Trends for reducing agents in blast furnace operation Hans Bodo Lüngen, Steel Institute VDEh
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1 Stahlinstitut VDEh 1 Trends for reducing agents in blast furnace operation Hans Bodo Lüngen, Steel Institute VDEh 2 nd German Polish Symposium Carbon materials for metal production, tradition and progress Freiberg, Germany, 16 th October Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
2 Stahlinstitut VDEh 2 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
3 Stahlinstitut VDEh 3 World Hot Metal, DRI, HBI and Crude Steel Production Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
4 Stahlinstitut VDEh 4 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
5 Stahlinstitut VDEh 5 The Process Steps for Crude Steel Production Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
6 Stahlinstitut VDEh 6 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
7 Stahlinstitut VDEh 7 Crude steel production and share of continuous casting in Germany Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
8 Stahlinstitut VDEh 8 Production routes for steel making in Germany Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
9 Stahlinstitut VDEh 9 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
10 Stahlinstitut VDEh 10 Hot Metal Production in the Blast Furnaces (Data per t HM) Fig Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
11 Stahlinstitut VDEh 11 Reduction of iron oxides ( I ) Reduction with carbon (direct) or carbon containing gases (indirect) 3 Fe 2 O 3 + CO = 2 Fe 3 O 4 + CO 2 (- 52,854 kj/kmol) 2 Fe 3 O CO = 6 FeO + 2 CO 2 (+ 36,463 kj/kmol ) 6 FeO + 6 CO = 6 Fe + 6 CO 2 (- 17,128 kj/kmol) Boudouard - Reaction at temperatures > 1,000 C CO 2 + C = 2 CO (+ 172,467 kj/kmol) Direct reduction = Indirect reduction + Boudouard - Reaction FeO + CO = Fe + CO 2 CO 2 + C = 2 CO FeO + C = Fe + CO (- 17,128.kJ7kmol) (+ 172,467kJ/kmol) (+ 155,339 kj/kmol) Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
12 Stahlinstitut VDEh 12 Reduction of iron oxides ( II ) Reduction with hydrogen 3 Fe 2 O 3 + H 2 = 2 Fe 3 O 4 + H 2 O (- 11,593 kj/kmol) Fe 3 O 4 + H 2 = 3 FeO + H 2 O (+ 77,586 kj/kmol) FeO + H 2 = Fe + H 2 O (+ 16,200 kj/kmol) Shift reaction CO 2 + H 2 = CO + H 2 O Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
13 Stahlinstitut VDEh 13 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
14 Stahlinstitut VDEh 14 Chemical and energetical tasks Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
15 Stahlinstitut VDEh 15 Physical tasks Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
16 Stahlinstitut VDEh 16 A Blast Furnacee cannot be Operated without Coke for Physical Reasons Fig Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
17 Stahlinstitut VDEh 17 Hot Metal Production in the Blast Furnaces (Data per t HM) Fig Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
18 Stahlinstitut VDEh 18 Composition of reducing agents Coke PC 1 PC 2 PC 3 Lignite 1 Lignite 2 Oil Nat. Gas Coke Oven Gas BOF Gas BF Top Gas Ash 9,2 8,2 6,8 10,5 6,0 5,2 0,1 0,0 0,0 0,0 0,0 % C 88,5 80,9 84,0 72,5 56,5 65,2 87,5 73,6 42,8 34,5 18,5 % N 1,2 1,0 1,5 1,4 0,7 1,0 0,4 1,3 23,8 10,4 44,3 % H 0,3 4,3 4,2 4,8 5,2 4,7 11,0 22,5 20,7 0,4 0,2 % O 0,2 4,7 2,5 9,8 30,8 23,7 0,0 2,7 12,7 54,6 37,0 % S 0,7 1,0 1,0 1,0 0,8 0,3 1,1 0,0 0,0 0,0 0,0 % Moisture 3,8 0,9 0,9 0,9 0,9 0,9 0,1 0,0 0,0 0,0 0,0 % LCV 29,9 31,7 32,9 29,1 21,5 24,3 41,0 46,8 36,2 7,1 2,5 MJ / kg Source: P. Schmöle, TKSE Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh 5
19 Stahlinstitut VDEh 19 Flame Temperature versus Injection Rate (O 2 addition = constant) Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh Source: P. Schmöle, ThyssenKrupp Steel AG
20 Stahlinstitut VDEh 20 O 2 Addition versus Injection Rate (Flame temperature = 2,150 C) Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh Source: P. Schmöle, ThyssenKrupp Steel AG
21 Fig.21 Stahlinstitut VDEh 21 H 2 Content in BF Top Gas depending on the Injection Rate (Flame temperature = 2,150 C) Source: P. Schmöle, ThyssenKrupp Steel AG Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
22 Stahlinstitut VDEh 22 Utilization of carbon in the blast furnace as a chemical raw material Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
23 Stahlinstitut VDEh 23 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
24 Stahlinstitut VDEh 24 Coke production in Germany and consumption by the German steel industry Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
