IIPironsteel Data11

ID
Institution 1 Worldsteel
Region Australia
Published In
Process 1
2010 Electric Arc Furnace
2 Worldsteel
Canada
2010 Blast Furnace
3 Worldsteel
Brazil
2010 Basic Oxygen Furnace
4 Worldsteel
EU
5 LBNL
EU
2010 Blast Furnace
6 IEA
EU
2007 Blast Furnace
7 APP
Australia
2010 Smelting Reduction
8 ULCOS
EU
9 ULCOS
EU
2006 Blast Furnace
10 ULCOS
EU
2002 Electrolysis
11 Worldsteel
Brazil
2008 Blast Furnace
12 IEA
EU
2008 Blast Furnace
13 Worldsteel
EU
14 EPA
USA
2010 Blast Furnace
15 LBNL
EU
16 LBNL
USA
2010 Blast Furnace
17 EPA
USA
2010 Hot Rolling
18 BEE
India
Coke Oven
19 BEE
India
2002 Sinter Plant
20 BEE
India
2002 Sinter Plant
21 SAIL
India
2006 Blast Furnace
22 NEDO
Japan
2008 Sinter Plant
23 IEA
China
2007 Blast Furnace
24 LBNL
Japan
2010 Blast Furnace
25 IEA
Japan
2007 Blast Furnace
26 IEA
Brazil
2007 Blast Furnace
27 NEDO
Japan
2008 Blast Furnace
28 IEA
Japan
2007 Blast Furnace
29 IEA
USA
30 LBNL
EU
31 EPA
USA
32 IEA
USA
2007 Direct Reduced Iron
33 IEA
Mexico
34 IEA
EU
35 IEA
EU
36 IEA
International
2007 Hot Rolling
37 IEA
Japan
2007 Coke Oven
38 EPA
Japan
2010 Sinter Plant
39 IEA
China
40 APP
South Korea
41 IEA
Japan
2007 Blast Furnace
42 IEA
Japan
2008 Coke Oven
43 IEA
EU
2007 Coke Oven
44 LBNL
USA
2010 Blast Furnace
45 IEA
India
46 APP
Japan
47 APP
Japan
48 APP
Japan
49 AISI
USA
2009 Electrolysis
50 VDEh
Germany
2004 Blast Furnace
51 LBNL
USA
2010 Blast Furnace
52 LBNL
USA
2010 Blast Furnace
53 LBNL
India
2010 Blast Furnace
54 LBNL
EU
55 LBNL
EU
56 LBNL
EU
57 UNIDO
EU
58 LBNL
USA
59 ULCOS
EU
2002 Electrolysis
60 LBNL
USA
61 LBNL
USA
62 LBNL
EU
63 EPA
USA
64 LBNL
EU
65 EPA
USA
2010 Continuous Casting
66 APP
EU
2010 Coke Oven
67 BREF
Japan
2009 Coke Oven
68 BREF
Japan
2009 Sinter Plant
69 BREF
Japan
2009 Sinter Plant
70 APP
South Korea
2010 Sinter Plant
71 NEDO
Japan
2008 Sinter Plant
72 APP
Australia
2010 Sinter Plant
73 APP
Japan
2010 Coke Oven
74 EPA
Japan
2010 Blast Furnace
75 APP
South Korea
2010 Blast Furnace
76 APP
China
2010 Blast Furnace
77 LBNL
Brazil
78 AISI
USA
79 APP
USA
2010 Hot Rolling
80 APP
China
81 APP
Japan
82 APP
Japan
2010 Hot Rolling
83 APP
South Korea
2010 Sinter Plant
84 APP
Japan
2010 Sinter Plant
85 BREF
EU
2009 Sinter Plant
86 LBNL
USA
87 LBNL
EU
88 APP
Japan
2010 Coke Oven
89 LBNL
Japan
2010 Sinter Plant
90 BREF
EU
2009 Coke Oven
91 LBNL
EU
2010 Coke Oven
92 APP
EU
2010 Blast Furnace
93 APP
China
2010 Blast Furnace
94 APP
EU
2010 Blast Furnace
95 LBNL
EU
2010 Blast Furnace
96 APP
EU
97 APP
EU
98 APP
International
99 APP
USA
100 APP
USA
101 APP
USA
102 VDEh
EU
2010 Hot Rolling
103 LBNL
USA
104 VDEh
EU
2010 Hot Rolling
105 APP
Japan
106 APP
USA
107 APP
EU
108 LBNL
USA
2010 Hot Rolling
109 EPA
Mexico
110 APP
USA
111 APP
USA
112 APP
EU
113 LBNL
EU
114 APP
EU
115 APP
EU
116 APP
EU
2010 Hot Rolling
117 VDEh
EU
2010 Hot Rolling
118 APP
Japan
119 LBNL 120 LBNL 121 LBNL
USA USA Japan
2002 Continuous Casting 2010 Sinter Plant 2010 Sinter Plant
122 LBNL
EU
2010 Coke Oven
123 LBNL
China
2010 Coke Oven
124 VDEh
EU
2010 Blast Furnace
125 VDEh
EU
2010 Coke Oven
126 VDEh
EU
2010 Hot Rolling
127 VDEh
EU
2010 Hot Rolling
128 VDEh
EU
2010 Sinter Plant
129 VDEh
EU
130 VDEh
EU
131 VDEh
EU
132 VDEh
EU
133 VDEh
EU
134 VDEh
EU
135 VDEh
EU
2010 Sinter Plant
136 VDEh
EU
2010 Hot Rolling
137 VDEh
EU
2010 Hot Rolling
138 VDEh
EU
2010 Sinter Plant
139 VDEh
EU
2010 Hot Rolling
140 VDEh
EU
141 VDEh
EU
2010 Hot Rolling
142 VDEh
EU
143 EPA
USA
2010 Hot Rolling
144 SAIL
India
2006 Blast Furnace
145 SAIL
India
2006 Sinter Plant
146 SAIL
India
2006 Coke Oven
147 SAIL
India
2006 Coke Oven
148 SAIL
India
2006 Sinter Plant
149 SAIL
India
2006 Blast Furnace
150 SAIL
India
151 SAIL
India
152 SAIL
India
2006 Hot Rolling
153 AISI
USA
2002 Blast Furnace
154 AISI
USA
155 AISI
USA
2003 Hot Rolling
156 AISI
USA
157 AISI
USA
158 AISI
USA
159 AISI
USA
160 AISI
USA
2001 Blast Furnace
161 ISIJ
Japan
162 JISF
Japan
2010 Blast Furnace
163 EPA
USA
2010 Sinter Plant
164 EPA 165 EPA 166 EPA
USA USA USA
2010 Sinter Plant 2010 Blast Furnace 2010 Hot Rolling
167 EPA
USA
2010 Hot Rolling
168 EPA
USA
2010 Hot Rolling
169 EPA
USA
2010 Hot Rolling
170 EPA
USA
2010 Hot Rolling
171 EPA
USA
2010 Hot Rolling
172 EPA 173 EPA 174 EPA 175 EPA 176 EPA
USA USA USA USA USA
2010 Hot Rolling 2010 Hot Rolling 2010 Electric Arc Furnace 2010 Electric Arc Furnace 2010 Electric Arc Furnace
177 EPA
USA
178 ITP
USA
179 ITP
USA
180 ITP
USA
2001 Hot Rolling
181 ITP
USA
182 ITP
USA
183 ITP
USA
184 ITP
USA
185 ITP
USA
186 ITP
USA
2005 Hot Rolling
187 ITP
USA
188 ITP
USA
189 ITP
USA
2006 Hot Rolling
190 ITP
USA
191 ITP
USA
192 ITP
USA
2009 Hot Rolling
193 ITP
Japan
194 ITP
EU
195 NEDO
Japan
2008 Hot Rolling
196 NEDO
Japan
2008 Sinter Plant
197 APP
EU
198 BREF
EU
2009 Sinter Plant
199 BREF
EU
2009 Sinter Plant
200 BREF
EU
2009 Sinter Plant
201 BREF
EU
2009 Blast Furnace
202 BREF
EU
2009 Blast Furnace
203 BREF
EU
2009 Blast Furnace
204 BREF
EU
205 BREF
Russia
206 BREF 207 EPA 208 EPA
EU USA EU
2009 Electric Arc Furnace 2010 Sinter Plant 2010 Blast Furnace
209 LBNL
USA
2010 Cross Cutting Technology
210 LBNL
USA
211 LBNL
USA
212 LBNL
USA
213 LBNL
USA
214 LBNL
USA
215 LBNL
USA
216 LBNL
USA
217 LBNL
USA
218 LBNL
USA
219 LBNL
USA
220 LBNL
USA
221 LBNL
USA
222 LBNL
USA
223 EPA
USA
224 EPA
USA
225 BREF
EU
226 APP
South Korea
227 APP
USA
228 APP
USA
229 APP
USA
230 APP
USA
231 APP
EU
232 BREF
EU
233 JP Steel
Japan
Electric Arc Furnace
Process 2 Polymer Injection
Type 1
Type 2 Fuel Substitution
Coke Oven
Co-generation
Top Gas Utilization
LD Slag Reduction Treatment
Slag Treatment
Quenching Self-Tempering
Process Control
Pulverized Coal Injection
Fuel Substitution
Top Gas Recycling Blast Furnace
Top Gas Utilization
Smelting Reduction
New Process
Smelting Reduction
New Process
Direct Reduced Iron
Hydrogen
Fuel Substitution
Electrolysis
New Process
Direct Reduced Iron
Biomass
Fuel Substitution
Coke Oven
Carbon Capture and Storage
CCS
Electric Arc Furnace Controls
Energy Management
Natural Gas Injection
Fuel Substitution
Basic Oxygen Furnace Gas Recovery
Waste Gas Recovery
Injection of Oil
Fuel Substitution
Hot Charging
Energy Management
Stamp Charging Battery
Process Control
Modification of Wind Boxes
Facility Management
Blast Furnace
LD Slag in Sintermaking
Slag Treatment
Nut Coke In Blast Furnace
Fuel Substitution
Sinter Machine Cooler Waste Heat Recovery Device
Waste Heat Recovery
Blast Furnace with Bigger Volume
Upscaling
Charging Carbon Composite Agglomerates
Fuel Substitution
Plastic Waste Use
Fuel Substitution
Biomass
Fuel Substitution
Top Pressure Recovery Turbine
Top Gas Utilization
Heating Hot Stove Air by BF and Coke Oven Gas Waste Heat Recovery along with Waste Heat Recovery
Steel Slag Usage
Slag Treatment
FUCHS-Shaft Furnace Scrap Preheating
Waste Heat Recovery
Oxyfuel Burners
Process Control
Direct Reduced Iron
Contender Process of BF
Direct Reduced Iron
Direct Reduced Iron
Direct Reduced Iron
Thin Slab Casting
New Process
Coke Dry Quenching (CDQ)
Waste Heat Recovery
Sinter Plant Waste Heat Recovery
Waste Heat Recovery
Smelting Reduction
New Process
Smelting Reduction
New Process
Blast Furnace Gas Turbine
Top Gas Utilization
Coke Oven Gas Recovery
Waste Gas Recovery
Coke Stabilization Quenching (CSQ)
New Process
Injection of Coke Oven Gas
Fuel Substitution
Direct Reduced Iron
Direct Reduced Iron
Direct Reduced Iron
Direct Reduced Iron
Electrolysis
New Process
Plasma Injection
Top Gas Utilization
Avoiding Blast Furnace Gas Flaring
Top Gas Utilization
Slag Heat Recovery
Waste Heat Recovery
Improved Hot Stove Combustion Control
Energy Management
Variable Speed Drives on Ventilation Fans
Energy Management
Increasing Power
Energy Management
Adjustable Speed Drives (ASDs)
Cross Cutting Technologies
Direct Reduced Iron
Foamy Slag Practices
Process Control
Electrolysis
New Process
Stirring Gas Injection
Process Control
Engineered Refractories
Facility Management
Airtight EAF Process
New Process
Direct Current Arc Furnace
New Process
Comelt
New Process
Recuperative Ladle Preheating System
Energy Management
Non-Recovery Coke Ovens
Process Control
Reduction of NOx by SCR Process
Exhaust Gas Treatment
Regenerative Activated Carbon Process
Selective Catalystic Reduction
Low Temperature Plasma
Multi-slit Ignition Oven Burner
Process Control
Biomass
Fuel Substitution
Coal Moisture Control
Process Control
Top Pressure Recovery Turbine
Top Gas Utilization
BF Gas Preheating System
Waste Heat Recovery
Dry Dedusting of Blast Furnace Gas
Top Gas Utilization
Using Unheated Tundish
Energy Management
Paired Straight Hearth Furnace
New Process
Continous Casting
Castrip
New Process
Blast Furnace
Slag Pulverization Process
Slag Treatment
Dust Recylcing in Rotary Hearth Furnace
Process Control
Regenerative Burner
New Process
District Heating Using Waste Heat
Waste Heat Recovery
Sinter Dust Control
Emissions Optimized Sintering
New Process
Hot Rolling
Integrated Casting and Rolling
New Process
Hot Rolling
Endless Strip Production (ESP)
New Process
SCOPE 21
Process Control
Improvements in Feeding Equipment
Process Control
Improvement of Oven Door and Frame Seals
Facility Management
Automation and Process Control System
Process Control
BLT Charging System
Process Control
Increase Hot Blast Temperature
Process Control
Increase Blast Furnace Top Pressure (> 0.5 Bar Process Control Guage)
Blast Furnace Control
Process Control
Direct Reduced Iron
Direct Reduced Iron
Direct Reduced Iron
Direct Reduced Iron
MultiGas Analyzer
Process Control
ProVision Lance-Based Camera System for Vacuum Degasser
Energy Management
High Temperature Membrane Module for Oxygen Enrichment of Combustion Air
Fuel Substitution
Improvement of Process Monitoring and Control
Energy Management
Blast Furnace
Development of Measures for Safe and Top Gas Utilization Pressure-Stable Operation of Top-Gas-Network
OG-Boiler System (Non-Combustion)
Waste Gas Recovery
Laser Contouring System
Facility Management
Basic Oxygen Furnace Bottom Stirring
Process Control
Proper Reheating Temperature
Energy Management
Improved Process Control (Neural Networks)
Energy Management
Lancing
Fuel Substitution
Tunnel Furnace-CONSTEEL Process
Waste Heat Recovery
Post Combustion of Flue Gas
Waste Heat Recovery
Contiarc Furnace
New Process
New-Scrap Based Steelmaking Process using Primary Energy
New Process
Hot DRI/HBI Charging to Electric Arc Furnace
Energy Management
Flameless Burners
New Process
Blast Furnace
Extended Universal Fuel Gas Measuring Device Energy Management
ECOARC
New Process
Near-Net Shape Casting Increased Bed Depth Improve Ignition Oven Efficiency
New Process Process Control Process Control
Variable Speed Drive Coke Oven Gas Compressors
Energy Management
Single Chamber System
Process Control
Improvement of Hearth Drainage Efficiency and Refractory Life
Process Control
Battery Underfiring with Advance Diagnostics and Control
Process Control
Innovative Reheat Furnace Management
Energy Management
Novel Post Combustion Method
Fuel Substitution
Blast Furnace Dust
Fuel Substitution
Charge Calculation in EAF
Process Control
Laser Based Optimization
Energy Management
Injection of Aluminium instead of Ferrosilicon Energy Management for Stainless Steel Making in EAF
Holistic Quality Driven Production Control
Energy Management
Continuous Temperature Monitoring and Control
Process Control
Dynamic Asymmetrical Control of AC EAF
Process Control
Blast Furnace
Control Modules for Sinter Plants
Process Control
Model Based Closed-Loop O2 Control
Energy Management
Optimization of Refractory Linings of Furnaces Facility Management
Quality Assurance in Sinter Plant
Facility Management
Preventing Scale Formation in Rolling
Process Control
Model Based Steel Temperature Measurement Energy Management
Throughput Optimisation in Rolling Mills
Process Control
Flow Optimizing Internals for Continuous Casters Tundishes
Process Control
Walking Beam Furnace
New Process
Tar Injection
Fuel Substitution
Curtain Flame Ignition System
Process Control
Mixing Ratio of Coke Oven and BF Gas Changed Process Control from 1:10 to 1:07
Designing of Coke Oven Battery Service Car
Facility Management
Optimizing Moisture in Sinter Raw mix
Process Control
Hydraulically-Driven Gas Regulating Valve
Facility Management
Modification of Side Wall Water Cooled Panels Facility Management and Water Header
Improving Ladle Temperature
Facility Management
Rolling Strand Temperature and Water Control Process Control
Using Used Automobile Oil Filters
Fuel Substitution
Direct Reduced Iron
New Process
Development of Oxygen-rich Furnace System for reduced CO2 and NOx emissions
New Process
Basic Oxygen Furnace
Post Combustion Optimization in Steelmaking
Waste Gas Recovery
Biomass
New Process
Direct Reduced Iron
New Process
MGGate for Continuous Caster
Process Control
Hot Oxygen Injection In Blast Furnace
Process Control
Tire Gasification Recycling Technology
New Process
Coke Oven
COURSE 50
New Process
Utilization of Waste fuels in sintering
Fuel Substitution
Reduction in sinter plant leakages Recuperator hot-blast stove Energy Efficient Drives
Facility Management Waste Heat Recovery Cross Cutting Technologies
Install Lubrication Systems
Facility Management
Process Control in Hot Strip Mill
Energy Management
Recuperative Burners
Waste Heat Recovery
Insulation
Facility Management
VSDs on Combustion air fans and controlling oxygen levels
Energy Management
Heat Recovery to the Product Heat Recovery from Cooling Water Transformer Efficiency Flue Gas Monitoring and Control Bottom Tapping
Waste Heat Recovery Waste Heat Recovery Energy Management Cross Cutting Technologies Process Control
Twin-shell DC arc furnace
New Process
Direct Reduced Iron
Direct Reduced Iron
Dilute Oxygen Combustion System
New Process
In-Situ Real-Time Measurement of Melt Constituents
Energy Management
Recycling of Waste Oxides in Steelmaking Furnace
Process Control
Automated Steel Cleanliness Analysis Tool (ASCAT)
Process Control
Hydrogen and Nitrogen Control in Ladle and Casting Operations
Process Control
On-line Laser-ultrasonic Measurement system Process Control
NOx emission Reduction by Oscillating Combustion
Process Control
Improving System Life of BOF and EAF Hoods,Roofs and Side Vents
Facility Management
Continuous Casting
Development of a process to continuously melt, refine and cast high quality steel
New Process
Development of Next Generation Heating System for scale free steel reheating
New Process
Recycling of BOF steelmaking slag
Slag Treatment
Elimination or minimization of oscillation marks
Process Control
Thermochemical recuperation for high temperature furnaces
Waste Heat Recovery
Smelting Reduction
New Process
Direct Reduced Iron
Pressure Control for Furnace
Process Control
Improvement by segregated charging of sinter Process Control materials
Natural Gas Based Zero-Reforming HYL Process New Process
Low Emissions and Energy Optimised Sintering Waste Gas Recovery Process
Environmentally Process Optimized Sintering (ESPOSINT)
Waste Gas Recovery
Recylcing Parts of Waste Gas to Other Parts of Waste Gas Recovery Sinter Strand
Sinter Plant
Use of High Quality Ore
Material Improvement
Oxy-Oil Injection
Fuel Substitution
Residue Injection
Fuel Substitution
Cyclone Converter Furnace
New Process
Smelting Reduction
New Process
Recycling of Stainless Steel Dust by Injection into EAF Improved Process Control Recovery of Blast Furnace Gas
Process Control Energy Management Waste Gas Recovery
Insulation of Steam Lines
Facility Management
Checking and Monitoring Steam Traps
Process Control
Recovery of Flash Steam
Waste Heat Recovery
Motor Maintenance
Facility Management
Minimizing Voltage Unbalances
Energy Management
Pump Controls
Energy Management
Efficient Pumps
Proper Pump Sizing
Facility Management
Multiple Pumps for Varying Loads
Facility Management
Impeller Trimming
Process Control
Adjustable Speed Drives on Pumps
Precision Castings, Surface Coatings or Polishing
Facility Management
Proper Fan Sizing
Facility Management
Heat Recovery from Compressor
Waste Heat Recovery
Preventice Maintenance
Facility Management
Energy Monitoring and Management System
Energy Management
Frequency Controlled Pumps and Fans
Auditory Rotary Machines for Pump Efficiency Cross Cutting Technologies
AIRMaster+Software Tool-Improved Compressed Air System Performance
Fan System Assessment Tool-Efficiency Enhancement for Industrial Fan Systems
Energy Management
Process Heating Assessment and Survey ToolIdentify Heat Efficiency Improvement Opportunities
Energy Management
Steam System Tools Tools to Boost Steam System Efficiency
Energy Management
Variable Speed Drives on Flue Gas Control, Pumps and Fans
Energy Management
Direct Reduced Iron
New Process
Waste Heat Recovery for Electric Arc Furnace
Waste Heat Recovery
Technology Polymer Injection
Co-generation
LD Slag Reduction Treatment
Quenching Self-Tempering
Hismelt
Hisarna
Hydrogen
Soda Solution Electrolysis
Biomass
EAF Controls
Injection of Oil
Hot Charging
Modification of Wind Boxes
LD Slag in Sintermaking
Nut Coke in Blast Furnace
Sinter Machine Cooler Waste Heat Recovery Device
Blast Furnace with Bigger Volume
Charging Carbon Composite Agglomerates
Plastic Waste Use
Charcoal Use
Top Pressure Recovery Turbine Dry Type
Heating Hot Stove Air by BF and Coke Oven Gas along with Waste Heat Recovery
Steel Slag Usage in Cement
Oxyfuel Burners
Midrex
HYLIII
Finmet
Circored
Thin Slab Casting
Coke Dry Quenching
Corex
Finex
Coke Stabilization Quenching
Injection of Coke Oven Gas
SL/RN Process
FASTMET
FASTMELT
ITmk3
Molten Oxide Electrolysis
Plasma Injection
Avoiding Blast Furnace Gas Flaring
Slag Heat Recovery
Improved Hot Stove Combustion Control
Variable Speed Drives on Ventilation Fans
Increasing Power
Adjustable Speed Drives (ASDs)
ULCORED
ULCOWIN
Stirring Gas Injection
Engineered Refractories
Airtight EAF Process
Direct Current Arc Furnace
Comelt
Non-Recovery Coke Ovens
Reduction of NOx by Selective Catalytic Reduction Process
Selective Catalystic Reduction
Multi-slit Ignition Oven Burner
Wood Char in Sintermaking
Coal Moisture Control
Top Pressure Recovery Turbine Wet Type
BF Gas Preheating System
Dry Dedusting of Blast Furnace Gas
Using Unheated Tundish
Castrip
Dust Recylcing in Rotary Hearth Furnace
Regenerative Burner
Sinter Dust Control
Integrated Casting and Rolling
Endless Strip Production (ESP)
SCOPE 21
Improvements in Feeding Equipment
Improvement of Oven Door and Frame Seals
Bell Less Top Charging System
Increased Hot Blast Temperature
Increased Blast Furnace Top Pressure (> 0.5 Bar Guage)
Rotary Kiln Direct Reduction
Coal-Based HYL Process
Coal-Based Midrex Process
Natural Gas-Based Midrex with CO2 Removal System
