annotated bibliography on energy efficiency

INTRODUCTION

An annotated bibliography on Energy Efficiency in Steel Industry aims

to create an awareness among the users, what has been done and what

is being done in the area of energy conversion. The coverage for this

bibliography is confined to Association of Iron and Steel Technology

(AIST) conference proceedings published over the years and few

selected journal articles. The main part is supplemented with Title

index to add value to the service. We hope that users would find the

contents useful and interesting.

Suggestions to increase the utility of such type of information services

from the JKC are always welcome.

Dr. N V Ramakrishna

i

AN ANNOTATED BIBLIOGRAPHY ON

ENERGY EFFICIENCY IN STEEL INDUSTRY

TITLE INDEX

Sl. No. Title Page No.

1. 25% Increased Reheating Throughput and 50% Reduced Fuel

Consumption

11

2. A Design Approach for Sizing a Closed-loop Cooling System 13

3. A Multi-Faceted Approach to Reducing Electricity Costs in the Steel

Industry

17

4. A New Model for Energy and Carbon Dioxide Calculations: Model

Development, Assumptions, and Applications to EAF Steelmaking

19

5. A system dynamics analysis of energy consumption and corrective

policies in Iranian iron and steel industry

32

6. Advanced Technology In Furnace Control System Furnace

Optimizing System (Level 2)

27

7. An empirical analysis of energy efficiency in China’s iron and steel

sector

31

8. An Investigation of NOx Formation and Control in an EAF Using a

Computational Fluid Dynamics Model

7

9. Analysis of Potential and Specific Problems of Heat Recovery in Steel

Plants

20

10. Applications of Fast Gas Analysis by Mass Spectrometry to Process

Control in the Iron and Steel Industry

10

11. Are Regenerative Burners OK for large Reheating Furnaces? 4

12. Assessment of Energy Efficiency Improvement and CO2 Emission

Reduction Potentials in the Iron and Steel Industry in China

32

13. Bethlehem Steel’s Evaluation of a Low-NOx Oxy-Fuel Burner 27

14. Biofuel Use in Ironmaking From a Life Cycle Analysis Perspective 18

15. Biofuel Use in Ironmaking From a Life Cycle Analysis Perspective 22

16. Carbon Taxes In Sweden Impact On The Steel And Utility Industries 3

17. Carbon Utilization In The EAF: Friend Or Foe 2

18. Characterization of Mixtures of Sugarcane Bagasse and Charcoal for

Injection Through Tuyeres of Blast Furnaces

18

19. Climate Change and the Iron and Steel Industry 1

20. CO2 Emissions from a Steel Mill and a Petro-Chemical Industry 33

21. Cockerill-Sambre 70 MW EAF : 2nd Generationg of DC Power

Supply

28

22. Combustibility of Charcoal for Direct Injection in Blast Furnace 17

ii

Ironmaking

23. Combustion Control of Carl Still Coke Oven • CST’s Experience 8

24. Component Protection For Today's Melting Environments - New

Approaches And Concepts

1

25. Continuous Steel Production from Ore Using Natural Gas 5

26. Control Method for Low Oxygen Concentration of Waste Gas is HSM

Reheating Furnace

24

27. Corporate Mass and Energy Simulation Model for an Integrated Steel

Plant

6

28. Cost-Effective Operation of a Blast Furnace Stove System 26

29. Current situation of energy consumption and measures taken for

energy saving in the iron and steel industry in China

33

30. Design and Installation of In-Duct Peak Temperature Control System

at CMC Steel South Carolina

29

31. Development of New Combustion Control System Based on Fuel Gas

Humidity at Continuous Annealing Line

25

32. DOE’s Industrial Technologies Program (ITP): Assessment Efforts to

Improve Energy Efficiency, Carbon Footprint and Profit in the U.S.

Steel Industry

14

33. Dynamic simulation as a tool to improve the efficiency of energy

systems. Applications in the steel industry

30

34. Elimination of Ladle Fume Emissions 3

35. Energy Analysis of EAF with electromagnetic stirring 4

36. Energy Efficiency and GHG Emissions for Alternate Ironmaking

Technologies

22

37. Energy Efficiency Improvement Opportunities in Steel Industry 4

38. Energy Efficiency of Carbon-Bearing Materials in Arc Steelmaking

Furnaces and Methods of Improving It

31

39. Energy Efficiency Opportunities In Electric Arc Steelmaking 2

40. Energy Optimization for EAF Melting Operations 7

41. Energy Recovery And BOS Stack Emission Reduction By Controlling

The Combustion Of Waste Gas

3

42. Exchange of Converters at voestalpine Stahl, Linz, Austria 29

43. Flameless Oxyfuel for Highly Visible Results 8

44. Flue Gas Flow Optimization for Energy Efficiency and Clean

Operationsin Integrated Steel Plants

15

45. Fuel Savings for Slab Reheating Furnaces through Oxyfuel

Combustion

6

46. Heat Recovery for the EAF of Georgsmarienhütte, Germany 16

47. Hot Stoves — More Than 50 Years of Experience — Design

Optimization and Future Concepts

18

48. Identifying Energy Efficiency Opportunities for the Steel Industry —

The Production Energy Optimization Concept

21

49. Improved Temperature Uniformity in Batch Reheat Furnaces with

Praxair's Dilute Oxygen Combustion(DOC) System

14

iii

50. Improvement in Combustion Efficiency and Productivity of Reheating

Furnaces of Rail & Structural Mill at Bhilai Steel Plant

11

51. Improvement Of Energy Usage And Environmental Impacts In A

Steel Plant

3

52. Improving Combustion Safety & Efficiency through Better

Measurement

25

53. Increasing Energy Efficiency of the Electric Arc Furnace at

TenarisTamsa

28

54. Industrial Experiences from Flameless Oxyfuel Operation in Walking

Beam Furnaces

12

55. Innovative Approach to the Use of Offgas Heat for High-efficiency

Green Power Generation

20

56. Installation of a 145 MMBtu/hr Oxyfuel Firing System on the #2

Reheat Furnace at ArcelorMittal’s 84 Hot Strip Mill

11

57. Insulating Firebrick - Maximizing Energy Savings in Iron and Steel

Applications Through Product Selection

29

58. Introduction Of Ceramic Burner Technology In The No. 5

Galvanizing Line At I spat Inland Flat Products

25

59. Ladle Heating And Drying With Ultra-Low NOx Emissions 26

60. Lowering Exhaust Gas Losses and Emissions with Newly Developed

Recuperative and Regenerative Burners

15

61. New Approaches to Melt shop Off gas Heat Recovery 16

62. Opportunities and Challenges in Steel Manufacturing: Engineering a

Brighter Future, The AIST 2008 Brimacombe Lecture

9

63. Ovako, Hofors Works - 13 Years Experience of Using Oxyfuel for

Steel Reheating; Background, Solutions and Results

9

64. Overview Global Warming Issues And EAF Production 2

65. Oxygen Enhanced Ladle Preheating Systems: Improved Tap-to-tap

Cycle Time and Operating Cost Reductions

17

66. Performance of the Regenerative Burners in BaoSteel 2050 Hot Strip

Mill Furnace Baoshan, China

6

67. Performances Enhancement of reheating furnaces using

oxycombustion

26

68. Preparing Your Company for the Future Energy Management Systems

Requirements Like ISO 50001

21

69. Process and Economic Benefits from Operation Improvements and

Equipment Alterations of the Bop Boilers

28

70. Process Control and Automation Systems Advancements for Reheat

Furnaces

24

71. Pusher Reheat Furnace: Technology Advancement 5

72. Realization of the Coexistence of Energy Savings and Environmental

Measures in the EAF Concept of ECOARCTM

23

73. Recent Cost Reduction Developments in the Heating of Steel 22

74. Reducing Vessel Fume Losses And Recycling Of BOF Residuals 3

75. Reduction in Specific Energy Consumption in Steel Industry – with 31

iv

special reference to Indian steel industry

76. Regenerative Burners in INI Large Structural Mill Furnace Incheon,

Korea

5

77. Reheat Furnace Fuel Switching 9

78. Steel Mill Saves Nearly 60% in Energy Costs with Direct Steam

Injection Heaters

12

79. Steel Mills: Energy Costs and the Green Planet 14

80. Steel Process Fans Energy Efficiency Upgrades: The Right Way, the

Only Way

22

81. Strategic Energy/CO2 Model for ArcelorMittal Burns Harbor 24

82. Strategies for Energy Reduction in Today's World” Low Cost/No Cost

Basic Things that May Have been Overlooked in your Oven or

Furnace Operations

14

83. Sustainable Energy Management System 5

84. Techint Innovative Combustion System (I.C.S.®) 4

85. The Benefits of Applying Regenerative Technology to Continuous

Reheat Furnaces

28

86. The case study of furnace use and energy conservation in iron and

steel industry

29

87. The Evaluation of EAF Performance —Operational Results 20

88. The Future of Green Bearing Protection 23

89. The Impact of Compound Plant Solutions and Cross Process

Optimization on Energy and Environmental Care for the Iron and

Steel Industry

13

90. The Performance and Actions of Saving Energy for Sinter Plant in

CSC

1

91. Thermal Modeling Of Lo-Vap Cooling 27

92. Total Cost and CO2 Emission Reduction Using Apollo® Electrode

System at ArcelorMittal Differdange DC Arc Furnace

20

93. Understanding Energy Use in the EAF: Practical Considerations and

Exceptions to Theory

7

94. Understanding Industrial Electric Bills 10

95. Update on Design and Operating Experience of Low Calorie Gas

Firing Gas Turbine for Steel Works

10

96. Use of High Percentage Quality DRI in EAF and Its Benefit in Cost

Reduction

20

97. Variables affecting energy efficiency and CO2 emissions in the steel

industry

30

98. What Makes A Good Oxyfuel Burner? 1

99. Wireless Technology: A Revolution in Temperature, Oxygen and

Carbon Measurements in Molten Metal

21

1

MAIN PART

1. The Performance and Actions of Saving Energy for Sinter Plant in CSC

C.-S. Lee, C.-T. Charng and H.-K. Wang

ISSTech Conference Proceedings PR-007-108 - 2003

China Steel Corporation is an integrated steel work in Taiwan, and includes a few kinds of productiveprocesses that need to input huge energy to produce the varieties of steel. Therefore, the demand of energy in integrated steel work is higher than the other industries. Based on the domestic survey, CSC consumed the energy of electricity and coal which occupied about 8% of whole energy consumption in Taiwan™s region. Due to the above reasons, saving energy is one of the essential operating policies in CSC.

