Johannes Schenk. Hans-Bodo Lüngen. Chair of Ferrous Metallurgy, Montanuniversitaet Leoben, Austria. Steel Institute VDEh, Germany

Transcription

1 EVALUATION OF THE CAPABILITIES OF DIRECT AND SMELTING REDUCTION PROCESSES TO ENHANCE THE ENERGY EFFICIENCY AND TO REDUCE THE CO 2 EMISSION OF THE STEEL PRODUCTION IN EUROPE Johannes Schenk Chair of Ferrous Metallurgy, Montanuniversitaet Leoben, Austria Hans-Bodo Lüngen Steel Institute VDEh, Germany

2 Outline of presentation State of the art technology and penetration of iron production with DR and SR processes Boundary conditions and requirements for the DR and SR processes to produce iron in Europe Possible concepts for integration of DR and SR processes into existing integrated iron and steelworks Comparison of energy consumption of the process routes Comparison of emissions of the process routes Hydrogen production and hydrogen reduction 2

3 Process Routes for Production of Crude Steel Routes with Direct Reduction and Smelting Reduction Source: Stahlfibel (Herausgegeben vom Verein Deutscher Eisenhüttenleute, 1999)

4 Production of Crude Steel, Hot Metal and DRI/HBI ( ) Hot Metal from BF is ~ 71 % of Crude Steel Production 74 DRI/HBI is ~ 5 % of Crude Steel Production Hot Metal from SR ~ 0.3 % of Crude Steel Production Quelle: World Steel Association, Steel Statistcal Yearbook 2014, own data

5 Classification of Direct Reduction Processes Iron Ore Source Pellets / Lump Ore Fine Ore Reduction Stage Shaft Furnace Fluidized Bed Rotary Hearth Rotary Kiln DR Processes Gas Production MIDREX HYL/ Energiron COREX DR-Shaft Gas Reforming FINMET 2 FIOR 2, Circored 2 Iron Carbide 2 Circofer 1 Coal Gasification COMET 1 FASTMET 3 ITMK3 RedIron 3 Iron Dynamics 3 SL/RN DRC others Energy Source Natural Gas Coal 1 Process tested in pilot scale, 2 Operation stopped, 3 Recycling of residues Plants in industrial scale are in operation

6 DRI/HBI Production by Process (production 2014: 74.6 million t) Other gas based

7 DRI/HBI Production by Region 2000/2014

8 World DRI/HBI Production and Transports

9 Classification of Smelting Reduction Processes Iron Ore Source Pellets / Lump Ore Fine Ore (Sinter and Pellet Feed) Pre-reduction Stage Shaft Furnace Fluidized Bed Cyclone Rotary Hearth SR Processes OxyCup 1 CCF 1 AusIron TECNORED 2 COREX FINEX HIsmelt 3 DIOS 1 Hisarna 2 ROMELT 1 IDI Redsmelt Fastmelt 1 Smelting Stage Char Bed In-Bed Processes Metal / Slag Bath In-Bath Processes Electrical Smelting Energy Source Coal Coal/ Electricity 1 Process tested in pilot or semi-industrial scale, 2 Pilot tests under execution, 3 Operation stopped Plants in industrial scale are in operation

10 Overview of Corex and Finex Plants (as of August 2015) Customer Type of plant Number of module Year of start-up POSCO, Pohang Works, Corex/Finex Korea plant /2003*)**) POSCO, Pohang Works, Korea Finex plant POSCO, Pohang Works, Korea Finex plant Jindal South West Steel, Toranagallu, India Corex plant Jindal South West Steel, Toranagallu, India Corex plant ArcelorMittal Steel South Africa; Saldanha Works, South Corex plant 1998 Africa Baosteel, Luojing/ Shanghai, China Corex plant ***) Bayi Steel, Xinjiang Corex plant ****) Baosteel, Luojing/ Shanghai, China Corex plant ***) Bayi Steel, Xinjiang Corex plant ****) Essar Steel, Hazira, India Corex plant Essar Steel, Hazira, India Corex plant Fe burden Iron ore fines Iron ore fines Iron ore fines Lump ore, pellets Lump ore, pellets Lump ore, pellets Lump ore, pellets Pellets, Sinter Lump ore, pellets Pellets, Sinter Lump ore, pellets Lump ore, pellets Capacity in million t/a HM Use of the export gas 0.8 Power plant, steel shop 1.5 Power plant, steel shop 2 Power plant, steel shop 0.8 DR plant, power plant, steel shop 0.8 DR plant, power plant, steel shop 0.8 DR plant, steel shop 1.5 Power plant, steel shop 1.5 Power plant, steel shop 1.5 Power plant, steel shop 1.5 DR plant (?), steel shop 0.8 Power plant, DR plant and steel shop 0.8 Power plant, DR plant and steel shop *) Conversion of a Corex plant to a Finex plant **) Idled 2014 ***) Idled 2012 and (to be) relocated from Shanghai (Baosteel) to Xinjiang (Bayi Steel) ****) Relocated from Shanghai (Baosteel) Source: Primetals

11 Available Plant Capacities for Ironmaking Technologies Biggest DR- und SR-Plant Modules are in the Capacity Range of Midsized Blast Furnaces DR-Technologies SR-Technologies

12 Primary Energy Use Comparison of Routes Coal Iron Ore Scrap (25 % Fe) Srap Hot Metal (75 % Fe) Crude Steel BF Route BOF Hot Metal (75 % Fe) Crude Steel FINEX Plant BOF DRI (75 % Fe) Crude Steel DR Shaft EAF Natural Gas

13

14 Net primary energy consumption: lowest with BF-BOF route Remark: The average conversion efficiency in Germany for electric energy production from fossil fuels was 43 % in 2013 (Source: Deutsches Bundes Umweltamt)

