Creating Customer Value as a Solutions Provider to Leading Stainless and Special Steel Producers Dr. Joachim von Schéele BOC India Ltd.
From Leading Gases Supplier To Leading Solutions Provider Linde has moved from being a gases supplier to a solutions provider, where a key component is to bring additional value to the customers. This is seen as the main way to Counteract commoditization Provide sustainable profitable growth The steel industry, and not at least the stainless and special steel sectors, is clearly in focus. A good partnership has provided the steel producers with less fuel costs, lower emissions, increased production flexibility, improved quality, etc. 12/09/2011 Fußzeile 2
Linde Boiler Plate 2011 The Linde Group is a world-leading gases and engineering company with around 48,500 employees working in more than 100 countries worldwide. In the 2010 financial year, it achieved sales of EUR 12.868 bn. The strategy of The Linde Group is geared towards long-term profitable growth and focuses on the expansion of its international business with forward-looking products and services. Linde acts responsibly towards its shareholders, business partners, employees, society and the environment in every one of its business areas, regions and locations across the globe. Linde is committed to technologies and products that unite the goals of customer value and sustainable development. 12/09/2011 Fußzeile 3
Industrial Gases Production and Supply Production Cryogenic (Oxygen, Nitrogen, Argon) Absorption (Oxygen, Nitrogen) Steam Reformer, Electrolysis (Hydrogen) Supply modes Gaseous via Pipeline Liquid via Tanker to Intermediate Onsite Storage and Vaporization Cylinder The cost relates mainly to Way and Size of Production Efficiency and Age of Production Electricity Price Purity Requirement Pressure Requirement Way and Distance of Supply 12/09/2011 Fußzeile 4
REBOX HLL A Solution for Increased Throughput, Fuel Savings, and Reduced Emissions in Large Reheating Furnaces At SSAB, Sweden REBOX HLL is applied in two 300 tph Walking Beam Furnaces. The mill is supplied with liquid oxygen at 12,000 Nm3/h, >5 times more than the usual limit for liquid supply.
Examples of Linde Solutions First Introduced at Stainless and Special Steel Producers Flameless Oxyfuel Preheating of Ladles (Outokumpu) Converters (Sandvik) Oxyfuel Direct Flame Impingement for Annealing (Outokumpu) Flameless Oxyfuel Heating in Soaking Pit Furnaces (Ascometal) Catenary Furnaces (Outokumpu) Walking Beam Furnaces (Outokumpu) HYDROFLEX (Sandvik) Flameless Oxyfuel Heating Using a Low Calorific Fuel (Dongbei Special Steel) 12/09/2011 Fußzeile 6
HYDROFLEX 12/09/2011 Fußzeile 7
Oxyfuel Solutions Energy Efficiency, Increased Throughput, Lowered Emissions Low flue-gas losses due to low flue-gas volume Low flue-gas losses even at high flue-gas temperatures Radiating compounds, H 2 O & CO 2 Possible to use high power input Possible to use Low Calorific Fuels 8 Molecules of Nitrogen Ballast! Oxyfuel 12/09/2011 Fußzeile 8
REBOX Oxyfuel Solutions Reduced CO 2 and NO X Emission Levels Fuel savings of up to 50% Reduction of CO 2 emissions by up to 50% Air fuel 70 mg NO X /MJ (as NO 2 ) 88 g NO 2 /t 80 kg CO 2 /t 425 Nm 3 /t 350 kwh/t 250 kwh/t Oxyfuel 70 Nm 3 /h 70 mg NO X /MJ (as NO 2 ) 66 g NO 2 /t 57 kg CO 2 /t AGA AGA A flue-gas volume that is - 75-85% smaller and having a - CO 2 content of 95% (dry basis) This small flue-gas stream with a high CO 2 content should be very suitable AGA for cleaning, storage and sequestration. CO 2 emission directly proportional to fuel consumption 12/09/2011 Fußzeile 9