2. What Makes A Good Oxyfuel Burner?

K. Grieshaber

Electric Furnace and Process Technology Proc. PR-025-20 - 1998

Oxyfhel burners have been used in electric arc furnace (EAF) steelmaking for approximately thirty years. Most furnaces have been equipped with burners at one time or another. Some have experiencedtremendous success while others have met with frustration and unmet expectations.

3. Component Protection For Today's Melting Environments - New Approaches And

Concepts

D. E. Bowen


The melting environment is a very severe one. People and equipment are constandy challenged to perform properly and over extended periods. Recent advances in furnace size and design have increased the rigors placed upon men and machines.

4. Climate Change and the Iron and Steel Industry

S. Friedman


In December of 1997, over 150 countries, including the US negotiated an international climate change agreement to reduce global greenhouse gas emissions. The majority of U.S. and global greenhouse gas emissions come from fossil fiel combustion for energy. About 35% of carbon emissions are from theindustrial sector. Aluminum, iron and steel are among the most energy intensive industries in this country. Reducing carbon emissions associated with these industries could play a part in the overall strategy toreduce domestic greenhouse gas emissions

2

5. Carbon Utilization In The EAF: Friend Or Foe

J. A. T. Jones


Carbon is one of the most utilized compounds in steelmaking but for the most part its’ contribution istaken for granted. Carbon is essential to the manufacture of steel. Steel is defined as any alloy of Feand carbon which contains less than 1.7 0/0 carbon. There are many different types of steel produced and these consist primarily of.metallic iron and varying lesser amounts of carbon and other alloying elements. Carbon is one of the key elements which give various steel grades their properties.

6. Energy Efficiency Opportunities In Electric Arc Steelmaking

E. Worrell, N. Martin, L. Price


The U.S. steel industry is a huge energy consumer and emission source of greenhouse gases. We discuss trends in production, energy use and emissions in the U.S. steel industry from a historic and international perspective. Cost-effective opportunities for energy efficiency improvement can be found throughout the industry. Focusing on electric steelmaking, we found that cost effective measures could have reduced 1994 energy use by 25%. This would have saved 5’% of total 1994 U.S. steel industry energy use. In integrated mills 110/0of total 1994 U.S. steel industry energy use could have been saved. Innovative policy instruments as used in some European countries (i.e. voluntary agreements) can helpto realize these potential energy efficiency gains while at the same time improving productivity of U.S. iron and steel industry.

7. Overview Global Warming Issues And EAF Production

H. D. Goodfellow, M. Thompson, L. Cibert, P. Morer


The Kyoto Climate Change Protocol set objectives for the dramatic reduction of greenhouse gases to address global warming issues. Carbon dioxide is the most significant greenhouse gas. A model of greenhouse gas emissions from electric arc steelmaking have been identified, calculated and ranked. Direct and indirect sources of carbon dioxide gas emissions are calculated and ranked. The most important sources of C02 have been determined to be indirect; in particular the generation of electricity. Potential strategies to reduce these C02 emissions have been evaluated.

8. Carbon Taxes In Sweden Impact On The Steel And Utility Industries

J. Sieurin


3

One of the greatest challenges as we go into the 21st century is the establishing of an ecologically sustainable society. The realisation that we can not continue to consume our natural resources in the way we do today is becoming more widespread. A clean environment is considered by more and more people to be an important part of a high standard of living. Development towards an ecologically sustainable society can be encouraged by laying down the rules of the game for the market, rules with an in-built Environmental awareness when it comes to decision-making.

9. Energy Recovery And BOS Stack Emission Reduction By Controlling The

Combustion Of Waste Gas

A. B. Snoeijer, H. J. Bilderbeek, B. F. Middel, T.

Steelmaking Proceedings, PR-049-625 - 2002

The potential to reduce gas emission from the BOS stack and to increase the calorific value of the recovered gas from the waste gas system of the BOFs in BOS nr 2 of CORUS Ijmuiden was investigated. Possible puffing or flaring of the converter gases causes the safe margin of the waste gas flow control system to be larger than necessary.

10. Reducing Vessel Fume Losses And Recycling Of BOF Residuals

P. Mink, S. Dye


An X-Ray Flourescence (XRF) technique has been applied as an aid in developing methods for reducing the fume losses from the BOF process. Typical XRF process traces indicated that the largest losses from the converter occur during the initial stages of the blow where lower iron losses are generally observed for higher silicon levels.

11. Elimination of Ladle Fume Emissions

M. Ricci


Numerous employee comments regarding emissions from EAF ladle drying resulted in air quality testing. High levels of several toxic compounds were detected in the fumes (i.e. phenol, carbon black, benzene and formaldahyde.

12. Improvement Of Energy Usage And Environmental Impacts In A Steel Plant

M. H. Tari, M. Larsson, M. Soderstrom, J. Dahl


Decisions regarding investments are usually highly integrated. However improvements in energy efficiency can still be made in several ways. New energy efficient technology can be installed or changes in processes can be made in order to improve energy recovery.

13. Energy Analysis of EAF with electromagnetic stirring

X. Zhang, C. Zhang, O. Widlund, J. Eriksson, M. Ra

4

Steel Properties & Applications Conference Proceedings, PR-264-021 – 2011

In this study, electromagnetic stirring (EMS) for electric arc furnace (EAF) application is investigated. The objective is to analyze EAF operations with and without EMS in order to provide necessary information to understand the benefits of EMS. Static material balance and energy balance models are built up including major chemical reactions. Impact of melt bath s tirring on scrap melting is analyzed. Major conclusions of the energy analysis are that EMS has significant impact on scrap melting, especially for large pieces of scrap; shorter melting time is expected with improved temperature and chemical composition homogenization; in addition, EMS has significant Environmental impact.

14. Are Regenerative Burners OK for large Reheating Furnaces?

G. Carrara

AISE Annual Convention and Exposition, PR-337-113 - 2003

In the last decade, hot mill operators urged furnace designers to give maximum consideration tothe improvement of the following strategic technical issues: • Steel heating quality (temperature uniformity, skid marks, head and tail temperature differential); • Fuel consumption; • Furnace operating reliability and maintainability; • Make furnaces friendlier to the surrounding environment.

15. Techint Innovative Combustion System (I.C.S.®)

P. Bonci


The Innovative Combustion System® by Techint (patent reference PCT WO 01/67000 A1) is the heart-equipment of the new generation of Techint furnaces.

16. Energy Efficiency Improvement Opportunities in Steel Industry

Thekdi, Arvind, Olszewski, Mitch; McElhaney, Karen

AISTech Conference Proceedings, PR-342-260 - 2004

Overview of the PresentationThis paper describes:• Major areas of energy use and magnitude for the steelindustry.• Opportunities for reducing energy use and and cost insteel plants• Tools available from the U.S. Department of Energy’s(DOE) Best Practices program to assess and analyzeenergy efficiency improvements• Results of plant-wide energy assessments carried outby several steel companies in cooperation with theDOE.

17. Pusher Reheat Furnace: Technology Advancement

J. J. Feese and F. Lisin


In today’s competitive marketplace steelmakers expect increased production rates, product quality, and reduced specific fuel consumption while simultaneously complying

5

with ultra low Nitrogen Oxide (NOx) emissions. A first step collaborative effort between Nucor Steel, Hauck Manufacturing Co. a burner supplier, and Forni Industriali Bendotti S.p.A. with partners Alchas Inc. engineers and furnace builders has provided a roadmap for success on an upcoming steel reheat pusher furnace installation. Burnerdesign and performance validation of the furnace heating zone was completed using Fluent® Computational Fluid Dynamics (CFD) software. A complete CFD model study of the planned furnace design heating zone, complete with novel triple air staged ultra low NOx burners utilizing preheated combustion air for fuel savings was conducted. Calculated velocity, temperature, and flow patternswere analyzed at various locations in the furnace including the flues. Results indicated excellent temperature uniformity of the steel and flue products; and combined with separate CFD modeling and laboratory testing verifying ultra low NOx burner emissions, the foundation for technical success was established.

18. Sustainable Energy Management System

Y. Lu, J. Liu, D. Bettinger and M. Schaler

AISTech Conference Proceedings, PR-346-204 – 2005

Due to the dramatic increase of energy prices – coke prices alone more than doubled in recent years and are predicted to stay in this range – energy savings are mandatory for the steel industry worldwide. The steelmaking process is well-known for a high amount of energy consumption, therefore for iron and steel producers reduction of energy costs must be a predominant goal.

19. Continuous Steel Production from Ore Using Natural Gas

N. A. Warner


A keynote address to the Business Roundtable’s National Summit on Technology and Climate Change expressed the view that methane will dominate the US energy scene for the next five or six decades and by the year 2030 methane will account for around 70% of primary energy usage because of its projected use to fuel turbines for electric power and for fuel cells for transport.1 The National Petroleum Council forecasts that the US demand for natural gas in 2025 will amount to about 0.8 x 1012 cubic meters.

20. Regenerative Burners in INI Large Structural Mill Furnace Incheon, Korea

S. J. O’Connor and J. Kondziela, Y. In and K. Gi


In late 2003 the INI Steel Company embarked on an energy savings program for it's large structural mill in Incheon, Korea. In February of 2004, four pairs of regenerative burners were purchased to replace the burners in the bottom preheat zone of the existing walking beam furnace. The burners were installed during the mill shutdown in August of 2004 and were immediately put into production. The burners were provided by Bloom

6

Engineering Company. The combustion system was engineered and installed byCombustech Ltd. of Incheon, Korea. Commissioning and testing was a joint effort between Combustech and Bloom.

21. Fuel Savings for Slab Reheating Furnaces through Oxyfuel Combustion

F. Erfurth, J. Grzych, R. Parron II, F. Miller, M.


With high fuel prices, fuel-savings technologies can provide significant economic benefits to steel mills. Reheating furnaces in integrated and mini-mills consume approximately half of the natural gas used to produce hot-rolled products. Recently, Praxair’s Dilute Oxygen Combustion technology (previously demonstrated for productivity improvements on mini-mill billet reheating furnaces) was extended to a slab reheating furnace. This flexible oxyfuel combustion system delivered significant fuel savings with no impact on other critical process parameters (steel surface quality, emissions, refractory, oxide scale, etc.) This paper reviews installation, startup, operating results and plans for installation on other slab reheating furnaces in the hot strip mill.

