THE NO WASTE CONCEPT AT GEORGSMARIENHÜTTE GMBH - THE ENVIRONMENTAL INNOVATIONS

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1 Dr. rer. nat. Zeljko Cancarevic MBA Reimund Laermann Dr. rer. nat. Marija Cancarevic Dr.-Ing. Henning Schliephake THE NO WASTE CONCEPT AT GEORGSMARIENHÜTTE GMBH - THE ENVIRONMENTAL INNOVATIONS 18. DNEVI ENERGETIKOV APRIL 2016 PORTOROŽ (SLOVENIA) 1

2 CONTENT Company Market Products Technology Simulation Capabilities Energy Management 2

3 COMPANY Manufacturer of quality and engineering steels Market leader in Germany Among Europe s top manufacturers Key Data 2014: 610 mil. Euro Turnover 1295 employees 3

4 COMPANY Key Figures Turnover in mil. Euro Rolled products in to Employed (Annual mean without apprentices)

5 COMPANY 5

6 LOCATIONS OF THE GMH GROUP 6

7 INTERNATIONAL GMH SALES OFFICES Schweden Russland UK Polen Frankreich Spanien Italien Türkei Japan China International GMH Sales-Offices Commercial Agents Representatives of the GMH Holding 7

8 COMPANY History 1856 Georgsmarienhütte is founded as an iron production plant located in the South of Osnabrück. Its name derived from King George V. and Queen Marie Klöckner acquires Georgsmarienhütte Dr. Jürgen Großmann and Drueker & Co. GmbH buy and incorporate Georgsmarienhütte The steel melting process at Georgsmarienhütte GmbH is changed from blast furnaceconverter to DC electric arc furnace Dr. Jürgen Großmann becomes 100 per cent shareholder and creates Georgsmarienhütte Holding GmbH A new walking-beam furnace replaces both of the 40+ year old walking-hearth furnaces A second ladle furnace is installed to expand secondary metallurgy Start of Operation: to - Two new production lines for bright bar and one saw-cutting installation New straightening and testing line for bar steel - New precision rolling stand for round bar steel KOCKS RSB + AUL - New steam extraction at the off-gas channel of the EAF - New roller hearth furnace for our heat treatment shop 8

9 COMPANY Corporate Goals Customer service orientation Efficiency Independence Continuous education of employees Environmental responsibility Profitability 9

10 COMPANY Our Vision BEING PROMPT Melt and treat in the morning Cast at noon Roll in the evening Finish over night MEANS REACTING WITH MAXIMUM PRECISION IN THE SHORTEST TIME POSSIBLE. CHALLENGE US! Ship the next day! 10

11 MARKET Our steel drives you forward We supply steel for powertrain engine transmission steering and chassis components of cars and trucks. Eighty per cent of our products find their end use in the automotive industry. Other customers are the mechanical engineering and capital goods industries. 11

12 MARKET Main Applications Fracture-split conrod Camshaft Piston Crankshaft ENGINE Common-Rail Injector Nozzle Gear shaft TRANSMISSION Cardan shaft Steering rack Knuckle Wheel hub BEARINGS Ball bearings 12

13 MARKET References 13

14 SIMULATION & INNOVATION Eike Runschke (CFD) Florian Schrader (CFD) Mustafa Budak (MAT) Arthur Borisov (MAT) Malvina Asad (MAT/DM) Kai Spinneker (CAE/PROG) Daniel Meyer (CAE/PROG) Sasha Telsemeyer (CAE/PROG) Michael Schmidt (WS6/CAE)* Zeljko Cancarevic

15 GMH Simulationslandschaft CFD Modellentwicklung CAE MAT (Programmierung & Datamining)

17 TECHNOLOGY 17

STEEL PLANT DC electric arc furnace Producer: MAN-GHH 1994 Modernized: SMS-Demag 2005 Tapping weight: 141 t Hot Heel: 20-70 t Scrap input: 150 t 2 cages Transformer: 2 x Tamini Installed Power:

18 STEEL PLANT DC electric arc furnace Producer: MAN-GHH 1994 Modernized: SMS-Demag 2005 Tapping weight: 141 t Hot Heel: t Scrap input: 150 t 2 cages Transformer: 2 x Tamini Installed Power: 130 MVA Primary voltage: 30 kv Secondary voltage: max. 720 V DC Secondary current: max. 131 ka DC Rectifying : 12-puls 4 thyristor blocks Cathode: graphite 30 Ground anode: Pin-Type; 268 pins 18

