UPDATE 01/2015 GIOVANNI NIGRIS EXECUTIVE VICE PRESIDENT DANIELI 20 TH MEXICAN STEEL FORUM CANCUN, MEXICO 28-30 JANUARY 2015 GREEN STEEL / LAYOUT AND PROCESS FOR ENVIRONMENTAL STEEL
GREEN STEEL ZERO WASTE in Steelmaking from a problem to a business opportunity
GREEN STEEL ENVIRONMENTAL SOLUTIONS NOISE Noise control indoor and outdoor AIR POLLUTION Fume treatment plants TOTAL ENERGY FUME ENERGY LOSS ENERGY LOST CHR TM Clean Heat Recovery To produce electric energy by recovering waste heat from the EAF EAF - BOF - LADLE SLAG ECOGRAVEL Process recovery system EAF DUST INDUTEC Process and Recover of ZnO BOF GAS CLEANING PLANT LADLE SLAG AND REFRACTORY BRICKS Synthetic DoloLime production ZERO-EMISSION TOTAL RECOVERY SCRAP SHREDDING PLANT
GREEN STEEL INDEX 1 2 3 4 5 6 CHR - CLEAN HEAT RECOVERY ECOGRAVEL PROCESS INDUTEC EAF DUST RECOVERY SYSTEM GREEN LAY OUT CFD ANALYSIS DANIELI CENTRO RECYCLING
GREEN STEEL ^ 1 2 3 4 5 6 CHR - CLEAN HEAT RECOVERY ECOGRAVEL PROCESS INDUTEC EAF DUST RECOVERY SYSTEM GREEN LAY OUT CFD ANALYSIS DANIELI CENTRO RECYCLING CHR - CLEAN HEAT RECOVERY
1 CHR - CLEAN HEAT RECOVERY CHR CLEAN HEAT RECOVERY FROM EAF HOT FUMES INTO ELECTRIC ENERGY WITH CONSEQUENT FUEL SAVING AND REDUCTION OF GREEN-HOUSE GAS EMISSION
1 CHR - CLEAN HEAT RECOVERY EAF ENERGY RECOVERY > Recovery of chemical energy not feasible > Scrap preheating has environmental and reliability problems > Different way to recover energy with good return on investment has been developed TOTAL ENERGY INPUT 100% PRIMARY FUMES ENERGY LOSSES 25-30% 700-1000 kwh/t 140-300 kwh/t
1 CHR - CLEAN HEAT RECOVERY CHR - CLEAN HEAT RECOVERY HPW ACCUMULATOR THE WAY Recover waste heat using high pressurized hot water HOW Using an Organic Rankine Cycle (ORC) to transform heat into electric energy REFILLING WATER EAF SETTLING CHAMBER HEAT EXCHANGER - ECONOMIZER TURBINE AND ELECTRIC GENERATOR EVAPORATOR ORGANIC FLUID CIRCUIT ORC
Temperature ( C) 1 CHR - CLEAN HEAT RECOVERY CHR - CLEAN HEAT RECOVERY PROCESS ENERGY ACCUMULATOR HEAT RECOVERY ORC TURBINE 240 230 220 210 200 190 180 170 160 150 0 20 40 60 80 100 Time (min)
1 CHR - CLEAN HEAT RECOVERY CHR - FIRST REALIZATION AT ABS 1 ABS STEELMAKING PLANT (ITALY) EAF DC 90T 2 1. ORC PLANT 2. HEAT EXCHANGER Pel = 1 MWe 2 1
1 CHR - CLEAN HEAT RECOVERY CHR - FIRST REALIZATION AT ABS 2 1. EAF 2. Settling chamber 3. Heat exchanger-economizer 4. Primary duct 5. Secondary duct 6. FDC (Forced Draft Cooler) 7. ORC (Organic Rankine Cycle) 8. Hot water accumulator 9. Bag filter 10. Stack 5 3 4 1 6 8 EAF HEAT EXCHANGER 165 yd (150 m) HPW CAN BE EASILY TRANSPORTED 7 NON-INVASIVE LAYOUT 9 10 HPW ACCUMULATOR + ORC PLANT
1 CHR - CLEAN HEAT RECOVERY CHR - ROI EAF heat size 120 t Extracted heat power (avg) 25 MWt Electrical power at generator 3.5 MWe Working hour per year 7.200 h/y Saved CO2 10,000 t/y Electrical energy yearly produced 25,000 MWh/y TOTAL ENERGY INPUT 100% PRIMARY FUMES ENERGY LOSSES 25-30% PRIMARY FUMES ENERGY LOSSES 25-30% ELECTRIC ENERGY ROI 2 5 years Recovered energy 15-20 kwh/t