22. Performance of the Regenerative Burners in BaoSteel 2050 Hot Strip Mill Furnace

Baoshan, China

S.J. O’Connor, J.C. Qin, and L. Deng


In late 2003 the Bao Steel Company embarked on an energy savings program for its 2050 hot strip mill in Baoshan, China. In February of 2004, eleven pairs of regenerative burners were purchased to replace the burners in the bottom heat 1 (Zone 4) and bottom heat 2 (Zone 6) zones of the No. 2 walking beam furnace. The burners were installed during the mill shutdown in September of 2004 and were immediately put into production. The burners were provided by Bloom Engineering Company. The combustion system was engineered by Bloom Combustion Products Ltd. of Shanghai, China. It was installed by Beijing Phoenix Company. Beijing Phoenix also made all required furnace modifications. Commissioning and testing was done by and Bloom Combustion Products Ltd. and Bloom Engineering Company

23. Corporate Mass and Energy Simulation Model for an Integrated Steel Plant

H. Gou and S. Olynyk


The increasing and volatile cost of energy along with Environmental concerns around air emissions including greenhouse gases (GHG), sulphur dioxide, nitrogen oxides and particulate, are leading many organizations and policy makers to strategies focusing on improving energy efficiency and reducing energy intensity.

7

24. Understanding Energy Use in the EAF: Practical Considerations and Exceptions to

Theory

J. A. T. Jones

ISSTech Conference Proceedings, PR-007-103-2003

Many EAF operations have been focused on energy efficiency in the EAF over the past 20 years. Most efforts at benchmarking operations have focused primarily on quantification of electrical energy input and oxygen consumption. While this is an excellent starting point for benchmarking activities, many other factors such as scrap composition, scrap yield, variations in raw material compositions and availability and proper utilization of auxiliary equipment can frequently tell a much more complete story as related to energy use and efficiency in the EAF. Many operations cannot account for the high degree of variability in operating efficiency that they experience day-to-day. This paper attempts to demonstrate through practical analysis of operations and real operating data, the reasons for variations in EAF operating efficiency. Reference is also made to the effect that these variations can have on the operation of the offgas system in order to demonstrate the close coupling of steelmaking and Environmental operations.

25. Energy Optimization for EAF Melting Operations

H. D. Goodfellow

ISSTech Conference Proceedings, PR-007-104 - 2003

Part 1 of this paper was presented at the 2002 EAF Conference. The paper examined the theoretical aspects of energy sources for an EAF and the potential benefits to steelmakers to measure off-gas chemistry in real time at the fourth hole. 1 The energy balance for a typical EAF melting operation showed losses in the off-gas of 39% of the total energy outputs for the melting of steel. The analysis also demonstrated the variability in the off-gas chemistry and the need for dynamic control to take advantage of efficiency opportunities. The technology involved to calculate a carbon balance was also described. An example was also shown of how the continuous measurement of off-gas chemistry could warn of explosive conditions within the furnace and to improve safe operating conditions.

26. An Investigation of NOx Formation and Control in an EAF Using a Computational

Fluid Dynamics Model

E. Chan, M. Riley, M. J. Thomson and E. J. Evenson

ISSTech Conference Proceedings PR-007-105 – 2003

The emission of nitrogen oxides is an important Environmental concern due to its role in the formation of photochemical smog and acid rain. The U.S. iron and steel industry annually emits 126,000 metric tons of NOx [1]. The steel industry currently faces increased regulatory pressure to reduce NOx emissions [2].The 1990 Amendments to the Clean Air Act have imposed new emission requirements for Electric ArcFurnaces (EAF)

8

located in non-attainment areas. Relatively little information is available in the openliterature on steel industry’s NOx emissions. The average EAF emits 0.25-0.3 kg NOx/net metric ton ofsteel [3, 4] although the NOx emissions of individual EAF plants can vary widely (0.02 to 0.4 kg/ton) [5].

27. Flameless Oxyfuel for Highly Visible Results

P. Vesterberg and G. Moroz


Steel producers are continuously striving for shorter heating cycles with more uniform heating properties in an effort to achieve more production capacity and reduced consumption of fuel. Emissions is an issue under constant discussion, with various approaches on how to enforce and motivate industry to reduce. The paper will present results from flameless oxyfuel installations in 10 continuous and batch type furnaces , including both reheating and annealing applications. Flameless oxyfuel combines the positive aspects of conventional oxyfuel combustion, such as up to 50% more throughput with 50% less fuel in an existing furnace with even better heating results. In flameless oxyfuel, flue gases dilute the flame, which is effectively spread into the furnace volume. The dispersed flame contains the same amount of energy as conventional oxyfuel, which in combination with an effective stirring, results in more uniform heating of the steel. This promotes better results in rolling, forging and annealing operations. The dilution of the flame brings down the flame temperature thus avoiding the creation of NOx, even with ingress air. Flameless oxyfuel is the result of close cooperation with steel producers to fully understand processes, customer constraints and challenges, paired with Linde’s proprietary combustion technology development. The development is based on accumulated know-how from over 90 all oxyfuel installations since the very first installation at Timken, USA, in 1990. “All oxyfuel” is defined as combustion in the whole furnace v i a a fuel, gaseous or liquid, and industrial grade oxygen, which completely replaces air.

28. Combustion Control of Carl Still Coke Oven • CST’s Experience

C.H.S. d’Andrea, G. Marietto, J.M. Clemente, O.J.


CST Arcelor Brasil coke oven batteries type “Carl Still Half-Divided Oven System” has a combustion system where the air/gas adjustments are carried out through an empirical form, which can generate waste of thermal energy and emissions of atmospheric pollutants. CST Arcelor Brasil is developing an alternative combustion control system for the monitoring of wasted gas for each heating wall, which has, as potential gains, the reduction in heat consumption and pollutants emissions, while preserving the operational stability of the coke oven batteries, thus contributing to the battery preservation.

29. Ovako, Hofors Works - 13 Years Experience of Using Oxyfuel for Steel Reheating;

Background, Solutions and Results

9

J. von Scheele, P. Fredriksson. E. Claesson, P. Ve


Since the very first oxyfuel installation, 1994, in a revamped reheating furnace at Ovako, Hofors works, Sweden, the technology has shown interesting results. Ovako can now present the results of oxyfuel installed in totally 48 pit and 2 rotary hearth reheating furnaces (fig 1), an increased throughput of 30-50%, fuel savings in the order of 30-45%, more uniform heating, less scale formation and reduced CO2 and NOX emissions.

30. Reheat Furnace Fuel Switching

W. McPherson, M. Fenton, P. Debski


Cost of Natural Gas – over the past several years, the price on natural gas grew rapidly. Today, a typical industrial user is paying an average of three times more than he did in 2002. But the rising price of natural gas is not the only aspect of this problem. Volatility of prices is even more detrimental to American industry. Volatility in prices causes poor budgeting, which often leads to product pricing that does not capture the cost of production. Those lucky enough to hedge supply when prices are down, then see prices rise have a meaningful cost advantage over those who didn’t hedge or who hedged at the wrong time

31. Opportunities and Challenges in Steel Manufacturing: Engineering a Brighter

Future, The AIST 2008 Brimacombe Lecture

K. Peaslee


The steel industry has experienced several profitable years after having weathered difficult economic times. Today, the large number of consolidations and increased foreign investment have resulted in a steel industry that is leaner and more profitable but still in a state of corporate flux. During the last three years, China has doubled their steelmaking capacity while North America’s capacity has not significantly changed. Steel related research has diminished with consolidations, reductions in research staff, and reduced government support. The industry has been successful in reducing costs and remaining competitive through implementing new technologies in steelmaking and casting. Today’s steel industry faces a number of opportunities and challenges especially in North America. This lecture will discuss two of the major challenges and opportunities that face the steel industry today: issues related to people – attracting and keeping the best technical leaders in the steel industry, and issues related to sustainability research – continuing excellence in solving the steel industry’s challenges in the areas of energy and the environment.

32. Applications of Fast Gas Analysis by Mass Spectrometry to Process Control in the

Iron and Steel Industry

R. Wright, P. Traynor

10


This paper describes how fast on-line gas analysis by mass spectrometry is used in the iron and steel industry to optimise various processes, based on accurate and complete analysis. Steel making gas analysis is used for better process control and end-point determination to expedite process-turnaround. Iron making gas analysis is used to operate more efficiently and safely. Coke oven gas analysis is used to optimise the gas cleaning. Waste gases from various processes are used as fuel gas, which needs to be characterised in terms of calorific value, Wobbe index and stoichiometric air requirement, but these gases have fast changing composition. These gases are also mixed to make mixed fuel gas. Fast complete gas analysis is required to optimise the mixing of these gases to provide mixed gas of constant calorific value (or Wobbe Index). The type of mass spectrometer used for on-line gas analysis is commonly referred to as a process mass spectrometer, or PMS. Processes that have benefited from PMS include coke oven, blast furnace (BF), direct reduction iron (DRI), basic oxygen furnace (BOF), electric arc furnace (EAF), argon oxygen decarburization (AOD) furnace, vacuum oxygen decarburization (VOD) furnace and Ruhrstahl-Hausen (RH) furnace. Additionally gas analysis by PMS is used to characterise the combustion properties of fuel gas used throughout the iron and steel industry.

33. Update on Design and Operating Experience of Low Calorie Gas Firing Gas

Turbine for Steel Works

C. Koeneke, T. Komori, K. Tanaka


China’s impressive growing economy has generated an enormous demand for steel and other material in recent years. Existing steel companies are undergoing expansion and new steel factories of different capacities are under construction around the world. These developments create additional high demand for power generation equipment that can operate efficiently with by-product gases, such as Blast Furnace Gas (BFG), Coke Oven Gas (COG), Finex Oven Gas (FOG) and other by-product gases. High efficiency combined cycles are being built in order to meet the above mentioned rapid steel demand expansion and power demand, together with the reduction of CO2 emissions.

34. Understanding Industrial Electric Bills

M. Costarell


Industrial electricity is a major expense, but the monthly bill does not offer any obvious indication to how close the plant is to the best price available. This discussion will develop a concise spread sheet to assess the electrical usage and then develop tools to rapidly estimate costs. The spread sheet and tools will then be applied in six illustrative scenarios. The target audience is plant managers and production personnel, persons that must make process decisions with a good estimate of the financial implications. For brevity, the discussion focuses on conditions where the local utility acts as the electricity

11

generator. Scenarios involving wholesale pricing, cogeneration, and deregulation are not included.

