steel factories and waste heat utilization systematic

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Energy Managers Days Slovenia, 23.11.2020

STEEL FACTORIES AND WASTE

HEAT UTILIZATION –

SYSTEMATIC APPROACH

FROM PRIMETALS

primetals.com

Restricted © Primetals Technologies 2015 All rights reserved.

Introduction

History of Energy Efficiency

LINZ AUSTRIA 40 YEARS AGO → HEAT RELEASED TO ENVIRONMENT

23.11.2020 Dr. Thomas Steinparzer / UP I&S ECO


Introduction

History of Energy Efficiency for Integrated Steel Plants


29.5

25

20

1960 1965 1970 1975 1980

2624.5 24

15

22.522

20.5 2019.5

-60%

(world)

1985 1990 1995 2000

30

European steel industry

[GJ / t crude steel]

High efforts in terms of energy efficiency already done by Iron & Steel Industry

2005

18.9

2010

Continues castingHigh top pressure

High Hot blast temperaturePreheat of combustion air

Top Gas Recovery TurbineStove Combustion Control

Waste heat recoveryReduce heat losses

Computer aided controlOxygen enrichment Blast

Steam recoveryBOF-Gas Recovery

Axial Blowers with Electric DriveHot charging at Reheating Furnaces

Reduction of losses in integrated energy systemReduction of excess gas burner losses

Optimization of gas recoveryImprove power plant eff.

-30,0%

(European)49 - 30

26.9

2322

20.520.3


Historical CO2

emissions of the European steel industry

Source: Eurostat

Steel Production

Source: Steel Statistical Yearbook 2018 (and years prior), World Steel Association

CO2 emissions

EU-28 crude steel production

10 %

20 %

30 %

40 %

50 %

60 %

70 %

80 %

90 %

100

110 %

1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 20502012 2014 2016 2018

DECARBONIZING THE STEEL INDUSTRY —

ACHIEVING 80% CO2 REDUCTION BY 2050




CARBON PRICING

The price tag on

carbon is increasing

• The case of Europe:

Emissions certificates

have seen steep price increases.

• Supply of certificates

to be tightened in 2021

• Carbon taxes are on

the horizon.

€4

€6

€8

€10

€12

€14

€16

€18

€20

€22

€24

€26

€28

€30

CO2 European Emissions Allowance (€/t)

2013 2014 2015 2016 2017 2018 2019 2020



Emissions trading scheme

implemented or scheduled

for implementation

Carbon tax implemented

or scheduled for

implementation

Emissions trading scheme

and carbon tax implemented

or scheduled

Trading schemes and

carbon taxes are on

the rise globally

• New emissions trading

schemes scheduled on

several continents

• Existing schemes will

be extended in scope

• Several regions combine

trading schemes with

carbon taxes

EU

China

Share of total emissions

covered by carbon pricing

Japan

65%

2%


CARBON PRICING

Source: World Bank Group. State and Trends of Carbon Pricing 2019



84% hot metal

71%

29%

BOF EAF

Reduction

gas CH4

Scrap

Raw materials preparation Ironmaking Steelmaking Casting & rolling

2018 (1,815 Mt)

BF-BOF

DR-EAF

t CO2 / tls

CO2 emissions in tons — considering OECD EU-28 – emission factor of 452 grams CO2 / kWh and BAT

utilization of BF top gas and LD gas in power plant

Scope 3 emissions for raw materials and credits also considered

1.586

0.785

80% HDRI

16% scrap

20% scrap

Considering credits for utilization of top gas in power plant and wet slag granulation.

