Energy and Resource Efficiency

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1 Metallurgical Plants and Rolling Mills Energy and Resource Efficiency Sustainable metallurgical plant and rolling mill technology

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3 TABLE OF CONTENTS 3 Contents Contents Preface 4 1 Metal production facts and figures Metal production Energy improvements realized to date, taking the example of iron and steel production 7 2 Future improvements in energy and resource efficiency Efficient metallurgical plant and rolling mill technologies 8 3 Downstream potentials 10 4 Outlook 10

4 4 PREFACE Blue Competence the VDMA sustainability initiative VDMA Metallurgical Plants and Rolling Mills is part of the VDMA sustainability initiative Blue Competence. Our members are committed to energy-efficient, resource-conserving solutions for metal production and processing. Metals form the basis for innovative products and sustainable economic growth. Our member companies see themselves as partners to their customers and develop demanding technological solutions in cooperation with them. The responsible use of natural resources has always been one of the top priorities of metallurgical plant and rolling mill equipment manufacturers. Over the past few decades, significant improvements have been made, not only in terms of energy efficiency but also in the use of other natural resources. In view of the environmental challenges we currently face and the resulting policy guidance, in combination with growing economic pressure as a result of rising energy and raw material prices, the companies concerned will realize further efficiency improvements. This brochure is intended to inform you about what has been achieved to date in connection with sustainable metal production and processing. It also shows what contribution our industry can make to sustainable development in the future.

5 METAL PRODUCTION FACTS AND FIGURES 5 1 Metal production facts and figures 1.1 Metal production Iron and steel production In 2011, some 1,515 million tonnes of crude steel were produced throughout the world. With 683 million tonnes, China is the world s largest steel producer, followed by the EU 27 with 177 million tonnes (Fig. 1). In 2011, Germany produced some 44 million tonnes of crude steel. The European Steel Association expects global steel production to reach 1,900 million tonnes in Fig. 1: World crude steel production by regions (in million tonnes) Other countries China Japan CIS NAFTA EU Source: World Steel Association Aluminium production Aluminium is the key non-ferrous metal and aluminium production has risen continuously over the past few years as a result of the increasing use of this lightweight material. In 2011, world aluminium production was about 42 million tonnes. It is expected that production will increase still further to 45 million tonnes by 2015 (International Aluminium Institute, IKB Deutsche Industriebank).

6 6 METAL PRODUCTION FACTS AND FIGURES Complex process chains: the example of steel production The process paths shown in Fig. 2 illustrate the technological complexity of the process and the problems involved in defining meaningful limits for the assessment of energy and process efficiency. Finally any assessment must always be based on the entire process chain with all its interactions. Fig. 2: Complex process chains: steel production as an example Steel scrap Gas Coal Iron ore Coking plant Sintering plant (pellets) Direct reduction Smelting reduction Mini blast furnace Blast furnace Elektric induction furnace Electric arc furnace Basic oxygen furnace Crude steel Ladle and vacuum refining Ingot casting Continuous casting Forging Rolling Hot/cold rolling/processing Finished steel product Almost two thirds of the crude steel produced comes from blast furnaces but one third is produced by the recycling of steel scrap. The fact that almost 100% of metal materials can be recycled is a decisive advantage in terms of sustainability.

7 METAL PRODUCTION FACTS AND FIGURES Energy improvements realized to date, taking the example of iron and steel production Germany is a reference market for the innovative and efficient production of iron and steel. As production rose over the past few decades, all the key sustainability indicators have been significantly improved. Some examples are given below (source: Wirtschaftsvereinigung Stahl). Between 1960 and 2010, specific primary energy consumption per tonne of crude steel produced was reduced by 40%. The iron efficiency indicator (the ratio of rolled steel produced to iron used) rose from 65% to 90% over the same period. The specific consumption of refractory materials fell from 50 kg to 10 kg per tonne of crude steel produced. From 1982 to 2010, the specific use of scrap in total crude steel production in Germany rose by 10% to a total of 45%. It was possible to reduce specific water consumption from 35 m³ per tonne of crude steel to less than a third of this figure (10.4 m³ per tonne of crude steel). With reference to crude steel production, specific carbon dioxide emissions fell by 13% from 1990 to Referred to finished steel products, the reduction was 21%. The technological developments of German metallurgical plant and rolling mill manufacturers have contributed to these significant efficiency improvements. In addition to the improvement of products, additional potential was identified and implemented in processes together with steel producers. Over the past 10 years, metal producers and manufacturers of rolling mill and metallurgical plant equipment have achieved average efficiency improvements of more than 15%. These improvements are well above the average for the machinery industry as a whole (Fig. 3). Over the next 10 years, further improvements of about 12% are expected; these will be in line with the average for the machinery industry as a whole. Fig. 3: Efficiency improvements by sectors of manufacturing industry finished products Next 10 years ( %) 20 Ø Paper and cardboard production 2. Beverage production 3. Leather goods 4. Textiles and clothing 5. Ceramics 6. Wood processing 7. Coal mining/oil and gas production 8. Machinery production 9. Food industry 10. Plastics and rubber 11. Metal processing 12. Vehicle manufacturing 13. Other chemicals/ pharmaceuticals 14. Metal production 15. Basic chemicals 16. Tobacco 17. Ore mining/production of minerals 18. Printing publication 19. Processing of minerals 20. Glass production Ø 12, Last 10 years ( %) 1) Not including use of technology. Source: VDMA/Roland Berger: The contribution of machinery and plant manufactureres to energy efficiency