35. Improvement in Combustion Efficiency and Productivity of Reheating Furnaces of

Rail & Structural Mill at Bhilai Steel Plant

P. Kumar, L. Parthasarathy, A. Singh, I. Gupta, P.


In the integrated steel plants, reheating furnaces constitute an important element of rolling mills, in which the semi-finished products (blooms, billets, and slabs) are heated to a suitable temperature for improving the plastic properties of the steel as needed for hot working. The design features and operating parameters determine the thermal performance of the furnace and also the quality of final rolled products. Rail & Structural Mill (RSM) of Bhilai Steel Plant (BSP), a unit of Steel Authority of India Limited (SAIL), India is provided with three continuous pusher type three zone reheating furnaces of capacity 75 ton/hour each for heating of blooms. These furnaces were installed during 1960-65. The blooms are heated to a temperature of about 12500C and rolled into either rails or heavy structural of various lengths and sections. These reheating furnaces are of old design and are provided with twenty injection burners seven each in top & bottom heating zones and six in soaking zone. The design capacity of burners in top/bottom heating zones and soaking zone are 2210 and 1430 Nm 3/hr respectively for mixed gas of calorific value (CV) 1400 Kcal/Nm 3. The furnace is also provided with ceramic and metallic recuperators for preheating of air and gas respectively. During the course of operation, the furnace operating parameters have changed and thermal performance of the furnace has deteriorated. This paper describes about the efforts made by Research & Development Centre for Iron & Steel (RDCIS) for improving thermal performance of the reheating furnaces of RSM of BSP by improving combustion efficiency of injection burners by incorporating suitable modification, introduction of new preheating zone to increase the furnace productivity and development of heat transfer mathematical model to enable selection of optimal thermal regimes by predicting bloom surface and core temperature.

36. 25% Increased Reheating Throughput and 50% Reduced Fuel Consumption

M. Lantz, D. Hassenzahl, G. Moroz, A. Lugnet, A. C


In 2005, ArcelorMittal Shelby, together with Linde, formerly known as Linde Gas, implemented a 5% oxygen enrichment technology on the Shelby, Ohio, seamless tube mill’s rotary hearth furnace, resulting in a 29% fuel savings. Later, ArcelorMittal Shelby sought to boost heating capacity in order to increase the seamless tube mill output for larger billet dimensions while reducing fuel consumption. So in 2007, Linde led a four-month, turnkey project to implement the Linde REBOX® oxyfuel solutions at the furnace. The result was a 25% increase in reheating capacity and a 50% decrease in fuel consumption over oxy-enrichment. Overall, fuel consumption decreased by 65% versus airfuel. This paper will explore the project’s objectives, implementation of flameless

12

oxyfuel with results from performance tests and daily operation, which also included improved temperature uniformity for better piercing results, a 50% reduction of scale formation and minimized nitrogen oxide (NOX) and carbon dioxide (CO2) emissions.

37. Installation of a 145 MMBtu/hr Oxyfuel Firing System on the #2 Reheat Furnace at

ArcelorMittal’s 84 Hot Strip Mill

E. Black, F. Erfurth, G. Kitko, M. Hernandez, J. K

PR-356-130 - 2009 AISTech Conference Proceedings

With fuel prices increasing, fuel savings technologies can provide significant economic benefits to steel mills. Since the implementation of Praxair’s Dilute Oxygen Combustion (DOC) technology on the #3 reheat furnace at ArcelorMittal’s Hot Strip Mill at Indiana Harbor1, both companies had agreed to install DOC on the next furnace, the #2 reheat furnace, at the same facility. The top primary zone of the #2 furnace was converted to DOC, instead of the bottom primary zone as in the #3 furnace. While the same methodology was used for the burner design, differences in flow fields within the two zones resulted in under performance of the system. To resolve these differences a Computational Fluid Dynamics (CFD) analysis was performed. The CFD model was helpful in identifying the root cause of the performance difference and aided in the development of a modified burner design that met performance criteria. It delivered significant fuel savings with no impact on the other critical process parameters (steel surface quality, emissions, refractory, oxide scale, etc.). This paper reviews system modification, startup, challenges and solutions, and operating results for the installation of DOC on the #2 reheat furnace.

38. Industrial Experiences from Flameless Oxyfuel Operation in Walking Beam

Furnaces

J. Engdahl, A. Lugnet, G. Moroz, J. von Schéele


Over the past five years, 30 flameless oxyfuel systems have been installed at15 steel mills located throughout the world. Compared with air-fuel technology, the effectiveness of the flameless oxyfuel technology has shown to result a in reduction of specific fuel consumption of up to 50 per cent, while significantly shortening heat cycle time, resulting in increased throughput capacity in ranges of 25 percent to 50 percent. In a furnace operating with 100 percent flameless oxyfuel, the specific energyintensity could be below 1 GJ/tonne (around 0.9 million Btu/ton), i.e., 25 percent lower than the best available air-fuel technologies. This paper discusses experiences from installations of flameless oxyfuel in slab reheating furnaces, along with important developments and results. We will discuss the installations of REBOX® HLL technology at the 300 tonnes/hour walking beam furnace at SSAB’s Borlänge mill and the stainless steel slab walking beam furnace installation at Outokumpu Stainless in Degefors.. By applying different versions of oxygen boosting or full conversion into flameless oxyfuel operations inwalking beam

13

slab reheating furnaces, combustion and heat transfer efficiency improved significantly, and the scale losses and emissions of CO2 and NOX were substantially reduced.

39. Steel Mill Saves Nearly 60% in Energy Costs with Direct Steam Injection Heaters J. Hernandez, M. Cohodes


This large U.S. Steel Mill, with international locations, operating as a steel sheet finishing operation and specializing in tin coating is a major supplier to the canning industry. Products made at this location are chrome and tin-plated steel. Markets served include container, construction, and service centers.

40. A Design Approach for Sizing a Closed-loop Cooling System

R. Christensen


Hard Hat Services, Inc. (Hard Hat Services) was retained to perform a review and evaluation of closed-loop cooling system configurations for a Continuous Annealing Line (CAL) quench water system. Cooling of the heated quench water was previously accomplished by mixing up to 5,000 gallons per minute (gpm) of plant recycle water with the quench water. Because plant recycle water consists of industrial process water that is collected throughout the larger facility, treated, and returned for industrial reuse; it typically contains elevated concentrations of oil and grease (O&G). The O&G from the recycle water was combining with fine iron particulates which resulted in the deposition of sludge on the quench water spray diffuser plate screens and nozzles. Clogged and partially clogged screens and nozzles affected the distribution of quench water on the steel coil, impacting both product quality and the ability to control and improve product quality. Consequently, the system was being shutdown approximately 24 hours every 6 weeks to clean the diffuser plates, resulting in a loss of production time.

41. The Impact of Compound Plant Solutions and Cross Process Optimization on

Energy and Environmental Care for the Iron and Steel Industry

J. Kriechmair, D. Bettinger


In the current economic crisis, energy efficiency and Environmental measures are still an important issue in the metals business. It can be shown that by applying best performance technologies energy consumption and Environmental emissions can be significantly reduced.

42. DOE’s Industrial Technologies Program (ITP): Assessment Efforts to Improve

Energy Efficiency, Carbon Footprint and Profit in the U.S. Steel Industry

J. Quinn, M. Martin, S. Nimbalkar, P. Garland, A.


14

The steel industry is critical to the worldwide economy, providing the backbone for construction,transportation and manufacturing. The production process for manufacturing steel is energy-intensive andrequires a large amount of natural resources. Energy constitutes a significant portion of the cost of steelproduction; up to 40% in some countries.1 As shown in Table I, the energy used to produce a ton of steelhas decreased by about 2% from 1998 through 2002. However, the dollar cost per ton of steel increased by 35% during the same time period. Thus increasing energy efficiency is one of the most cost-effective ways to improve the Environmental performance of this industry.

43. “Strategies for Energy Reduction in Today's World” Low Cost/No Cost Basic

Thingsthat May Have been Overlooked in your Oven or Furnace Operations

J. Puskar


Technologies related to steel industry ovens and furnaces have come a long way since James and Daniel Heaton first established their Hopewell furnace in 1803 near my native Youngstown, Ohio. Today we’ve got exotic heat recovery systems, fuel air ratio control systems run by computers, and refractory materials that once flew to outer space.

44. Improved Temperature Uniformity in Batch Reheat Furnaces with Praxair's Dilute

Oxygen Combustion(DOC) System L. Cates, L. Rosen


As the performance requirements for materials increase, the technologies used to produce them must improve as well. Reheat furnaces used for forging operations are one example of equipment that must meet tighter performance specifications. Recent advances in materials development and processing techniques have resulted in narrower allowable ranges of the temperature distribution in furnaces surveyed per AMS-2750D. This paper will present results from recent installations of Praxair’s DiluteOxygen Combustion Firing System using pulse fired control systems. The pulse fired DOC burners have demonstrated the ability to meet a temperature uniformity of less than ± 15 F, with NOx emissions of 0.01 lb/mmBtu or less, while reducing fuel consumption by as much as 70%

45. Steel Mills: Energy Costs and the Green Planet

S.P. Pisano, A.G. Fennell


In the current world-wide cost and legislative climate, energy efficiency is not only good business; it can be the difference in meeting Environmental requirements. This paper will examine current leading-edge thermal technologies and fuels options across the range of operations for a modern steel mill. The inter-relationship between process optimization, alternate fuel utilization, waste heat direct recovery and Environmental emissions will be discussed. Applications examples will be presented. The conclusion to be drawn is that

15

minimizing energy costs and Environmental responsibility are accomplished in the same process

46. Flue Gas Flow Optimization for Energy Efficiency and Clean Operationsin

Integrated Steel Plants

A.J. Basu, V.B. Dutta, M. Pei


Eco-friendly integrated steel plant is essential to present society, but is also a challenge to fulfill. Besides contributing to noise and Environmental pollution, each of these plants is also responsible for consuming enormous electricity while generously contributing to green-house effect. This paper addresses flue gas flow optimization approach to energy savings through minimizing system resistance and flow turbulence resulting into vibration and noise reduction. The methodology is being implemented to a specific case study (work in progress), where 15% ~ 25% energy savings is feasible. This outcome will result into improved Environmental compliance of pollution prevention equipment (electrostatic precipitator in this case). Return on the investment is expected to be less than a year. “Environmentally Friendly” and “Cleaner Production” – which were just buzz words a decade ago - has now become an integral partof our society. Several energy consumption reporting protocol are being initiated, where CO2 emissions data is the measuring stick. The purpose is to track energy improvements in different industrial sectors. The Carbon Dioxide Information Analysis Center [1] – does indipendent monitoring of CO2 emissions worldwide as shown in Figure 1. This fact has been further substantiated through dynamic CO2 emissions data simulation by David Bleja [2]. Data collected on amount of CO2 emitted per minute by several industrialized nations (including BRIC countries). Figure 1: Amount of CO2 emission per minute by world’s industrialized nations. The US heavy industrial sector consumes 33% of country’s total energy. Dependence on fossil fuel and global awareness of the impact of carbon emission are now forcing the heavy industry sector to start looking into efficient ways of energy management, conservation and storage. Meanwhile, the integrated iron & steel plants have realized their responsibility and have come a long way.