MultiGas Analyzer
High Temperature Membrane Module for Oxygen Enrichment of Combustion Air
Development of Measures for Safe and PressureStable Operation of Top-Gas-Network
Basic Oxygen Furnace Bottom Stirring
Proper Reheating Temperature
Improved Process Control (Neural Networks)
Lancing
Tunnel Furnace-CONSTEEL Process
Contiarc Furnace
Hot DRI/HBI Charging to Electric Arc Furnace
Flameless Burners
Extended Universal Fuel Gas Measuring Device
ECOARC
Near-Net Shape Casting Increased Bed Depth Improve Ignition Oven Efficiency
Variable Speed Drive Coke Oven Gas Compressors
Single Chamber System
Improvement of Hearth Drainage Efficiency and Refractory Life
Battery Underfiring with Advance Diagnostics and Control
Blast Furnace Dust
Laser Based Optimization
Injection of Aluminium instead of Ferrosilicon for Stainless Steel Making in EAF
Holistic Quality Driven Production Control
Continuous Temperature Monitoring and Control
Control Modules
Model Based Closed-Loop O2 Control
Optimization of Refractory Linings of Furnaces
Quality Assurance in Sinter Plant
Preventing Scale Formation in Rolling
Model Based Steel Temperature Measurement
Flow Optimizing Internals for Continuous Casters Tundishes
Tar Injection
Mixing Ratio of Coke Oven and BF Gas Changed from 1:10 to 1:07
Designing of Coke Oven Battery Service Car
Optimizing Moisture in Sinter Raw mix
Hydraulically-Driven Gas Regulating Valve
Modification of Side Wall Water Cooled Panels and Water Header
Improving Ladle Temperature
Rolling Strand Temperature and Water Control
Modified Rotary Hearth Furnace
Development of Oxygen-rich Furnace System for reduced CO2 and NOx emissions
Post Combustion Optimization in Steelmaking
Sustainable Steelmaking using Biomass and Waste Oxides
Suspended Hydrogen Reduction of Iron Oxide Concentrates
COURSE 50
Utilization of Waste fuels in sintering
Reduction in sinter plant leakages Recuperator hot-blast stove Energy Efficient Drives
Install Lubrication Systems
Process Control in Hot Strip Mill
Insulation
VSDs on Combustion air fans and controlling oxygen levels
Heat Recovery to the Product Heat Recovery from Cooling Water Transformer Efficiency Flue Gas Monitoring and Control Bottom Tapping
Twin-shell DC arc furnace
Tecnored
Redsmelt
Recycling of Waste Oxides in Steelmaking Furnace
Automated Steel Cleanliness Analysis Tool
On-line Laser-ultrasonic Measurement system
NOx emission Reduction by Oscillating Combustion
Recycling of BOF steelmaking slag
Elimination or minimization of oscillation marks
Dios Process
Comet
Pressure Control for Furnace
Improvement by segregated charging of sinter materials
Natural Gas Based Zero-Reforming HYL Process
Low Emissions and Energy Optimised Sintering Process
Environmentally Process Optimized Sintering
Recylcing Parts of Waste Gas to Other Parts of Sinter Strand
Use of High Quality Ore
Oxy-Oil Injection
Residue Injection
Cyclone Converter Furnace
Romelt
Recycling of Stainless Steel Dust by Injection into EAF Improved Process Control Recovery of Blast Furnace Gas
Insulation of Steam Lines
Checking and Monitoring Steam Traps
Recovery of Flash Steam
Motor Maintenance
Minimizing Voltage Unbalances
Pump Controls
Efficient Pumps
Proper Pump Sizing
Multiple Pumps for Varying Loads
Impeller Trimming
Adjustable Speed Drives on Pumps
Precision Castings, Surface Coatings or Polishing
Proper Fan Sizing
Heat Recovery from Compressor
Preventice Maintenance
Energy Monitoring and Management System
Frequency Controlled Pumps and Fans
Auditory Rotary Machines for Pump Efficiency
AIRMaster+Software Tool-Improved Compressed Air System Performance
Fan System Assessment Tool-Efficiency Enhancement for Industrial Fan Systems
Process Heating Assessment and Survey ToolIdentify Heat Efficiency Improvement Opportunities
Steam System Tools Tools to Boost Steam System Efficiency
Variable Speed Drives on Flue Gas Control, Pumps and Fans
Iron Carbide Process
Waste Heat Recovery for Electric Arc Furnace
Technology Description Coke or Anthracite is used in EAF to insulate molten steel and thus minimizing energy use. University of New South Wales (UNSW) has demonstrated that polymers such as rubber from tyres can replace some of the coke in EAF. Therefore used rubber tyres are utilized in EAF instead of disposing them in to landfill. This has resulted in coke savings. Surplus by-product gases from BF and Coke Oven are usually flared. A 70 MW co-generation plant was commissioned which converts surplus BF and Coke Oven gases into electrical energy by using heat from their combustion to fuel two package boilers. These produce steam that drives a 105 MW turbine (rated capacity). Each boiler can generate 35 MW of electricity, with a combined capacity of 70 MW. The facility has been designed to accommodate a third boiler if additional by-product fuel becomes available. LD slag has high expansion potential when used in confined layers. This creates problems for road applications. An LD slag reduction treatment process was started to use treated slag in the base layers of road. This process involves stimulating the free oxides reaction to air and water through a repeated humectation and airing process. During its expansion reduction treatment the LD slag is permanently monitored through laboratory testing according for its use as road base and sub-base paving.
Steel's high strength to weight ration means less material consumption and lower emissions compare to other construction materials. A cost effective in-line quenching self-tempering process was developed that accomodates characteristics of high strength steels. Pulverized Coal Injection (PCI) is a process in which fine granules of coal are blown in large volumes into the BF. This provides a supplemental carbon source to speed up the conversion of iron ore into metallic iron. However, PCI can not entirely substitute the coke. Certain amount of metallurgical coke has to be added anyhow. In Top Gas Recycling Blast Furnace (TGRBF), O2 is blown in the blast furnace instead of hot air to eliminate N2 in off-gas. Part of the off-gas containing CO and H2 is utilized again as the reducing agent in BF. CO2 from the off-gas is captured and sebsequently stored. Hismelt process involves the pre-reduction of iron ore by gases coming from a hot bath. The prereduced iron is then melted in the bath to produce hot metal. The excess gas produced during the process is used for power generation, production of direct reduced iron (an alternative iron input for scrap), or astechnology based on bath-smelting. It combines coal preheating and partial pyrolysis in a HIsarna is a fuel gas. reactor, a melting cyclone for ore melting and a smelter vessel for final ore reduction and iron production. It requires significantly less coal usage. Furthermore, it is a flexible process that allows partial substitution of coal by biomass, natural gas or even Hydrogen(H2).
Hydrogen could be used as a reducing agent, as its oxidation produces only water. Hydrogen, either pure, as a synthesis gas (syngas) produced by reforming methane or as natural gas, can be used in conventional direct-reduction reactors or in more futuristic flash reactors. In Soda Solution Electrolysis, iron ore is dispersed in a soda solution. Electrolysis is assumed to dissociate water into OH-ions and free hydrogen, which would then reduce Fe2O3 and regenerate water.
Biomass can be used to generate the reducing agent, either from charcoal for example or syngas. Biomass in such a scheme would need to be grown in a sustainable way.
Use of carbon capture and storage technology is a necessary precondition to the continued use of fossil fuel based reducing agents in steel production. The process is based on capturing carbon dioxide (CO2) from large point sources and storing it in such a way that it does not enter the atmosphere. It can also be used to describe the scrubbing of CO2 from ambient air as a geoengineering technique. This emerging technology could be based on various capture and storage options, some of which only need to be adapted to the steelmaking context, while others still need basic research. Energy audit at Tenariss Dalmine plant found several areas where the energy could be saved through more better use, improvements in existing equipment and processes, and strengthening of training activities . One potential area of energy saving was optimising EAF controls. Natural gas injection in BF allows a reduction in coke utilization with associated benefits. This technology requires little extra capital investments and special equipment except for the gas pressure equalizer and gas distributor and considerably decreases coke consumption. Injection of natural gas improves productivity and generally improves the performance of the blast furnace due to a decrease in heat demand for direct reduction, belly solution loss, and silicon transfer reactions. BOF can become a net energy supplier if the heat of the exhaust gas and the gas itself is recovered. Heat recovery methods are classified as a combustion method or as a non-combustion method. Noncombustion method facilities are designed to recover about 70% of the latent heat and sensible heat. By reducing the amount of air entering over the convertor, CO is not converted to CO2. The sensible heat of the off-gas is first recovered in a waste heat boiler, generating high pressure steam. The gas is subsequently cleaned and stored. The recovered converter gas can be mixed with other byproduct gases.
Heavy fuel oil or waste oil can also be injected into the blast furnace. Oil contains hydrogen which has certain benefits over Carbon monoxide. Hydrogen reduction does not result in CO2 as a by-product, and thus helps to reduce CO2 emissions. Charging slabs at an elevated temperature into the reheating furnace of the hot rolling mill will save energy. Hot charging not only saves energy, but also improves material quality. It reduces material losses, enhances productivity (by up to 6%), and may reduce slab stocking. During the stamp charging process the coal is compacted outside the coke oven, into a single briquette (coal cake), having almost the same dimensions as the oven chamber. The major benefits which can be derived from stamp charging technique are improvement in bulk density of coal charge. Stamp charging can increase throughput of a heat recovery oven by up to 28% while at the same time maintaining high-quality coke production. All sinter machines are provided wind boxes for suction of air through sinter bed. This helps for ignition of sinter and has direct impact on coke breeze consumption as well as specific heat consumption. To reduce air infiltration through wind boxes, stationary damper of pre-designed size with predetermined slits were installed in the wind boxes of Bhilai Steel sintermaking facility. LD slag was utilized in the Blast Furnace in addition to its usage in Sinter Plant to partly replace lime stone flux and manganese ore usage.
Layer charging of Nut coke in Blast furnace ( in addition to its usage in Sinter) was carried out for optimum utilisation of undersized coke fraction and increasing BF productivity.
This device is a waste heat recovery device, which is constructed as an auxiliary to the sintering machine cooler. It comprises mainly a boiler/economizer, pure water feed device, deaerator, steam drum, etc. After heat exchange with the sintered ore in the cooler, the exhaust gas is introduced into the boiler/economizer. Steam is generated by heat exchange with water. This steam can be utilized to run a steam turbine to generate electricity. Size affects blast furnace efficiency. A larger blast furnace is usually more efficient because the heat losses are lower. Moreover, it is usually more economical to install energy efficient equipment in larger blast furnaces. Switching to larger blast furnaces requires modern technologies and high capital costs.
Carbon Composite Agglomerates (CCB) are the mixtures of fine iron ore (hematite, magnetite, ironbearing ironmaking dust, and pre-reduced iron-bearing ore fine) and fine carbonaceous materials (fine coke fine coal, charcoal, and char) adding some binding agents in most cases. CCBs were tested in some practical blast furnaces and it revealed that the use of CCB can improve the energy efficiency of a BF. Furthermore, the effective use of non-coking coal, and iron-bearing dust and sludge in steel works would extend the variety of raw materials and promotes resource recycling. Plastic waste can also be injected into blast furnaces as a partial substitute for coke and coal. Plastic waste can also be added to the coke oven. The option is limited by the availability of plastic waste and by the claims of other uses, such as recycling and incineration. The maximum level of plastic injection at the tuyere level is though to be 70 kg/t hot metal. This limit is set by the thermochemical and kinetic conditions in the raceaway. Charcoal has a lower mechanical stability, much lower ash content and much higher volatile material content (20 35%) than coke. The use of charcoal in large blast furnaces is limited due to its low mechanical resistance. The largest charcoal blast furnaces are one order of magnitude smaller than the largest coke blast furnaces. However, Charcoal BF reduces CO2 substantially provided charcoal is produced sustainably. BF Gas has a pressure of 0.2-0.236 MPa (2-2.41 kg/cm ) and temperature of approx. 200C at the top. This technology is a method of generating electrical power by employing this heat and pressure to drive a turbine generator. Although the pressure difference over the generator is low, the large gas volumes can make the recovery economically feasible. The system comprises dust collecting equipment, a gas turbine, and a generator. Generating methods are classified as (1) wet or (2) dry depending on the BF-gas purification method. Dust is removed by a dry-type dust collector in the dry method. Normally, mixtures of gases are used to heat a hot blast stove. A typical mix consists of 60% BF gas and 40% Coke oven gas or natural gas. The application of gas enrichment is relatively expensive as enrichment gas is more expensive than blast furnace gas. To minimise the costs, waste heat can be recovered and used for preheating the combustion gas and/or combustion air for the stove. Besides reducing costs for enrichment gases, a waste heat recovery unit will increase the overall stove system efficiency by up to 8 percentage points, a saving of 0.24 GJ/t HM. About 100 200 kg of BOF slag is generated per tonne of liquid steel. It can also be used in the cement clinker manufacturing process. The result is an increase in clinker production of up to 15% with no net increase in CO2 emissions. The shaft technology has been developed in steps. With a single shaft furnace at least 50% of the scrap can be preheated whereas a finger shaft furnace allows preheating of the total scrap amount. A further modification is the double shaft furnace which consists of two identical shaft furnaces positioned next to one another and which are serviced by a single set of electrode arms.
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Oxy-fuel burners can be installed in EAFs to reduce electricity consumption by partially substituting electricity with fuels. By using a fuel-efficient oxy-fuel flame at the beginning of the melting process, a greater overall melting efficiency is achieved with a faster melt rate. It also reduces electrode consumption and tap-to-tap time. Steelmakers are now making wide use of stationary wall-mounted oxygen-gas burners (OGB) and combination lance-burners (CLB), which operate in a burner mode during the initial part of the melting period. When a liquid bath is formed, the burners change over to a mode in which they act as oxygen lances. Midrex is shaft-reactor DRI process developed by Midrex/Kobe Steel. Iron oxide, in pellet or lump form, is introduced through a proportioning hopper at the top of the shaft furnace. As the iron ore descends through the furnace by gravity flow, it is heated and the oxygen is removed from the iron ore (reduction) by counterflowing gases that have a high H2 and CO content. These gases react with the Fe2O3 in the iron ore and convert it to metallic iron, leaving H2O and CO2. Metallization rate is 93% while carbon content varies between 1.5-2.5%.
HYL III is a process designed for the direct reduction of iron ores by use of H2 and CO reducing gases. The HYL III plant comprises two main process sections: the reducing gas generation and the reduction sections. Typically, the reducing gas generation section consists of a conventional natural gas-steam reformer to produce the H2 + CO required as make-up for the reduction process. The basic components of the reduction circuit, aside from the reactor, are: a gas heater to increase the reducing gases temperature up to 925C; a scrubbing unit for dedusting, cooling and H2O elimination from top gases; the recycle gas compressor and the CO2 removal unit. The Finmet process is a multiple fluidized bed process which utilizes a H2 rich reducing gas produced by steam reforming. The iron oxide feed to the Finmet process is in the form of iron fines under 12 mm in size. Reduction is carried out at intermediate reduction temperatures, but at a higher operating pressure than most DR processes. The process produces hot briquetted iron, HBI. The Circored process is a two stage fluidized bed process. It operates at low reducing temperatures and uses natural gas to produce reducing gas by means of reforming. The process uses ore fines that have a particle size between 1mm and 0.03mm. It produces HBI. In Thin Slab Casting, the steel is cast directly to slabs with a thickness between 1.2 and 2.4 in (30 and 60 mm), instead of slabs with a thickness of 4.72-11.8 in (120-300 mm). Thin slab or strip casting processes reduce the steel rolling energy needs significantly. This technology enables faster production of thin products. It results in considerable savings in capital cost outlay, completion and delivery times and energy costs. Coke Dry Quenching (CDQ) is an alternative to the traditional wet quenching of the coke. Instead of water, an inert gas such as Argon or N2 is used to quench the coke. After the quenching, heat of the inert gas is utilized in a heat recovery boiler. Resulting steam generates electricity. The process reduces dust emissions and recovers the sensible heat of the high temperature coke. This heat recovery accounts for approximately 45% of energy consumption in coke ovens.