8 8 FUTURE IMPROVEMENTS IN ENERGY AND RESOURCE EFFICIENCY 2 Future improvements in energy and resource efficiency 2.1 Efficient metallurgical plant and rolling mill technologies Management consultancy Roland Berger estimates the future potential for efficiency improvement in the metal processing industry at up to 37% by 2050 (compared with 2010). This figure includes improvements as a result of technological development, at about 17%, and improvements in the use of technology, at about 20%. The key factors in efficiency improvement are process optimization and the consistent use of high-efficiency technologies. These result in the improvement of overall processes. However, there is also potential for optimization in individual areas of metallurgical plant and rolling mill technology. Established or feasible measures that can be applied to secure specific improvements in energy and resource efficiency and to reduce carbon dioxide emissions are available for all stages of metallurgical plant and rolling mill processes. Table 1 gives an overview of selected measures which are already applied in the industry. It should be noted that not all these measures can be applied simultaneously as some of them refer to different process routes.

9 FUTURE IMPROVEMENTS IN ENERGY AND RESOURCE EFFICIENCY 9 Table 1: Selection of measures available for improving energy and resource efficiency Process stage Solutions for CO 2 avoidance Potential, kg CO 2 per tonne Sintering plant Sintering plant with waste heat recovery Use of substitute fuels (e.g. lubricants) in sintering plant Up to 57 Up to 20 Coking plant Coke dry quenching Up to 27 Blast furnace Use of extremely pure ore Direct injection of reduction agents Coal injection, coal dust injection Gas injection, natural gas injection Improved blast furnace control Automation of cowper stoves Up to 55 Up to 24 Up to 22 Direct reduction Coal gasification (Syngas) Depends on process Basic oxygen furnace Electric arc furnace Continuous casting Hot/cold rolling General Energy recovery from furnace gas Improved energy efficiency through automation Scrap preheating Use of hot DRI Improved process control Higher transformer efficiency Bottom stirring/gas purging Compact strip casting Hot casting Automated monitoring systems Recuperator burners Hot charge/direct rolling Waste heat recovery (annealing line) Process control for hot rolled wide strip Combined generation of heat and power Preventive maintenance Energy monitoring/management systems Up to Up to 35 Energy saving similar to scrap preheating Up to 17 Up to 10 Up to 11 Energy saving 50% compared with conventional continuous casting Up to 35 Up to 35 Up to 30 Up to 17 Up to 15 Up to 82 Up to 35 Up to 9 Source: Reference Document Iron and Steel production, European Commission/BAT; US Environmental Protection Agency/State-of-the-Art Clean Technologies for Steelmaking In addition to the direct contribution of plant builders to efficiency improvement in the metallurgical process chains, plant design can also help reduce emissions via the utilization of by-products for energy and resource conservation. For example, slag granulation technology means that blast furnace slag can be used as a substitute for clinker in the cement industry. This can save considerable quantities of carbon dioxide, which would otherwise be released during clinker production. There is also further potential for waste heat recovery from slag.

10 10 DOWNSTREAM POTENTIALS OUTLOOK 3 Downstream potentials Apart from the efficiency improvements which can be achieved directly or indirectly in metal production and processing, it is also necessary to take into consideration the potential that can arise as a result of the use of metal materials. The example of steel There is considerable potential for carbon dioxide reduction in the energy and transport industries as well as in households and commercial enterprises as a result of the use of steel. The net carbon dioxide savings potential is considerably higher than the emissions caused by steel production. In general, the ratio of carbon dioxide savings to steel use in all sectors is about 6:1. The use of high-grade steel materials opens up potentials in a number of different areas, from lightweight design in vehicles via more efficient power plant technology and energy conversion through to the increased use of renewable energies. 1) The example of aluminium There are further possibilities for reducing the weight of vehicles by using diecast aluminium components. Depending on the individual model, the average weight saving is available up to 44 kg. Considering the overall number of vehicles and the distances which they are driven, there is therefore enormous potential for fuel savings and carbon dioxide emission avoidance. The same applies to highly turbocharged engines, which are mainly made from high-performance alloys for weight saving reasons. In addition to the effects of downsizing, these engines also contribute to resource conservation and emission reduction as a result of weight savings. 4 Outlook The member companies of VDMA Metallurgical Plants and Rolling Mills offer efficient, environmentally compatible innovations in line with market requirements for energy efficiency, environmental protection, ergonomics and safety. The companies operating under the umbrella of Blue Competence will continue to work in close cooperation with their customers on technological solutions that help achieve these objectives. At the European level, they are striving to define the best available technologies and to establish global benchmarks. By providing plant designs which are both economical and sustainable, these companies play their part in the conservation of resources and the reduction of emissions in connection with metal production and processing, not only in Germany or Europe but also for their customers throughout the world. 1) Calculations made by the Boston Consulting Group on behalf of Wirtschaftsvereinigung Stahl

11 PUBLICATION DETAILS 11 Publication details VDMA Metallurgical Plants and Rolling Mills Lyoner Straße Frankfurt am Main Germany Phone Fax Internet Graphic design und layout VDMA design office Production h. reuffurth gmbh digital media & print Sources of images Title page: Gettyimages Page 8: Fotolia Copyright VDMA April 2015

12 VDMA Metallurgical Plants and Rolling Mills Lyoner Straße Frankfurt Germany Contact Dr. Timo Würz Phone Internet