25 Stahlinstitut VDEh 25 Location of the Coke Oven Plants in Germany Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
26 Stahlinstitut VDEh 26 Operated coke oven plants in Germany Company Hüttenwerke Krupp Mannesmann (HKM) Location Duisburg Huckingen Capacity, million t/a Production 2012, million t Coke dry Salzgitter Flachstahl Salzgitter Pruna Duisburg Schwelger n Zentralkokerei Saar Dillingen Remarks 2nd battery under constr. Partly under repair Arcelor Mittal Prosper Bottrop Total Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
27 Stahlinstitut VDEh 27 Coke plant, Schwelgern, Commissioned Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
28 Stahlinstitut VDEh Quality parameters of coke 38 I 40, I 10 Medium grain size, grain structure, grain size distribution CSR / CRI All physical coke quality parameters are to be discussed in combination regarding the impacts on the mass and gas flows in the blast furnace (Source: Dr. P. Schmöle, TKS) H.-B. Lüngen Stahlinstitut VDEh
29 Stahlinstitut VDEh 29 Requirements on blast furnace coke properties in Germany (average of 6 companies) Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
30 Stahlinstitut VDEh 30 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
31 Stahlinstitut VDEh 31 Integrated blast furnace plants in Germany Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
32 Stahlinstitut VDEh 32 Average ferrous burden composition of the blast furnaces in Germany Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
33 Stahlinstitut VDEh 33 Consumption of reducing agents of the blast furnaces in Germany Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
34 Stahlinstitut VDEh 34 Examples for Extraordinary Operation Modes 2010 Country B F FIN I D A NL S Works BF No. Hearth diam. m AM Gent A 11.1 AM Dunkerque Ruukki Raahe Ilva Taranto TKSE Duisburg Ha va Linz A 14.9 Tata IJmuiden SSAB Luleå Bell coke Nut coke Total coke kg/t HM kg/t HM kg/t HM Injectants Coal Oil Plastics Total injectants Total reductants kg/t HM kg/t HM kg/t HM kg/t HM kg/t HM Oxygen in blast % Productivity HM production t/m 3 (WV)x24h Million t Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
35 Stahlinstitut VDEh 35 Reducing Agents Consumption in Blast Furnaces in the World Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
36 Stahlinstitut VDEh 36 Average slag volume of blast furnaces in Germany Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
37 Stahlinstitut VDEh 37 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
38 Stahlinstitut VDEh 38 Conventional BF (Reference ArcelorMittal Gent A) Ore 1581 kg Coke 286 kg Top gas Vol m 3 (STP) Temp. 150 C CO 23.0 % CO % H % N % Export gas 932 m 3 (STP) Dust 11 kg db C-Input 402 kg Top gas to hot stoves Coal 197 kg Ind. Red % Vol. 480 m 3 (STP) L.C.V MJ 1200 C Export energy 3072 MJ Blast 875 m 3 1t hot metal 263kg slag Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh RAFT 2131 C Hot stoves Oxygen 51 m 3
39 Stahlinstitut VDEh 39 Oxygen Blast Furnace, Source ULCOS Coal 150 kg Ore 1584 kg Coke 201 kg C-Input 289 kg - 28 % 1t hot metal 260 kg slag Oxygen 188 m 3 Ind. Red % RAFT 2000 C 1200 C Top gas Vol m 3 (STP) Temp. 147 C CO 44.7 % CO % H % N % Dust 11 kg db Vol. 303 m 3 (STP) 900 C Heater 1341 MJ Vol. 448 m 3 (STP) VPSA Product gas Vol m 3 (STP) CO 67.6 % CO % H % N % Exported gas 16 m 3 (STP) L.C.V. 104 MJ Tail gas Vol m 3 (STP) CO % CO 6.0 % H % N % L.C.V MJ Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
40 Stahlinstitut VDEh 40 Introduction Process steps for steelmaking Steelmaking in Germany Hot metal production in blast furnaces Is it possible to operate a blast furnace without coal or coke? Cokemaking in Germany Blast furnace reducing agents consumtion The UCLOS oxygen blast furnace process The EU benchmark system Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
41 Stahlinstitut VDEh 41 Hot metal CO 2 benchmarking curve Industry average: 1630 kg CO 2 /t HM Specific CO 2 emission in kg/t HM Benchmark based on the average of the 10% best performers in the EU 1475 kg CO 2 /t Benchmark of the EU- Commission 1328 kg CO 2 /t Allocation in 2013 due to the cross-sectoral reduction factor 1129 kg CO 2 /t Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
42 Stahlinstitut VDEh 42 Thank you very much for your attention Yours Hans Bodo Luengen Dr. Hans Bodo Luengen Steel Institute VDEh Dr.-Ing. H.B. Lüngen Stahlinstitut VDEh
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