Waste gas heat of a sintering plant is recovered as steam or electric energy. The heat recovery efficiency is 34% for waste gas from sintering machine proper. The system is composed of a waste heat recovery boiler, economizer, dimineralized water supply equipment, de-aerator, steam drum, etc. For realizing high-efficiency recovery, a high-temperature exhaust section is separated from a low-temperature exhaust section and heat is recovered only from high-temperature exhaust section. Corex is a smelting reduction process. It takes lump iron ore or pellets as input. Oxide ore is first prereduced from the hot gases coming from melter gasifier. Hot metal is formed in melter gasifier where oxygen and coal are injected. Pulverized coal is also sometimes added. Finex is fluidized-bed smelting reduction process. It utilizes fine ore and non-coking coal. Iron ore is first pre-reduced in fluidized-bed reactors by reducing gas coming from melter gasifier. Subsequently, hot metal is produced in the melter gasifier. Coal and oxygen are supplied in the melter gasifier. Blast furnace Gas Turbine utilizes the BF off-gas to generate electricity. Combined gas turbines and steam cycles can produce electric efficiencies in excess of 42% in steel mill applications. This represents an important efficiency gain. A critical factor is the gas turbine inlet temperature, which directly impacts the gas turbine efficiency. The latest designs operate at 1300C. Coke oven gas (COG) is rich in hydrogen and therefore has a relatively high heating value of 17.6 MJ/m3. About 70% of COG is used in iron and steel production processes, 15% to heat coke ovens and 15% for power generation. COG is also used to fuel equipments such as boilers and reheat furnaces. Coke Stabilization Quenching (CSQ) is a new wet quenching technology which is to date has only been applied in Germany. It brings the hot coke into contact with water from both top and bottom. High quenching rate and low reaction time is the essence of the process. Dust emissions as low as 6 g/t coke have been achieved. Coke moisture after the CSQ is approx 2%. High quality coke after CSQ can result in energy savings in BF. Coke oven gas (COG) can also be injected in blast furnace. The maximum level for COG injection at the tuyre level is thought to be 0.1 ton/ton hot metal. This limit is set by the thermo-chemical conditions in the furnace. Analysis indicated that Pulverized Coal Injection leads to higher energy effectiveness than that of coke oven gas. The SL/RN process is a kiln based process that uses lump ore, pellets, beach sand or ilmenite ore and solid carbon to produce hot or cold DRI. The process operates at high temperature and atmospheric pressure. This is the most widely used coal based direct reduction process. The final metallization is about 93% and carbon content about 0.1 to 0.2%. The FASTMET process is based upon a rotary hearth furnace. The iron oxide feed to a FastMet furnace is in the form of dried greenballs made of iron ore and coal. After introduction, the greenballs are heated in 3 burner/ reaction zones; all fired by side-wall mounted burners. Zone 1 has three burners, Zone 2 has five burners and Zone 3 has two burners. All burners are designed for air/natural gas or oxygen enriched air/natural gas combustion. A water cooled chill plate is positioned after Zone 3 for cooling of the hot DRI product to 1000-1200C prior to discharge from the RHF.
Hot, metallized DRI produced from FASTMET is directly charged to a specially designed electric melter (FASTMELT) to produce hot metal. ITmk uses the same type of rotary hearth furnace (RHF) as the FASTMET process. The process uses low-grade iron ore and coal to produce iron nuggets of superior quality to direct reduced iron (97% iron content). The mixing, agglomeration, and feeding steps are the same, but the RHF is operated differently. In the last zone of the RHF, the temperature is raised, thereby melting the iron ore and enabling it to easily separate from the gangue. The result is an iron nugget containing iron and carbon, with almost no oxygen or slag. Molten oxide electrolysis (MOE) is an extreme form of molten salt electrolysis, a technology that has been producing tonnage metal for over 100 years -- aluminum, magnesium, lithium, sodium, and the rare-earth metals are all produced in this manner. What sets molten oxide electrolysis apart from all molten salt electrolytic technologies is its use of carbon-free anodes which, in turn, facilitates the production of oxygen gas at the anode. Iron oxide will be electrolysed and reduced to iron. MOE offers powerful environmental advantages over conventional technology. Even in recognition of the use of carbon in the generation of electricity, MOE ranks lowest among breakthrough technologies in terms of CO2 emissions per unit metal product. The plasma-heated blast furnace process requires neither hot blast nor oxygen nor an additional auxiliary reductant. With this process concept, a portion of the top gas flow is fed to a plasma burner without any prior treatment. It is heated to a temperature of about 3400C. The CO2 content of the top gas is transformed to CO by an endothermic reaction with carbon from the coke, resulting in a calculated flame temperature of 2150C. Where a blast furnace is fitted with a two bell charging system, gas is lost to the atmosphere every time the furnace is charged. It is possible to recover most of this. It is done by allowing the high pressure gas between the two bells to discharge into the low pressure side of the gas collection system just prior to opening the top bell for charging. In modern blast furnaces around 0.25-0.30 tons of liquid slag with a temperature of approximately 2640F (1450C) are produced per ton of pig iron. A number of slag heat recovery systems have been proposed. However none have been applied commercially due to technical difficulties that arise in the development of a safe, reliable and energy-efficient system. Hot stove automation can help to reduce the energy consumption of the stoves and increase the reliability of the operation by running the operation more efficiently and closer to optimum conditions. It also increases stove lifetime and optimize the gas mix. It also includes Improvement of combustion through more efficient burners and adaptation of combustion conditions (fuel/oxygen ratio). In a BOF plant, large fans are used to control air quality. The BOF process is a batch process and as a consequence the volumes of flue gases vary widely over time. This can make the installment of variable speed drives a cost effective option.
Transformer losses can be as high as 7% of the electrical inputs. These losses will depend mainly on the sizing and age of the transformer. Converting the furnace operation to higher power, or more specifically to ultra-high power (UHP), increases productivity and reduces energy losses. The increased power can be reached by installing new transformers or paralleling existing transformers. As flue gas flow varies over time, adjustable speed drives (ASDs) offer opportunities to operate dust collection fans in a more energy-efficient manner. Flue gas ASDs have been installed in various countries (e.g. Germany, UK). Operation of the ASDs will permit the production of additional efficient steel heats. ULCORED is a new direct reduction process which utilizes 100% oxygen. Direct-reduced iron (DRI) is produced from direct reduction of iron ore (in form of lumps or pellets) by a reducing gas produced from natural gas. The reduced iron is in solid state and for melting the iron, electric energy is required. This is carried out in an Electric Arc Furnace (EAF). Off-gas consists of only CO2, facilitating its sequestration. By covering the arc and melt surface with foamy slag, heat losses through radiation from the melt can be reduced. Foamy slag can be obtained by injecting carbon and oxygen, or by lancing of oxygen only. Slag foaming increases the electric power efficiency by at least 20% in spite of a higher arc voltage. ULCOWIN is the Electrolysis of iron ore in an alkaline solution at approx 100 degree celcius to produce iron and give off oxygen. This technique consists of injecting an inert gas in the bottom of the EAF to increase the heat transfer in the melt. In addition, increased interaction leads to an increased liquid metal yield of 0.5%. Furnaces with oxygen injection are sufficiently turbulent, reducing the need for inert gas stirring. Refractories in EAF have to withstand extreme conditions such as temperatures over 2900F (1600C), oxidation, thermal shock, erosion, and corrosion. These extreme conditions generally lead to an undesired wear of refractories. Refractories can be provided by a controlled microstructure: alumina particles and mullite microballoons coated uniformly with carbon and carbides. The refractories can be either sintered or cast and can therefore be used in a wide range of components at EAF mills. In EAF operation, there is a large amount of air ingress: around 30 000 Nm3 in a standard EAF of 165 ton (150 tonne) steel with a heat duration of 1 hour. This air is at ambient temperature, the N2 content and the non-reactive oxygen are heated in the furnace and exit with the fumes at high temperature, resulting in significant thermal losses. Airtight furnace has been assessed to be of potential benefits. With airtight operations, about 80% of the savings can be attributed to a reduction of energy losses in the fumes. The remaining 20% are accounted for by reduced thermal losses due to a reduced elaboration time. In a DC furnace, one single electrode is used, and the bottom of the vessel serves as the anode. This arc furnace achieves an energy savings of approximately 5% in terms of power unit consumption in comparison with the 3-phase AC arc furnace. In addition, it also has other features, including higher melting efficiency and extended hearth life.
The Comelt furnace is an EAF on a DC basis with side electrodes provided by VAI. In most cases the furnace is featured with four slanted electrodes. It results in electric energy transmission by four inclined DC arcs. The essential advantages are: high productivity, reduction of total energy consumption and reduction of electrode consumption. The ladle of the caster is preheated with gas burners. Fuel consumption for preheating the ladle containing liquid steel is estimated at 0.02 MBtu/ton (0.02 GJ/tonne) liquidsteel. Heat losses can occur through lack of lids and through radiation. The losses can be reduced by using recuperative burners and using oxyfuel burners. Unlike the by-product type of coke plant, in non-recovery cokemaking, all of the volatiles in the coal are burned within the oven. It provides the heat required for the cokemaking process. The oven is a horizontal design and operates under negative pressure. Primary combustion air is introduced though ports in the oven doors which partially combusts the volatiles in the oven chamber. Secondary air is introduced to complete the combustion process into the sole flues which run in a serpentine fashion under the coal bed. NOx in the flue-gas is catalytically reduced by ammonia to N2 and H2O. Vanadium Pentoxide or Tungsten Oxide on a Titanium Oxide carrier are often used as catalyst. Other possible catalysts are iron oxide and platinum. Sintering exhaust gas contains SOx, NOx, dust and dioxins. These contaminants are processed, adsorbed, decomposed and/or collected as non-toxic by-products by Regenerative Activated Carbon process. It increases the quantity of steam recovery, and improve total fuel savings. SOx and dioxins contained in the sinter flue gas are removed in this process by adding sodium bicarbonate and Lignite. Lignite Injection produces dioxin < 0.2 ng-TEQ/Nm3. Active radicals of low-temperature plasma remove SOx, NOx and HCl simultaneously. Dioxin also decreased with the addition of Lignite to the process. Reliability and stability have been proven. Core technology includes full-scale magnetic pulse compressor, stabilizing pulse width and rising time, proper reactor capacity design, and energy saving technology through additives. Multislit Burner consists of fuel exhaust nozzles located in the sintering floor width direction and a slit-like burner tile containing these fuel exhaust nozzles. The fuel supplied from the fuel exhaust nozzles reacts to the primary air inside the burner tile, then to the secondary air supplied to flame outer periphery area. By using the slit-like buruner tile, non-flamed places can be eliminated. By controlling the ratio between the primary air and the secondary air the length of the flame can be controlled to minimize the ignition energy. Biomass utilization practices for iron and steelmaking are being developed to replace coke breeze in the sintering process. Charcoal has been found to be as effective a fuel and reductant for the bath smelting of iron ores. Wood char has been shown to be a suitable replacement for coke breeze in the sintering process, resulting in process improvements and reduction of acid gas levels in process emissions.
Coal moisture control reduces the carbonization heat amount and improves the productivity and coke quality. It is accomplished by controlling the moisture of the feed coal for coke making from a normal 8 - 10% to approximately 6% without hindering the feeding operation. Generally, lowpressure steam is used as the humidity control heat source. However, in some cases the sensible heat of the coke oven gas (COG) is collected by using a heat medium and used as part of the heat source. Top gas pressure in modern blast furnaces is approximately 3.6-36 psig (0.25-2.5 bar gauge). Electric power can be generated by employing blast furnace top gases to drive a turbine-generator. Although the pressure difference over the generator is low, the large gas volumes can make the recovery economically feasible. This is typically the case when the top pressure is in excess of 22 psig (1.5 bar gauge). In the wet method dust is removed by Venturi scrubbers. The flue gases are used to heat the combustion air of the blast furnace. The exit temperature of the flue gases is approximately 250C. Dry type dedusting does not require water scrubbing. Instead it employs an electro-precipitator or a bag filter to clean the BFG. Dry dedusting eliminates generation of polluted water and slurry. It 3 improves gas cleanness with dust content of <5mg/Nm . Dry dedusting occupy 50% less land area than wet type dedusting. Practices in Brazil have shown that the use of a cold tundish is operationally feasible. It brings with it several main benefits: a 70% reduction in the time for machine return after interruptions at the beginning of the cycle, a reduction of natural gas consumption, a 90% increase of the lifetime of the tundish lids etc. The practice was not found to have any influence on the quality of the product. In order to use a cold tundish successfully, an efficient and controlled drying of the tundish is required. The Paired Straight Hearth (PSH) furnace is a new coal-based reduction process for making metallized pellets for EAF or Smelting processes. The PSH process uses non-metallurgical coal as a reductant to convert iron oxides such as iron ore and steelmaking by-product oxides to DRI pellets. In this process, a multi-layer, nominally 120 mm tall bed of composite green balls made from oxide, coal and binder is built up and contained within a moving refractory hearth. The pellet bed absorbs radiant heat energy during exposure to the high temperature interior refractory surfaces of the PSH while generating a strongly reducing gas atmosphere in the bed that yields a highly metalized DRI product. The Castrip process has been developed to allow the direct casting of thin strip from liquid steel. Gauges currently ranging from 0.8 mm to 2.0 mm. More tolerant of high residual elements without loss of quality. It enables greater flexibility in ferrous feed sourcing. Slag is a by-product of iron and steelmaking. Slag pulverization is a process during which water is sprayed when the slag temperature is at 600-800 C. The water spray produces hot steam, which reacts with free calcium oxide and magnesium oxide. Consequently, the slag is pulverized due to the volume expansion. It makes the iron and steel separate naturally from the slag.
Dust recycling in the rotary hearth furnace (RHF) was applied at Nippon Steels Kimitsu Works in 2000. The dust and sludge, along with iron oxide and carbon, are agglomerated. The iron oxide is reduced at high temperatures. Zinc and other impurities in the dust and sludge are expelled and exhausted into off-gas. DRI pellets made from the dust and sludge have 70% metallization and are strong enough to be recycled to the blast furnaces. A regenerative burner is a heat recovery system that recovers the waste heat of the furnace exhaust gas to heat-up the combustion air of the furnace. The regenerative burner uses heat reservoirs and dual heat-recovering generators at each burner. During combustion, one side of a burner combusts fuel while the other accumulates the exhaust heat into the heat-recovering generator. Then the burners switch so that the one accumulating heat combusts the fuel and the other now accumulates exhaust heat. District heating using waste heat in the steel industry saves energy. It also a method for sharing resources with nearby residential and commercial buildings. Production increase leads to increased dust generation, thereby increasing particulate emissions. These emissions - off/waste gas are dust-laden, containing a wide variety of heavy metal hazardous air pollutants (HAPs). By sending waste gas to Electrostactic Precipitators (ESPs) through negatively charged pipes, the particulate matter (PM) in the waste stream becomes negatively charge. Routing the stream past positively charged plates will then attract and collect the negatively charged PM, thereby producing clean waste gas. It increases the quantity of steam recovery. The Emissions Optimized Sintering (EOS) process for sinter plants was developed by Outokumpu Technology. EOS can be retrofitted with minimum production interference. EOS reduces the substantial off-gas volume. It achieves so through housing the entire sinter strand, re-circulating offgases and using its CO content as an energy source to minimize off-gas volumes, cutting off-gas cleaning investment and operational costs, as well as significantly minimize NOx, SOx, CO and CO2 emissions. When applying direct rolling, the casted slab is rolled directly in the hot strip mill, saving handling and energy costs. Direct production of hot-rolled strip by connecting the thin slab caster with the hotrolling process was introduced around 1990. In existing integrated plants this option may be difficult to implement, as the rolling stands need to be located directly next to the continuous caster. This leads to high retrofit costs. A new development of Thin Slab Casting and direct rolling is Endless Strip Production (ESP). Construction of an ESP plant by Arvedi started in 2008 in Cremona (Italy). Process results in improved liquid steel yield (up to 98%). SCOPE 21 has three sub-processes. (1) rapid preheating of the coal charge, (2) rapid carbonization, and (3) further heating of coke carbonized up to medium temperatures. The aim of dividing the whole process into three is to make full use of the function of each process in order to maximize the total process efficiency. In this technology, significant energy savings can be achieved by rapidly heating the coal at 350C in advance (low temperature carbonization) and directing it into a 850C oven, unlike the conventional 1200C coke oven. The technology reduces the coking time from 17.5 hours to 7.4 hours and improves coke quality.
An additional screen is installed on the conventional sloping chute. It promotes a more desirable distribution of granulated ore on the palette. The screen with a sloping chute places coarser granulated ore in the lower part of the palette and finer ore on the upper part. This achieves high permeability. Coke oven leaking doors can be a major source of pollution. With the advent of recovery type ovens, the design of oven doors has under gone evolutionary change. The important features of the leakproof door include: (1) a thin stainless steel diaphragm with a knife edge as a sealing frame built in between the door body and the brick retainer, (2) spring loaded regulation on the knife edge for selfsealing, (3) provision for air cooling of the door body, and (4) large size gas canals for easier circulation of gas inside oven. Instead of conventional constant heating of the coke ovens, programmed heating enables optimization of the fuel gas supply. Optimization leads to proper utilization of fuel gas to heat the oven at the various stages of the coking process. It stabilizes coke battery operations and conditions and results in more consistent coke quality. Process control also increases battery life time. With the Bell Less Top (BLT) charging systems, input materials like coke and sinter are screened before charging. Proper distribution of input materials improves the coking rate and increases productivity. A variety of techniques can be applied to increase the hot blast temperature including preheating of the fuel in conjunction with insulation of the cold blast line and waste gas flue. The feasibility of this depends on the waste gas temperature; e.g. at waste gas temperatures below 250C heat recovery may not be a technically or economically attractive option. In some cases, imported heat may be used, e.g. sinter cooler heat, if the distances are reasonable. A preheated fuel medium reduces energy consumption. Blast furnace off gas cleaning is performed using either a dust catcher or cyclone in conjunction with an annular gap wet scrubber. The scrubber consists of a movable cone assembly which allows the top pressure of the furnace to be controlled accurately and consistently. Increased top pressure helps good furnace operation and reduced fuel rate by decreasing velocity of the gases and by increasing retention time for the gas-solid reactions. Optimized process control of the blast furnace is achieved through an expert system that uses various process models. It observes the blast furnace on a continuous basis and uses the various process models to perform calculations and diagnose process disturbances. Expert systems can be run in advisory mode or in full closed loop. The rotary Kiln is a rotating cylindrically shaped reactor of 3-6 m diameter and ~ 85 m length installed at an incline. The capacity of the kiln depends on metallization degree and does not exceed 225,000 300,000 t/annum. The coal consumption is about 800 kg/t DRI. It is operated in countercurrent flow with solids moving down the incline in opposite direction to the gases. Iron ore and coal are jointly charged to the kiln from the charge end.
Coal-based HYL reactor principle of operation is same as gas based HYL process. Oxide material is fed from top and is reduced by a counter current flow of H2 and CO containing gas. Similar to gas based HYL process, furnace top gas is cooled and cleaned and its CO2 is removed and then recycled into reducing gas circuit. Reducing gas is produced in a coal gasifier that can process practically any kind of carbon bearing material. Coal and Oxygen are injected into gasifier and almost all carbon in the coal is gasified. Midrex reactor and its auxiliary systems are same as for gas based Midrex plants. The reactor includes dynamic top and bottom seals and operates at a relatively low pressure of 1.5 barg. Oxide material flows downward by gravity through several zones while product is discharged at a controlled rate from the bottom. Spent gas from shaft furnace is cleaned and cooled in a venturie scrubber and then cleaned from CO2 and H2S. Treated gas is recycled into reducing gas circuit, which is produced by coal gasification. Midrex has developed a new concept, employing a CO2 removal system that allows for even lower emissions. This option uses an amine-type system that removes CO2 from the top gas. This stream is then preheated, with part of it added to the reformed gas, which goes to the shaft furnace. The remainder is used for top gas fuel in the reformer burners. The MultiGas analyzer improves continuous emissions monitoring (CEM) and on-line process tuning of combustion-dependent systems. This multi-gas analyzer technology combines advanced Fourier transform infrared spectroscopy with advanced electronics and software. This portable compact system provides real-time measurements and on-line feedback for operational tuning. It measures criteria and hazardous air pollutants that are not typically monitored on-site in real-time, such as formaldehyde and NH3. The lance-based fiber-coupled optical pyrometer measures melt temperature in a vacuum degasser. It is used for producing ultra-low carbon steel through ladle treatment operation. Temperature control in the ladle is crucial to downstream processes, especially in the continuous caster. To produce desired grades of steel, process models based on melt temperature and chemistry. It measures melt temperature automatically before and after oxygen blowing. The flame temperature in reheat furnace can be raised by enriching the combustion air with oxygen. Thermal processing equipment which previously had to rely on high-quality fossil fuels can now be operated with previously unusable process gases and biogases. This benefit arises by oxygen enrichment. To produce O2 at low cost, a new method involving ceramic membranes was developed in a collaborative project. Following this, investigations were conducted on the lab-scale furnace to determine whether the combination of high-calorific gas and air could be replaced by a combination of low calorific gas and oxygen for use in reheating furnaces. It was demonstrated that the necessary furnace chamber temperature can also be achieved with low-calorific gases.