1 CHR - CLEAN HEAT RECOVERY CHR - FIRST REALIZATION AT ABS POWER BALANCE Removed power from waste heat recovery Nominal ORC power ENERGY BALANCE Energy recovered in 1 year COST BALANCE Energy cost (average) Energy cost recovered White certificates* ENVIRONMENTAL BENEFIT CO2 saved 5,5 MWt 1 MWe 5.760.000 kwhe/y 0.08 /kwh 460.000 /y 320.000 /y 2300 tons/y * depending by country
GREEN STEEL ^ 1 2 3 4 5 6 CHR - CLEAN HEAT RECOVERY ECOGRAVEL PROCESS INDUTEC EAF DUST RECOVERY SYSTEM GREEN LAY OUT CFD ANALYSIS DANIELI CENTRO RECYCLING ECOGRAVEL PROCESS
2 ECOGRAVEL PROCESS ECOGRAVEL PROCESS CAN SOLVE WITH PROFIT THE SLAG PROBLEM COMING FROM EAF - BOF - LADLE
2 ECOGRAVEL PROCESS THE COMMON APPROACH Chaotic management of surface areas Significant slag disposal costs in authorized landfills Outdoor slag deposit areas mean less space for storage
2 ECOGRAVEL PROCESS GREEN STEEL ABS PROJECT
2 ECOGRAVEL PROCESS ECOGRAVEL PROCESS Ecogravel is a CE-marked product in compliance with the following standards: > EN 12620: Aggregates for concrete > EN 13242: Aggregates for hydraulically bound materials for use in civil works and road construction > EN 13043 Aggregates for bituminous mixes and surface treatments for roads, airports and traffic areas
2 ECOGRAVEL PROCESS CONTROL OF THE PROCESS The quality and the control of the process A - B - C determinate the good characteristics of the final product STEP A HOT SLAG STEP B CONTROLLED COOLING STEP C STORAGE AND STABILIZATION
2 ECOGRAVEL PROCESS GREEN STEEL ABS PROJECT CRUSHING AREA STAGES: > DEFERIZZATION > CRUSHING > SCREENING 1. DEFERIZZATION UNIT 2. JAW CRUSHER 3. HAMMER MILL 4. VIBRATING SCREENS 1 2 1 1 4 4 3
2 ECOGRAVEL PROCESS ECOGRAVEL APPLICATIONS > Pre-fabricated items > Aggregate for concrete > Aggregate for bituminous conglomerate > Road construction
2 ECOGRAVEL PROCESS ECOGRAVEL APPLICATION IN CONCRETE Concrete containing Ecogravel aggregate The concrete is inspected by the mobile lab team The concrete is poured and finished like conventional concrete It takes less time to pour, finish and set
2 ECOGRAVEL PROCESS ECOGRAVEL APPLICATION IN CONCRETE > Precast concrete products > Precast wall and bricks > Precast items for sewage treatment
2 ECOGRAVEL PROCESS ECOGRAVEL APPLICATION IN BITUMINOUS CONGLOMERATES 2005-2013: 8 YEARS OF EXPERIENCE IN THE PRODUCTION AND APPLICATION OF ECOGRAVEL IN BITUMINOUS ROAD LAYERS > Just as easy to pour as a normal bituminous conglomerate > Economy: lowers the cost of bituminous conglomerates > Increased road durability 2 1 1 2 1. Binder with 100% Ecogravel and normal bitumen 50/70 2. Road surface with 100% Ecogravel and hard modified bitumen
2 ECOGRAVEL PROCESS THE TOTAL SERVICE FULL SERVICE MANAGEMENT OF SECONDARY MATERIALS IN THE MELTSHOP ECOGRAVEL SERVICE Danieli offers, in collaboration with our partners, the turnkey global service of management and handling of secondary materials in the meltshop, through men and equipment.