47. Lowering Exhaust Gas Losses and Emissions with Newly Developed Recuperative

and Regenerative Burners

J.G. Wüenning


The reduction of waste gas losses is often the most effective and economic way to increase the efficiency of industrial furnaces. This article will present two new burner models, enabling to cut waste gas losses of finned recuperative burners almost in half. The regenerative burner achieves highest efficiency but one has to accept a certain expenditure for cyclic switching and exhaust gas suction. This might not be justified for smaller burner sizes and furnaces. The new gap flow recuperative burner reaches almost

16

the same efficiencies with a recuperative system. Both burner models use flameless oxidation technology for lowest Nox-emissions.

48. New Approaches to Melt shop Off gas Heat Recovery

J.A.T. Jones, P. Safe


Even though vast improvements in energy efficiency have been made to the steel industry in the past 10 years, some stages of the process have output offgas streams that contain more than 50 % of the total energy input. As energy costs continue to rise and resources become scarcer, energy recovery is becoming an important cornerstone for the sustainability of the steel industry. Energy recovery can provide cost savings, resource savings, and reduction of carbon footprint/greenhouse gas emissions. The nature of many steelmaking processes makes it challenging to recover the energy from the offgas stream due to high dust loading and thermal cycling in batch processes. This paper describes the evaluations conducted by WorleyParsons for several steelmaking facilities and explores the challenges and the novel heat recovery solutions that are under development to allow the energy in the offgas to be recovered.

49. Heat Recovery for the EAF of Georgsmarienhütte, Germany

H. Schliephake, C. Born, R. Granderath, F. Memoli,


The target for any optimization for an EAF or other industrial furnaces is either to increase product quality or lower energy consumption. If you look at the different ongoing discussions the current focus is clearly on the energy reduction. There has been a lot of progress in minimizing the input of primary energy like slag management, optimized charging schemes or intelligent furnace control systems (i.e. EFSOP). How great this progress is and will be is still undetermined, however, a large amount of the energy supplied to the EAF will be lost in the off-gas and cooling water of the respective process. When you view heat recovery, you should view it as a secondary option behind reducing the energy input. It is better to use one (1) kWh less then to recover one (1) kWh. Figure 1 explains that the energy contained in the off-gas of an EAF adds up to at least 25% (for furnaces with optimized use of chemical energy) or up to approximately 30%, making off-gas by far the biggest source for heat recovery. This doesn’t apply to all type of mill equipment. For example, large walking beam reheating furnaces typically measure cooling water as the biggest energy loss.

50. Oxygen Enhanced Ladle Preheating Systems: Improved Tap-to-tap Cycle Time and

Operating Cost Reductions

J. Kelly, F. Dentella, A. Recanati, J. Visus, E. M


17

Energy costs and stricter emissions requirements are a perennial concern of steelmakers. And although ladle preheating consumes a relatively small portion of the overall energy budget of a steelmaking plant, it is an inefficient energy consumer and can benefit from improvements in combustion technology. Furthermore, poor ladle preheating can have a large effect on the energy efficiency of the largest energy consumers within the steelmaking shop, the EAF or BOF itself and the LMF station or other secondary metallurgical facility with reheating capability. Modern steelmaking ladles need to be preheated to in excess of 2100 F which means that more than 60% of the fuel energy is exhausted to the stack when air fuel burners are used. Praxair’s Dilute Oxygen Combustion system provides a means of cutting energy consumption by as much as a half, while also lowering carbon emissions and reducing NOx. Adequate control of ladle brick temperature is critical to the operation of the modern steelmaking facility. Not only is it necessary for temperature management at tap and during secondary treatment, it is also necessary for adequate control of temperature during casting. Cold ladles can lead to excessive temperature drop during casting and in extreme cases inability to complete the cast. Figure 1 shows a schematic of the effect of time from end cast on a ladle to tap on the subsequent rate of temperature drop between the end of secondary ladle treatment and the caster. As the time from end cast to tap extends, the rate of temperature loss and the variability in the rate of temperature loss increases. The increase in variability is due to inconsistent use of covers and ladle preheaters. Ladles with more than 120 minutes between end of cast and tap were consistently put on preheaters and show better temperature control than ladles in the 90 to 120 minute group. When the expected time from end cast to tap was in the 60 to 90 minute range, operators noted that ladles which were placed on the air fired preheaters tended to be colder than ladles which sat under a cover. Changing the practice so that all ladles with more than 90 minutes from end cast to tap were preheated improved temperature uniformity. However, ladles with end cast to tap times of more than 60 minutes continued to present significant temperature control issues. The air fired preheaters were unable to rapidly bring ladles up to temperature and preheated ladles tended to be cold on the bottom.

51. A Multi-Faceted Approach to Reducing Electricity Costs in the Steel Industry

B.E. Zak


With the economy still weak and competitive pressures continuing to rise, reducing expenses is imperative for steel producers.

52. Combustibility of Charcoal for Direct Injection in Blast Furnace Ironmaking

K.W. Ng, L. Giroux, T. MacPhee, T. Todoschuk


Substitution of fossil fuel injection by charcoal is a feasible way to reduce GHG emission of blast furnaceironmaking. Previous modeling work showed that emissions of the process can be reduced by 25% whilemaintaining furnace productivity and products

18

quality. To prepare for industrial implementation of charcoalinjection, combustibility of charcoal was investigated.

53. Hot Stoves — More Than 50 Years of Experience — Design Optimization and

Future Concepts

M. Gantenberg, F. Eschmann, E. Schaub


Paul Wurth has more than 50 years of experience with hot stove technology especially with the external combustion chamber type. The PW design with an optimized refractory concept ensures minimal thermal and mechanical stress in refractory and mechanical parts which leads to stove lifetimes of more than 30 years.

54. Biofuel Use in Ironmaking From a Life Cycle Analysis Perspective



Replacement of fossil carbon by bio-carbon is one of the effective approaches to reduce the CO2 emission intensity of the ironmaking process. Because of the plentiful supply of raw biomass material in Canada, it is anticipated that a novel ironmaking process based solely on bio-carbon will be developed in the long term to achieve drastic reduction in GHG emissions. As a starting point of this long-term development, a hypothetical bio-ironmaking process was examined from the carbon life cycle assessment perspective. The objectives are to develop a possible technological pathway and to identify obstacles and challenges that may be encountered in industrial scale implementation of bio-ironmaking. For example, roadside forestry harvesting residues generated by the Canadian forestry industry have been identified as sufficient to meet the carbon demand of the ironmaking capacity in Canada. Results of analysis revealed that GHG emission associated with the carbon life cycle in bio-ironmaking was 62.8 kg CO2eq/tHM compared to 1552 kgCO2eq/tHM in the conventional process. To achieve this drastic reduction, it is important to ensure the bio-carbon consumed in bio-ironmaking originates from renewable sources to maintain CO2 neutrality. Moreover, the charcoal-making capacity in Canada would need to be increased substantially in the future to cope with the demand of bio-ironmaking.

55. Characterization of Mixtures of Sugarcane Bagasse and Charcoal for Injection

Through Tuyeres of Blast Furnaces

S.T. Viana, P.T. da Silva, P.S. Assis


Energy is the basis for humanity development. Most of the energy used in the world comes from fossil fuels and its intense consumption is the main responsible for most of the environment problems of nowadays. In this context, it?s interesting to think about

19

sources of renewable energy, in other to reduce impacts and guarantee continuity of energy offer to future generations.

56. A New Model for Energy and Carbon Dioxide Calculations: Model Development,

Assumptions, and Applications to EAF Steelmaking Thomas P. Battle, James M. McClelland


In the past decade or so, there have been an increasing number of studies published examining the environmental footprint of various iron- and steelmaking technologies. These studies cover a wide range of technology options – from in-depth looks at a particular technology, possibly for a particular location in the world, to studies covering a number of linked technologies and their interrelationships. The results often express the favorable results for some technology of interest - reduced energy consumption, orless carbon dioxide emitted, for example. There is no common framework for these models; they have been developed by a number of different groups, carry with them sometimes quite different assumptions, and are developed for different purposes. In this paper the development of a new model will be presented. Key assumptions will be discussed, illustrated with examples from EAF steelmaking.

57. Use of High Percentage Quality DRI in EAF and Its Benefit in Cost Reduction

Joachim D’Souza


Many challenges have taken place in the Steel Industry for the last 50 years. Electric Furnace Steelmaking has moved into a more prominent role as producers strive to reduce costs and meet increasing quality demands with stringent environmental standards. The tools, the equipment available for the Electric Arc Furnace production with DRI has enabled to reach the level of production those of Integrated Steel mills. A DRI production process was first pioneered in 1955. The early process required 5~10 years of pilot operation before satisfactory commercial operation was achieved. Proven technologies are now available to produce DRI or HBI from either fines or lump iron ore, using either gas or coal as a reductant. Shafts, kilns, rotary hearths and fluidized beds are the various types of reactorvessels employed to reduce the ore to metallized iron. The first commercial plant operated in 1957 in Monterrey in Mexico to make DRI with 1 million tons per annum capacity using fixed bed reactors.