STEEL PLANT Ladle furnace 2 Producer: Year: 2007 Electrode Ø: Pitch circle: Primary voltage: Installed power: Secondary current: Heating rate: SMS Demag 400 mm 750 mm

19 STEEL PLANT Ladle furnace 2 Producer: Year: 2007 Electrode Ø: Pitch circle: Primary voltage: Installed power: Secondary current: Heating rate: SMS Demag 400 mm 750 mm 30kV 25 MVA 38 ka max. > 45 C/min at 140 t ladle capacity Cover type: SIDE DRAFT HOOD (SIR) Dedusting plant: Bag-Jetfilter-Plant Closed water circulation with air cooler 19

STEEL PLANT Degassing Type: Ladle degassing -( ASEA -Type) Producer: Standard Messo 1981 Suction power: 300 kg air/h at < 1 Torr and 20 C Vacuum production: 6 injectors 2 condensers Min.

20 STEEL PLANT Degassing Type: Ladle degassing -( ASEA -Type) Producer: Standard Messo 1981 Suction power: 300 kg air/h at < 1 Torr and 20 C Vacuum production: 6 injectors 2 condensers Min. pressure: Steam pressure: < 1 Torr after 2 min 128 bar Steam temperature: 190 C Ladle stirring: Flow-Controller Ar/N2 Process control: Analysis hardness & alloying calculation data gathering 20

21 STEEL PLANT Continous casting Type: Model: Modernized: 6 Strand Bow Type 1987/SMS 2001/VAI Casting diameter: 240 mm 2 und 165 mm 2 Casting radius: Ladle content: Tundish: Mould level control: Mould type: 998 m 140 t 25 t Slide gate Tubular mould 800mm chrome-coated 21

STEEL PLANT Ingot casting facility Casting process: Block weight: Shapes: Group alignment: Caster: Reoxidation: Cooling facilities: Topping treatment: rising group casting Rolling and forging ingot

22 STEEL PLANT Ingot casting facility Casting process: Block weight: Shapes: Group alignment: Caster: Reoxidation: Cooling facilities: Topping treatment: rising group casting Rolling and forging ingot from 35 t to 44 t Square round polygonal- and slab forms Single dual quadruple or sextuple casting Independant casting portal electronic display of casting speed Casting under protection gas and flux powder at air in moulds or under covers Isolating 22

23 WASTE HEAT WE SHOULD START WITH THE 4 RS : REDUCE REUSE RECYCLE RETHINK 23

24 WASTE HEAT 24

25 WASTE HEAT 25

26 (Source: Doznejamo.com) 26

27 (Source: (Source: WELL THE OBVIOUS SIMPLEST WAY IS TO HOT? COLD THERMOELECTRIC GENERATOR (TEG) STIRLING ENGINE ELECTRICITY The typical efficiency of TEGs is around 5 8%! The potential efficiency of a Stirling engine is high! HIGHLY DEPENDENT ON DT! 27

28 LET'S SEE THE REALITY Electricity Production in D 2013 Graph: Bruno Burger Fraunhofer ISE; Data: EEX Transparency Platform / 28

29 When you can measure what you are speaking about and express it in numbers you know something about it - Lord Kelvin (Source: 29

30 TO MEASURE IS TO KNOW REDUCE REUSE RECYCLE RETHINK 30

31 IMPLEMENTAION (MANAGEMENT) Well you have to start first with the management team. The implementation of energy management systems in the organizational structure. Creation of the Energy Management Department Reporting directly to the Managing Director (Engineering) Representatives in all departments on behalf of the Energy Management Department Georgsmarienhütte GmbH Geschäftsleitung Vertrieb Geschäftsleitung Einkauf Geschäftsleitung Technik Geschäftsleitung Personal Stahlwerk Walzwerk Finalbetrieb PSPT Innovation & Simulation Energiemanagement Umweltmanagement Qualitätsmanagement 31

32 People The System Technology THE THREE PILLARS OF THE ENERGY MANAGEMENT AT GMH Engage Motivate Empower Measure Connect Unify Rethink Optimize Simplify 32

