensors: EFSOP Off gas composition Off gas flow sensor Off gas temperature sensor Off gas pressure sensor Measurements: CO, CO2, H2, O2, H2O Flow Temperature Pressure 19

20 i EAF Technology MODULE # 2 Dynamic Control Of Melting Process MODULE # 3 Dynamic End Point Control Uses key sensor data to calculate real-time Mass & Energy Balance With M&B calculate NET ENERGY = Electrical + Chemical Losses (actual energy imparted to charge) With Net Energy calculate MELTING % = real-time fraction solid & liquid Control EAF on MELTING % for precise control of Melting Dynamics reduced total energy reduced PON efficient Chemical and Electr Eg precise onset of flat bath i EAF dynamically monitors key sensor data for use in Bath/Slag Model i EAF dynamically selects the optimum refining path and dynamically optimizes both the chemical energy & electricity profiles i EAF dynamically determines when the endpoint T & C is reached 20

21 i EAF Technology Maximizing energy OBJECTIVE 1: How To Maximize In- EAF Energy Utilization Efficiency 21

22 i EAF Proven Benefits 22

23 i EAF Proven Benefits Module 1 35% 30% 25% ArcelorMittal - Sestao 35% 30% RIVA Verona Electricit y Nat Gas 20% 25% Oxygen 15% 20% Charge C 10% 15% Injected C 5% 10% Prod tivity 0% -5% -10% 70% 60% 50% NUCOR Auburn 5% 0% 20% 18% 16% 14% HYLSA - Monterrey Customer Verified Facilities Allowing 40% 12% 10% Public Disclosure 30% 8% 20% 6% 10% 4% 2% 0% 0% 23

24 i EAF steel plant confirmed energy savings MODULE # 1 Optimization & Dynamic Control Of Chemical Energy MODULE # 2 Dynamic Control Of Melting Process MODULE # 3 Dynamic End Point Control 24

25 Energy Efficiency Holistic Approach Opportunities & Benefits: EAF Process Optimization Process (i EAF ) provides benefits > $2.5M/year. Improve in Control is energy loss prevention with benefits > $400k/year. Improvements in downstream maintenance equipment cost > $300k/year Holistic Approach EAF Energy improvements Fast Combustion Forced Air Mixing- a good Fume System strategy can save capital cost for more than $500k per combustion chamber. ** 1M tls EAF Production 25

26 i STEEL i Recovery Intelligent Energy Recovery System 26

27 i Recovery Technology After we have maximized In-EAF Energy Efficiency NEXT STEP. OBJECTIVE 2 Recover residual post-eaf Energy efficient recovery of residual energy left in off-gas exiting the EAF Objective 2 recover remaining energy in off-gas exiting EAF 27

28 i Recovery Technology Traditional EAF Forced Flow Cold Water Cooling cold water flow at 4-5 bar picks up ~50 C passing through cooling system exit water cooled by cooling tower evaporation recovered cold water treated and re-circulated temperature & pressure of exit water to low to be useful for energy recovery 28

29 i Recovery Technology Heat Recovery Technology pressurized ~20 Bar hot 216 C (420 F) Two LEVELS Possible LEVEL 1 waste duct cooling to ~ 600 C (1100 F) LEVEL 2 Waste Heat Boiler to ~ 200 C (390 F) Combined Level 1 & 2 recovers ~ 75-80% of off-gas Sensitive energy or ~20% of total EAF energy input 29

30 i Recovery Technology Hot Pressurized Water discharged to Steam Drum High Pressure Saturated Steam produced for use downstream Make-up Water added & hot water pressurized for re-use 30

31 i Recovery Technology EAF Heat Recovery System appearance similar to traditional cold water systems Proven Technology similar heat recovery systems widely employed in BOF steelmaking Now being adapted for use in EAF several commercial installations now in place Excellent ROI especially for shops that are refurbishing existing fume system 31

32 i Recovery Technology Uses for Saturated Steam 32

33 i STEEL Conclusions 33

34 i Steel Conclusions The Key Is to reduce Operating Costs & Increase Productivity while at the same time reducing Emissions Improving Energy Utilization Efficiency achieves the goal of reducing costs, increasing productivity & lowering emissions PROGRESSIVE STEPS to improve Energy Utilization Efficiency First - maximize In-EAF Energy Efficiency Second recover residual energy in off-gas 34

35 i Steel Conclusions Maximizing In-EAF Energy Efficiency 3 Progressive Steps STEP 1 Dynamic Chemical Energy Control (Off-Gas analysis) STEP 2 Real-time Mass & Energy Balance (Off-Gas full analysis, temperature, pressure & velocity), controlling the EAF on Net Energy STEP 3 End Point Prediction (C&T) Recovery of Residual Post-EAF Energy Traditional Cold Water fume system cooling pressure & temperature too low to be useful Pressurized Hot Water cooling similar to BOF can recover ~ 20% of Total EAF Energy Input as continuous saturated steam Steam can be used to replace boiler used to produce in-plant steam (vacuum degasser, heating, cooling, air compressor) OR, To generate electricity; typical EAF generate 24,000 MWh per yr (7.5% saving) 35

36 i Steel Conclusions EAF installations demonstrated significant improvements energy savings, operating cost savings & GHG emission reductions Demonstrated Energy Savings STEP 1 Off-Gas Optimization; ~ 29 kwh per tls STEPS 2 & 3 Dynamic Energy Control; ~12-14 kwh per tls (additional) Demonstrated GHG Emissions Savings > 18% 1 Million Ton/ yr EAF using electricity from 68% thermal (USA) STEP 1: Off-Gas Optimization - Direct 15 kwh (equiv) per tls - Indirect 14 kwh per tls STEP 2 & 3: Dynamic Energy (Chem + Elect) - Direct 6 kwh (equiv) per tls - Indirect 7 kwh per tls Off-Gas Heat Recovery (@ 300 days/yr) - Steam Replacement (coal fired boiler 20t/hr) - Electricity Generation Average Energy Savings Mega Watt Hrs 15, ,000 7,000 93,600 28,800 Annual GHG Savings metric tons 10,000 20,000 8,360 4,000 8,000 4, ,130 20,970 36

37 Thank you. 37

38 For more information please contact: Tenova Goodfellow Inc. Canada Sales & Marketing Tel: Fax: