Ironmaking and Steelmaking Processes

Ironmaking and Steelmaking Processes

Pasquale Cavaliere Editor Ironmaking and Steelmaking Processes Greenhouse Emissions, Control, and Reduction

Editor Pasquale Cavaliere Department of Innovation Engineering University of Salento Lecce, Italy ISBN 978-3-319-39527-2 ISBN 978-3-319-39529-6 (ebook) DOI 10.1007/978-3-319-39529-6 Library of Congress Control Number: 2016946050 Springer International Publishing Switzerland 2016 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper This Springer imprint is published by Springer Nature The registered company is Springer International Publishing AG Switzerland

Preface Recently, many improvements have been made in ironmaking processes. Additionally, legislative regulations have been modified. As a result, an updated approach to, and description of, the new problems is not present in the literature as a scientific book. Recent technological and metallurgical improvements due to the new regulations and the provisional future regulations need a key point in the scientific literature. Our book offers a complete panorama of industrial steelmaking problems, leading to partial or total solutions of high-quality products with low greenhouse emissions impact. The aim of the book is to provide readers with an in-depth knowledge of specific topics within the field of steelmaking with a focus on greenhouse emissions control and reduction. The chapters are written by acknowledged specialists in their fields. Beginners and experts will both find in the book a useful instrument and resource for topics relating to steel-production-product quality and plant efficiency-greenhouse emissions abatement. The book describes the main phases of steel production, from raw materials to refining, through the discussion of the control, operations, and instrumentation, always relating to the effect on the emissions and pollutants. The book gives also a broad panorama of the different legal regulations all around the world, coupled with the different technological solutions, thanks to the contribution of scientists from 18 different countries. The book is divided into four main parts reflecting the following broad areas of steelmaking: Sintering plants operations, from raw material handling to the big plants productivity to the most innovative technologies available for hazardous emissions control and reduction Blast furnace operations, from CO 2 mitigation to recent technologies finalized to the furnaces efficiency to the numerical modelling of blast furnaces operations Electric arc steelmaking, from the emissions control to the most recent technologies available for carbon and special steel Greenhouse emissions, from the energy consumption to the radically innovative technology to the future trends of steelmaking v

vi Preface Due to the importance of the topic, it is believed that the book will be revised in the future reflecting changes in technologies and legal regulations and standards. My special acknowledgments to the passion and cooperation of all the authors and reviewers who made possible the realization of the book and the reduction of the publication time with their hard work and prompt responses. My special thanks to the professionalism of the editorial office assistants. Finally, I would like to dedicate the work to my parents and to my children, Paolo and Alessandro. Lecce, Italy Pasquale Cavaliere

Contents Part I Sintering Plants Operations 1 Sinter Plant Operations: Raw Materials... 3 Jin-Luh Mou and R. John Morrison 2 Predictions of PCDD/F, SOx, NOx, and Particulates in the Iron Ore Sintering Process of Integrated Steelworks... 27 Jose Adilson de Castro, Daniele Aparecida Nogueira, Marcos Flavio de Campos, Vagner Silva Guilherme, and Elizabeth Mendes de Oliveira 3 Dangerous Emissions Control and Reduction in Sinter Plants... 39 Pasquale Cavaliere and Angelo Perrone 4 Pollutants Emission and Control for Sintering Flue Gas... 59 Tingyu Zhu, Wenqing Xu, Yangyang Guo, and Yuran Li 5 Sinter Plant Operations: Hazardous Emissions... 75 Jin-Luh Mou and R. John Morrison Part II Blast Furnace Operations 6 Recent Trends in Ironmaking Blast Furnace Technology to Mitigate CO 2 Emissions: Top Charging Materials... 101 Hesham M. Ahmed, E.A. Mousa, M. Larsson, and N.N. Viswanathan 7 Dangerous Emissions in Blast Furnace Operations... 125 Lei Gan and Huining Zhang 8 Mathematical Simulation of Blast Furnace Operation... 139 Jursová Simona, Pustějovská Pavlína, Brožová Silvie, and Bilík Jiří vii

viii Contents 9 CO 2 Emission Reduction in Blast Furnaces... 151 Pasquale Cavaliere and Alessio Silvello 10 Recent Trends in Ironmaking Blast Furnace Technology to Mitigate CO 2 Emissions: Tuyeres Injection... 173 E.A. Mousa, H.M. Ahmed, N.N. Viswanathan, and M. Larsson 11 Low CO2 Emission by Improving CO Utilization Ratio in China s Blast Furnaces... 199 Mingyin Kou, Laixin Wang, Jian Xu, Shengli Wu, and Qingwu Cai Part III Electric Arc Steelmaking 12 Dioxin Emission Reduction in Electric Arc Furnaces for Steel Production... 215 Pasquale Cavaliere 13 Emission of High Toxicity Airborne Pollutants from Electric Arc Furnaces During Steel Production... 223 João F.P. Gomes 14 Use of Sustainable Inorganic Binders in the Treatment of Bag-House Dust... 237 Beste Cubukcuoglu 15 Dangerous Emissions During Steelmaking in Electric Arc Furnaces... 247 Dana-Adriana Iluţiu-Varvara 16 Electric Arc Furnace... 267 Jorge Madias Part IV Greenhouse Emissions 17 Technological Methods to Protect the Environment in the Ukrainian BOF Shops... 285 B.M. Boichenko, L.S. Molchanov, and I.V. Synegin 18 State of the Art in Air Pollution Control for Sinter Plants... 301 Christof Lanzerstorfer 19 Risk Assessment and Control of Emissions from Ironmaking... 321 Tao Kan, Tim Evans, Vladimir Strezov, and Peter F. Nelson 20 CO 2 Emission in China s Iron and Steel Industry... 341 Tingyu Zhu, Wenqing Xu, and Mingpan Shao 21 Particulate Matter Emission in Iron and Steelmaking Plants... 355 Wenqiang Sun, Liang Zhao, Xiaoling Li, and Yueqiang Zhao

Contents ix 22 Recent Progress and Future Trends of CO2 Breakthrough Iron and Steelmaking Technologies for CO 2 Mitigation... 373 M. Abdul Quader, Shamsuddin Ahmed, and Raja Ariffin Raja Ghazillaa 23 Manganese Emissions From Steelmaking... 389 Donghui Li, Jack Young, Sina Mostaghel, and Kinnor Chattopadhyay 24 Potential of Best Available and Radically New Technologies for Cutting Carbon Dioxide Emissions in Ironmaking... 411 Volodymyr Shatokha 25 Greenhouse Gas Emissions and Energy Consumption of Ironmaking Processes... 427 Hong Yong Sohn and Yousef Mohassab Index... 457