33 THE THREE PILLARS OF THE ENERGY MANAGEMENT AT GMH PEOPLE From top-level management to the trainee SYSTEM Energy transparency Data acquisition and archiving Controlling and reporting Plausibility check Limit monitoring and variety tracking KPI TECHNOLOGY Congestion control Power monitor Measuring equipment management Tag optimization Network structure detection and optimization Instrumentation and control Technology optimization 33

34 TIME LINE EM HOLDING WORKSHOP ENO (Energieeffizienz Netzwerk Osnabrück ) 2012 ENERGY AMBASSADORS 2010 THE SYSTEM MESSDAS 2010 CERTIFICATION: DIN EN % REDUCTION OF THE COMPRESSED AIR CONSUMPTION 2012 DBU-Projekt - "SIMULATION OF " 2012 CERTIFICATION: DIN EN ISO RECERTIFICATION: DIN EN ISO LIGHT OUTPUT REDUCTION 2011 Various Actions to enhance to employee participation and awareness 2011 ENERGY MANAGEMENT DEPARTMENT 2013 FURTHER REDUCTION OF THE COMPRESSED AIR CONSUMPTION 2013 OPTIMIZATION OF THE DISTRICT HEATING SYSTEM 2013 THE COMPETENCE CENTER (GMH & HOCHHUTH) 2013 ENERGY OFFICERS 34

35 MESSDAS 35

36 MESSDAS 36

37 MESSDAS 37

38 MESSDAS 38

39 USE OF WASTE HEAT OF THE ELECTRIC FURNACE TO GENERATE STEAM REDUCED THE CONSUMPTION OF NATURAL GAS TO ~ 25 MILLION KWH/YEAR OF NATURAL GAS. SAVINGS OF ~ TONS OF CO2 IN AN AVERAGE YEAR.

40 EM PROJECTS The Systematic Application: LIGHTING 65% LIGHT OUTPUT REDUCTION (58 KW/H TO 20 KW/H) RETURN ON INVESTMENT (ROI) IN 14 YEARS IMPROVING LIGHTING QUALITY IMPROVING LIGHTING CONDITIONS IN ITS FACILITY (ENHANCING EMPLOYEE SATISFACTION) 40

2010 2011 2012 2013 2014 110.279.081 95.163.595 94.923.429 141.591.073 136.600.

098.979 16.000.000 140.000.000 12.497.889 14.000.000 120.000.000 11.046.057 11.107.321 12.000.000 100.000.000 10.000.000 80.

41 EM PROJECTS The Systematic Application: COMPRESSED AIR Nm³ kwh Druckluft Erzeugung [Nm³] Stromaufnahme Kompressoren [kwh] 41

42 SUMMARY Reduce compressed air consumption by 35% within three years (from to 95.1 mio. Nm 3 /year). Reduce light output from an average of 58 kw/h to 20 kw/h while improving the quality of lighting. Use of waste heat of the electric furnace to generate steam reduced the consumption of natural gas to ~ 25 million kwh/year of natural gas. Savings of ~ tons of CO2 in an average year. Use of 25% of industrial waste heat at the site Approximately 30% of water savings by adjusting and optimizing the consumers requirements. STRATEGY: GMH determination is to improve the sustainability of our energy consumption and REDUCE THE AMOUNT OF ENERGY NEEDED and emissions generated per unit of output. 42

43 Our achievements were rewarded and GMH is the first certified steel plant in Germany according to the DIN EN (2010). Furthermore in 2012 GMH receive energy management system certification according to DIN EN ISO as one of the first steel plants in Germany ever GMH is the first steel plant in Germany admitted to the club of outstanding climate-protection company 43

44 Dr. rer. nat. Zeljko Cancarevic MBA Reimund Laermann Dr. rer. nat. Marija Cancarevic Dr.-Ing. Henning Schliephake THANK YOU! 18. DNEVI ENERGETIKOV APRIL 2016 PORTOROŽ (SLOVENIA) 44

A CFD Study of Particle-Laden Flow of a Tundish Water-Model

A CFD Study of Particle-Laden Flow of a Tundish Water-Model CONTENT A Study of Particle-Laden Flow of a Tundish Water-Model Dipl.-Ing. (FH) Eike Runschke M. Sc. Gerold Haskamp Dr. rer. nat. Zeljko Cancarevic MBA Dr.-Ing. Henning Schliephake Content CONTENT Company