Peter Zonneveld, MD Danieli Corus. Innovative Technologies in Modern Sustainable Steel Making

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1 Peter Zonneveld, MD Danieli Corus Innovative Technologies in Modern Sustainable Steel Making May 2012

2 Challenges for the Steel Industry Swings in Raw Materials, due to economics; Raw material availability/access (India); Raw material prices and Quality; Conversion cost; Plant availability; Energy conservation; Environmental legislation (CO2). May 2012

3 How plant builders can help meet these challenges? In Blast Furnace Iron making: Design for wide range of Raw Materials > 80% Pellets; Highest Productivity > 3 t/m 3 /24hrs; Build a furnace that lasts > 25 years; Lowest Coke rate <250Kg/tHM; Highest PCI and Oxygen enrichment > 250 Kg/tHM; O2 40%; Low water consumption Dry Gas Cleaning & Slag Granulation; May 2012

4 How plant builders can help meet these challenges? In Basic Oxygen Steelmaking: Highest Productivity at lowest OPEX; Clockwork logistics, no time lost; Flexibility with types/grades of steel; Lowest consumption of fuels, fluxes and alloys. May 2012

5 How plant builders can help meet these challenges? Energy & Environment: Minimize emissions and preserve the environment; Minimize Fuel and Energy consumption; Turn Waste Heat into Value; Utilize plant reverts and residues, to practically zero waste. May 2012

6 Iron Making Technologies May 2012

7 Challenges: Raw material cost, Coking Coal & Iron Ore

8 EU Bosh Performance Country Facility Hearth Diameter Blow-In Date Total Production MtHM Specific Production thm/m 3 WV Netherlands IJmuiden BF Apr-86* 49 21,000 Germany Hamborn BF Dec ,640 Italy Taranto BF Oct ,512 Germany Bremen BF3 9.2 Sep ,905 United Kingdom Port Talbot BF Sep ,470 Sweden Oxelosund BF4 8.6 Aug ,365 Italy Taranto BF Dec ,243 * Hearth repair 2002

9 Pulverized Coal Injection May 2012

10 Injection Rates Tata Steel IJmuiden Baosteel Taiyuan Severstal NA Masteel Shougang TATA G Jindal Steel & Power Ltd. 260 kg/t 210 kg/t 200 kg/t 190 kg/t 190 kg/t 190 kg/t 180 kg/t 180 kg/t

11 High Availability - Process Monitoring Radar and Temperature Profile Meter Above and In Burden Probes > 500 Thermocouples Refractory Wear Rods

12 Slag Granulation May 2012

13 Main Features of the Plant Vitreous content of the slag sand > 98% Water content of the dewatered slag at discharge < 10% Size of slag sand, 98% < 3 mm Plant availability > 98% H2S emission < 5 mg/ Nm³ SO2 emission < 50 mg/nm³

14 New development towards Dry Slag Granulation

15 Dry Slag Granulation

16 Semi-Industrial Scale Plant 2009/2010

17 Long Term Alternative Ironmaking Technology Tecnored Hisarna

18 Steel Making Technologies May 2012

19 Steel Melt Shop Logistic Model

20 Steel Technology overview Desulphurization station Removal of slag Gas cooling Gas cleaning De-dusting Automation Logistic models Sublance Static-Dynamic Model (SDM) Slopping prevention (Ascon) Waste Gas Analysis (WGA) Bottom Stirring (BAP)

21 Hot Metal Desulphurization

22 Desulphurization Hot Metal Ladle desulphurization station consisting of: reagent injection and slag skimming Mono, Co/Multi-injection of Lime/Calcium Carbide and Magnesium Lowest Sulphur aim: 0.001% Typical injection time: 6to14min Low heat & iron losses

23 In the Converter: The Sublance, still considered the Ultimate Tool Side-shift car With sublance Automatic Probe Charger Probe Recovery Chute Seal Cap, Skull Remover Maintenance Position

24 Performance of the system Speed: Measurements available four (4) seconds after the probe enters the bath Accuracy: Exceptional, improvements through further development of interpretation of data by SDM Model and DIRC computer 20 Recent Availability: development: 15 phosphorus In excess of 98% reliable measurements prediction 10 Hitting rates may exceed 90% Model performance: Parameter Temperature 7 C Carbon content 0.018% Phosphorous prediction % Manganese prediction 0.015% = Standard Deviation

25 Value of the Sublance System After development of several tools, the Sublance + SDM proved superior accuracy for endpoint Carbon and Temperature. Higher Productivity up to 25% Highest Hit rate > 90% Lower cost Consumable Hot metal Scrap Oxygen Aluminium Ferro manganese Economization Reduced by 10 kg/t Increased by 10 kg/t Reduced by 1.0 standard m³/t Reduced by 24 kg/heat Reduced by 60 kg/heat Energy Equivalent to 20 C 40% more heats per lining life Proven Reliability of over 98%

26 Real time P-measurement with DIRC will allow safe tapping P max for steel grade

27 Bath Aggitation Process; Metallurgical Advantages Decrease Fe-slag endpoint: >=3% Higher Mn-endpoint: +0.03% to 0.05% dep. on C Decrease P-endpoint: % depending on C Better yield of alloying and desoxidation materials

28 BAP Stirring Elements New development replaceable tuyeres

29 Energy & Environmental within the Iron & Steel industry: An issue of everybody s concern

30 Environmental: Off Gas Treatment at Sinter Plants Removal of: Dust, including PM 10 Dioxins NOx SO2, HF Heavy metals

31 Typical Lay-out of Off Gas Cleaning Plant

32 Energy Conservation Programs: Turning waste heat into Value

33 Three Programs Dedicated to Energy Consumption Reduction Reducing energy consumption at a single plant Optimization of energy streams across the entire steel works Turn Waste Heat into Value Focus = single plant Impact = medium Payback < 1 year Focus = entire works Impact = very high Payback = 2-7 years Focus = local / works Impact = medium-high Payback = 2-4 years Minor to no CAPEX CAPEX required

34 Examples Off-gas from HSM Reheat Furnaces Steam Power CO 2 prevented t/year 116 GWh / year t/year Steam Power CO 2 prevented 0 t/year 67 GWh/year t/year

35 Program 2. Energy Streams Across the Works Maximizing value creation through conceptual improvements Gas recovery: WHR: On-site usage: BFG, BOFG, COG coke-ovens, sinter plant, BOF, reheat furnaces cogeneration, H2 production, etc. CO 2 Ultimate goals: No flaring of valuable process gases Neutral power balance or sale into grid (no purchase!) No NG or coal consumption for utility generation

36 Example Analyzing Energy Streams

37 Program 3. Waste Heat to Value Waste heat recovered into: (pre-)heating drying steam generation power generation co-generation also combined with co-firing

38 Waste-2-Power is more attractive than wind and solar Required subsidy 370 /MWh No subsidy required at 55 /MWh Required subsidy 600 /MWh

39 The bar is raised higher than ever before Dick Fosbury High jumper back in 1968 set new records on high jump at 224 cm. Now at 248 cm Steelmakers also need to set new records, we owe it to The World It is Danieli Corus s mission to support you in this endeavor!