Various types of monitoring systems make it possible to increase process control of BOF, which can lead to increased productivity and energy and cost savings. Examples of such systems are: exhaust gas analysis systems, a contour sensoring system, and simultaneous determination of steel/slag composition. The monitored data can also be used as input into models of the BOF process which can help to improve understanding and to optimize the process. An example of a process control system is an oxygen management system for oxygen supply to the BOF process. For commissioning of a power plant linked to the top gas network of an integrated iron and steel mill, gas management studies were performed. To optimise the top gas network, steady-state and transient conditions were calculated for the pressure and mass flow in the top gas system for the current configuration, for various operating modes and malfunctions and for the planned operating configuration. As a result, weak points were identified and measures were developed to improve the operation of the network. The OG-type system basically has no space between the throat and the hood skirt, and controls pressure at the closed throat. The non-combustion-type system keeps gas temperature low and shuts out combustion air. Therefore, the cooling device and dedusting device installed in the system are smaller than those installed in the combustion-type system. Since the system handles gas that mainly consists of CO, attention is paid to sealing for the flux and coolant input hole and the lance hole, and leak control at the periphery of devices, as well as purge at the gas retention part. The OGtype system is frequently used because of its operational stability. The Laser Contouring System (LCS) allows rapid measurements of vessel wall and bottom-lining thickness in the steel furnace or ladle environments. The LCS measures refractory lining thickness and incorporates high-speed laser-based distance measuring equipment. With a laser scan rate of over 8,000 points per second, a single vessel scan can include over 500,000 individual contour measurements. LCS is available as a mobile platform or a fixed position installation. BOF Bottom Stirring is of the major innovations in the BOF steelmaking which involves the introduction of small amount of inert gas from the furnace bottom. This is also referred to as combined blowing. The injected gas provides mild stirring of the bath during and after top blowing with oxygen. The introduction of the gas promotes a desirable carbon-oxygen equilibrium in the bath and slag. The heating operation should also ensure dissolution of the inclusions in the metal in the absence of excessive grain growth. However, lowering the heating temperature below the optimum limit will increase the rolling forces and moments, and hence increase the load on the electric drive motors. It may increase the wear of the mill equipment. Improved process control can help to reduce electricity consumption beyond that achieved through classical control systems. For e.g. neural networks or fuzzy logic systems analyze data and emulate the best controller. For EAFs, the first fuzzy logic control systems have been developed using current power factor and power use to control the electrodes in the bath.
During decarburization, oxygen is usually injected under supersonic condition to increase gas penetration into the molten bath. Now-a-days stationary wall-mounted oxygen-gas burners (OGB) and combination lance-burners (CLB) is being used which operate in a burner mode during the initial part of the melting period. When a liquid bath is formed, the burners change over to a mode in which they act as oxygen lances. Placing the oxygen injection points lower in the sidewall makes supersonic injection more effective and also gives hot combustion gases a longer time to penetrate the scrap, which promotes scrap preheating. The Consteel system is the commercial process that continuously pre-heats and feeds the metallic charge into the EAF while simultaneously controlling gaseous emissions. The charge is pre-heated by the furnace off-gas as it is automatically transported to the EAF. The pre-heated charge is fed into the EAF where it is melted by the liquid steel in a continuous cycle. The EAF gases are sent to a fumecleaning plant where CO and pollutants are burned in a combustion chamber without consuming fuel. Post-combustion is a process for utilizing the chemical energy in the CO and H2 evolving off the steel bath to heat the steel in the EAF ladle or preheat scrap to 570-1470F (300-800C). Post combustion helps to optimize the benefits of oxygen and fuel injection. It is critical that post-combustion is done early at melt down while the scrap is still capable of absorbing the evolved heat. The injectors should be placed low enough to increase CO retention time in the scrap in order to transfer its heat. The post-combustion oxygen flow should have a low velocity to promote mixing with the furnace gases and avoid both scrap oxidation and oxygen rebound from the scrap to the water cooled panels. The injectors should also be cooled extremely well as the post-combustion area often gets overheated. In order to distribute the chemical energy uniformly and to make its utilization efficient, it is preferable to bifurcate the post-combustion oxygen flow and to space out the injectors in the colder areas of the shell. Contiarc furnace is fed continuously with material in a ring between the central shaft and the outer furnace vessel. The charged material is continuously preheated by the rising process gas in a countercurrent flow. Simultaneously the material moves down constantly. Located below the central shaft is a free-melting volume in the form of a cavern. The efficient use of primary energy in the heating and melting steps should be possible in a countercurrent reactor. In a reactor designed in this way, the scrap to be molten is continuously charged at the top. Fed material is transferred to the liquid state with tapping temperature roughly above liquidus by the combustion of fossil fuels with O2. Since it is physically impossible to significantly superheat the melt in the presence of solid material, superheating occurs in a separate vessel by electricity. The melting vessel here is a counter current reactor as stipulated above, and the superheating vessel is an EAF with a power requirement comparable to that of a ladle furnace.
In recent years the majority of captive DRI production units installed have been focused on charging of Hot DRI/HBI to the EAF at temperatures in the range of 600 C. The hot DRI charging practice utilizes the same basic reduction units as are used in cold DRI melting. However, the cooler unit at the bottom of the reactor allows material discharge at temperatures in excess of 600 C. The Hot DRI can be transferred to the EAF using one of 4 methods: Pneumatic transportation, Electro-mechanical conveyor transport, Gravity feed from an elevated reactor and Transport in insulated bottles using mobile equipment. A widely used technique to enhance furnace efficiency is extensive air preheating, but the drawback is a parallel increase of NOx emissions. Another technique is the use of Flameless Burners. Flameless airfuel combustion uses air as oxidizer, while flameless oxyfuel uses commercial oxygen as an oxidant. This technology carries out combustion under diluted oxygen conditions using internal flue gas recirculation and the flame becomes invisible. In smelting plants, various media, e.g. natural, process and industrial gases, are used or produced in the large-scale installations. Co-ordination of the media used in the smelting plant seldom takes place, or only for individual media. Moreover, off-gas flows with exploitable heat potential are only partially used. The aim is to closely link the individual generation and consumption structures to achieve integrated energy management in the steelworks. A management system with functions for forecasting the expected consumption and generation of media across multiple facilities will enable energy-efficient and cost optimised used of media. ECOARC is a new generation of a shaft-type electric arc furnaces for continously charging scrap. It allows a plant to substantially reduce electricity consumption. ECOARC furnace produces lower dioxins and dust emissions. The off gas from ECOARC includes a large volume of combustible ingredients, which minimizes the necessary amount of fuel for post combustion. This technology combines casting and hot rolling. It saves energy and increasing productivity. Increasing bed depth in the sinter plant results in lower fuel consumption. It also improves product quality. A slight increase in productivity can also be achieved. Large fuel reduction can be achieved by improving the ignition oven efficiency. To improve efficiency, inner pressure of the ignition oven is regulated by controlling each window box located immediately under the ignition oven. Coke oven gas is generated at low pressures and is pressurized for transport in the internal gas grid. However, coke oven gas flows vary over time due to the coking reactions. Variable speed drives on coke oven compressors can therefore be installed to reduce compression energy. Single Chamber System (SCS) coking reactors are coke ovens with large coke oven volume and widths between 17.7 33.5 in (450-850 mm). The process includes the use of preheated coal. The reactors are separate process controlled modules with rigid, pressure stable, heating walls to absorb high coking pressure. This allows much thinner heating walls to be constructed, thus improving heat transfer and combustion. The high load bearing capacity of the side walls allows a greater range of coal bends to be charged.
The behaviour of the dead man and the hot metal flow patterns in the blast furnace hearth were studied in the project. As a result of the project, an online system for determining the position of the dead man was installed. The effects of its position on the flow behaviour of the hot metal during tapping were identified. Another aspect covered by the project was the simulation of thermomechanical stresses in the hearth lining and in individual refractory bricks. Battery Underfiring with Advance Diagnostics is achieved by controlling the heating walls individually and developing innovative diagnostic systems to detect disturbances in the heating walls (e.g. raw gas escaping from the coke wall and blockage of the combustion gas and air nozzles). At BFI, work on this project included designing and building a test reactor to simulate a coke oven heating flue. With the results obtained it was possible to draw conclusions about the quality of coke wall heating and to devise measures to improve the efficiency of coke oven heating. The experimental work on the test reactor was supplemented by simulations. Targeted reheating and heat treatment at high temperatures are of crucial importance for the production of high-quality metal products with defined material properties. The reheating furnaces are usually operated with a fuel gas surplus. This leads to unnecessarily high energy costs and CO2 emissions. This research project focuses on lowering energy costs and assuring product quality by undertaking a series of improvements. This research project focuses on lowering energy costs and assuring product quality by undertaking a series of improvements (innovative furnace management concept with continuous burn-out measuring system, new understoichiometric burner with forced burn-out, and more appropriate transport rollers made from new materials for transporting the charged stock) on the preheating furnace. Systems consisting of thermal regenerators and laminar-flow burners are being developed step by step for industrial use and tested in industrial facilities. Systems consisting of thermal regenerators and laminar-flow burners are being developed step by step for industrial use. A system was developed for operation with low-calorific fuel gases such as process gases and biogas. The aim is to achieve optimal furnace operation with low energy demand, variable fuel gas input, a high quality of the charge material, and long life. In several development stages, systems were implemented on reheating furnaces in the steel industry. In the normal sintering process carbon-containing dusts, e.g. blast furnace dust, are added to the sinter mix without any prior conditioning. Since the fuel contained in the dust burns out too rapidly, it is not being used to the extent that it could be for the sintering process. The aim is to develop a new process for pelletising the fine-grained carbon-containing dust as an alternative fuel for the sintering process. Because of its unfavourable combustion behaviour, alternative fine-grained sintering fuel cannot be considered as fully equivalent replacement for conventional sintering fuel which is coke breeze. For selection of scrap types for crude steel production in EAF, it is necessary to know the metallic yield, chemical composition and the specific energy consumption of each individual scrap type. A statistical method was developed to determine these parameters from the analysis of a EAF steel sample and the total energy consumption of the melt.
A laser based off-gas analysis system was developed. This made it possible to analyse in detail the conditions in the off-gas from the EAF, which vary considerably over time. The energy performance of the furnace was analysed and evaluated as a function of the energy losses. This enabled the post combustion oxygen feed rate to be controlled in a targeted manner to make better use of the chemical energy content of the furnace off-gas for the melting process. To save electrical energy and improve the metal yield when making stainless steel in an electric arc furnace a new process was developed and tested under industrial conditions. This involves injecting a reagent (fine grained aluminium or calcium carbide) into the molten slag. The injection of aluminium causes exothermic reduction of the chromium in the slag. The formation of metallic chromium makes it possible to save on costly alloying elements to adjust the chromium content in the steel, while the reduction of the chromium oxide contained in the slag improves the foamability of the slag during injection of coal and oxygen, which additionally contributes to saving electrical energy. In steelmaking, the important criteria for production management are compliance with the specified chemical composition, while maintaining the metallurgical conditions for achieving process temperature control. To achieve multi-criterial optimisation of these different and partly conflicting parameters, BFI has developed a model that adapts itself dynamically as the melt progresses through the process route. Its target function consists in the assessment of energy consumption and the costs of the alloying agents used, while the description of processes involved in the production chain, including their sequencing and interactions, are reflected in the auxiliary conditions along with all product and equipment-related constraints. To achieve further improvements in the production of casting melts for steel castings, continuous temperature monitoring and control are required during the smelting process. This will enable the necessary melt temperature (tapping temperature) to be reliably achieved so that subsequent temperature adjustments are no longer needed. The novel fibre-optical temperature measuring technique DynTemp has already proven its fitness for industrial use in measurements with manual lances in foundry operations. The aim is to optimise the melting rate while limiting the heat load on the wall cooling elements. The control system monitors and evaluates the electrical variables as well as the heat load on the watercooled wall elements. If the heat load is heavy, the arc radiation onto the area concerned is suitably reduced, for which purpose the furnace is operated asymmetrically for a time. In melting phases in which the heat load on the wall is non-critical, the control system adjusts the currents for a poweroptimal operating point. Modular program system for comprehensive sinter plant and blast furnace control performs fuel requirement and permeability prediction for sinter plants, burden calculation and optimised selection of blast furnace charge materials mass balance, heat balance and flame temperature. It also performs Mathematical measuring error analysis and offers Energy-optimised hot blast stove control.
This technology offers continuous combustion gas analysis. It offers Model-based, closed-loop control of air factor. It deploys special measuring technique to analyse O2 content near to stock material surface. Development of a new method for the thermo-mechanical durability analysis of refractory designs. It involves application of the wedge splitting method to the quantitative determination of fracture mechanics parameters, determination of the crack resistance behaviour (R-curves) and numerical simulation (FEM) of thermomechanical stresses under boundary operating conditions. Quality assurance in sinter plant is achieved by measurement of temperature and permeability directly beneath the strand by means of a measuring pallet. Knowledge-based and numerical application functions and simulation models were delopyed in this regard. Analysis of the scale formation mechanisms was carried out. Laboratory and field experiments were performed. Prediction of scale formation with BFI scale model was achieved. As remedy, furnace temperature control was optimized. Optimisation of furnace atmosphere was also done. In electric steel plants the adjustment of liquid steel temperature as required for casting is carried out by EAF or ladle furnace. For an energy efficient process control, a new measuring and control concept was developed. Continuous monitoring of the liquid steel temperature enables optimal control of the electrical energy required to heat the melt. Target temperature is thus can precisely be adjusted. Equipment of the rolling mill was fitted with additional temperature measuring points. Simulation of time-discrete material throughput was carried out. Statistical analysis of the system performance was performed. Increase of the material throughput, based on temperature optimisation and coupling of all the process steps was achieved. On-site systematic analysis of process, plant and equipment was carried out. Model experiments in a modern fluid flow laboratory were conducted. Numerical flow simulation by means of CFD was performed. Design- and process-related measures to optimise the flow conditions were thus realised. A walking beam furnace represents the state-of-the-art of efficient reheating furnaces. In a walking beam furnace, the stock is placed on stationary ridges and a revolving beam walks the product along through the furnace until the exit where the beam returns to the furnace entrance. WCI Steel also employed a state-of-the-art combustion control in the walking beam furnace. A reduction in overall fuel consumption by 37.5% per ton produced compared to three pusher-type furnaces was achieved. Increasing tar injection had always been a problem for BF operators. Unburnt tar used to come out through the tap hole, causing splitting problems. The group suitably modified the brass nozzles of a continuous casting machine and welded these at the tip of the tar injection lance. This reduced the top diameter and helped increase tar velocity and atomisation of tar inside the furnace. The divergent flow of tar increased surface area contact of tar with oxygen and improved its combustibility.
Optimisation trials for burner design were conducted at Combustion Research Unit (CRU) with different burner variants. The concept involves mounting specially designed small-capacity burners on the roof in a single row across the sinter bed. The flame configuration is such that intense flame touches the top of the sinter bed with uniform heating of sinter mix across the bed width. Several measures were taken to improve coking process. One was changing the mixing ratio of the coke oven and BF gases to derive advantage of increased flame height from a leaner gas thus assisting in plugging of small cracks in the oven brick work by graphite deposition. It has resulted in lowering stack emission and achieving uniform coke slab temperature. To facilitate maintenance of batteries and equipment other than pusher machines, a battery service car was designed, fabricated and erected in coke pusher track using inhouse resources. With overall dimensions of 13610 mm x 86900 mm x 11120 mm, the car has provision of 3 platforms to facilitate battery and equipment maintenance at 3 different suitable levels. It also has provisions for regulation of 5 doors in a single parking position, thus minimising time required for placement of the car. Moisture in sinter raw-mix generates fines that become part of return sinter. Apart from other operational problems, variations of moisture level in sinter raw-mix have direct impact on production and quality. Online moisture measurement sensor was installed for iron ore fines, which contribute 76.6% of total initial moisture. The accurate online moisture measurement system that has been installed is able to minimise the variation of moisture in the range of 0.1% of the span. This has improved the sinter strength, reduced generation of sinter return fines and increased productivity by around 3-4%. The new hydraulically-driven valve has a simplified mode of actuation by connecting a lever to the butterfly plate shaft. Rotational motion is acquired through a hydraulic cylinder. Benefits derived from this innovation include: low space requirement, inbuilt pressure relief valves, individual isolation valves and bypass valves make operations safer. More durable parts requiring lower spares consumption. At Alloy Steel Plant of SAIL, due to the bath level of the furnace being slightly high, liquid metal would touch the bottom part of the side wall panel, resulting in water leakage in the furnace. Moreover, hot metal coming in contact with water is a major safety hazard. The solution was to either deepen the bottom of the furnace or increase the height of the water header from the furnace bottom. Since the first would make the vessel unsafe, the only option left was to modify the side wall water cooled panels and water header. Accordingly all water-cooled panels were removed, wall panel height was shortened by about 300 mm and the main water supply header was raised by about the same measure. At SAIL plant, it was found that ladles in SMS-1 were heating up only to around 875C, leading to ladle heating time of 2.45 hours against the standard of 1.20 hours. Also, ladle heating was not uniform. On examination, it was found that the primary reason for improper heating of ladles was gas flow at only 375 Nm3/hour against the norm of 480 Nm3/hour. It was determined that converting the hose system to adjustable pipe system would be the final solution to the problem. The hose pipe was removed and telescopic pipe system with steam connection fabricated. The entire job was done using inhouse resources.
After implementation of the technique the quenched rolled stock was snapping between the finishing group of stand and the coiler due to the resistive force of the high volume of quenching water being injected at a high pressure on the rolled stock. Successively, the intermediate cooling zone was introduced to distribute the volume of quenching water between the two cooling zones. This feasibility study has indicated that of the approximately 120,000 tons of steel available to be recycled from used oil filters (UOFs), a maximum blast furnace charge of 2% of the burden may be anticipated for short term use of a few months. The oil contained in the most readily processed UOFs will be pyrolized at a rate of 98% resulting in additional fuel gas of 68%. Condensable hydrocarbon is of fraction 30%, with the remaining 2% resulting as carbon being added into the burden. The objective was to develop a coal-based and coke-free ironmaking process based on RHF and a melting/refining unit to provide high quality/inexpensive hot metal for BOF steelmaking. Developmental work was conducted with the use of a specially designed furnace with a capacity of 6.0 kgs. of pellets. It was aimed to find the optimum operating conditions to increase the productivity by at least a factor of three. Intention was also to decrease the carbon rate by 50% in comparison with current practice in industry. The purpose of this work was to develop an O2-enriched furnace system that will reduce CO2 and NOx emissions under typical steel industry operating conditions. The combination of the latest burner technology for air-fuel combustion with O2-enrichment should result in both lower NOx and CO2 emissions. A modification to an ultra-low-NOx burner design to accommodate O2-enriched combustion was made and installed in a pilot reheat furnace. The burner was tested and optimized within its range of operating configurations. In the EAF, and the BOF for producing steel, the major off gas is CO. If the CO can be combusted to CO2, and the energy transferred to the metal, this reaction will reduce the energy consumed in the EAF. It will allow for more scrap melting in the BOF which would significantly lower the energy required to produce steel. This reaction is referred to as post combustion. In order to optimize the post combustion process, computational fluid dynamic models (CFD) of the two steelmaking processes were developed. A new process for ironmaking was proposed to employ renewable energy in the form of wood charcoal to produce hot metal. The process was aimed at the market niche of units ranging from 400,000 to 1 million tons of hot metal a year. In the new process, a Rotary Hearth Furnace (RHF) would be combined with a smelter to produce hot metal. This combination was proposed to overcome the technical hurdles of energy generation in smelters and the low productivity of RHFs.