58. Total Cost and CO2 Emission Reduction Using Apollo® Electrode System at

ArcelorMittal Differdange DC Arc Furnace

O. Gervais, S. Alameddine, T. Fregonese, Y. Renard


Beginning in 2008, the GrafTech Apollo® Electrode System was introduced on the DC

arc furnace of ArcelorMittal Differdange, Luxembourg with the aim of reducing the total

20

cost of the graphite electrodes. Under stable arc furnace operating conditions, the first 6

months of 2008 showed a significant and consistent improvement in electrode specific

consumption. This result was achieved through 2 factors: a) the substantial elimination of

stub losses; and b) a consistently lower breakage rate.

59. The Evaluation of EAF Performance —Operational Results

A.Grosse, A. Opfermann, S. Baumgartner


One of today’s most relevant tasks is to ensure sustainable economic, ecological and social development in the steel industry whilst maintaining commercial success and competitiveness in economically demanding times. A further increase in energy costs can be expected in the medium term. Furthermore, trading in CO2 certificates poses a challenge in the near future. An increase in energyefficiency guarantees improved competitiveness, not only in the competition between companies, but also in the competition between the material steel and rival materials. For this reason the aim must be the reduction of energy consumptions and emissions through optimizing the steelmaking process under local circumstances.

60. Analysis of Potential and Specific Problems of Heat Recovery in Steel Plants

Carsten Born, Ralf Granderath


Heat recovery in Electric Steel plants means offgas content. Talking about heat recovery in the EAF steel plant means talking about heat recovery from the EAF waste gas. Figure 1 shows the energy balance of a typical 150 t stainless steel producing EAF1 ; the energy losses in the offgas are the biggest losses by far. Heat recovery from cooling water is an interesting option especially for Consteel furnaces with their reduced mechanical stress for shell and roof, but hereinafter the focus belongs to the EAF offgas.

61. Innovative Approach to the Use of Offgas Heat for High-efficiency Green Power

Generation

J.K. Cotchen, A. Fleischanderl, G. Enickl


The production of steel from hot metal is a process that requires a high level of energy and high temperatures both in the product itself and the steelmaking equipment. It is the objective of the steelmaker to implement robust equipment and simplify processes in order to achieve the highest levels of system availability and production output. For a long time, energy cost issues were only secondary.

62. Wireless Technology: A Revolution in Temperature, Oxygen and Carbon

Measurements in Molten Metal

D.G. Janu, R.R. Rote, T.W. Junker

21


The initial installations of wireless technology have been implemented into steel mills for the use of sensor probes in molten steel. The system eliminates the conventional wires that transmit the signals between the pole used to measure temperature, oxygen and/or carbon in the steel and the instrument located in the pulpit. Likewise, the system eliminates the wires between the signal lights and remote scoreboards. The benefits seen thus far include: improved safety, reduced costs, increased reliability of measurements,increased pole life and increased accuracy of measurements. The wireless system can be installed at all locations where an existing measurement pole is used: : BOF, Q-BOP, EAF, LMF, degasser, caster tundish, blast furnace, hot metal mixer.

63. Identifying Energy Efficiency Opportunities for the Steel Industry — The

Production Energy Optimization Concept Rusty Steele, Fabio Mielli


Steel is a very energy intensive industry. According to the U.S. Department of Energy steel industry accounts for 3% of total U.S. energy consumption. The U.S. Steel industry reduced significantly its energy consumption by ton of Steel but it still remains behind countries like Korea, Japan, Germany and France. Integrated Steel Mills are the major contributor pushing this gap (U.S. EAF operations have better performance when compared against other countries).To meeting government policy on Energy Efficiency Opportunities (EEOs), metal processing companies are increasing energy efficiency to reduce costs under the current financial conditions. One of the major issues with EEOs is the lack of data available on energy use or the limited understanding of this data. A major piece of data that is missing is the energy use linked to production data that is needed to identify energy reduction opportunities.

64. Preparing Your Company for the Future Energy Management Systems

Requirements Like ISO 50001

Edgardo La Bruna, Gianfranco Zafred


Probably no long-term topics are more in the public eye than Energy and Climate Change. Energy is directly related to competitiveness and is particularly important with intensive energy users like the metal industry. As the previous management systems norms ISO 9000 and 14000 did for quality and environment, the chances are that the future ISO 50001 will establish a common set of rules for energy management. Companies that delay the process to implement such ISO programs paid a many times higher price by losing markets and competitiveness. Basic energy management principles to start moving into the right direction and reducing the impact on the future changes..

65. Recent Cost Reduction Developments in the Heating of Steel

Steven J. O'Connor, Anthony G. Fennell

22


In the past several years, regenerative firing of reheat furnaces has made great advancements in China. Scale-free heating, once thought of as merely a theoretical possibility, is now being seriously considered. This paper will discuss both of these concepts as they apply to the heating of steel.

66. Biofuel Use in Ironmaking From a Life Cycle Analysis Perspective



Replacement of fossil carbon by bio-carbon is one of the effective approaches to reduce the CO2 emissionintensity of the ironmaking process. Because of the plentiful supply of raw biomass material in Canada, itis anticipated that a novel ironmaking process based solely on bio-carbon will be developed in the longterm to achieve drastic reduction in GHG emissions. As a starting point of this long-term development, ahypothetical bio-ironmaking process was examined from the carbon life cycle assessment perspective. Theobjectives are to develop a possible technological pathway and to identify obstacles and challenges thatmay be encountered in industrial scale implementation of bio-ironmaking. For example, roadside forestryharvesting residues generated by the Canadian forestry industry have been identified as sufficient to meetthe carbon demand of the ironmaking capacity in Canada. Results of analysis revealed that GHG emissionassociated with the carbon life cycle in bio-ironmaking was 62.8 kg CO2eq/tHM compared to 1552kgCO2eq/tHM in the conventional process. To achieve this drastic reduction, it is important to ensure thebio-carbon consumed in bio-ironmaking originates from renewable sources to maintain CO2 neutrality.Moreover, the charcoal-making capacity in Canada would need to be increased substantially in the future tocope with the demand of bio-ironmaking.

67. Energy Efficiency and GHG Emissions for Alternate Ironmaking Technologies

Yakov Gordon, Michiel Freislich and Sunil Kumar


In the changing global market scenario for raw materials for the steel industry, a number of novel iron andsteelmaking process technologies are being developed to provide the steel companies with economically-sustainable alternatives for iron- and steel-making. In addition, the steel industry is also focusing on eduction of energy consumption as well as green-house gas (GHG) emissions to address the crucial subject of climate change. In this context, it is important to assess these critical issues for the alternate iron- and steelmaking technologies that have been developed. This paper presents a comparative evaluation of energy-efficiency and GHG emissions for some selected iron- and steelmaking technologies that are being considered for implementation. In this work, Hatch’s G-CAP™ and En-MAP™ tools that were developed with the main objective of

23

quantifying and qualifying the potential energy savings and CO2 abatement within the iron and steel industry, were employed in the evaluation conducted.

68. Steel Process Fans Energy Efficiency Upgrades: The Right Way, the Only Way

Dan Banyay


Industrial fan manufacturers have a variety of aerodynamic designs that have been utilized successfully throughout the years for the challenging duties in steelmaking processes. Each application has unique requirements that need to be fulfilled, such as aerodynamic performance, resistance to erosion and build-up, range of operating temperatures, and long-term mechanical reliability. Of course, the design selected must satisfy these needs, plus use the least amount of energy possible.

69. The Future of Green Bearing Protection

KwongVoon Wong


All industries are looking to lower their energy costs while maximizing production. Traditionally, radial lip seals have been used to prevent lubrication egress and contamination I ngress on rotating machinery. Radial lip seals tend to consume a significant amount of power to overcome the drag and friction created by the contact nature of the seal to the shaft. The average service life of a radial lip seal is usually measured in months, which typically does not meet the production demands. Advancement in labyrinth seal technology, also known as the bearing isolator, has been introduced to replace traditional radial lip seal technology.

70. Realization of the Coexistence of Energy Savings and Environmental Measures in

the EAF Concept of ECOARCTM

Y. Sato


Effective usage of energy has been one of the most important issues for EAF as the biggest energy consumer in the Mini-Mill industry. In addition, the Environmental measures have become the most important problem, but the coexistence with Environmental measures is difficult because of the conventional scrap preheating system. Against this background, JP Steel Plantech Co. (SPCO) has introduced a new energy saving furnace, called “ECOARCTM.”

71. Control Method for Low Oxygen Concentration of Waste Gas is HSM Reheating

Furnace

H.-H. Cheng, Y.-L. Hsu, C.-M. Liao, T.-S. Huang, C

24


In the hot strip mill, slabs are heated above 1150°C for the subsequent rolling process, so the low-temperature slabs are pushed into the reheating furnace from charging side and heated gradually via the preheating zone, heating zone and soaking zone and extracted at the discharging door, as shown in Figure 1. Oxygen is an essential element for the combustion reaction in the reheating furnace, whilethe oxygen in the furnace also participates in some of the reactions, including the formation of nitrogen oxides (NOx), or oxide layer in the surface of the slab (Figure 2). Excess oxygen in the furnace not only increases the energy consumption and slab scale, but also increases the slab scale and thermal NOx, or otherwise some negative effects while oxygen deficiency. The best situation is to meet the complete combustion of fuel under the premise of minimizing the residual oxygen or in other words, to maintain low oxygen in the exhaust gas.

72. Process Control and Automation Systems Advancements for Reheat Furnaces

G. Hurd, E. Rodriguez, J. Kaufman, J. Ward, H. Wu


An advanced reheat furnace Level 2 Control System can provide significant quality and efficiency improvements over conventional Level 2 systems. The automation system on the Bar Mill Reheat Furnace at Gerdau’s Midlothian, Texas plant was recently upgraded with an innovative Level 2 system incorporating an on-line multidimensional thermal model of heat exchange for steel temperature calculation. In addition, Model Predictive Control Technology was integrated into the control strategy to develop process models and real time process control.

73. Strategic Energy/CO2 Model for ArcelorMittal Burns Harbor

A. Kirk, H. Pielet, M. Atkinson, H. Silva


As an integrated iron and steel plant with coke ovens, a sinter plant, blast furnaces, BOF steelmaking, plate and strip finishing facilities and a power plant, ArcelorMittal Burns Harbor has a number of options for how it uses the energy produced internally and for how much electricity and natural gas it purchases. These options affect both the daily operation of the plant and the strategy for long-term capital improvements. To better understand the effects of operating and capital-improvement choices on energy use and CO2 generation, a Strategic Energy/CO2 Model was developed.

