THE VALUE OF ENERGY & RESOURCE TOWARDS AN EFFICIENT FUTURE STEELMAKING

Transcription

1 THE VALUE OF ENERGY & RESOURCE TOWARDS AN EFFICIENT FUTURE STEELMAKING Dr. Alexander Fleischanderl primetals.com

2 The Value of Energy and Resource Content 1. Introduction a. Economy Facts & Figures b. Scrap market situation 2. Raw Material Flexibility 3. Resource Efficiency Effective By-Product Management 4. Energy Efficiency Waste Heat Recovery Potential 5. Emission Control Contribution to low Capex and Opex Page 2

3 Economic Figures for the Steel Industry Population, GDP, Material Extraction, Society s Well Being Source: Angus Maddison Page 3

4 Cost Structure Steelmaking Comparison of Regions Alan Grimmond, McLellan and Partners Ltd, OECD STEEL COMMITTEE 13 May 2011 Page 4

5 Scrap Market Impact on World Scrap Prices Scrap availability expected to grow Scrap price expected to decrease in Asia/China 2017 about 180mio to of scrap processed in Chinese steel plants expected to increase! Lifecycle of infrastructure years Cars and consumer goods years Regulations that force smaller EAF and IF to close down will increase scrap availability further Scrap in China act. ~ 80 US$/t cheaper compared to Hot Metal Average scrap ratio in China 2016: 10.8% Target 2017 according 13rd planning: >11% Target scrap ratio for 2020: >20% Pressure on integrated steel producers to increase scrap rate further Scrap recycling system needs to be improved to assure quality Small IF and EAF with total capacity 120mt per year closed 2016/2017! Page 5

6 Raw Material Flexibility - Jet Technology Introduction - Motivation Available energy in LD converter limits maximum possible scrap / HBI rate Typical values ~ 20%, depending on hot metal composition and temperature For higher rates of solid charges additional energy source required Carbon injection => Jet Process Electric energy => EAF Jet process directly uses chemical energy to melt scrap / HBI => thus no conversion losses resulting in highest efficiency Coal is injected via converter bottom and post combusted with hot blast from top, easy adaption to changing scrap or HBI rates Hot Blast blown from top ensures excellent mixing and therefore, high post combustion and heat transfer to the bath Normal operation mode allows up to 50% scrap or HBI, with hot heel operation even up 100% (1) Benefit from low scrap and/or HBI price (2) Benefit from low up-grade capital expenditure (3) Benefit from substantial yield improvement of 2% (4) Benefit from reduced CO 2 emissions Page 6

7 Raw Material Flexibility - Jet Process Bottom blowing converter with hot blast from top Hot blast generation with pebble heater Energy storage and heat exchange with efficiency η > 90% Gas fired during tapping and charging time Additional energy input Chemical heat through carbon injection Latent heat of hot blast Higher efficiency High post combustion rate up to 60% (vs.11-12% LD/BOF) Heat transfer from off gas to bath up to 90% Efficient usage of chemical energy of coal injected Flexible scrap and HBI rates Rates from 0% up to 100% of scrap or HBI possible For 100% hot heel operation required Page 7

8 Raw Material Flexibility - Jet Technology / POSCO Flexibility in Operation Source: Increased Scrap Rate at the BOF Process by the Application of Hot Air Post Combustion PS-BOP Project The 6 th China-Korea Joint Symposium on Advanced Steel Technology, Nanjing, China, October 9-10, 2014 Page 8

9 By-Product Management Slag Valorization DSG Granulation & Waste Heat Recovery voestalpine BF#A Start-Up May 2017 Dry Slag granulation a development that has been in the pipeline for many years Current initiative is backed by the drive to recover energy Prototype plant built at voestalpine Linz BF#A Potential to recover ~20 MW th or ~6 MW el from a BF slag flow of 1 to/min Production of a dry valuable slag product is key (>98% glass) No water consumption for the granulation process obviously No odor problems with sulphur Dry product handling no drying required Page 9

10 By-Product Management Slag Valorization DSG Granulation & Waste Heat Recovery Major Results from Pilot Trials: Cement grade slag granulate o > 98% glass content o Evenly sized granulate (1 3 mm) o Dry slag product properties High off-gas temperature (~ 600 ºC) CFD Model validated up-scale Absolutely no sticking Page 10

11 By-Product Management Ferrous Oxides Recycling for DR Plants / US Texas Fines Recycling Plant Feed material pellet fines, sludge, HBI chips and fines, misc. dust Annual approx t/a Capacity Design 24.6 t/h (briquettes) Capacity Binder system inorganic binder Briquette size approx. 5 ccm Start-Up of Plant Acceptance Page 11

12 Energy Efficiency Waste Heat Recovery for EAF Waste Gas Arvedi Italy About 30% of the Energy Input leaves with the Off- Gas Modular Waste Heat Recovery System Tailor-made Solutions Page 12

13 Energy Efficiency Waste Heat Recovery from EAF Waste Gas Arvedi Italy EAF WHR Arvedi / Italy Key Performance Indicators Arvedi: Steam production Annual steam production Savings in natural gas (CH 4 ) CO 2 savings per year 17 t/h to Nm³ to Page 13

14 Energy Efficiency Waste Heat Recovery from Sinter Cooler Waste Gas Page 14

15 Energy Efficiency Waste Heat Recovery from Sinter Cooler Waste Gas Actual status: Circular Coolers Innovation: Shaft Cooler Page 15

16 Emission Control Energy Saving Assistant/ eservice Potential to reduce power consumption by more than 20% Increased reliability Just in Time Warehousing Page 16

17 Emission Control PRIMZERON Fabric Filter Standard Bag-filter Design PRIMZERON Filter Design Page 17

18 Emission Control PRIMZERON Fabric Filter Austria / Foundry: Am³/h Germany / EAF: Am³/h Absolute Emission Tight: Lowest Sound Emissions: Minimum Pressure Loss: Maximum Flexibility: Robust and Weather Resistant: Shortest fabrication and Erection: < 2mg/Nm³ Reduction level of 57dB Lowest ever achieved levels Modular Construction Massive, no corrosion, explosion proof Premanufactured concrete panels Page 18

19 Conclusion The Value of Energy Towards an Efficient Steelmaking 1. Modern steelmaking production processes are close to theoretical minimum for energy and carbon intensity 2. 60% reduction in energy consumption sine Less than 20 GJ/mt for average world crude steel production 3. Main challenge remains the immense cost pressure on production cost dominated by raw material and energy cost 4. Raw material flexibility, yield improvement, energy efficiency and carbon footprint are the key levers to stay/become competitive a. Increased and flexible Scrap / HBI rates for BOF steelmaking (modular system) b. Waste heat recovery from steel production & slag processing, waste gases still not fully tapped c. Valorization of by-products (maximize market price, replacement of primary raw materials 5. Mid-term transformations expected to happen a. Scrap Pre-heating for EAFs (i.e Quantum) 30% less energy intensive b. Direct rolling (i.e. Winlink and ESP) 40% less energy intensive c. I4.0 Fully automated plants (i.e robotic systems) d. TPOpt rule based guidance for steel grade quality control e. Carbon-2-Fuel and chemicals f. Hydrogen Metallurgy 6. Intelligent Gas Cleaning a. New low cost approach for high performance bag filters b. Energy Saving Assistant for de-dusting systems (I4.0) c. esevice, edocumentation, etc Page 19

20 THANK YOU primetals.com