The basic feasibilities of a novel alternative ironmaking technology based on the direct gaseous reduction of fine iron oxide concentrates in a suspension reduction process are investigated. The ultimate objective is to eliminate or drastically reduce the generation of CO2 in the steel industry. The process would use gaseous reducing agents, such as hydrogen, natural gas, a reducing gas generated by partial combustion of coal or waste plastics, or a combination thereof. The process can be a part of an overall continuous direct steelmaking process, in which case the product from this process will be collected in a molten state, or the product may be collected in the solid state to be used as a feed to a secondary steelmaking process. The need for improved active flow control has been recognized as part of the Steel Industry Technology Roadmap. MAG-GATETM, an electromagnetic system for active molten metal flow control has been developed. Excellent agreement between predicted and actual flow control has been found. Preliminary designs are described for the next step of a beta test at an operating billet/bloom or slab caster. The technology provides independent control over the casting rate to meet tight specifications on the heat removal rates in all commercial grades. Increased levels of blast furnace coal injection are needed to further lower coke requirements and provide more flexibility in furnace productivity. The direct injection of oxygen into the furnace blowpipes or tuyeres offers the potential for better coal dispersion in the blast at high local oxygen concentrations. Material and energy balances on the blowpipe-tuyere zone show that oxygen use is optimized when the oxygen is injected at high temperature. Tire gasification recycling technology subjects the tyres to thermal cracking by external-heating type rotary kiln. It utilizes oil-containing gases and dry-distilled carbon as fuels. It returns steel chords as steel scrap for high grade steel manufacturing. The project COURSE 50 involves the development of hydrogen amplification technology using unused coke oven gas sensible heat (800C). It also aims fot the development of iron ore reduction technology using hydrogen. Collection of CO2 from blast furnace gas by using unused exhaust heat at steel mills is also being investigated. Waste materials with available caloric content (e.g., oils from the cold rolling mill) can be used as fuel. It reduces the energy demand satisfied by the primary fuel. Use of the waste material may be limited by permitted emissions limits because oils and other organics in the sinter feed increase emissions of organic compounds. Reducing air leakage from the sintering plant reduces fan power consumption. Improving fan efficiency is a potential energy saving option in other iron and steel processes as well as in other industrial sectors. The hot-blast stove flue gases can be used to preheat the combustion air of the blast furnace. An efficient hot-blast stove can run without the need for natural gas. High-efficiency alternating current (AC) motors can save 1 or 2 percent of the electricity consumption of conventional AC drives. High roll loads of steel lead to increased roll wear and high energy consumption. In addition, specific combinations of rolling loads and speeds can cause stands to vibrate which leads to a special type of roll banding and increased wear of the equipment. These problems can be solved by installing a lubrication system.
Improved process control of the hot strip mill may lead to indirect energy savings through reduced product rejects, improved productivity, and reduced down time. The primary aim is to control the oxygen level, and hence optimize the combustion in the furnace, especially as the load of the furnace may vary over time. The savings depend on the load factor of the furnace and control strategies applied. A recuperator is a gas-to-gas heat exchanger placed on the stack of the furnace. There are numerous designs, but all rely on tubes or plates to transfer heat from the outgoing exhaust gas to the incoming combustion air, while keeping the two streams from mixing. Recuperative burners use the heat from the exhaust gas to preheat the combustion air. Replacing conventional insulating materials with ceramic low-thermalmass insulation materials can reduce the heat losses through furnace walls. The potential energy savings for insulating a continuous furnace were estimated to range from 2 to 5 percent. Controlling oxygen levels and using Variable Speed Drives (VSDs) on the combustion air fans on the reheating furnace helps to optimize combustion in the furnace. Excess air can substantially decrease combustion efficiency as it leads to excessive waste gases. Fuel-air ratios of the burners should therefore be checked regularly. The use of VSDs on combustion air fans on the reheating furnace also helps to control the oxygen levelespecially as the load of the furnace may vary over time. The savings depend on the load factor of the furnace and the control strategies applied. In cases that it is not possible to hot-charge the slabs directly from the caster, energy can be recovered bringing exhaust gases that leave the high temperature portion of the process into contact with the relatively cool slabs. This will preheat the slab charge. Waste heat can be recovered from the hot strip mill cooling water. Low pressure steam can thus be produced from recovered heat. High efficient transformers help to reduce energy loss and increase productivity. The use of Variable Speed Drives (VSDs) can reduce energy usage of the flue gas fans. This in turn reduces the losses in the flue gas. Eccentric bottom tapping leads to slag-free tapping, shorter tap-to-tap times. It also reduces refractory and electrode consumption, and improves ladle life. A twin-shell furnace includes two EAF vessels with a common arc and power supply system. The system increases productivity by decreasing tap-to-tap time, and reduces energy consumption by reducing heat losses. The Tecnored process is based upon a low pressure moving bed reduction furnace. The Technored process consists of pelletizing of the iron ore fines with cement and coke fines. The pellets are dried at 200 C and fed to the top of the furnace. The internal pressure of furnace is about 3.5 to 5.2 psig. Below the hot pellet area lump coke is fed into side feeders in the furnace. Hot blast air at about 1550 C is blown in through tuyeres located in the side of the furnace to provide combustion air for the coke. A small amount of furnace gas is used for pet coke drying and preheating. Cold blast air is blown in at a higher point to promote post combustion of CO in the upper shaft.The process produces liquid pig iron.
The iron ore is fed to a Redsmelt furnace in the form of green pellets made of fine iron ore, reductant and binders. Pellets are screened to a size between 8 to 16 mm. Pellets are then 2 distributed onto the RHF in a layer up to 30 kg/m . While traveling throughout the furnace in 12 to 18 minutes, pellets are heated up to 1370 C. Drying of the pellets, devolatilization of coal and iron ore reduction takes place during the heating process. To prevent reoxidation of metallized iron the final zones of the furnace are operated in sub-stoichiometric atmosphere. The hot DRI product is then fed to the submerged arc furnace (SAF) for smelting into Hot metal and slag. The Diluate Oxygen Combustion (DOC) system injects fuel gas and oxygen into the furnace through two distinct, high velocity jets. Traditional furnaces use only one burner, through which both gases enter the furnace. By using two separate jets, the fuel gas and oxygen are heated by the furnace gases before reacting with each other. The dilution effect of the gases mixing in the furnace prevents high peak flame temperatures and significantly reduces NOx generation. The DOC system also differs from the traditional furnace by injecting oxygen instead of air. This technology employs a laser-induced breakdown spectroscopic (LIBS) technique to measure, insitu and in real-time, the constituents of the melt in a process furnace. By allowing in-situ, real-time measurement of melt constituents, this technology will improve product quality by reducing defects. It will increase furnace life by diagnosing the state of the furnace, and provide necessary data to develop and validate computer modeling and simulation. The aim is to develop an effective operating practice for recycling of waste oxide agglomerates in the steelmaking furnace. The application of the concept to high tonnage steel production operations requires many challenges to be overcome. Slopping, caused by the violent evolution of gas during steelmaking interferes with the recycling of waste oxide agglomerates directly into the steelmaking process. The project will examine the mechanism of slopping and develop operating practices which will permit the addition of these agglomerates while avoiding slopping. The aim is to develop, build, evaluate, demonstrate, and integrate the use of Automated Steel Cleanliness Analysis Tool (ASCAT) in up to two steel mills. The ultimate goal is to develop technology that will allow steel producers to evaluate the quality of steel during production. The development and use of ASCAT will allow critical assessments and adjustments to be made within the production cycle. The purpose of this project is to identify and quantify the sources of hydrogen and nitrogen in ladle and casting operations. The data generated will be used as inputs to develop a model to predict hydrogen and nitrogen pick up and identify the major sources. The hydrogen pick up from water associated with slag making materials, such as Ca(OH)2, alloys, and carburizers will be examined.
The On-line Laser-ultrasonic Measurement (LUT) is an inspection technique that combines fiberoptics with laser ultrasonics, allowing non-contact inspection on high-temperature material during manufacture. The LUT provides real-time wall thickness and temperature profiles for each tube produced. Characteristic signature profiles can be used to immediately identify known causes of defects and apply the proper corrections to the production line. This project focuses on a new technology that reduces NOx emissions while increasing furnace efficiency for both air- and oxygen-fired furnaces. Oscillating combustion is a retrofit technology that involves the forced oscillation of the fuel flow rate to a furnace. These oscillations create successive, fuel-rich and fuel-lean zones within the furnace. The load heats up faster due to the more luminous fuel-rich zones and a longer overall flame length. Steel manufacturing leads to the generation of large amounts of heat, dust, and waste gases in BOFs and EAFs. Furnace hoods, roofs, and sidewall systems are water-cooled components that enable the off-gases >3,000F to be properly cooled and processed prior to being discharged. These components are also subjected to physical wear and tear caused by slag particulates from the steelmaking process. This aggressive environment erodes conventional carbon steel furnace components. The aluminum bronze alloy has been demonstrated successfully in the basic oxygen furnace as a material that can stand up to the harsh steelmaking environment. It has also been shown to perform equally well in electric arc furnace applications, even though conditions differ significantly between the two processes. In the continuous steelmaking process, three contiguous vessels connect the electric arc furnace (EAF) with the continuous casting process. They replace current batch ladle operations. The vessels are designed for fast, near-equilibrium reactions to ensure a large degree of control, productivity, and flexibility. They will also reduce maintenance in the oxidizing conditions of the EAF and the oxidizer, and in the reducing conditions of the reducer and finisher. The use of two vessels in series with similar near-equilibrium conditions allows for optimum refining and minimizes variations in fluid flow and composition (chemistry, inclusion). therefore it contributes to the reliability and flexibility of the process. The primary aim of this program is to develop and test a scale free heating system that reduces scale formation in the steel reheating process, resulting in a significant reduction in energy use, improvement in steel quality, and significant cost advantages for steel industry. Several options were analyzed for generating process atmosphere required for scale free heating and options for energy use optimization through waste heat utilization. The options considered are: use of 100% oxygen, cold or preheated oxygen enriched air (35% and 45% O2 in air) and preheated air for sub stoichiometric combustion of natural gas. A detailed economic analysis model was developed to account for effects of all major variables involved in steel reheating.
Michigan Technological University is developing an integrated system of technologies to recover the iron value from BOF steelmaking slag. It will also divert the residual non-iron bearing fraction into a feedstock for the manufacture of acid mine drainage (AMD) neutralizing agent. In this project, technologies are being developed to separate iron from the BOF slag and prepare those iron units for furnace charge. Oscillation marks are the most recognizable feature of continuous casting. They can be related to the subsurface defects. The physical surface defect of the oscillation marks themselves does not necessarily pose a significant problem in many grades. But many subsurface defects have been found to be associated with oscillation marks. The presence of oscillation marks and the related defects found on the surfaces of product rolled from cast slabs requires extra slab surface treatment. Thus, if the defects related to oscillation mark formation can be eliminated, increased hot charging ratios would be possible. One approach for utilizing the energy contained in waste heat is called Thermo Chemical Recuperation (TCR). This new technique recovers sensible heat in the exhaust gas from an industrial process, furnace, or an engine. The TCR then uses that heat to transform the hydrocarbon fuel into a reformed fuel with a higher calorific heat content and utilizes this reformed fuel for process heating. The Dios process is a bath smelting process, intensively investigated in Japan. Iron oxide is preheated in the first of two fluidized bed reactors in series and pre-reduced to 15-25% in the second reactor using cleaned off-gas from the smelter. In addition, a small amount of coal fines is injected into the smelter off-gas to cool the off-gas and provide additional CO and H2 for pre-reduction. Coal is gravity fed into the smelter. Oxygen is injected into the smelter for combustion of coal and for post combustion. The Comet process is a coal-based system. It produces sponge iron from ore fines and limestone in a rotary hearth furnace. A laboratory, 100-kg/hr installation was brought on-streamin Nov. 1996. A pilot 1.5-tonne/hour plant has been built at Sidmar, Ghent, Belgium. Productivity, cost, price, energy consumption and environmental impact of the technology are being established. Heating furnaces have a large number of apertures, for example, raw material charging ports, extraction ports, and cracks in the furnace ceiling and side walls. Flame erupts through these apertures, and external air is sucked into the furnace. Eruption of flame through these apertures when the internal furnace pressure is high is undesirable regarding furnace efficiency. So that it becomes necessary to adjust the opening of the damper in the smoke stack to obtain the optimum pressure in the furnace. This system improves product yield and the quality/strength of product sintered ore. It achieves so by maintaining a constant raw material particle size and charging position when charging raw materials to sintering furnaces used in producing sintered ore. Specifically, because a constant particle size is maintained, the permeability of the sintering mixture is increased, resulting in improved sintering efficiency, and the material return ratio due to poor sintering is reduced.
Natural Gas Based Zero-Reforming HYL Process is a moving bed shaft type reactor operating at relatively elevated pressure of approximately 8 bar. Feed material in the form of pellets and/or lump is charged through a set of pressurizing and depressurizing bins and sealing valves. Iron ore is reduced by a counter current flow of reducing gas which contains mainly H2 produced by selfreforming of natural gas inside the reactor. Fresh reduced iron plays the role of catalyst in the reactor. Due to high content of H2, reduction reactions are fast and residence times of 2 4 hours have been achieved. Low Emissions and Energy Optimised Sintering Process collects all waste gases of the second half of the strand. These gases are recirculated to the system across the entire length of the sinter strand. The oxygen remaining in the recycled gas provides most of the oxygen required to burn the fuel. Environmentally Process Optimized Sintering (EPOSINT) uses the fact that the release of particulate matter from the sinter bed tend to be more concentrated in those wind boxes towards the discharge end of the sinter strand. Those windboxes are selected for waste gas recycling where the burnthrough is at or near the bottom of bed. It was established that the temperature of the recycled gas should be the same as the gas which goes to waste gas stack in order to avoid corrosion problems in resulting gases at temperature below the acid dew point. The concept of selective recycling technique is based on a local suction of the sinter waste gas under the strand and its local recycling above the bed. This selective suction is the main differecen between this and emissions optimized sintering. Advantages of this system over conventional gas recycling includes: Effective utilization of unused oxygen in the waste gase and separate treatment of the waste gas from different sections according to the composition of gas. The idea of this technique is to use preferably sinter or pellets as raw materials with high iron content and low gangue content. Sinter with an iron content of 61-63.5% and pellets with an iron content in the range of 66.6-66.8% are used. Other critical factors are moderate ash content of coke and low ash content of coal for injection. Oxy-oil burners are installed at all tuyeres designed for the use of heavy oil only. Oil and oxygen is separately fed and the oil must be preheated upto 220 C. The amount of oxygen enrichment is 79%. With oxy-oil injection technology, the amount of oil-injection doubles. In practice, oxy-oil injection works very reliably. Used oils, fats and emulsions of used oil and water and generated throughout the industry. These residues can be injected into the blast furnace at the tuyeres level as a partial substitute of coke and the coal. Cyclone Converter Furnace (CCF) is a joint project of Corus, the Nederlands and Ilva, Italy. The most important part of the project is the development of cyclone reactor. In the cyclone, the iron ore is pre-reduced and melted. The molten mixture falls in to the lower part of the vessel where the reduction is completed. The fuel consists of granular coal which is injected together with oxygen in the lower part of vessel. Romelt process has been under development in Russia for approx 10 years. This process is similar to other bath smelting process but does not use a pre-reducer. This process uses ore or waste oxides.
Dust recycling plants tests by co-injection with carbon and /or FeSi as reducing agents were carried out. FeSi use as a further reducing agent allows reaching the recovery of Cr, Mn, Ni and Fe by 81, 38, 97 and 93% respectively. Based on general experience and practices with industrial control and management systems, improved process controls may result in savings of 25 percent of energy use. Approximately 1.5 percent of the gas used in the blast furnace may be lost during charging. This gas could be recovered by applying proper charging methods. Insulation can typically reduce energy losses and help ensure proper steam pressure at plant equipment. The application of insulation can lead to significant energy cost savings with relatively short payback periods. The improvement of existing insulation can often lead to further savings. This measure can consist of applying more or better insulating material. A simple program of checking steam traps to ensure they operate adequately can save significant amounts of energy. In systems with a regularly scheduled maintenance program, leaking traps should account for less than 5% of the trap population. Attaching automated monitors to steam traps in conjunction with a maintenance program can save even more energy, without significant addition in costs. When a steam trap purges condensate from a pressurized steam distribution system to ambient pressure, flash steam is produced. The energy can be recovered by a heat exchanger and used for space heating or feed water preheating. The potential for this measure is site dependent. Sites using multi pressure steam systems can route the flash steam formed from high-pressure condensate to reduced pressure systems. The purposes of motor maintenance are to prolong the motor life and to foresee a motor failure. Preventative measures to avoid motor break down include voltage imbalance minimization, load consideration, motor alignment, lubrication and motor ventilation. The purpose of predictive motor maintenance is to observe ongoing motor temperature, vibration, and other operating data to identify when it becomes necessary to overhaul or replace a motor before failure occurs. A voltage unbalance degrades the performance and shortens the life of three-phase motors. A voltage unbalance causes a current unbalance, which will result in torque pulsations, increased vibration and mechanical stress, increased losses, and motor overheating. These effects can reduce the life of a motors winding insulation. Voltage unbalances may be caused by faulty operation of power factor correction equipment, an unbalanced transformer bank, or an open circuit. The objective of any control strategy is to shut off unneeded pumps or to reduce the load of individual pumps. Remote controls enable pumping systems to be started and stopped relatively quickly and accurately. They reduce the required labor with respect to traditional control systems. Pump efficiency may degrade 10 to 25% in its lifetime. Industry experts, however, point out that this degrading performance is not necessarily due to the aging of the pump but can also be caused by changes in the process. Nevertheless, it can sometimes be more efficient to buy a new pump, also because newer models are more efficient. A number of pumps are available for specific pressure head and flow rate capacity requirements.
A pump may be incorrectly sized for current needs if it has a high bypass flow rate, or has a flow rate that varies more than 30% from its best efficiency point flow rate. Where peak loads can be reduced, pump size can also be reduced. A smaller motor will however not always result in energy savings, as these depend on the load of the motor. Only if the larger motor operates at a low efficiency, replacement may result in energy savings. Parallel pumps offer redundancy and increased reliability. The energy savings were estimated at 58% per year in one case study. Trimming reduces the impellers tip speed, which in turn reduces the amount of energy imparted to the pumped fluid. As a result, the pumps flow rate and pressure both decrease. A smaller or trimmed impeller can thus be used efficiently in applications in which the current impeller is producing excessive heat. Adjustable Speed Drives (ASDs) better match speed to load requirements for pumps. As for motors, energy use of pumps is approximately proportional to the cube of the flow rate. Therefore, relatively small reductions in flow may yield significant energy savings. New installations may result in short payback periods. In addition, the installation of ASDs improves overall productivity, control and product quality. The use of castings, coatings or polishing reduces surface roughness, abrasions and dents that in turn increases energy efficiency. It may also help maintain efficiency over time. This measure is more effective on smaller pumps. Most of the fans are oversized for the particular application, which can result in efficiency losses. However, it may be more cost-effective to control the speed than to replace the fan system. In an assessment of a plant, it was discovered that a much smaller venting system than the one currently installed would meet venting requirements. More than 85% of the electrical energy used by an industrial air compressor is converted into heat. A 150 hp compressor can reject as much heat as a 90 kW electric resistance heater or a 400,000 Btu/hour natural gas heater when operating. This heat can be recovered. Preventive maintenance involves forseeing a failure or breakdown and to carry out subsequent preventive measures in advance. Several estimates place the energy savings at 2 percent of total energy use. Energy monitoring and management systems help provide for optimal energy recovery and distribution between processes at the plant. These systems may reduce energy consumption by 0.5 percent. Now a days most pumps and fans can be frequency controlled and may therefore be set to any given rotational speed to obtain the desired set point value for the flow rate. Their use enables a better and faster adjustment of water flow rates and off-gas flow rates according to the demands pf different process conditions. ESCO-PRO (POSCO venture company) developed auditing methodology for pump efficiency to measure temperature and pressure of fluid. From the inlet and outlet temperature and pressure measurement, the pump efficiency is calculated.