74. Development of New Combustion Control System Based on Fuel Gas Humidity at

Continuous Annealing Line

Koji Iwata, Kenta Karube, Shinji Tanaka


25

In ironworks by-product gas that comes from coke oven, blast furnace and steel making converter is processed through water to refine. It makes the gas moisturized. By-product gas is used for fuel gas of a heating furnace. We executed the investigation and proved the fact that the change of water vapor in fuel gas is larger than our estimation in a year and a day. And it has bad influence on combustor efficiency. Then the new combustion control system that controls combustion air flow according to the temperature of fuel gas was developed.

75. Introduction Of Ceramic Burner Technology In The No. 5 Galvanizing Line At

Ispat Inland Flat Products

John A. Marino


The No. 5 galvanizing line was recommissioned after a complete rebuild in 1997 at the Ispat Flat Productsplant in East Chicago, Indiana. The line is designed with 15 heating zones with 422 single ended radianttube burners, and two gas jet cooling zones. The first tube to be identified as failing was in zone 8 in August of 1997. By the end of 1999, 105 additional tubes had been identified as failing – 25% of the tubes. During the line shutdown in March 2000, 148 (35%) of the tubes were replaced. During the last shutdown in January 2001, an additional 225 tubes were replaced – 53%. Only 49 tubes have not yet been replaced, and these are mostly in zones 1 to 5. All of the tubes in zones 7 through 15 have been replaced.

76. Improving Combustion Safety & Efficiency through Better Measurement

Mark Menezes, Scott Mawhinney

AISE Annual Convention and Exposition, PR-991-125 – 2001

Modern measurement technologies typically boast excellent accuracy and repeatability under “reference” or “laboratory” conditions. Unfortunately, measurements are rarely made under laboratory conditions – as a result, performance is always worse in the “real world”. Using specific gas and steam flow examples to illustrate, this paper presents the key reasons for this deviation between laboratory and real world performance. It also presents tools that allow the user to quantify expected deviations prior to installation – in real applications, with real products. Finally, the presented tools allow the user to calculate the impact of different maintenance and installation practices on measurement accuracy and repeatability, andultimately to determine the “best practice” for any given application.

77. Cost-Effective Operation of a Blast Furnace Stove System

Gregory C. Walsh and Alexander Mitterer


26

This paper revisits the problem of optimal control of a blast furnace stove system. Previous work focused on increasing thermal efficiency which implicitly assumes all sources of energy available to the stove system are of equal cost. In this paper we instead attempt to minimize the consumption of natural gas, used in the system studied to enrich the top gas. More top gas is used and thermal efficiency suffersin the resulting two-step control policy, but the natural gas consumption is reduced up to 31%. After a detailed model of the stove system is constructed and identified using plant data, the current controlpolicy and the newly derived optimal control policy are simulated and compared.

78. Performances Enhancement of reheating furnaces using oxycombustion

O. Delabroy, G. Le Gouefflec, C. Lebrun, A. Barbot


Increasing the performances of reheating furnaces in steel plants always comes down to three main drivers: productivity increase, Environmental issues (NOx reduction) and product quality. This paper shows how oxycombustion is the right solution for all those three drivers. For instance, the obstacle to a productivity increase is, in many cases, the furnace itself. Usual furnace limitations are the temperature at the recuperator entrance (if any), vault temperatures, billet buckling at the exit, limited fuel or air flow rate. All these limitations can be overcome using oxycombustion. Also, oxycombustion has a major influence on the reduction of thermal inhomogeneities in the billet, which will directly enhance the mill performancesand the final product quality. This last benefit is illustrated using in-house 3D modeling, adapted to the specificity of oxycombustion, including the calculation of furnace atmosphere, oxidation (scaling issue) and heat transfer at the billet. Illustrations of the performances of oxycombustion are given on an industrial reference: L.M.E. at Trith St Léger, France. Oxy-fuel burners have been installed on the 92 t/h reheating furnace.

79. Ladle Heating And Drying With Ultra-Low NOx Emissions

Charles W. Armour


One way or another, we’re all affected by stringent air quality legislation, both existing and pending. We must make substantial reductions of atmospheric emissions of NOx, CO, and eventually CO2 into the atmosphere. . Not the least of these are products of combustion from certain types of burners on furnaces, ladle heaters, or other processes. And operators, maintenance people, and certainly crane operators may become exposed to an undesirable indoor environment.

80. Bethlehem Steel’s Evaluation of a Low-NOx Oxy-Fuel Burner

A. P. Martocci, M. F. Riley, J. L. Jensen, C. L. B


27

Bethlehem Steel has been proactive in its history of energy efficiency, and one aspect of that activity is partnering with others. Under the U.S. Department of Energy’s NICE3 (National Industrial Competitiveness through Energy, Environment, and Economics) Program, burners at a batch furnace in the 160 plate mill of Bethlehem’s Burns Harbor Division were converted to low-NOx oxyfuel burners based on Praxair® Dilute Oxygen Combustion technology. Four burners with a total firing capacity of 24 MMBtu/hr were installed and operated on coke oven gas. A fuel reduction of 60% from baseline air burner operation was achieved. Slab heating uniformity was satisfactory. NOx emissions were reduced by 60% from the baseline. This NOx reduction was achieved with the existing furnace structure that allows air infiltration through the furnace doors. Particulate emissions were also significantly lower. Increased deterioration of the burner block was noted. Net furnace operating costs were approximately 40% below baseline costs. Operating cost savings total $200,000 annually, based on 1998 fuel costs, or $300,000 annually, based on fuel costs for January-June 2000.

81. Thermal Modeling Of Lo-Vap Cooling

En-Sheng Chen, Millet L. Wei, C. David Besterman


A Lo-Vap cooling system utilizing a low-rate, evaporative, water/air spray cooling mechanism was developed at Bethlehem Steel’. Multiple nozzles, spaced equally along a trunnion ring circumference,provided a distributed, runoff type, water/air spray to a BOF trunnion ring interior. Each nozzle (Figure 1) sprayed a water/air mixture directly toward an upper area of the inner web and allowed a certain amount of runoff water to flow downward to cool the lower portion of the inner web. This design has shown to be effective in maintaining desirable temperatures in a BOF trunnion ring.

82. Advanced Technology In Furnace Control System Furnace Optimizing System

(Level 2)

M. Cornero


In order to illustrate the performance of our level 2 optimizing systems, we have chosen a few, yet significant examples from our many references showing the benefits gained from the installation of the STEIN HEURTEY optimizing system, in terms of : energy savings, production increase, final product quality improvement.

83. Process and Economic Benefits from Operation Improvements and Equipment

Alterations of the Bop Boilers

David A. Velegol, Bernard H. Walsh


28

The purpose of this paper is to describe the achievements in energy conservation, operations and maintenance cost reductions through the successful retrofit installation of a warm-up sparging steam system in the Basic Oxygen Process (BOP) boilers at Weitton Steel Corporation, Weirton, WV. Additionally, BOP boiler operation and maintenance cost reductions are described, and result fromimproved control philosophy applied to feedwater flow/steam drum level control. Streamlining of the Weir-ton Steel fuel system and the discovery of substantial additional opportunities to further reduce operating cost were also major project benefits.

84. The Benefits of Applying Regenerative Technology to Continuous Reheat Furnaces

John C. Dormire


For over a century regenerative technology has been used in the steel industry mostly for preheating combustion air. Typically applied in open hearths, soaking pits, coke ovens, crucible furnaces, and batch reheating, regenerators were used as much to achieve higher flame temperatures as to improve thermal efficiency. A typical design would include several checker work chambers serving the entire furnace. During one portion of the cycle the checkers functioned as flues and stored heat from the exitingexhaust gases. The cycle was then reversed allowing the combustion air to pass through the hot checkers, thus preheating the air. Cycle times were measured in minutes.

85. Cockerill-Sambre 70 MW EAF : 2nd Generationg of DC Power Supply

Jacques du Part, Philippe Michett, Serge Dallenoga


ALSTOM has developed an improved rectifier design for DC EAF application. The first paper, showing predicted improvement over typical DC EAF, was presented at the ISS 52nd EAF Conference in 1994. Several years of electrical operation at the COCKERIL-SAMBRE DC EAF in Marcinelle, Belgium, gives us feed back and material for analysis. Comparison with other power supply technologies will also be discussed.

86. Increasing Energy Efficiency of the Electric Arc Furnace at TenarisTamsa

F. Martell, R. Mendoza, M. Melendez, A. Llamas

AIST Iron & Steel Technology January, PR-PM0113-3 - 2013/01

Optimization of energy input into an AC EAF has been accomplished at Tenaris Tamsa. This work intends to prove that energy efficiency criteria can be applied for power control of the EAFs without affecting productivity.

29

87. Insulating Firebrick - Maximizing Energy Savings in Iron and Steel Applications

Through Product Selection

Andy Wynn, Ermanno Magni, M. Marchetti, Steve Cher

AIST Iron & Steel Technology May, PR-PM0512-1 - 2012/05

Differences in performance can be achieved by a wide range of insulating firebricks (IFBs) currently available. Since suppliers manufacture IFBs by different techniques, the brick microstructures can be very different, leading to a wide variety of thermal conductivities within the same class of product.

88. Design and Installation of In-Duct Peak Temperature Control System at CMC Steel

South Carolina

Sam Matson, Christy Hofherr, Dan Vidusek


Installation of an in-duct peak temperature control system in the direct evacuation system can effectively cool the gas and reduce the baghouse operating temperature. This paper will review the key design parameters, installation and operation of the in-duct peak temperature control system at CMC Steel South Carolina.

89. Exchange of Converters at voestalpine Stahl, Linz, Austria

Helmut Lechner, Gerald Wimmer, Herbert Moser


The converters were exchanged at voestalpine Stahl, in Linz, Austria. The benefits experienced after conducting this revamp include a plant capacity increase, metallurgical yield increase and significant cost reductions.

90. The case study of furnace use and energy conservation in iron and steel industry David Yih-Liang Chan a, Kuang-Han Yang

Energy 35 (2010) 1665–1670

This work was performed on-site energy audits of 118 .rms in the Taiwanese iron and steel industry during 2000–2008. It was found that the total potential energy savings was estimated about 79,160.8 KL of crude oil equivalent (KLOE). It was indented to generate potential electricity savings of 170,322.8 MWH, fuel oil savings of 22,235.1 kL, steam coal savings of 4922 tons, and natural gas (NG) savings of 10,735 kilo cubic meters. It was represented a total reduction of 217,866.5 tons in carbon dioxide emissions, equivalent to the annual carbon dioxide absorption capacity of a 5836 ha plantation forest. This study has established a national database presenting information and energy saving methods for energy users and has indented the potential areas for making energy savings to provide a energy conservation reference. It can assist the energy users in performing energy audits and increasing energy utilization efficiency.