Introduction

Production Route 2020

Coils

Bar mill

DR-EAF

Billet caster

ESP

Pelletizing

DR plant

Sinter plant

Coal

Additives

Iron ore

EAF

LD (BOF) converter

Coking plant + PCI production

Blast furnace

Twin VD

Twin ladle furnace

0.27

0.22

0.04

0.54

0.93

0.21

0.15



84% Hot metal

CH4 /

Green H2

Scrap

Raw materials preparation Ironmaking Steelmaking Casting & rolling

DR-EAF

t CO2 / tls

CO2 emissions in tons — considering OECD EU-28 – emissions factor of 452 grams CO2 / kWh and BAT

Scope 3 emissions for raw materials and credits also considered

0.279

80% HDRI

16% scrap

20% scrap

Introduction

Production Route Future 2050

Coils

Bar mill

H2 DR-EAF

Billet caster

ESP

Pelletizing

DR plant

Sinter plant

Coal

Additives

Iron Ore

EAF

LD (BOF) converter

Coking plant + PCI production

Blast furnace

Twin VD

Twin ladle furnace

0.04

0.05

0.20

Biomass

55%

45%

BOF EAF

2050 (2,170 Mt)

High performance

& lightweight

CCS

CO2

separation


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For Slovenian Steel Market

Possible Solutions


Overview Energy Efficiency Solutions

Slovenian Steel Market

Dr. Thomas Steinparzer / UP I&S ECO 23.11.2020

EAF Secondary

metallurgy

CONTINUOUSCASTING

HOTROLLING

Integrated energy

management

system

• Energy management system (EMS)

• Material and energy cost optimization

• Manufacturing execution system (MES) including: Energy forecast, energy planning system

Process

optimization• EAF optimization

• Foaming slag manager,

• Laser off-gas analyzer

• Direct hot charging

• Continuous casting

optimization

• Furnace

optimization

• Mill pacing

Advanced

control • Electrode control system

• Energy Saving Assistant for Dedusting

Electrics • Variable frequency speed drives (VSD) for pumps and fan, Condition Monitoring System (CMS), Green Button

Energy efficiency

systems• EAF waste heat recovery

• Preheating of scrap (Quantum EAF)

• Endless Strip Production (Arvedi ESP) • Furnace waste

heat recovery

• Roll gap

lubrication

Slovenian steel production is mainly scrap and electric arc furnace based


Overview

Energy Efficiency Potential / Benchmark Mini Mill


6,05,0

2,7

0123456789

10

To

tal E

ne

rgy C

on

su

mp

tio

n[G

J/t

o]

Melting (EAF) Casting & Rolling

Others Total

200

250

300

350

400

450

500

550

600

650

700

750

800

850

0 5 10 15 20 25 30 35 40 45 50 55 60 65

Oxygen consumption EAF[Nm³/ton of billet]

Electricity consumption at EAF

QEAF

[kWh/ton of billet]

6020

20

Typical Electric Energy Consumption

Meltshop

Casting & Rolling

Others (WTP, GC,Bulidings, etc.)

30

70

Natural Gas Consumption

Meltshop

Casting & Rolling

Main consumer: EAF

Main consumer: RHF

Typical, non-binding figures



Why Waste Heat Recovery ?

• Cost savings in terms of primary energy sources (e.g.: natural gas)

• Efficiency increase of complete steelmaking process

• Utilization of waste heat within steel plant

• Reduction of CO2 emissions

• Approx. 30% of total energy input leave furnace with off-gas

➢ Sankey diagram of an electric arc furnace

DECARBONIZING YOUR PLANT —

ELECTRIC ARC FURNACE



Possibilities for Waste Heat Utilization

1. Hot Water Production for Heating Purpose

✓ District heating, internal heating, cooling

✓ Most efficient way to use the recovered energy

2. Steam Production

✓ Low saturated pressure steam (typically 4 – 12 bar) sufficient

✓ Usually applied to heat up other media

✓ Internal steam consumers: VD / VOD plants with steam injectors, annealing / pickling lines

✓ External steam consumers: Power plants (feed-water pre-heating), Hot water for heating or

cooling purpose, Chemical industry (distillation, ab-/ desorption), Food industry, Sea water

desalination plants

3. Electrical power generation

✓ Power generation via ORC units or steam turbines

✓ Market leader for ORC (Turboden) is part of the MHI group

✓ Advantages: well proven technology, good part load characteristic,

fully automatic operation → no additional manpower,

high availability Source: Turboden, Italy




Reference Example: Video Italian Mini Mill


https://www.youtube.com/watch?v=b6YxrVX_npk



https://www.youtube.com/watch?v=b6YxrVX_npk





Example for Waste Heat Recovery Applications in Stainless Steel Route

RFEAF AOD

Steam VOD

el. PowerG

Storage

system

Waste heat recovery

Integrated Waste Heat Recovery Concept

Waste heat utilization Hot Water Generation for

District Heating 1

2

3




• EAF Quantum (-13%)With scrap preheating compared to

conventional EAF (both 150 t heat

size)