Flameless Oxyfuel Flame Mode Flameless Oxyfuel Burners Flameless Mode 12/09/2011 Fußzeile 10
General Benefits of Oxyfuel in Vessel Preheating Benefits from higher heating temperature of a steel-making vessel: No need to have too high temperature of the steel in the EAF/BOF/AOD Shorter heating cycles for less number of vessels needed Only 75-80% flue gases due to less fuel and no nitrogen in combustion smaller flue-gas system 50-55% lower fuel consumption compared to cold air fuel system Possibility to reach very high pre-heating temperatures when wanted (Example 1500 o C for atomizing customer) Simple, compact and low weight installation as compared to air-fuel system with recuperator or regenerative solution Added features in Flameless oxyfuel: Further improved heat distribution in vessel Ultra low NO x emissions Extended refractory lifetime due to higher and more even temperature distribution in vessel 12/09/2011 Fußzeile 11
Flameless Oxyfuel in Ladle Preheating Results from Acerinox, Spain Drying of refractory, 24 hours Final temperature of 1,175ºC Fuel consumption: 1,000 Nm 3 NG Average thermal efficiency is 84% Drying cycle of 12 hours Final temperature of 1,175ºC Fuel consumption : 759 Nm 3 NG From 900ºC to 1,175ºC Final temperature after 1 hour 325ºC outside temperature Fuel consumption: 111 Nm3 NG 12/09/2011 Fußzeile 12
Vessel Preheating with Flameless Oxyfuel Increased temperature uniformity in ladle/converter Decreased fuel consumption Lower NOx formation Increased heating capacity Installations of flameless oxyfuel for preheating Sandvik 90 t converters 1.4 MW Outokumpu, Avesta 90 t ladles 1.5 MW Acerinox 90 t ladles 2.0 MW Ovako, Hofors 90 t ladles 1.4 MW Ovako, Smedjebacken 100 t ladles 1.5 MW Ovako Imatra 80 t ladles 1.0 MW Kanthal 5 t ladles 0.2 MW Outokumpu, Tornio 90 t converters 2.0 MW >25 Foundries 0.5-20 t 0.15-0.5 MW 12/09/2011 Fußzeile 13
Ferrochrome Converter at Outokumpu, Tornio 2.5 MW Flameless Oxyfuel Used for Drying and Heating 12/09/2011 Fußzeile 14
REBOX Installations of REBOX Oxyfuel Solutions in Steel Reheating Have Resulted in: Capacity Increase by up to 50% Fuel Savings of up to 50% Reduction of CO 2 Emission by up to 50% Reduction of NO X Emission Improved temperature uniformity, max. +/-10 C Decrease of Scaling Losses by up to 50% 12/09/2011 Fußzeile 15
More than 120 REBOX Oxyfuel Installations Examples of sites where installations have been made ArcelorMittal, Galati (RO) * ArcelorMittal, Shelby (US) Ascométal, Les Dunes (FR) Ascométal, Fos-sur-Mer (FR) Brach, Bremen (DE) Buderus, Wetzlar (DE) Dongbei Special Steel, Dalian (CN) Ellwood City Forge, Ellwood City (US) Evraz Steel, Claymont (US) * Kalyani Carpenter Special Steel, Pune (IN) * Michigan Seamless Tube, South Lyon (US) North American Forgemasters, New Castle (US) Outokumpu, Avesta (SE) Outokumpu, Degerfors (SE) Outokumpu, Nyby (SE) Outokumpu, Tornio (FI)* Ovako, Hofors (SE) POSCO, Pohang (KR) Scana Steel, Björneborg (SE) SSAB, Borlänge (SE) ThyssenKrupp Steel, Bruckhausen (DE) ThyssenKrupp Steel, Finnentrop (DE) Timken, Canton (US) Uddeholm Tooling, Hagfors (SE) Usiminas, Cubatao (BR) Commissioned 2011 * Under way 12/09/2011 Fußzeile 16
Flameless Oxyfuel Increases Capacity Over Air-fuel and Conventional Oxyfuel Comparison of total heating time at Ovako s Hofors Works, Sweden, using different combustion technologies 12/09/2011 Fußzeile 17