30

91. Dynamic simulation as a tool to improve the efficiency of energy systems.

Applications in the steel industry

T. Henrion, A. Werner,

EPJ Web of Conferences, 05001 (2012) 33

To answer the need in reducing the amount and costs of the energetic consumptions in large industries, improvement methods mostly based on stationary considerations are being used today. It is difficult with such approaches to consider potentials hidden in time dependent effects. The batch operated processes of an Integrated Iron and Steel Plant (IISP) typically show time dependent behaviour. Therefore, dynamic considerations are used in this paper to increase the efficiency of energy systems (steam and hot water networks) in a European IISP. This allows the consideration of potential improvements not only through modifications of the process design and operating conditions but also through optimized control parameters, and enhancement of the transient operation procedures. This paper describes an improvement procedure for the considered energy systems. The physical modelling of all main components (sources, network piping, valves and control devices), is carried out with the simulation program APROS. The potential use of the physical dynamic models is then illustrated by a practical example, which deals with the operating conditions enhancement of a steam turbine. Finally, the application range of the developed simulation models is discussed. Especially, their further utilization for the implementation of model predictive control is outlined.

92. Variables affecting energy efficiency and CO2 emissions in the steel industry

Sari Siitonen n, Mari Tuomaala, Pekka Ahtila

Energy Policy 38 (2010) 2477–2485

Specific energy consumption (SEC) is an energy efficiency indicator widely used in industry for measuring the energy efficiency of different processes. In this paper, the development of energy efficiency and CO2 emissions of steelmaking is studied by analysing the energy data from a case mill. First, the specific energy consumption figures were calculated using different system boundaries, such as the process level, mill level and mill site level. Then, an energy efficiency index was developed to evaluate the development of the energy efficiency at the mill site. The effects of different production conditions on specific energy consumption and specific CO2 emissions were studied by PLS analysis. As theory expects, the production rate of crude steel and the utilisation of recycled steel were shown to affect the development of energy efficiency at the mill site. This study shows that clearly defined system boundaries help to clarify the role of on-site energy conversion and make a difference between the final energy consumption and primary energy consumption of an industrial plant with its own energy production.

93. Energy Efficiency of Carbon-Bearing Materials in Arc Steelmaking Furnaces and

Methods of Improving It

G. A. Dorofeev

Metallurgist, Vol. 54, Nos. 3–4, 2010

31

This article examines results from the use of carbon-bearing materials in different generations of arc steelmaking furnaces. It is shown that the changes which have occurred in the design of electric furnaces and electric steelmaking technology have been accompanied by decreases in the degree of secondary combustion of CO to CO2, the value of the coefficient which characterizes the assimilation of heat from this reaction, and the efficiency of the use of carbon as an energy carrier.

94. Reduction in Specific Energy Consumption in Steel Industry – with special

reference to Indian steel industry

Chinmoy Samajdar

Energy and Environmental Engineering Journal Volume 1, Issue 3, December, 2012

Integrated Steel Plants (BF-BOF route) constitute around 70% of world steel production and are energy intensive. Energy savings in integrated steel plants will substantially reduce the overall specific energy consumption in the steel industry. The study shows that reduction in specific energy consumption in steel plant operations has three dimensions: minimisation of energy requirement for the process, maximisation of energy utilisation and minimisation of energy losses. For energy efficiency, while in the existing steel plants the focus should be on better operations management in maintaining uninterrupted process flow and incorporating continual innovation, the future must be oriented towards judicious technology management with adoption and absorption of new energy efficient technologies and shifting towards more continuous operations. In applications, advanced steels can offer substantial energy savings over the life cycle of the product.

95. An empirical analysis of energy efficiency in China’s iron and steel sector

Yi-Ming Weia, Hua Liaoa,b, Ying Fana

Energy 32 (2007) 2262–2270

Using Malmquist Index Decomposition, this paper investigates energy efficiency of China’s iron and steel sector during the period 1994–2003. Provincial panel data is employed, allowing various energy inputs and product outputs. The energy efficiency improvement is decomposed into two components: technical change (production frontier shifting effect) and technical efficiency change (catching up effect) over time. Our empirical results indicate that the energy efficiency in China’s iron and steel sector increased by 60% between 1994 and 2003, which is mainly attributable to technical progress rather than technical efficiency improvement. The energy efficiency gaps among provincial iron and steel sectors during this period have widened. However, energy efficiency of iron and steel plants owned by the state has slowly improved in some regions, such as Shanghai, Liaoning, Beijing and Hubei. Nevertheless, technical efficiency in these four regions has decreased considerably. Energy efficiency in China’s two largest private-own iron and steel bases (Heibei and Jiangsu) improved significantly.

96. Assessment of Energy Efficiency Improvement and CO2 Emission Reduction

Potentials in the Iron and Steel Industry in China

Ali Hasanbeigi, William Morrow, Jayant Sathaye, Eric Masanet, Tengfang Xu

32

Energy Analysis and Environmental Impacts Department, Environmental Energy

Technologies Division, Lawrence Berkeley National Laboratory Nov 2012

China’s annual crude steel production in 2010 was 638.7 Mt accounting for nearly half of the world’s annual crude steel production in the same year. Around 461 TWh of electricity and 14,872 PJ of fuel were consumed to produce this quantity of steel in 2010. We identified and analyzed 23 energy efficiency technologies and measures applicable to the processes in the iron and steel industry. The Conservation Supply Curve (CSC) used in this study is an analytical tool that captures both the engineering and the economic perspectives of energy conservation. Using a bottom-up electricity CSC model, the cumulative cost-effective electricity savings potential for the Chinese iron and steel industry for 2010-2030 is estimated to be 235 TWh, and the total technical electricity saving potential is 406 TWh. The CO2 emissions reduction associated with cost-effective electricity savings is 130 Mt CO2 and the CO2 emission reduction associated with technical electricity saving potential is 231 Mt CO2. The FCSC model for the iron and steel industry shows cumulative cost-effective fuel savings potential of 11,824 PJ, and the total technical fuel saving potential is 11,964. The CO2 emissions reduction associated with costeffective and technical fuel savings is 1,173 Mt CO2 and 1,188 Mt CO2, respectively. In addition, a sensitivity analysis with respect to the discount rate used is conducted to assess the effect of changes in this parameter on the results. The result of this study gives a comprehensive and easy to understand perspective to the Chinese iron and steel industry and policy makers about the energy efficiency potential and its associated cost.

97. A system dynamics analysis of energy consumption and corrective policies in

Iranian iron and steel industry

Nastaran Ansari, Abbas Sei

Energy xxx (2012) 1-10

Iron and steel industry is the most energy intensive industrial sector in Iran. Long time subsidized energy has led to low energy efficiency in this industry. The sudden subsidy reform of energy prices in Iran is expected to have a great impact on steel production and energy consumption. A system dynamics model is presented in this paper to analyze steel demand, production and energy consumption in an integrated framework. A co-.ow structure is used to show how subsidy reform affects energy consumption in the long run. The main focus of this paper is on direct and indirect natural gas consumption in the steel industry. Scrap based Electric Arc Furnace technology has been evaluated as an energy efficient way for steel making. The energy consumption in steel industry is estimated under various steel production and export scenarios while taking into account new energy prices to see the outlook of possible energy demand in steel industry over next 20 years. For example it is shown that under reference production scenario, potential reduction in gas consumption forced by complete removal of energy subsidy and utilizing scrap could lead to 85 billion cubic meters of gas saving over the next 20 years.

98. CO2 Emissions from a Steel Mill and a Petro-Chemical Industry

Ta-Chang Lin1, Chia-Yu Lee1,

Aerosol and Air Quality Research, 12: 1409–1420, 2012

33

The CO2 emissions and energy flows of a steel mill A (mill A) and petro-chemical industry B (PCI B) in southern Taiwan were investigated in this study. And the feasibility of integrating the energy flows of mill A and nearby waste management plant E (WMP E) was also evaluated in order to improve the energy efficiency and reduce the CO2 emission. The results show that the annual energy consumption of mill A and PCI B were 6,045,518 and 11,957,543 KLOE (kiloliter of crude oil equivalent), respectively. Mill A utilized less than 5% of Taiwan’s total annual energy consumption, but it used high CO2 emission coefficient fuels and accounted for 8–9% of Taiwan’s total CO2 emission inventory. However, the energy efficiency was improved, and at l east 15% of total steam produced in mill A came from waste heat recycling. By recovering waste heat in mill A, 63,420 tonnes of heavy fuel oil (HFO) consumption was prevented, and thus 177,513 tonnes of CO2 were not emitted. Furthermore, WMP E is able to produce about 578,993 tonnes of process steam (17.6 kg/cm2G × 275°C) annually. These results show that creating a steam-network between mill A and WMP E can not only reduce the amount of energy consumed by the industrial park, but also brought an extra benefit of 95 million NTD/yr for WMP E. This is the first study of an innovative steam-network at an industrial park in Taiwan, and the results of this work can further be applied in other locations to improve energy efficiency and reduce CO2 emissions.

99. Current situation of energy consumption and measures taken for energy saving in

the iron and steel industry in China

Z.C. Guo a, Z.X. Fu

Energy xxx (2009) 1–5

A survey of the key issues associated with the development in the Chinese iron and steel industry and current situations of energy consumption are described in this paper. The apparent production of crude steel in China expanded to 418.78 million tonnes in 2006, which was about 34% share of the world steel production. The iron and steel industry in China is still one of the major high energy consumption and high pollution industries, which accounts for the consumption of about 15.2% of the national total energy, and generation of 14% of the national total wastewater and waste gas and 6% of the total solid waste materials. The average energy consumption per unit of steel is about 20% higher than that of other advanced countries due to its low energy utilization efficiency. However, the energy efficiency of the iron and steel industry in China has made significant improvement in the past few years and significant energy savings will be achieved in the future by optimizing end-use energy utilization. Finally, some measures for the industry in terms of the economic policy of China’s 11th -year plan are also presented.

annotated bibliography on energy efficiency

Documents

steel plants

steel sector

steel industry title

continuous steel production

integrated steel plant

energy simulation model

furnace control system

chinas iron