2 ECOGRAVEL PROCESS A TYPICAL ROI 1 Mtpy liquid steel production average 0,20 t slag / tls Residual materials > 200,000 tons / year EAF slag > 3% recovered scrap Recovered materials > 194,000 tons / year slag > 6,000 tons / year scrap Operational conditions > 250 wddpy, 1 shift/day, 100 t/h productivity
2 ECOGRAVEL PROCESS A TYPICAL ROI OPERATIONAL COST PRODUCT SALES REVENUES Unit $/unit $/t slag $/year Unit Ton/year $/ton $/year Electric energy KWh/t 5.1 0.1 0.51 102,000 Disel fuel* L/t 0.3 1.7 0.51 102,000 Ecogravel Ton 194,000 4 776,000 SAVINGS Consumables $/t 1.5 1-150,000 Unit Ton/year $/ton $/year Labor** n# 5 60,000-300,000 Scrap recovery Ton 6,000 230 1,380,000 Total yearly cost ($) 654,000 Avoided slag disposal cost Ton 194,000 10 1,940,000 * Amount based on the consumption of a front loader and a truck only ** Yearly cost of a salary
2 ECOGRAVEL PROCESS LANDFILL BEFORE AFTER WITH DANIELI IN A SHORT TIME CUSTOMER
GREEN STEEL ^ 1 2 3 4 5 6 CHR - CLEAN HEAT RECOVERY ECOGRAVEL PROCESS INDUTEC EAF DUST RECOVERY SYSTEM GREEN LAY OUT CFD ANALYSIS DANIELI CENTRO RECYCLING INDUTEC EAF DUST RECOVERY SYSTEM
3 INDUTEC EAF DUST RECOVERY SYSTEM INDUTEC EAF DUST RECOVERY SYSTEM FOR A ZERO-WASTE STEEL MELTSHOP
3 INDUTEC EAF DUST RECOVERY SYSTEM THE EAF DUST WAYS MELTSHOP 1Mt/y EAF dust 15-25 kg/ton of liquid steel 15-25% zinc content, 14-18 % iron content LANDFILL TRADITIONAL WAY WAELZ FURNACE INNOVATIVE WAY LANDFILL (regulation) REUSE (certification) INDUTEC CZO (CRUDE ZINC OXIDE) ZINC PLANTS EZINEX SHG ZINC SHG ZINC
3 INDUTEC EAF DUST RECOVERY SYSTEM THE INDUTEC PLANT AND PRODUCTS EAF DUST INDUTEC Pig Iron Inert slag CRUDE ZINC OXIDE EZINEX Zinc ingots Alkaline Salt (NaCl+KCl) Lead cement
Price US$ per tonne 3 INDUTEC EAF DUST RECOVERY SYSTEM THE MARKET CONTEXT Regulated toxic waste High disposal cost Historical price graph for Zinc 2600 Zn current price Economics driven by zinc price CZO price = Zn LME (US$/T) x (Zn%-8%) x 85% - 250 (T/C) - 25 (penalty) - 100 (washing) - 50 (freight) 2400 2200 2000 1800 1600 5 may 2011 26 apr 2012 18 apr 2013 10 apr 2014 Date
3 INDUTEC EAF DUST RECOVERY SYSTEM THE INDUTEC PLANT PROCESS
3 INDUTEC EAF DUST RECOVERY SYSTEM THE PROCESS MASS BALANCE EAF Dust (15% Zn) Coal: 90 Kg/t Electric energy: 600 KWh/t INDUTEC 27% Crude zinc oxide Natural gas: 20 nmc/t Oxygen: 90 nmc/t 37% Pig iron 36% Inert slag
3 INDUTEC EAF DUST RECOVERY SYSTEM PRODUCTS Indutec for EAF dust: CRUDE ZINC OXIDE Zinc 58 62 % Iron 0.5 2 % Lead 5 6 % Halides (NaCl+KCl) PIG IRON Iron 92 94 % Carbon 3 4 % Copper < 2% SLAG - Acetic leaching test Elem. Units Assay Limit As mg/l n.r. 0,50 Cd mg/l 0,01 0,02 Cr 3+ mg/l n.r. 2,00 Cr 6+ mg/l n.r. 0,20 Hg mg/l n.r. 0,05 Pb mg/l < 0,01 0,20 Cu mg/l < 0,01 0,10 Zn mg/l 0,35 0,50
3 INDUTEC EAF DUST RECOVERY SYSTEM A TYPICAL INDUTEC PLANT LAYOUT
3 INDUTEC EAF DUST RECOVERY SYSTEM RECOVERED PRODUCTS Input > 40,000 tpy EAF dust @ 15% of Zinc content Operational conditions > 250 wddpy, 6-7 t/h productivity Output > 10,000 tpy CZO @ 58% of Zn content > 8,000 tpy Pig iron > 16,000 tpy Inert slag ROI 2 years - high disposal cost 4 years - low disposal cost