Server

• Energy Saving

Assistant (-1%)Improved control of gas

cleaning plant

• Waste-heat recovery EAF-Quantum (-6-9%)Energy recovery of off gases

• Waste-heat recovery EAF (-12-14%)Energy recovery of off gases

• Waste-heat recovery reheating furnace (-2%)Uses off gas heat for steam production

• Arvedi ESP (-39%)Combined casting/rolling

• WinLink (-40%)Direct rolling of long products

Summary possible CO2 reductions and solutions

Total CO2 savings potential

115,200 tons p.a.

TOTAL

-25%*CO2 equivalents

*Quantum Srap Pre-Heating, Waste-heat

recovery EAF & RHF, Energy Saving

Assistant



Outlook &

Conclusions


HYFORHYDROGEN-BASED FINE-ORE REDUCTION


HYDROGEN STEELMAKING & CCU

-91%** Use of 100% hydrogen

• Hydrogen

H2O

CO2 equivalents

CCU — CARBON CAPTURE AND UTILIZATIONGasFerm*

16–49%CO2 reduction

Microbial fermentation of carbon and hydrogen-rich offgases, to produce ethanol or

other basic chemicals. Substantially mitigates CO2 emissions while simultaneously

reducing NOx, SOx and particulate emissions.

Gas cleaning

Gas holder Compression

By-products and

residuals utilization

LANZA TECHPROCESS

From stack

Ethanol

C2H5OH

• H2 Steelmaking for Slovenian Market not reasonable since scrap based routes.

• CCU: For EAF based plants not reasonable due to low CO2 content in off-gas



Public Funding & Conclusions

Public Funding

• Besides European „Green Deal“, most countries apply already now funding schemes for industrial

energy efficiency.

• Examples for key support schemes for heat recovery with support levels typically between 30-40% of

investment or fixed support per MWh:

Conclusions

• Slovenia is due to EAF based steelmaking routes already rather low in CO2 emissions compared to

other countries.

• Nevertheless, highest potential for further reasonable CO2 reduction resp. energy saving is waste heat

recovery for EAF and RF.

• Public funding is an important instrument for facilitating energy efficiency projects.

➢ Steel plants can become hubs of a future smart energy communities and sector coupling (i.e. waste

heat for district heating, etc.)


UK Poland Italy Spain France Germany Austria

Scheme NameBEIS

IHRS

White

Certificates

White

Certificates

FNEE

Grant

Certificats

d’Economies

d’Energie

BAFA Grant

Waste Heat

Extraction

Grant


THANK YOU

Restricted © Primetals Technologies 2020. All rights reserved.

The information (including, e.g., figures and

numbers) provided in this document contains

merely general descriptions or characteristics of

performance based on estimates and assumptions

which have not been verified.

It is no representation, does not constitute and/or

evidence a contract or an offer to enter into a

contract to any extent and is not binding upon the

parties. Any obligation to provide and/or

demonstrate respective characteristics shall only

exist if expressly agreed in the terms of the contract.

These estimates and assumptions have to be

analyzed on a case-to-case basis and might change

as a result of further product development.

Primetals Technologies excludes any liability

whatsoever under or in connection with any

provided information, estimates and assumptions.

The provided information, estimates and

assumptions shall be without prejudice to any

possible future offer and/or contract.

Any use of information provided by Primetals

Technologies to the recipient shall be subject to

applicable confidentiality obligations and for the own

convenience of and of the sole risk of the recipient.


Dr. Thomas Steinparzer

Head of Technology & Innovation, ECO Solutions

I&S TI ECO

Primetals Technologies Austria

Turmstrasse 44

A-4031 Linz

T +43 (732) 6592 9821

M +43 (664) 6150345

F +49 (732) 6592

E [email protected]

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steel factories and waste heat utilization systematic

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