15 Indirect CO 2 Emissions: 0 kg CO 2 /kwh (BF + FINEX) 0 kg CO 2 /Nm³ O 2 (BF + FINEX) 0,6 kg CO 2 /kwh (DR+EAF) 0,3 kg CO 2 /Nm³ O 2 (DR+EAF) 162 kg CO 2 /t Pellet 1400 kg CO 2 /t Burnt Lime Direct Emissions Conversion of fossil carbon and calcination in the process (no credits considered) Indirect Emissions Production and transport of raw materials (pellets, sinter, coke, burnt lime) Production of electric energy and oxygen Substantial lower CO 2 emissions for DR-Shaft + EAF Route Total: ~ 35 % Direct: ~ 60 %

16 Indirect CO 2 Emissions: 0 kg CO 2 /kwh (BF + FINEX) 0 kg CO 2 /Nm³ O 2 (BF + FINEX) 0,6 kg CO 2 /kwh (DR+EAF) 0,3 kg CO 2 /Nm³ O 2 (DR+EAF) 162 kg CO 2 /t Pellet 1400 kg CO 2 /t Burnt Lime Direct Emissions Conversion of fossil carbon and calcination in the process (no credits considered) Indirect Emissions Production and transport of raw materials (pellets, sinter, coke, burnt lime) Production of electric energy and oxygen Substantial lower CO 2 emissions for DR-Shaft + EAF Route Total: ~ 35 % Direct: ~ 60 %

17 Total 0.6 % decrease Natural Gas 11 % increase Coal 18 % decrease Basis: Crude Steel Production with BF+BOF 2013 in EU million tons

18 Use of Coke Oven Gas for DRI Production in Integrated Route Iron Ore Srap Hot Metal (75 % Fe) Scrap (25 % Fe) Crude Steel (85 %) Coal BF Route BOF Coke Oven Gas (1.9 GJ/t HM) DRI (75 % Fe) Scrap (25 % Fe) Crude Steel (15 %) DR Shaft EAF Case Study: 100 % of Coke Oven Gas is utilized for Steelmaking with DR-Shaft EAF Route

19 Overall Effect for Integrated Steel Works by Utilization of COG for DR-Shaft-EAF 3 % lower total energy consumption 15 % lower fossil energy consumption Production increase by 17 %

20 Upstream Substitution of COG Overall Effect for Integrated Steel works by Utilization of COG for by DR-Shaft+EAF NG for hot rolling 11 % lower direct CO 2 Emission is considered in CO 2 10 % lower total CO 2 Emission Balance

21 Use of Coke Oven Gas for DRI Production in Integrated Route Iron Ore Srap Hot Metal Crude Steel Coal BF Route BOF DRI (150 kg/t HM) Coke Oven Gas (1,7 GJ/t HM) DR Shaft Case Study: Use of DRI in BF 100 % of Coke Oven Gas is utilized for DRI Production for BF

22 Overall Effect for Integrated Steel Works by Utilization of COG to produce DRI for BF 3 % lower total energy consumption 11 % lower fossil energy consumption Production increase by 5 to 7 %

23 Upstream Substitution of COG by NG for hot rolling is considered in CO 2 Balance Overall Effect for Integrated Steel Works by Utilization of COG to produce DRI for BF 6 % lower direct CO 2 Emission 6 % lower total CO 2 Emission

24 Combination of BF-Route and Smelting Reduction Use of LRI (Low Reduced Iron) produced in FINEX as substitute for Sinter in Blast Furnace Iron Ore Srap Hot Metal Crude Steel Coal BF Route BOF Coal LRI (Low Reduced Iron, Met %) FINEX Hot Metal Reduction in comparison to separate routes Coal: 40 kg/t HM CO 2 -Emission: up to 100 kg/t Steel

25 Race Between Fossil Fuels and Renewable Energies In 2013 the world has added more capacity for renewable power each than coal, natural gas, and oil combined for the first time. Source: Siemens, Presentation at VDEh, WG "Efficiency increase and CO2 mitigation along the value added chain steel, Oct. 12, 2015

26 Conversion of Energies into Chemical Power Steel Industry Source: Siemens, Presentation at VDEh, WG "Efficiency increase and CO2 mitigation along the value added chain steel, Oct. 12, 2015

27 Production of Steel on Renewable Energies Process Concept of DR-Shaft and Electric Arc Furnace was investigated in ULCOS Direct Reduction Shaft Process is operated with 100 % H 2 Pellets, Lump Ore Fuel Gas Flue Gas Scrubber Scrap Gas heater Reduction Shaft Reducing Gas Charging Bin Hydrogen Air HDRI Recycle Gas HDRI (Hot Direct Reduced Iron) Electric Arc Furnace Steel Recycle Gas Compressor

28 Summary and Conclusions Annual production of DRI/HBI and hot metal in SR plants corresponds to 5.3 % of world steel production Overall energy consumption of the steelmaking routes (BF + BOF, FINEX + BOF and DR-Shaft + EAF) are nearly the same Steelmaking route of DR-Shaft + EAF has significantly lower CO 2 -emission as BF + BOF and FINEX + BOF Prospective for DR- and SR-Technologies in Europe: Integration of BF + BOF route with DR- und SR-Technologies Reduction of specific energy consumption Reduction of CO 2 emissions Increase of capacity and productivity of existing plants Growth of electric power production from renewable energies will drive the convergence between energy market and industries. Supply of hydrogen enables low CO 2 steel production Steel industry in Europe has to become prepared for the challenges and chances of this change in the next decades

29 THANK YOU FOR YOUR ATTENTION Johannes Schenk Chair of Ferrous Metallurgy, Montanuniversitaet Leoben, Austria Hans-Bodo Lüngen Steel Institute VDEh, Germany