The software tool models the supply-side of a compressed air system to identify efficiency improvement opportunities. Using plant-specific data, the free software tool evaluates the operational costs for various compressed air equipment configurations and system profiles. The software provides estimates of potential savings gained from selected energy efficiency measures and calculates the associated payback periods. The Fan System Assessment Tool (FSAT) quantifies energy consumption and energy savings opportunities in industrial fan systems. It also determines the economic benefit of system alterations. FSAT allows users to input information about their fans and motors and calculates the energy used by the fan system and the overall system efficiency. It approximates potential energy and cost savings, and helps determine which options are most economically viable when multiple opportunities exist. The Process Heating Assessment and Survey Tool (PHAST) identifies ways to increase energy efficiency by surveying all process heating equipment within a facility, identifying the equipment that uses the most energy, and evaluating energy use under various operating scenarios. Two suite of software tools help enable facilities to evaluate steam systems and to identify opportunities for improvement. Steam System Scoping Tool evaluates the plants entire steam system and identifies areas that are the best opportunities for improvement, suggesting various methods to save steam energy and boost productivity. Steam System Assessment Tool (SSAT) develops approximate comparable models of real steam systems to quantify the magnitude (energy, cost, and emission savings) of key potential steam system improvement opportunities. Variable speed drives (VSDs) match speed to load requirements for motor operations in a better manner. VSD systems are offered by many suppliers and are available worldwide. The Iron Carbide process is a two stage fluidized bed process that operates at a lower temperature than other DR processes. It operates at low pressures and uses steam reforming to produce the H2 which is mixed with CH4 to make the carburizing gas. It produces Fe3C powder which contains about 6% carbon. The waste heat of the electric arc furnaces exhaust gas (especially the furnace for DRI melting) is recovered as steam, hot water or electric energy. The steam recovered in this manner can be directly used or used according to the purposes such as power generation, sea water desalination, for freezers, air separation, for degasification systems, etc. It is also possible to superheat the steam to enhance the power generation efficiency.
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Energy Savings Potential Electrical energy consumption per billet tonne was reduced from 424 kWh to 412 kWh.
After apply the technology, nearly 8 million Giga Joule (GJ) of excess BF gas was utilized annually. In addition, close to 400,000 GJ of excess coke oven gas annually was used.
There is no direct energy saving for the steel industry.
There is no direct energy saving for the steel industry.
The energy savings due to coal Injection in BF have been calculated at 3.23 MBtu/ton (3.76GJ/tonne). According to an expert, if good quality of coal is used, replacement ratio is roughly roughly 0.8 Tonne Coke/1.0 Tonne Pulverized Coal.
A 26% C-saving/tHM at the BF should be feasible by the technology.
With no raw material processing required, the HIsmelt process uses less energy to produce each tonne of hot metal.
Hisarna technology opens the opportunity of 20% improvement in steel industry energy efficiency.
Hydrogen can be produced from energy efficient Reforming Process. Nearly 90% of the energy brought in the system is recovered as H2(73%) and steam (17%).
Energy requirement is up to 3800 kWh/t or 13.7 GJ/t for electrolysis and 1300 kWh/t or 4.7 GJ/t for subsequent production.
PCI can be substituted fully by charcoal in large BFs i.e approximately 40% of the carbon input. Smelting reduction proces can accomodate more charcoal even upto 100% of carbon input.
This process consumes significant amount of energy.
This technology results in 14% reduction in electricity consumption. Additionally a 6% reduction in natural gas consumption were achieved all together.
Fuel savings are estimated to be 0.9 GJ/tHM.
Total savings by using this technology vary between 0.46-0.79 MBtu/ton steel (0.54 and 0.92 GJ/tonne). It Depends on the way in which the steam is recovered. Worldwide energy saving potential stands at 250 PJ. According to an expert opinion, average figure for the amount of recovered BOF gas is 125 Nm/t steel. The upper average heat recovery value is in the range of 1025 MJ/t steel. However, these values depend strongly on the converter and the primary dedusting plant operation and on the CO limit for start/stop of gas recovery.
1 ton of Oil replaces 1.2 tons of Coke.
Energy savings of 0.60 GJ/tonne rolled steel are estimated.
This technology conserves coking coal due to use of higher proportion of high volatile & poor coal in the blend. It increases the BF coke yield by 3 to 4%.
A reduction in the specific heat consumption in Sinter Plant-2 at Bhilai Steel from 65 Mcal/t Sinter (262 MJ/t) to 45 Mcal/t Sinter (188 MJ/t) is reported.
A small reduction in the energy consumption was achieved due to a decreased lime usage.
With the replacement ratio of 0.6 kg BF coke daily, savings of about 65 tonnes of BF coke/day has been achieved by charging 100 tonnes of nut coke/day.
Steam recovery rate is 60,000 kcal/t-Sinter for annual sintered Ore production of 1 million tons. Equivalent crude oil consumption was reduced by 7500 t/y. An expert reports that for the sinter cooler hot air flow of 3 400000 Nm /h at 320C, 30t/hr low pressure steam at the temperature of 240C can be recovered. If this steam is utilized in a steam turbine, upto 7 MW of electric power can be generated.
A Larger BF is usually more efficient because the heat losses are lower (lower surface/volume ratio).
On charging 30% CCB, coke rate and the total reducing agents rate are reduced by 30.2% and 6.3% respectively.
0.4 Mt of Plastic Waste is used per Year in the Japanese Iron and Steel industry, which equals energy savings of 20 PJ/yr.
The most efficient Charcoal-fired BF at Acesita used 16.2 GJ charcoal/t pig iron. However it does not result in significant energy efficiency gains.
7000 kW of electricity can be generated from a 1 Million t/y Blast Furnace. According to an expert the efficiency of Dry-type TRT is approximately 20-30% higher than that of Wet-type TRT, due to higher inlet temperature of BFG.
On a Global Level, the energy saving potential by the implementation of this technology is 0.2 EJ/yr.
The Material requires little or no additional fuel to convert it into cement clinker. Energy Efficiency gains are however Limited.
With single shaft furnace upto 70 kWh/ton (77kWh/tonne) liquid steel of electric power can be saved. Finger shaft furnace allows savings up to 100 kWh/ton (110 kWh/tonne) liquid steel.
Electricity savings are 80 kWh/tonne or 0.14GJ/tonne Steel.
Gas use in the process is 10.4 GJ/t which is lower than blast furnace Ironmaking fuel usage.
This technology requires only 55-60% of total thermal energy as natural gas for reforming if the reductants from the exhaust gas are optimaly reused.
Finmet process gas usage is 12.4 GJ/t which is lower than Blast Furnace.
Gas usage is 11.5 GJ/t which is lower than Blast Furnace.
Energy savings are in range of 1 2 GJ of Primary Energy/t of product. Saving potential is 0.3-0.4 EJ/yr if this technology is applied to quarter of world production.
The most efficient coke ovens use CDQ and may use up to 40% less energy. About 1.5 GJ/t coke energy can be recovered from Steam Power Generation if the full energy content of the recovered steam is accounted. According to an expert about 500 kg/t-coke high pressure and high temperature steam can be recovered with the technology. This steam if fed to a power plant, electricity generation in the range 15-17 MW is possible.
Fuel savings are 0.55 GJ/tonne sinter.
Dry fuel consumption was down to 770 kg/tHM from 940 kg/tHM by applying this technique. Moreover, Oxygen consumption falls to 455 m3 STP/tHM from 520 m3 STP/tHM.
The technology results in net energy gain by CO2 removal of 310 Mcal/t-HM.
Power up to 300 MW can be generated by using this technology.
Worldwide about 250 PJ of COG could be recovered and used for power generation.
The average chinese coke making energy consumption dropped from 180 kg coal equivalent (kgce) per tonne of coke in 1995 to 166 kgce (4.9 GJ/t coke) in 2000. This decreased energy consumption was attributed to the installation of more than ten sets of coke dry quenching (CDQ) and new advanced wet quenching.
The replacement rate of COG is about 1.0 ton of gas for 0.98 ton of coke.
Energy consumption decreases because no coke oven and sinter plants are required. Total electricity consumption is 999.74 kWh/metric ton liquid steel.
Energy consumption of the technology is 12.3 GJ/tHM which is less than Mini-BF.
The process consumes 5 GJ/tHM less energy comparing to Blast Furnace.
Technology consumes 3 GJ/tHM less energy comparing with Blast Furnace. No electrictiy is used.
The Process is expected to use 2000 kWh/ t Iron. With electricity losses of 50%, it is expected that the technology will use energy similar to modern BF route.
Technology requires an additional external energy Input of 1560 kWh/tHM .
Energy savings by the implementation of this technology are expected to be about 30 kBtu/ton (35MJ/tonne) hot metal.
Associated energy savings would be approximately 0.30MBtu/ton (0.35 GJ/tonne) Pig Iron.
Estimated energy savings are 0.03 MBtu/ton (0.04 GJ/tonne) pig iron.
This technology reduces the power demand by approximately 20%, or 0.9 kWh/ton Crude Steel (1.0 kWh/tonne).
Power consumption dropped by 10 and 20 kWh/ton (11 and 22kWh/tonne) respectively for 2 furnace lines.
Electricity savings are estimated to be 15 kWh/ton (16.5 kWh/tonne) or 0.06 GJ/tonne steel.
This technology consumes 20% Less Energy.
The net energy savings are Estimated at 6-8 kWh/tonne Steel.
Energy requirement for this process is 6 400 kWh/t or 23 GJ/t (electrolysis + annealing).
Electricity savings can vary between 11 and 22 kWh/ton (12 to24 kWh/tonne) or 0.07 GJ/tonne steel.
Savings of 10 kWh per ton (11kWh/tonne) steel are expected by applying this technology.
Airtight process technology Includes a post-combustion practice and an efficient fume exhaust control. Corresponding energy savings are around 100 kWh/ton (110 kWh/tonne).
Electricity savings of 0.32GJ/tonne steel are estimated.
Reduction of energy consumption of approximately 100 kWh/tonne is expected compared to the conventional EAF.
Potential energy savings stand at 50 percent, or approximately 0.017 MMBtu/ton (0.02 GJ/tonne) of crude steel.
Electrical power of about 630-700 kWh/t Coke can be produced.
An Increase in energy consumption and ammonia consumption occurs.
An additional electricity consumption is 1200 kW or 8.6 MJ/t Sinter is needed which equals around 0.4% of total sinter energy consumption. Overall energy consumption increases as the off-gases have to be reheated before coming in contact with catalyst. Furthermore, SCR device consumes electricity.
Total heat Input for Ignition was reduced by approximately 30% compared with conventional burner (about 2.5Mkcal/t-Sinter).
This technique reduces demand for fluxing agents. A relationship between charcoal use and an increased sinter plant productivity has been demonstrated. A substitution of around 20% of coke breeze with charcoal in sintering plants is technically feasible. A fuel blend of 20% charcoal and 80% coke breeze can increase the sinter plant productivity by 8%. Sinter yield is also expected to improve by using charcoal in blend.
Fuel savings of approximately 0.3 GJ/t are reported.
Electricity savings are 0.11 GJ/tonne hot metal.
Reduction in fuel input is estimated to be 426 kJ/kWh. Thermal efficiency was increased by 3.3%. Dry dedusting will increase the power generated by TRT systems by 30% compared to wet-type dedusting. This 3 will also lead to 7-9 Nm /tHM reduction in recirculated water consumption.
This technology will result in 78% reduction of natural gas consumption.
It enables higher productivity smelting operations. When used as a pre-reducer with a smelter,the combine Process is suitable BF/Coke oven replacement with 30% less energy usage.
Thin slab casting saves approx 0.9 MBtu/ton (1 GJ/tonne). In turn compared to thin slab, Castsrip Technology saves another 0.9 MBtu/ton (1 GJ/tonne).
Fuel ratio of BF decreases to 0.2kg/t-Pig Iron. JSIM reports the energy saving of 1400 TJ/year achieved by installing 2 units of this system in Japan.
NEDO reports the energy savings of 1900-2390 GJ/year for the system with 110 tonne/h billets heating.
800 TJ/year energy can be provided for district heating using sinter cooler waste heat.
This technology increases energy consumption by about 0.002 to 0.003 GJ/t sinter.
EOS will result in coke breeze savings. An increased but negligible electricity consumption is also expected.
The specific energy consumption should be 40% lower than that needed for a traditional rolling mill. Energy savings of 60% with regard to the traditional cycle are possible.
Specific energy consumption decreases by 40% than required for a traditional rolling mill.
Energy consumption decreases by 21%.
This technology improves productivity by 5%. Energy consumption due to coke use decreases by 0.07 MBtu/ton sinter (79 MJ/tonne sinter).
This technology can lead to fuel savings of about 10%. Estimated energy savings therefore are calculated to be 0.15 MBtu/ton (0.17 GJ/tonne) Coke.
An increased fuel efficiency is reported.
The total energy savings possible by a combination of techniques is of the order of 0.4 GJ/t Pig Iron.
This technology reduces Fuel input rate i.e. Coke rate and tuyere level injectants. Furnaces Operating at High pressures can produce electricity in order of 0.35 GJ/tHM using recovery turbines.
By implementing this technology, reduced coke consumption of approximately 0.458 ton/ton-hot metal was achieved in 2000 at VoestAlpine.
The coal consumption is about 800 kg/t DRI.
This technology does not require coking coal, coke and natural gas. Production of hot DRI that could be charged to EAF to achieve significant energy savings.
This technology does not require coking coal, coke and natural gas. Production of hot DRI that could be charged to EAF with significant energy savings.
The energy savings when charging at over 600 C are 120 kWh/t or even more.
This technology potentially lowers CEM operational energy use by 70%.
It reduces energy use due to reduced processing time.
Savings of natural gas is estimated. Process gas can be reused.
Total energy savings due to this system are estimated to be 1.5% of the electricity used for Oxygen production.
This technology ensures energy-efficient operation of the gas network.
OG-boiler system recovers 65% of the sensible heat of the total exhaust gas which is about 70 kg/t.
It reduces energy usage via rapid real-time measurement and no loss of process time occurs.
Flux quantities are reduced by more than 10%. Less Iron is Lost to slag. Oxygen consumption is reduced.
A reduction of the heating temperature by 212 F (100C) decreases unit fuel consumption by 9% to 10%. However under certain conditions total energy consumption may not decrease with a decrease in heating temperature.
Electricity savings of 30 kWh/t Steel are estimated by the implementation of the technology.
Electricity savings of 0.14 GJ/t crude steel are reported. Natural gas savings can make up to 20 to 40 kWh/t steel.
Electricity savings are estimated to be 60 kWh/t for retrofits or 0.22GJ/tonne.
For a particular post-combustion system, electricity savings ranged from 6 to 11%.
This furnace reduces energy losses (200 kWh/ton or 220 kWh/tonne less than with conventional furnace systems. Also electric power consumption reduces by 23 kWh/ton or 25 kWh/tonne.
About 32% reduction of primary energy Intensity for liquid steel production compared to the conventional EAF is expected by this technology.
Charging hot DRI at temperatures up to 600 C rather than Cold DRI results in a melting energy reduction of 150 kWh/t of crude steel (>0.5 GJ/ton).
Process requires 40% less fuel consumption excluding additional electricity requirement for Oxygen production. The production of 1 Nm2 of Oxygen requires approximately 0.5 kWh of electricity.
Energy efficiency was optimized to lower the consumption peaks.
This furnace consumes 200 kWh/ton power. Oxygen injection rate is 40m 3N/ton.
Electricity savings may amount for 176 kWh/t and primary energy savings for 4 MBtu/t (4.2 GJ/t). Electricity savings of 0.05 kWh/ton (0.06 kWh/tonne) are estimated.The savings amount to 0.3 ton Coke per kton Sinter per 0.4 inch (10 mm) bed thickness increase. The Ignition Energy was reduced by approximately 30%.
Variable Speed Drive System on a compressor at a coke plant at Corus in The Netherlands saved 5-7 kBtu/ton (6-8 MJ/tonne) coke.
SCSs have an improvement in Thermal Efficiency from 38% to 70%.
This technology increases blast furnace productivity.
It is possible to save about 180 TJ per million tonnes of coke by reducing the fuel gas consumption by 5%.
This technology improves the performance of the furnace and its Energy Efficiency. It is possible to reduce the Oxygen concentration to approx. 7 % by volume.
Savings of up to 30 % in Fuel Gas have been achieved relative to Recuperative Combustion air Preheating Systems.
Significant increase in the substitution ratio makes it possible to save corresponding amount of fuel in sintering.
Energy-Optimal charging of scrap by using this technology.
The electrical energy demand of the furnace was decreased by about 17 kWh/t or 4 %.
Electrical energy demand was significantly decreased by approximately 10%.
The technology reveals significant saving potential in terms of energy.
An improvement in energy efficiency of up to 5 % is expected by the application of this technology.
The melting rate was Improved by as much as 8 % by increasing the mean electric power Input and by shortening the power-off times.
This technology minimizes sinter plant and Blast Furnace energy requirements
Oxygen content was reduced by 1.5 % in a heating furnace with a throughput of 450 t/h. Energy savings are 2.4 %.
Optimisation of the operating point and process optimisation by applying the technology.
It will decrease recoverable materials cycles.
Energy savings are achieveable by the implementation of this technology.
This technology ensures better utilization of rolling mill capacity and optimises throughput. Energy Saving occurs through improved product flow.
An increase of the plant and equipment efficiency can be observed. Furthermore an increase in yield is expected.
This technology results in 25% Less Electricity Consumption comparing to conventional Reheat Furnace.
Maximum monthly tar Injection rate was increased from 8 kg/tHM to 12 kg/tHM in BF-2 and thereby saving same amount of coke.
This technology reduces the specific gas consumption by 30% to 50%.
Specific heat consumption decreases.
A reduction in heat leakages from coke oven may result in energy savings.
Power consumption will be reduced as no separate motor is required.
This technique increases Furnace Capacity by 18-20 Tonnes. Power Consumption was Reduced from 800 kWh to 620 kWh/Tonne of Liquid Steel.
Extra gas consumption worth 1.25 Hours was reduced by this technology.
Quenching water is efficiently used.
Estimations Indicate that a 2% Charge of UOFs (40 lb UOF/NTHM) would Contribute about 0.72lb Coke/NTHM.
Saving of 110 kg reductant Coal per tonne of DRI is expected.
By applying this technology, fuel firing rate was decreased from 325-365 KW to 200-220 KW.
Energy requirement for BOF reduces by 30%. 50 to 100 kWh/tonne of steel electricity reduction in EAF is estimated.
Productivity gains as high as 50% could be achieved replacing coal with Wood Charcoal. An Increase of less than 5% in total carbon consumption is achievable.
This technology will require ~ 38% less energy than the blast furnace process or 7.4 GJ/ton of hot metal.
Each 10% Increase in sequence length across the US steel Industry results in an annual energy savings of Approximately 2.3 x 1012 Btu.
By applying this technique, coal Injection can be increased by 75 pounds per ton of Hot Metal (lb/thm).
Energy savings are substantial and corresponds to 5 months worth of entire domestic energy consumption of City of Himeji.
Energy savings are 0.18 GJ/tonne sinter.