REBOX Oxyfuel Solutions Use of a Low Calorific Fuel For Coke Oven Gas, Blast Furnace Top Gas, BOF Gas, and other in-house gases. And Producer Gas. Combusting Low Calorific in-house gases with oxygen provides the flame temperature needed in reheating and annealing operations. Air / BFG Flame: - Diffuse - bad definition - T = 1,300 C - efficiency <5% LHV 3.2 MJ/Nm 3 With oxygen a fuel of Oxyfuel Flame: - stable and compact 3.3 MJ/Nm 3 (0.9 kwh/nm 3 ) - T = 1,900 C, efficiency >35% is upgraded to be like a 7.7 MJ/Nm 3 (2.1 kwh/nm 3 ) fuel combusted with air. Oxygen + Bad Fuel = Air + Good Fuel LVH 3.2 MJ/Nm 3 12/09/2011 Fußzeile 18
Ascométal, Fos-sur-Mer, France Soaking Pit Furnaces 40% Reduce Fuel Consumption Reduced Emissions of CO 2 & NO x Scale Losses Reduced by 0.3 per cent points 12/09/2011 Fußzeile 19
Ascométal, Fos-sur-Mer, France Soaking Pit Furnaces Linde s experience in reheat furnaces gives us the confidence to fully benefit from the advantages of the REBOX oxyfuel solutions. By revamping our existing pit furnaces in this way, we should be able to reach today s production level with 9 instead of 13 furnaces while reducing our fuel consumption and emissions of CO 2 Michel COSTES, Director of ASCOMETAL Fos-sur sur-mer Plant. kwh/tonne heated steel 375 350 325 300 275 250 225 200 175 Only air-fuel First oxyfuel installation 9 oxyfuel + 4 air-fuel furnaces 150 2001 2002 2003 2004 2005 2006 07-jan 07-feb 07-mar 07-apr 07-may 07-jun 07-jul 12/09/2011 Fußzeile 20
Outokumpu, Nyby, Sweden REBOX DFI Installation in Annealing Line 4 MW installed power 120 oxyfuel flames, four burner rows 2 m long unit at entry of strip annealing furnace Furnace throughput capacity increased by 50%, from 23 to 35 tph 12/09/2011 Fußzeile 21
REBOX Oxyfuel Solutions Outokumpu, Avesta, Sweden Catenary Furnace Converted into All Flameless Oxyfuel Operation 40 MW Flameless Oxyfuel; Capacity 150 tph 12/09/2011 Fußzeile 22
REBOX Oxyfuel Solutions Outokumpu, Degerfors, Sweden Walking Beam Furnace Converted into All Flameless Oxyfuel Operation Linde Gas Turn-key delivery Combustion system with flameless burners, furnace upgrade, new flue gas system, flow train, control system Furnace data Dimensions: 27 m length, 5 m wide Fuel: LPG Stainless steel: all grades, 1,550 mm wide 140-300 mm thickness Performance Guarantee 35% more through put 30% fuel savings (down to 0.97 GJ/ton cold charged) NO X emission <70mg/MJ (350 mg/m3) Revamped in 25 days 12/09/2011 Fußzeile 23
REBOX at Outokumpu, Degerfors More Heating Capacity in a Walking Beam Furnace Temperature (C) 1400 1200 1000 800 600 400 200 0 0 5000 10000 15000 Time (s) Stainless steel slabs 166 mm thick Top fired with wall-mounted flameless oxyfuel burners Air-fuel Oxy-fuel 2.9 H 3.8 H 12/09/2011 Fußzeile 24
Outokumpu, Tornio, Finland Startup in October 2011 Walking Beam Furnace at Hot Rolling Roll REBOX Solution: HLL Fuel: Propane and CO (from FeCr production) Expected results Throughput capacity Fuel consumption 15% more (from 250 to 288 tph) 8% less 12/09/2011 Fußzeile 25
Kalyani Carpenter Special Steel, Pune, India Startup in January 2012 Walking Beam Furnace Material size REBOX Solution: Fuel: 240 x 280 x 3700 mm Flameless and HLL Oil Expected results Throughput capacity 33% more (from 30 to 40 tph) Fuel consumption 25% less Increased temperature uniformity Reduced scale formation 12/09/2011 Fußzeile 26
Do We Reach our Targets? Wins Margins Customer Retention For India our Targets Include Tripling of Top Line Quadrupling of Bottom Line We trust we can achieve this, but only by being a Solutions Provider Car bottom furnace at Uddeholm Tooling, all equipped with flameless oxyfuel 12/09/2011 Fußzeile 27
Creating customer value as a solutions provider to leading stainless and special steel producers Thank you very much for your kind attention joachim.von.scheele@linde-gas.com 12/09/2011 Fußzeile 28