The blast furnace fit for the future?
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1 The blast furnace fit for the future? Linz, Austria 7 th European Coke and Ironmaking Congress Peter Schmöle, Head of Competence Centre Metallurgy
2 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusions The blast furnace Fit for the future? Peter Schmöle
3 Introduction Steel production in the world, Electric steel 24.8% OH steel 0.5% 1793 Scrap 31.5% DRI / HBI 4.0% Corex / Finex hot metal 0.3% Oxygen steel 74.7% Blast furnace hot metal 64.2% Dominant position of the blast furnace route The blast furnace Fit for the future? Peter Schmöle
4 Introduction Shares of metallic charge with increasing shares in the last years The blast furnace Fit for the future? Peter Schmöle
5 Introduction Blast furnace seize as inner volume Inner volume: Volume between 1 m below chute in vertical position and taphole level but the biggest blast furnaces in Asia! The blast furnace Fit for the future? Peter Schmöle
6 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusions The blast furnace Fit for the future? Peter Schmöle
7 Metallurgical efficiency Energy consumption Real vs. ideal case Today the blast furnace is operated close to thermodynamic equilibria The blast furnace Fit for the future? Peter Schmöle
8 Metallurgical efficiency Energy consumption Real vs. ideal case Ideal case: Process at thermodynamic equilibrium Today the blast furnace is operated close to thermodynamic equilibria The blast furnace Fit for the future? Peter Schmöle
9 Metallurgical efficiency Energy consumption Real vs. ideal case Ideal case: Process at thermodynamic equilibrium without cooling losses Today the blast furnace is operated close to thermodynamic equilibria The blast furnace Fit for the future? Peter Schmöle
10 Metallurgical efficiency Consumption of reducing agents BF s in Germany Why? Asymptotic pattern to a minimum at the end of the 1990 th The blast furnace Fit for the future? Peter Schmöle
11 Metallurgical efficiency Sinter composition, thyssenkrupp SE Higher silica input via fine ores Lower Fe contents in sinter The blast furnace Fit for the future? Peter Schmöle
12 Metallurgical efficiency Carbon and ash contents in BF coke, thyssenkrupp SE Higher ash contents Lower C content in coke The blast furnace Fit for the future? Peter Schmöle
13 Metallurgical efficiency BF slag volume, thyssenkrupp SE Increasing slag volumes Higher consumption of reducing agents The blast furnace Fit for the future? Peter Schmöle
14 Metallurgical efficiency Conclusion The BF is operated at 96 to 93 % efficiency level. (State of the art operation related to a non-realistic process at the thermodynamic equilibrium and w/o heat losses) Since end of 1990 th the cumulated reducing agents consumption increases caused by higher slag volumes lower C contents in coke change from oil / natural gas to pulverized coal injection The blast furnace Fit for the future? Peter Schmöle
15 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusions The blast furnace Fit for the future? Peter Schmöle
16 Alternative benchmark process modes Different auxiliary reducing agents, HBI charging PC HBI NG H 2 Coke kg / t HM PC kg / t HM NG kg / t HM 100 H 2 kg / t HM 40 HBI kg / t HM 400 PC = Pulverized Coal HBI = Hot Briquetted Iron NG = Natural Gas H 2 = Hydrogen The blast furnace Fit for the future? Peter Schmöle
17 Alternative benchmark process modes Energy input without energy for HBI production To suppress the energy for HBI production is an ecological prestidigitation The blast furnace Fit for the future? Peter Schmöle
18 Alternative benchmark process modes Energy input with energy for HBI production In total higher energy input included energy for HBI production The blast furnace Fit for the future? Peter Schmöle
19 Alternative benchmark process modes Use of HBI in the blast furnace From the energetic point of view it is cockeyed to cut the upper part of the BF, to shift the indirect reduction to an external process and to loose the sensible heat of the HBI in-between. To report only the energy consumption and/or the CO 2 emissions of the BF and to forget energy need and CO 2 emissions for HBI production creates something like an perpetual motion machine The blast furnace Fit for the future? Peter Schmöle
20 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input 40 kg H 2 / t HM 100 kg NG / t HM 200 kg PC / t HM Steps from C to more H 2 based reduction process The blast furnace Fit for the future? Peter Schmöle
21 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input Steps from C to more H 2 based reduction process with changing gas compositions The blast furnace Fit for the future? Peter Schmöle
22 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input Steps from C to more H 2 based reduction process with changing gas compositions The blast furnace Fit for the future? Peter Schmöle
23 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input That s a little bit like gas generation with associated hot metal production The blast furnace Fit for the future? Peter Schmöle
24 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input Steps to hydrogen metallurgy effect decreasing CO 2 emissions The blast furnace Fit for the future? Peter Schmöle
25 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input with exploding CO 2 abatement costs The blast furnace Fit for the future? Peter Schmöle
26 Alternative benchmark process modes Conclusion Charging of cold HBI is contra-productive from the energetic point of view. With higher hydrogen input the energy need and also the energy export increase. Shifting the reduction reactions from carbon to hydrogen causes lower CO 2 emissions, but exploding CO 2 abatement costs The blast furnace Fit for the future? Peter Schmöle
27 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusions The blast furnace Fit for the future? Peter Schmöle
28 Cross-industrial network thyssenkrupp project Carbon2Chem Chemical use of gases Blast furnace Converter Coke plant State of the art Top gases Power plant Steel production CO 2 Electrical energy Today Blast furnace Converter Coke plant Chemical use of top gases Top gases Power plant Synthesis Steel production Methanol Synthetic fuel Fertilizer Alcohol Polyalcohol Polymers Future Source: thyssenkrupp Process Technologies Significant reduction of CO 2 emissions and high value by-products The blast furnace Fit for the future? Peter Schmöle
29 Cross-industrial network Today Electric power Injection coal Oxygen Coking coal COG, BFG, BOFG Iron ore Integrated iron and steel works Steel Electric power Power plant Carbon to CO 2, internal production of electric power The blast furnace Fit for the future? Peter Schmöle
30 Cross-industrial network Future Chemical products Injection coal Oxygen COG, BFG, BOFG Synthesis Chemical raw materials Iron ore Coking coal Integrated iron and steel works Steel Power plant Electric power Green electric power High value by-products, carbon to chemicals, use of excess green electric power The blast furnace Fit for the future? Peter Schmöle
31 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusions The blast furnace Fit for the future? Peter Schmöle
32 Conclusion State of the art, potentials and new ideas Blast furnace as world champion in energy efficiency No chances for further energetic improvements from the metallurgical point of view Hydrogen blast furnace Increasing energy consumption, lower CO 2 emissions, non-competitive costs Rethinking the bounds Cross-industrial network of steelmaking, chemicals industry and energy sectors to create an integrated economic and ecological optimum The blast furnace Fit for the future? Peter Schmöle
33 Conclusion Statements of clerical and political experts Pope Francesco, 2015: Climate change is a global problem. Chancellor Merkel, 2015: The G7 leaders had committed themselves to the need to decarbonise the global economy in the course of this century The blast furnace Fit for the future? Peter Schmöle
34 Conclusion To realise this decarbonisation of the global economy we need steel.. Automotive lightweight design Infrastructure Energy transformation Sustainable construction Green energies Energy supply and distribution The blast furnace Fit for the future? Peter Schmöle
35 Conclusion and blast furnaces Steelmaking without fossil energy based blast furnaces.. the touchdown will be a disaster!
36 The blast furnace fit for the future? Linz, Austria 7 th European Coke and Ironmaking Congress Peter Schmöle, Head of Competence Centre Metallurgy
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