Reducing air leakage from sinter plant reduces fan power consumption by approximately 2.7-3.6 kWh/ton (0.011-0.014 GJ/tonne) of sinter. Energy savings are 0.08 GJ/tHM. Electricity savings of 0.01GJ/tonne rolled steel are calculated.
Electricity savings are 0.016GJ/tonne rolled Steel.
Energy savings are 0.30GJ/tonne rolled Steel.
Energy savingsare 0.70 GJ/tonne rolled Steel.
Energy savings are 0.16 GJ/tonne rolled Steel.
Energy savings are 0.33 GJ/tonne rolled steel.
Fuel savings are 50% compared to no-product heat recovery. Energy savings of 0.03 GJ/tonne rolled steel is estimated by the implementation of the technology. Electricity savings are 0.06GJ/tonne Steel. Electricity savings of 0.05GJ/tonne steel are estimated by using this technology. Electricity savings of 0.05GJ/tonne steel are estimated by using this technology.
Electricity savings are 0.07GJ/tonne Steel.
This technology ensures high productivity and energy efficiency in the furnace. Full metalization upto 99% can be achieved.
Less energy usage since no coke oven is required.
This technology reduces the fuel required to operate furnace by up to 50% over air-fuel combustion.
A cumulative saving of 26 trillion Btu for the steel industry is estimated.
Savings of 15 trillion British thermal units (Btu) Annually by recycling waste oxides can be achieved.
Energy savings are estimated to be at least 3.2 billion MJ per Year or about 0.25% of the steel industry energy consumption
Better control results in energy savings by an estimated 400 million kilowatt hours (kWh) per year.
Energy savings are estimated to be 23 billion Btu.
Efficiency or productivity increases by 5% or more. It improves heat transfer by up to 13%.
Technology saves more than 5.3 billion Btu per year in a BOF skirt installation, with an additional 4 billion Btu annual savings from installations in other system components.
A total of 10% energy savings will occur by reducing the energy needed for auxiliary operations. Savings of 20 kWhr/t in auxiliary energy are reported.
This technology could offer upto 12% energy savings which are approximately 0.18 MM Btu/ton.
Iron recovered from BOF Slag saves 10 million British thermal units (Btu) per ton of new steel.
This technique will lead to significant energy savings amounting 30 x 106 GJ/year.
This technology leads to the Net Reduction in Continuous Reheating Furnace Fuel Use of 35 trillion Btu/year.
Net energy consumption decreases by 3 to 4%. Low direct electrical power consumption. Coal Consumption in Dios process is 950 kg/tHM.
Coal injection rate for Comet is 297 Kg fixed carbon per ton of DRI which shows significant savings comparing to blast furnace.
LPG consumption was reduced by 83.3 tons/y. Electric power savings were 24,734kWh/y.
Coke consumption decreased by 2.8 Kg/t-sinter. Crude oil consumption was reduced by 1988 t/yr.
This technology does not require Coking Coal and Coke. Lower Natural Gas Consumption compare to reformer Base HYL Process. Production of Hot DRI that could be charged in EAF with significant Energy Savings.
There is a slight Increase in the use of Electrical Energy from the additional fan. Solid Fuel Consumption is reduced by 5 - 7 Kg/t Sinter (12.5% of the Fuel Demand).
There will be a decrease in solid fuel requirement by 2 -5 Kg Coke/t Sinter. Moreover, there will be additional electricity consumption due to additional fan.
A 6% reduction in coke consumption was reported. Installing additonal fans results in more electricity consumption.
The use of high quality ore increases productivity and energy efficiency of of ironmaking process.
Up to 130 kg/t hot metal Oxy-Oil Injection is applied. The savings of coke is thus about 15 kg/t hot metal.
Reduction of coke rate at the blast furnace can be between 3 and 8.5 kg/t hot metal.
Coal consumption of this furnace is 700-750 kg/tHM. Energy consumption per tonne steel will be lower. Furthermore, power can be generated from the flue-gases which exit the cyclone at about 1800C.
Its Coal consumption is reported to be 900-1200 Kg/tonne. Energy consumption per tonne steel will be lower.
It Increases the electrical power efficiency by at least 20% inspite of a higher arc voltage. This technology may result in savings of 2-5 Percent energy use, approximately equal to 0.04 MMBtu/ton (0.05 GJ/tonne) of Sinter. Energy savings are 0.07 GJ/tHM.
Insulation can typically reduce Energy Losses by 90%.
A simple program of checking steam traps to ensure they operate properly can save significant amounts of energy. Energy savings for a regular system of steam trap checks and follow-up maintenance is estimated to be up to 10%
Depending on the pressures involved, the Flash Steam contains approximately 10% to 40% of the Energy Content of the Original Condensate.
The savings associated with an ongoing motor maintenance program could range from 2% to 30% of total motor system energy use.
A 2.5% unbalance will reduce motor efficiency at full load operation.
Pump controls upgrading saved 62% of fountain pumps total energy consumption at Cisco Systems.
Replacing a pump with a new efficient one reduces the energy use by 2% to 10%. Higher efficiency motors have been shown to increase the efficiency of the pump.
Correcting pump oversizing can save 15% to 25% of electricity consumption for pumping on average for the U.S. Industry.
The Installation of parallel systems for highly variable loads on average would save 10% to 50% of the Electricity consumption for pumping for the U.S. Industry.
The largest salt producer in the UK after Trimming the Impeller, found the power reductions of 30%.
The technology is estimated to save between 20% and 50% of pump energy consumption.
Energy savings are 36 MWh (or2%) per year.
Installation of a smaller vent blower resulted in electricity savings of 896,000 kWh per year.
A heat recovery unit can recover 50 to 90% of the available thermal energy. When used for space heating, the recovered heat amounts to 20% of the energy used in compressed air systems annually.
Fuel savings are 0.09 GJ/tonne product. Electricity savings amount 0.05 GJ/tonne product. By the implementation of the technology, fuel savings are 0.02 GJ/tonne product. Electricity savings are estimted to be 0.01 GJ/tonne product.
A plant in Germany saves 325000 kWh of electricity/year by the adaptation of this technology.
Energy savings depend on how the pumps are operated. A reduction of 20-30% in electricity use is estimated.
Implemented source energy savings in TBtu are 0.94.
Implemented source energy savings amount 0.05 Tbtu .
Implemented source energy savings are 5.09 Tbtu.
Implemented source energy savings are 19.08 Tbtu.
Electricity savings of 42% are possible through the use of VSDs on pumps and fans per year.
Energy input is 12.6 GJ/t product.
Approximately 130 kWh/t-s of energy can be recovered (Efficiency 30%).
CO2 Emission Reduction Potential CO2 savings were equivalent to the removal of approximately 4,000 cars from the road.
Indirect emission offsets by the technology are 1,259 tonnes of NOx and 539,616 tonnes of CO 2 annually.
No need for slag landfill sites. Indirect CO2 emissions are reduced.
Technology reduces overall construction-related CO2 emissions by up to 30%. In 2007 savings of 14000 Tons of CO2.
If the World average was 180 kg Pulverised Coal/thm, Some 10 Mt CO2 could be saved.
A 15% reduction of CO2/tHRC Emissions should be Feasible without CCS. Upto 50% CO2 Reduction is possible with CCS.
This technology can reduce CO2 emissions per tonne of hot metal by close to 20% when compared to the typical BF route.
20 % reduction of CO2/t HRC without carbon capture and storage (CCS) is expected. Morevoer, reduction of upto 80% in CO2/t HRC is possible with CCS.
If the technology spreads through Japanese steel industry, CO2 emissions will be reduced from 1.64 tCO2/t-steel to 1.15 t-CO2/t-steel.
GHG emissions will decreased if the electricity is produced from clean energy technologies.
Biomass is CO2 neutral if strict conditions are met in producing it.
Overall emissions reduction potential by using CCS in Iron and Steel Industry ranges between 0.5 Gt to 1.5 Gt of CO2/yr.
Direct and indirect CO2 emissions reduction potential of the technology is 34 Kton/year.
Savings of 54.9 Kg CO2/tHM are estimated by the application of the technology.
Emissions reduction potential of this technology is 46 Kg CO2/tonne steel. Worldwide CO2 saving potential stands at 25 MtCO2.
Oil contains hydrogen which reduces overall CO2 emissions.
Emissions decreases by 30.2 Kg CO2/tonne rolled steel by applying this technique.
Emissions reduction is unlikely.
Decreased energy consumption results in decreased emissions.
Reduction in Limestone usage Results in Reduced Calcination-Related Emissions.
Less utilization of BF coke will eventually result in lower on-site emissions.
CO2 emissions in China can be reduced by 37 Mt/yr, if all BFs were as efficient as the largest ones in operation.
Reductions in coke input rate may ultimately reduce BF emissions.
It lowers CO2 emissions (by about 30% in comparison to the use of coke and/or coal) due to their higher hydrogen content.
CO2 from Charcoal-based steelmaking was 0.30-0.55 t CO2/t steel which is much lower than coal and coke.
If TRT were Installed Worldwide at all the Furnaces Working at Elevated Pressure, it could Reduce CO2 Emissions by 10 Mt.
CO2 saving potential of the technology on global level is about 20 Mt CO2/yr.
The credits are roughly 0.6 t CO2/t clinker substitute. The total savings potential is approx 50 Mt CO2.
Emissions are reduced by 35 Kg CO2/tonne liquid steel.
Emissions are reduced by 23.5 KgCO2/tonne steel.
Use of 80 percent hot charged DRI in the EAF results in only one-half the carbon emissions per ton of steel produced compared to the Blast Furnace/BOF route.
Assuming 360 g CO2 /kWh of Electricity, 0.77 t of CO2 is emitted per tonne of steel by the process.
NOx Emissions are less than 300 mg/Nm.
Estimated CO2 emissions savings are 20 - 40 Mt/yr.
Given about 300 Mt coke production with CDQ & 600 g CO2/kWh, global CO2 emissions reduction potential is about 25 Mt CO2.
Emissions reduction of 57.2 Kg CO2/Tonne sinter is estimated.
NOx emissions from the technology are 14 g/tHM compared to minimum BF NOx emissions of 553 g/tHM.
NOx emissions from the process are 49 g/tHM compared to minimum BF NOx emissions of 553 g/tHM.
24 Blast Furnace - Combined Cycle Gas turbines in Japan reduces 11 Mt CO2/year.
Emissions saving potential of 25 Mt CO2 is estimated.
Dust emissions are reduced by no impact on GHG emissions.
Emissions reduction due to avoiding excess gas flaring
Total CO2 emissions are 3.1988 metric ton/metric ton Liquid Steel.
Fastmet process reduces the CO2 by 1241 kg/tHM. NOx emissions are in the range of 0.3 - 1.5 kg/tHM.
CO2 reduction of 1 tCO2/tHM is estimated.
CO2 Reduction of 1tCO2/tHM is expected.
This technique would generate No CO2.
Plasma injection would enable direct CO2 emissions to reduce by more than 50%.
Reducing the gas escape will lower the emissions.
There will be a reduction in CO2 emissions if the recovered heat is adequately utilized.
Emissions are reduced by 22.6 Kg CO2/tHM.
Emissions reduction of 0.51 Kg CO2/tonne liquid steel is estimated.
Decreased energy consumption will lower emissions.
Reduction in emissions will occur when the technology is Used with CCS.
Emissions reduction of 10.6 Kg CO2/tonne steel is estimated.
Zero CO2 emissions will occur by the use of the technology.
Emissions saving potential of the technology is 11.7 Kg CO2/tonne Steel.
Energy savings will result in reduced emissions.
Significant emissions reduction can be expected due to reduction in energy consumption.
Emissions reduction potential of the technology is 52.9 Kg CO2/tonne steel.
Reduced energy consumption will eventually result in reduced emissions.
Emissions reduction of 1.1 Kg CO2/tonne liquid steel is estimated.
SOx emissions from the technology are comparable. NOx emissions are possible higher.
A deNOx efficiency of 90% can be achieved.
The Efficiency in NOx reduction can be as high as 80-90% depending on operating temperatures, addition of NH3 and design. A NOx reduction efficiency of about 80% has been achieved at sinter plants depending on the catalyst Type used, operating temperature and NH3 addition.
SOx was reduced by more than 70%. NOx was reduced by more than 95%.
CO2 emissions reduction of approximately 10-15 Kg/ton of sinter is estimated.
Charcoal is Greenhouse neutral i.e. CO2 liberated in the sintering process is absorbed By the next crop of growing trees.
Emissions reduction potential of the technology is 6.7 Kg CO2/tonne coal.
Emissions are reduced by 17.6 Kg CO2/tonne Hot Metal.
The technology does not have impact on GHG emissions.
Fuel savings will lead to emissions reduction.
In comparison with Blast Furnace route, the total CO2 emissions per ton of hot metal produced is expected to decrease by one third.
Potential GHG emissions savings are about 90% comparing to conventional casting.
This will provide a substitute for Cement in Building Industry and will thereby reduce Energy Use in and CO2 Emissions from the Cement Industry.
Lower emissions due to reduced energy consumption.
Up to 50% NOx reduction is possible with high temperature combustion.
Fossil energies such as LPG/LNG are substituted resulting in reduced emissions.
It does not Impact GHG emissions but significantly reduces particulate matter.
Off-gas volume can be reduced by 50-60%. This will significantly minimize NOx, SOx, CO and CO2 emissions.
Environmental emissions will drastically decrease due to reduced energy consumption by avoiding reheat furnaces.
NOx content reduced by 30%. NEDO reports the CO2 reduction of 400,000 t-CO2/year.
Visible emissions can be kept below 5% of all the coke oven doors per battery. A Plant in Germany has achieved 93% reduction in fugitive emissions.
The technology leads to emissions reduction of 3.8 Kg CO2/tonne Coke.
Lower emissions due to reduced energy consumption are expected.
Emissions reduction potential of the technology is 24.4 Kg CO2/tHM.
Significant CO2 and particulate matter emissions are the limitations of the process.
Environmental benefits are comparable to Blast Furnace route.
Environmental benefits are comparable to Blast Furnace route.
The use of Hot DRI (HDRI) provides even greater savings of 47 Percent. The Stack CO2 emissions per ton of DRI are reduced by 250 kg/t DRI, about 50 Percent.
It reduces environmental emissions.
Potential emission reductions per installation per year are 550 tons CO2 . NOx emissions reduces by 2.5 tons NO2.
This technology will decrease anthropogenic CO2 emissions.
This technology reduces off-site emissions.
Environmental emissions are reduced due to avoiding gas flaring.
CO is prevented from converting to CO2 by the technology.
Ladle lifetime extension does create the opportunity for reduced consumption of raw material and refractory landfill usage.
Emissions reduction potential of the technology is 17.6 Kg CO2/tonne steel.
Significant emissions savings due to reduced energy consumption are expected.
Emissions reduction of 35.5Kg CO2/tonne steel is achievable.
Waste gas and dust volumes are considerably reduced by the technology.
Depending on the CO2 emission of the electricity grid, the significant amount of CO2 emission will also be reduced.
Environmental emissions are lower due to energy savings.
Emissions of NOx decreases by 40%.
Reduction in environmental emissions due to avoiding gas flaring.
Emissions reduction by this technology amounts 9.9 Kg CO2/tonne sinter. Emissions were reduced due to lower energy consumption.
Emissions are reduced by 0.12 Kg CO2/tonne Coke.
The larger dimension ovens decrease the specific environmental emissions because fewer pushing operations are required per tonne coke. Emissions are directly proportional to number of pushes.
There will be a reduction in NOx emissions.
This technology lowers CO2 emissions.
Reduction of pollutants because flue gas is utilized.
Reduced emissions since oxidation of CO to CO2 is reduced.
Reduction in emissions because CO is not let to oxidize rather it foams the slag.
Reduction in emissions is expected.
The technology monitors CO formation in the waste gas.
The technology does not impacts GHG emissions.
There will be related CO2 emission reduction.
This will lead to CO2 emissions reduction of approximately 20,000 tonnes per annum.
Hazardous stack emissions reduces.
The new car helped in enhancing emission control activities such as door regulation, T-bolt tightening and lintel repair.
The technology does not impacts GHG Emissions.
Reduction in fuel consumption results in lower emissions.
For Certain, CO2 generation is lowered by 330 kg per tonne of DRI due to savings of 110 kg of reductant Coal alone.
Potential savings are 40 45% in fuel usage. A corresponding reduction in CO2 emissions is obvious.
CO is combusted to produce CO2 and the energy.
If Wood charcoal is used for Iron production net CO2 and sulfur emissions can be significantly reduced.
Even when natural gas or coal is used significant reduction in carbon dioxide emissions 39% and 69% of the Blast Furnace value, respectively are estimated.
For a 4000 tpd furnace emissions are reduced by a total of 25,000 t/yr, with 95% of that total being CO2 emissions.
CO2 emissions are reduced comparing with tire burning by conventional incineration.
The goal is to cut total CO2 emissions by about 30%.
Emissions reduction of 19.5 Kg CO2/tonne sinter can be achieved.
Emissions reduction of 2.0 Kg CO2/tonne sinter is estimated. Emissions are reduced by 4.9 Kg CO2/tHM. The technology has the emissions reduction potential of 1.6 Kg CO2/tonne rolled steel.
Emissions are reduced by 15.1KgCO2/tonne rolled steel.
Emissions are reduced by 35.2 KgCO2/tonne rolled steel.
Emissions are reduced by 1.9 KgCO2/tonne rolled steel. Emissions are reduced by 10 KgCO2/tonne steel. Emissions reduction potential of the technology is estimated to be 8.8KgCO2/tonne steel. Emissions reduction of 8.8 Kg CO2/tonne steel are expected.
Emissions reduction potential of the technology is 11.1KgCO2/tonne Steel.
NOx emissions are reduced by this technology to less than 0.015 lb/MMBtu.
Reduction in Landfills will reduce CO2 emissions.
CO2 emissions decreases.
GHG emissions could be expected to Drop by 0.3 million metric tons Carbon Equivalent/year.
The technology reduces NOx emissions by up to 75%.
It reduces CO2 emissions by 550 metric tons/year.
Total emissions reduction potential over 10 Years is 17.81 MM Tons CO2 and 10,465 Tons NOx.
It reduces Landfills and thus associated GHG emissions.
Environmental savings are estimated to be 1857 x 106 kg of CO2 /year.
A reduction in CO2 by 0.46 million metric tons can be achieved. Additionally, TCR will reduce NOX emissions.
CO2 emissions in the Ironmaking process decreased by 4 to 5%.
Lower emissions due to energy savings by the technology.
Process has better environmental performance compare to blast furnace route and HYL reformer based process.
Abatement of specific NOx emissions in the range of 25 - 50%.
The technology reduces Up to 40% Off-gas volume. Abatement potential of specific NOx emissions is about 25 - 30%.
A slight decrease in NOx emissions of about 3% is reported.
This technique will reduce CO2 emissions by 15-80 kg/t hot metal.
Reduction in CO2 emissions is roughly 50 kg/t hot metal.
Emission corresponding to Coke Savings are reduced.
Since no coke oven plant, sinter or pellet plant are required, a remarkable reduction of emissions can be achieved.
Since no coke oven plant, sinter or pellet plant is required, a significant emissions reduction compared to conventional primary ironmaking can be expected.
Emissions are reduced by 5 kg CO2/tonne sinter. Emissions are reduced by 4.0 Kg CO2/tonne Hot Metal.
Emissions are reduced by 15 Kg CO2/tonne product.
The technology has the emissions reduction potential of 3.7 Kg CO2/tonne product.
Implemented CO2 savings in metric tons are 55,069
Implemented CO2 savings amount 3,022 metric ton.
Implemented CO2 savings are 273,638 metric tons.
Implemented CO2 savings are 1,472,115 metric tons.
If saturated steam power generation is assumed, Power Generation will amount 2.8 MWh with corresponding CO2 emission reduction 12,600 t/y.
Costs Using rubber tyres, steelmaking costs are 80% of what they were when using coking coal.
Total investment costs are estimated to be $14.5/t crude steel.