3 INDUTEC EAF DUST RECOVERY SYSTEM A TYPICAL ROI OPERATIONAL COST Unit Unit/ton $/unit $/ton Eafd Labor hour 1.5 20 29.99 Electric energy KWh 600 0,1 60.00 Natural gas Nm3 20 0,2 4.00 Coal Kg 90 0,1 9.00 Oxygen Nm3 90 0,12 10.80 Fluxant Kg 20 0,18 3.60 Maintenance 15.00 Slag disposal Ton 16,000 30 480,000 Total yearly cost 5,680,000
3 INDUTEC EAF DUST RECOVERY SYSTEM A TYPICAL ROI PRODUCT SALES REVENUES Unit Ton/year $/ton $/year Crude Zinc Oxide Ton 10,000 500 5,000,000 Pig Iron Ton 8,000 250 2,000,000 7,000,000 SAVINGS Unit Ton/year $/ton $/year Eaf dust Ton 40,000 90 3,600,000
GREEN STEEL ^ 1 2 3 4 5 6 CHR - CLEAN HEAT RECOVERY ECOGRAVEL PROCESS INDUTEC EAF DUST RECOVERY SYSTEM GREEN LAY OUT CFD ANALYSIS DANIELI CENTRO RECYCLING GREEN LAY OUT
4 GREEN LAY OUT GREEN LAY OUT FUMES TREATMENT PLANT NOISE CONTROL GAS CLEANING PLANT VISUAL IMPACT IN STEELMAKING
4 GREEN LAY OUT GREEN STEEL LAYOUT WITH MODULAR DESIGN 1 Quenching tower 2 Injection of activated coal 3 Sound proofing of bag filter 4 Fan silencers 5 Elephant house 6 EAF shell relining area 7 Material handling system 8 Slag rake station 9 Ladle deslagging 10 Ladle refractory removal 11 Tundish deslagging 12 Ladle & tundish drying stations 13 Enclosure for LF noise control 14 VD secondary fumes suction 15 CCM torch cutting 15 Twin VD 14 8 CCM 16 7 9 1 13 Twin LF EAF 5 Tundish Relining Area Ladle Relining Area 12 11 10 Shell Removal 6 2 3 4
4 GREEN LAY OUT STANDARD FTP (EAF FUME TREATMENT PLANT) CANOPY HOOD SECONDARY LINE STACK PRIMARY LINE BAG HOUSE CYCLONE HP COOLER FANS / SILENCERS DUST STORAGE AREA
Decibel 4 GREEN LAY OUT DOGHOUSE 120 100 80 60 40 20 0 Hertz
4 GREEN LAY OUT OUTDOORS NOISE CONTROL > Noise modeling > Fan silencers > Soundproofed fan room
4 GREEN LAY OUT VISUAL IMPACT > Architectural design > Use of colors > Landscaping > Green buffer belt
GREEN STEEL ^ 1 2 3 4 5 6 CHR - CLEAN HEAT RECOVERY ECOGRAVEL PROCESS INDUTEC EAF DUST RECOVERY SYSTEM GREEN LAY OUT CFD ANALYSIS DANIELI CENTRO RECYCLING CFD ANALYSIS
5 CFD ANALYSIS CFD ANALYSIS COMPUTATIONAL FLUID DYNAMIC IN FUME TREATMENT PLANTS
5 CFD ANALYSIS CFD ANALYSIS IN FUME TREATMENT PLANTS QUENCHING TOWERS FLOW DEFLECTORS COOLERS BAG FILTERS SETTLING CHAMBERS CYCLONES FIELDS OF APPLICATION MOBILE DUCTS SECONDARY SUCTION LINES: CANOPY HOODS OPTIMIZATION Y-velocity component CHIMNEYS
5 CFD ANALYSIS CFD ANALYSIS IN FUME TREATMENT PLANTS COMPUTATIONAL FLUID DYNAMICS ANALYSIS NUMERICAL SOLUTION OF MATHEMATICAL EQUATIONS FOR THE PREDICTION OF THE BEHAVIOR OF FLUID FLOWS APPROACH > Analysis of the physical-engineering real problem > Pre-processing Definition of the geometrical model; Spatial discretization of the domain (mesh definition); Definition of the phenomena; > Model identification Mathematical model (conservation equations); Physical models ( turbulence, combustion, etc); Material properties and operative conditions; Boundaries conditions; > Numerical resolution > Analysis of results
52.0 м 32.0 м 5 CFD ANALYSIS CFD ANALYSIS - CANOPY HOODS OPTIMIZATION TARGETS > Determination of the canopy hood efficiency during steelmaking processes (charging, melting and tapping phases) > Calculate visible fugitive emissions through the openings > Design optimization (shape and flow rate) FROM GEOMETRICAL MODEL TO CFD MODEL EAF Area Model Boundaries 162.5 m
Plume velocity [m/s] 5 CFD ANALYSIS CFD ANALYSIS - CANOPY HOODS OPTIMIZATION 1 THERMO CAMERA 2 PROFILE TEMPERATURE AND VELOCITY 3 MODEL INPUT DATA Time [s] 0 100 200 300
Mass Fraction of Fumes [%] Temperature [ C] 5 CFD ANALYSIS CFD ANALYSIS - CANOPY HOODS OPTIMIZATION RESULTS ANALYSIS > temperature profiles at outlet ducts > mean and max fumes mass fraction at openings > hood capture efficiency > flow optimization > feasible no visible emission design 200 180 160 140 120 100 80 60 40 20 Time [s] 0 50 100 150 200 250 300 OUTLET DUCTS 45 s 90 s 2.0% 1.8% 1.6% 1.4% 1.2% 1.0% 0.8% 0.6% 0.4% 0.2% 0.0% Time [s] 0 50 100 150 200 250 300 OPENINGS
GREEN STEEL ^ 1 2 3 4 5 6 CHR - CLEAN HEAT RECOVERY ECOGRAVEL PROCESS INDUTEC EAF DUST RECOVERY SYSTEM GREEN LAY OUT CFD ANALYSIS DANIELI CENTRO RECYCLING CENTRO RECYCLING
6 DANIELI CENTRO RECYCLING DANIELI CENTRO RECYCLING INNOVATION IN SCRAP RECYCLING TECHNOLOGY
6 DANIELI CENTRO RECYCLING DCR TOP BRANDS DANIELI LYNX DANIELI RIVERSIDE DANIELI HENSCHEL DANIELI CENTRO RECYCLING Created in 2010, combines the expertise of three top brands with decades of experience in the market A winning team Specialising in turnkey projects and single-unit machines at both scrap recyclers and steelmakers Shredder plant solutions After sales, re-design and wear parts Pre-shredder shear and baler
6 DANIELI CENTRO RECYCLING DCR SCORECARD ONE OF THE LEADING SUPPLIER FOR METAL SCRAP RECYCLING EQUIPMENT 118 SHREDDER PLANTS 443 SCRAP SHEARS 272 BALING PRESSES Our experience with customers in more than 80 countries worldwide is the best sum of our consistency. Reliability not only in the supply of machines, but also in our process know-how, automation, assistance and turnkey plants.
6 DANIELI CENTRO RECYCLING PRE-SHREDDERS TWO SHAFT PRE-SHREDDER FOR STEEL SCRAP 4 versions from 400 to 800 kw Production from 35 to 110 t/h > Reduction of explosions in the shredder > Detection of un-shreddable material > Smoothing of shredder electricity consumption > Increase of the production chain availability
6 DANIELI CENTRO RECYCLING SHREDDERS HAMMER ROTOR SHREDDER FOR STEEL SCRAP 19 versions from 800 to 10.000 HP Production from 10 to 250 t/h > Non-ferrous downstream separation > Environmental protection solutions (dust extraction, noise insulation) > Increased quality in terms of cleanness, size and density > Energy consumption reduction in an EAF
6 DANIELI CENTRO RECYCLING SHEARS THE WIDEST RANGE OF HYDRAULIC SHEARS AVAILABLE IN THE MARKET CIC INCLINED BOX 500-1,100 T CIV PRESS WINGS BOX 600-1,250 T CIB SIDE PRE- COMPRESSION BOX 800-1,600 T
6 DANIELI CENTRO RECYCLING BALING PRESSES INPUT SCRAP SINGLE, DOUBLE & TRIPLE ACTING BALERS FOR STEEL SCRAP OUTPUT BALES 20 versions bale size from 220x220 to 600x600 mm Production from 0,1 to 50 t/h
6 DANIELI CENTRO RECYCLING GREEN STEEL BAT - BEST AVAILABLE TECHNIQUES > Air pollution control > Noise control > Water pollution control > Water conservation > Energy saving > Zero waste process
GREEN STEEL ENVIRONMENTAL SUSTAINABILITY: HOW TO TRANSFORM A PROBLEM INTO A BUSINESS OPPORTUNITY
UPDATE 01/2015 GIOVANNI NIGRIS EXECUTIVE VICE PRESIDENT DANIELI 20 TH MEXICAN STEEL FORUM CANCUN, MEXICO 28-30 JANUARY 2015 GREEN STEEL / LAYOUT AND PROCESS FOR ENVIRONMENTAL STEEL