Road paving and road maintenance costs are 70% of the original after using this technology.
Investment of coal grinding equipment is estimated at $50-55/t Coal injected. Cost of PCI plant largely depends of the size of blast furnace and the layout of the plant. The layout of the plant can make it difficult to install PCI accessories with some alternative arrangements which would ultimately increase the installations costs. Investment and/or operational costs are not available because technology is still in research.
Production costs are in the range of 95% to 65% of the conventional route costs.
Investment and/or operational costs are not available because the technology is still in research.
An Investment of 80 M has been estimated for heat exchange reformer method of production of hydrogen.
High cost of electricity is likely.
Total production costs for charcoal may range from $355 to $474 depending on type of wood
CCS for BF could cost around $40/t CO2-$50/t CO2. CCS for DRI could cost below $25/t CO2.
An Investment of 3.8 Million over two years aimed at energy savings was made.
Retrofit Capital Cost is $7.8/tHM.
Retrofit capital costs are $34.4/tonne steel. According to an experts opinion, the installation costs vary in a wide range depending on the scope of supply and the country of installation. Basically the Return of Investment is between 2,5 and 4 years. Payback is a strong function of the natural gas prize.
Retrofit capital cost is $23.5/tonne rolled steel.
Material cost of sinter manufacture is reduced by $ 1.98 /ton sinter.
Net savings of over Rs. 2.5 crore during 2007-08 were obtained.
Equipment costs 3000million approximately. Construction costs are 500million. An expert reports general cost for heat recovery equipment and turbine is around 4 million.
Investment cost is high for large blast furnaces.
Investment for the plastic injection plant at Voest Alpine Austria was about EUR 20 million for an injection capacity of upto 220000 t/year.
Charcoal accounts for 40% of Pig-Iron costs in charcoal based BFs.
Equipment costs approximately 400million. Construction costs are 400million approximately.
An efficient hot blast stove can run without the need for natural gas.
Technology can easily be Integrated into virtually any existing cement plant at low capital cost.
Equipment costs around 600 million while the construction costs are 100 million approximately.
Retrofit Capital Cost is $7.5/tonne steel.
Doubling the Midrex plant capacity increases the cost by just 50%.
Operating costs are decreased by about $6-8/ton DRI as compared to a typical DRI process.
Total cost per net metric tonne steel is $185.12 when used in EAF.
Total cost per net metric tonne Steel = $185.27 when used in EAF.
Retrofit capital cost is $234.9/tonne hot rolled steel.
Retrofit capital costs are 109.5$/tonne coke. The cost of a 3-chamber plant can be estimated to be in the range of 60-70 million including equipment and installation costs.
Retrofit capital cost is $4.7/tonne sinter.
Production costs can be 80% of traditional BF-BOF route.
Capital cost of Finex are 80% of conventional Blast Furnace capital cost.
Cost data has not been provided.
It requires extra compressor.
Total steel cost per net metric ton liquid steel is $180.74 when used with EAF.
Capital cost is similar to Itmk3 Process i.e. $296.10/ANNUAL mt liquid steel when used with EAF.
Capital cost is similar to Itmk3 Process i.e. $296.10/ANNUAL mt liquid steel when used with EAF.
Capital Cost is $296.10/ANNUAL mt L.S. when used with EAF.
Operating cost would depend on electricity prices.
Cost of hot stove, PCI injection system and Oxygen plant will be eliminated.
Any incremental cost is unlikely.
Total cost of slag heat recovery including CAPEX and OPEX, is $2.5/GJ.
Retrofit capital cost is $0.47/tHM.
Retrofit capital cost is $0.31/tonne liquid steel.
Investment of $1.1 Million for 2 Furnace Lines was made.
Retrofit capital costs are $2/tonne steel.
Cost of reformer are avoided.
Retrofit capital cost is $15.6/tonne steel.
Electricity Cost is Likely to be the Driving Factor for the technology diffusion.
Retroftit Capital Cost is $0.94/tonne Steel.
Retrofit capital costs are $6.1/tonne steel.
Maintenance costs would decrease due to a simpler plant design.
Costs were estimated to be $0.08/ton ($0.09/tonne) of product.
Investment cost of a US coking plant producing 1.2 Million tonnes of coke per year was $365 Million Including coke oven facilities, coke handling/blending and power plant.
Investment cost was EUR 47 Million in 1976.
Investment cost Including sulphuric acid plant and waste water treatment Plant in 1987 were approximately EUR 21 Million. Investment of about EUR 30 Million was quoted Including reheating system in 1997 for a SCR Unit at Corus Ijmuiden.
Equipment costs low with high pollutants removal efficiency.
Investment cost at an Indian plant was 16 Lakhs.
Cost of Charcoal production is being reduced by using "Cheaper Cuts" i.e. the leaves and the twigs of Malle Trees.
Coal moisture control costs for a plant in Japan were $21.9/t of steel.
Retrofit capital cost is $31.2/tonne hot metal. According to an expert there is no standard price for TRT, especially retrofit. It depends a great deal on actual gas condition and site condition.
Cost savings of 3-5% for boiler.
Investment costs are 70% compared to Wet-Type dedusting equipment cost.
The life time of the Tundish Lids will increase by 90%.
The cost of production is estimated by Bricmont to be $193.86/nt ($213.63/mt) of DRI of 95% Metallization.
Annual operating and maintenance costs are 20-25% less than conventional rolling.
Revenue generated is equivalent to 3.8 billion Yuan/year, based on 1,000 Yuan ($130 2006 US)/t scrap steel.
This technology results in waste reduction and therefore decreases the disposal costs.
Equipment (3 pairs) costs 9 million. Construction costs are 1 million (approx.).
Investment cost is roughly $22.3 million.
Investment for Last Generations ESPs Costs around EUR 35 Million in Sinter Plants with 500-600 m2 Sinter Strand.
Investment cost at sinter plant of Corus, Ijmuiden was EUR 17 million with 1.2 MNm3/h waste gas flow from three sinter strands.
Equipment costs 200 million. Construction costs are 50 million approximately.
Processing costs are characterized by lower energy consumption and lower costs for consumables.
Production costs are 82% and Construction costs are 84% of conventional coke oven.
Cost of material return due to poor sintering is reduced.
Investment cost for replacing doors of a coke oven battery is around EUR 6 million in a coke oven plant with 100 ovens and coke production of 1.2 - 1.5 Mt Coke/y.
Retrofit capital costs are 0.37 $/tonne coke.
Operating costs will be lower thanks to reduced coke consumption and high attainable PCI rates.
Lower operating costs because coke ratio reduces by 2.8% per 100C rise in blast temperature when it is maintained between 1000C to 1200C.
Retrofit capital costs are $ 0.56/tHM.
Low capital cost is expected since pelletizing or sinter plants are not required.
Low quality and low cost coal is used.
Low quality and low cost coal is used.
Midrex expects that in most cases, this will result in a net decrease in operating Cost.
Lower operation costs, reduced maintenance and performance verification time result in labor savings of up to 80%.
Assuming a 330 day production Year and $40 per tonne profit yields an annual profit increase of $0.870 Million.
If the O2 can be provided cost-efficiently,this will reduce operating costs of the technology.
Process control can lead to cost savings.
At $40 per ton profit, this equates to a net profit Increase of $3,520 per day or $1.1 M (Profit) over a 330 day work year.
Costs can be reduced because Vacuum Treatment process is not required. Vessel life is also prolonged.
Improved heat distribution leads to reduced tap-to-tap times of about 6%, leading to estimated annual cost savings of $4.0/t.
The technology reduces the electrode consumption by about 0.8 kg/t comparing to conventional furnace.
There will about 19% reduction in the energy cost per tonne of liquid steel produced.
Flexibility of scrap mixing reduces the costs for the process. Electrode consumption is as low as 0.8-1.0 kg/ton. Investment cost is $ 31 (assuming 15% Less than conventional Casting systems. Full Retrofit Cost $103)/ ton of Steel.
Retrofitting cost is 0.47 $/tonne coke.
This technology prolongs blast furnace life. Repairs and Relining are as Late as possible and as early as necessary.
It lowers energy costs.
Inexpensive low calorific-value gases such as process and biogas can be used.
This technology is expected to bring savings of 5 10 % in scrap costs.
Reduction in cost of electricity.
Cost decreases due to savings in alloying agents such as Cromium.
Cost savings are obtained due to on-line monitoring of the amount of alloying agent.
This technology reduces costs of rejections and re-works/re-melts.
The economical mode of operation reduces the consumption of refractory gunning mixes by around 10 %.
Costs are reduced.
Financial savings of 1.1 mill / year corresponding to scale reduction of 20% was obtained.
The technology is reliable and inexpensive. Lower maintenance costs are expected. Significant savings in operating costs are estimated.
Reduction of Labour costs is expected.
Minimisation of subsequent corrective measures will reduce the cost of material loss.
Evaluation of attainable savings will be performed on the basis of energy balance of whole process.
Coupling of work processes in case of interruptions, thereby less wear occurs.
This technology provides swift and cost-effective solution of defined problems.
Lower operational costs compared to alternative transmission systems.
Cost savings can occur due to utilization of wastes from coke oven.
Annual savings amounting Rs. 15 crore has been obtained.
Net annual savings of Rs. 2.2 Crore were achieved.
Cost savings of approximately Rs. 1.5 crore were achieved due to this technological development. Out of which Rs. 1 crore is recurring saving.
Estimated annual recurring savings as a result of this innovation are Rs. 1.1 crore.
Monatory savings achieved due to this innovation is to the tune of Rs. 18 crore per year on recurring basis.
Annual savings of Rs. 8.64 crore were obtained.
Annual monetary gain has been assessed to be around Rs. 1.53 crore.
Financial benefit occrued from this Innovation Amounts to Rs. 85.8 crore per annum.
Delivery cost can be around $30/gross ton. Coke Savings of $0.043/NTHM (Net Ton of Hot Metal)are possible.
Elimination of cokemaking and high temperature agglomeration processes would lead to lower capital and operating costs.
Fuel savings are offset to some extent by the cost of the Oxygen. However O 2 production technologies are becoming more economical.
Low cost raw materials can be used.
Initial capital cost ranges from $175,000 to $250,000 per strand.
Net savings of $0.84/tm corresponding to coal injection increase can be obtained. Savings of another $1.95/thm due to productivity increase.
Monitory savings corresponds to 22000 tons/yr Iron Ore, 79000/ton coal or 100000 Kilolitres of heavy oil-equivalent.
The tentative total cost of project Phase 1 Step 1 is about 10 billion.
Retrofitting cost is 0.29/tonne sinter.
Retrofit capital Cost is 0.14$/tonne sinter. Retrofit capital cost is $2.2/tHM. Retrofit capital costs are $0.31/tonne rolled steel. Savings of about $0.28/ton ($0.31/tonne) corresponding to energy savings are calculated.
Retrofit capital cost is $1.1/tonne rolled steel.
Retrofit Capital Cost is $3.9/tonne rolled steel.
Retrofit Capital cost of $15.6/tonne solled steel is estimated.
Retrofit Capital Cost is $0.79/tonne rolled steel.
Annual operating costs increases by 32% compared to no-heat recovery. Retrofit Capital Cost is $1.3/tonne rolled steel. Retrofit Capital Cost is $4.3/tonne Steel. Retrofit capital cost is $3.1/tonne steel. Retrofit capital costs are $ 5.0/tonne steel.
For 30% TECNORED HOT METAL/70% SCRAP TO EAF, WITHOUT CO-GENERATION, Total Cost is $190.98/net metric ton liquid steel.
Wide variety of low cost solid reductants can be used.
Low capital and operating costs are estimated for the technology.
Commercial cost ranges from $750000 to $2 million. Project aims at producing the system costing sess than $100,000.
Savings of up to $180 million annually corresponding to recycling waste oxides. Also $120 million can be sSaved by avoid Landfills for waste oxides.
Successful industry wide implementation will reduce waste in processing. It saves the steel Industry at least $40 million annually.
Estimated annual savings are $20 million when technology is in widespread commercial use.
Cost Savings can $234 million per Year.
Maintenanace costs are 5% comparing with former maintenance.
Capital cost for the equipment is $35 million for a 1,000,000 tpy facility.
Total operating cost of SFH with preheat air is $13,028,057/yr. SFH with Preheat oxygen costs $14,807,465/yr.
Investment costs for the technology are 65% of that of BF investment cost.
Low cost reductant is used.
Cost savings are 413,000/y.
Equipment Costs 80 million. However construction costs are 30 million approximately.
Investment cost is EUR 14 million.
Investment cost for a suction area of 250 m2 is about EUR 15 million.
European investment costs for the gas recycling system were quoted at EUR 8-10 million excluding deNOx, deSOx and other abatement equipment.
The economic benefits are connected with increased productivity, reduced energy consumption and decrease in demand of reducing agents.
Additonal costs will arise for air enrichment to provide constant huge amounts of Oxygen and additional requirement of injection unit maintenance.
The Capital costs of installing the direct injection of residues is about EUR 4 - 6 million.
Calculations show that the annual operating costs can be reduced by 9% with the use of this technique. Capital costs were estimated to be $0.19/ton ($0.21/tonne) of sinter. Retrofit capital costs are $0.47/tonne hot metal.
Weirton Steel Corporation found that for Every 100 feet of piping insulated, Energy savings could be upto $19000 each year.
Using automatic monitoring it is estimated that an additional 5% cost over steam trap maintenance can be saved.
The economics of heat recovery projects are most favorable when the waste steam heat content is high and the flow is continuous.
A correction of the voltage unbalance from 2.5% to 1% will result in electricity Savings of 9,500.
The project reduced maintenance costs and increased the pumping system's equipment life.
For a given duty, a pump that runs at the highest speed suitable for the application will generally be the most efficient option with the lowest initial cost.
Less wear on the system resulted in less maintenance, less downtime, and longer life of the equipment. The use of multiple pumps is often the most cost-effective solution for varying loads, particularly in a static head-dominated system.
Maintenance costs were reduced by impeller trimming.
This technology reduces wear on equipment thereby it reduces future maintenance costs.
Additional cost of coating would be paid back in 5 months.
Cost savings are $35,840.
Energy associated cost savings are expected.
Annual operating costs are $0.03/tonne product. Retrofit capital costs are $0.02/tonne product. Retrofit capital costs are $0.23/tonne product.
Investment cost is roughly EUR 67000.
$63,000-$65,000/year reduction in power costs.
Implemented cost savings in US$ are 5,095,041.
Implemented cost savings are US$ 346,200.
Implemented cost savings amount US$ 38,957,875.
Implemented cost savings are US$ 101,131,495.
Costs are $1.3/t Product.
Lower production costs. No storage costs as the product does not oxidize.
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http://www.energystar.gov/ia/business/industry/downloads/ENE RGY_STAR_Iron_and_Steel_Guide.pdf http://www.energystar.gov/ia/business/industry/downloads/ENE RGY_STAR_Iron_and_Steel_Guide.pdf
pg. 63
pg. 64
pg. 64
http://www.energystar.gov/ia/business/industry/downloads/ENE RGY_STAR_Iron_and_Steel_Guide.pdf http://www.energystar.gov/ia/business/industry/downloads/ENE RGY_STAR_Iron_and_Steel_Guide.pdf
pg. 65
pg. 68
pg. 75
pg. 12
pg. 12
pg. 60
pg. 102
pg. 103
pg. 106
pg. 110
pg. 113
pg. 116
pg. 500
www.jase-w.eccj.or.jp/technologies/pdf/iron_steel/S-5.pdf
Link to Webpage 2 http://www.theaustralian.com.au/news/onesteel-runs-withtyres-idea/story-e6frg6yx-1111117846344
Page Num
pg. 119
http://www.cst.com.br/english/products/co_products/catalog _products/acerita/acerita.asp
http://www.arcelormittal.com/index.php?lang=en&page=763
www.iea.org/textbase/nppdf/free/2007/tracking_emissions.p pg. 120 df
http://www.ulcos.org/en/docs/Ref25%20%20ULCOSpublic.pdf http://www.teamorissa.org/Convention_%20Presentations_% 20Sessionwise/Session-3/Session3-2%20200907%20HIsmelt%20Bhubaneswar_PPT_2.pdf
pg. 02
http://www.tatasteeleurope.com/en/news/news/2009/2009_ pilot_plant_could_reduce_emissions
pg. 01
pg. 01
www.ulcos.org/en/docs/Ref17%20-%20ULCOS_%20Korea.pdf pg. 08
www.iea.org/papers/2009/CCS_Roadmap.pdf
pg. 25-33
http://www.tenovagroup.com/pdf/exhibition/The%20electric %20arc%20furnace%20of%20Tenaris%20Dalmine.pdf
http://www.energystar.gov/ia/business/industry/downloads/ pg. 84 ENERGY_STAR_Iron_and_Steel_Guide.pdf
pg. 09
http://www.google.com/url?sa=t&source=web&cd=8&ved=0 CEwQFjAH&url=http%3A%2F%2Frevistademetalurgia.revistas. csic.es%2Findex.php%2Frevistademetalurgia%2Farticle%2Fdo wnload%2F155%2F153&ei=ZpvKTYO7OcmewaAmIyuAw&usg=AFQjCNEdgjBJ07yrw3kFyW1khrg7KAmXWw http://www.beeindia.nic.in/industrial_sectors/documents/steel/Bhilai.zip pg. 03
www.sesagoa.com/pdf/stamp-charging-technology.pdf
http://www.deepdyve.com/lp/hindawi-publishingcorporation/mineral-processing-of-a-converter-slag-and-itsuse-in-iron-ore-PZx6ciyKDG
http://meveus.iehk.rwthaachen.de/moodle/file.php/1/homepage/papers/60_I_and_S_C oke.pdf
www.cfd.com.au/cfd_conf03/papers/037Yag.pdf
old.vpvb.gov.lv/ippc/bat/bat_ES1/EdzelzsTerauds_Pr200907.p pg. 355 df
http://www.acobrasil.org.br/site/portugues/biblioteca/Folder pg. 02 _Meio Ambiente_Ingles.pdf
www.iea.org/textbase/nppdf/free/2007/tracking_emissions.p pg. 123 df
pg. 11
http://www.midrex.com/uploads/documents/New%20Develo pments%20in%20the%20Midrex%20DR%20Process.pdf
www.hbia.org/Technical/openpdf.cfm?filename=DRProcess/1 995-2DR.pdf HYLIII
http://www.selaslinde.com/production_programme/special_furnace_designs/r eduction_gas_heaters/finmet.php
http://www1.eere.energy.gov/industry/steel/pdfs/ironmaking pg. 29 _process.pdf
pg. 10
www.iea.org/papers/2008/JPRG_Info_Paper.pdf
pg. 21
www.teamorissa.org/Convention_%20Presentations_%20Sess ionwise/Session-3/Session3-1%20COREXFINEX%20Environmental%20India_PPt_1.pdf www.teamorissa.org/Convention_%20Presentations_%20Sess ionwise/Session-3/Session3-1%20COREXFINEX%20Environmental%20India_PPt_1.pdf
http://www.jisf.or.jp/en/statistics/sij/docs/steel_P12_P15.pdf pg. 01
www.stahlonline.de/VDEh/Eisen_und_Stahlerzeugung/Potentials_COG_ pg. 02-13 Diemer_Killich_Knop_Luengen_Reinke_Schmoele.pdf www.uhde.eu/cgibin/byteserver.pl/archive/upload/uhde_brochures_pdf_en_17 .00.pdf
www1.eere.energy.gov/industry/steel/pdfs/ironmaking_proce pg. 15 of 50 ss.pdf
www.asiapacificpartnership.org/pdf/Steel/3rd_meeting/The% pg. 02-04 20Kobe%20Midrex%20Process.pdf
www1.eere.energy.gov/industry/steel/pdfs/ironmaking_proce pg. 21 ss.pdf
www1.eere.energy.gov/industry/steel/pdfs/ironmaking_proce pg. 21 ss.pdf
http://www.iea.org/textbase/nppdf/free/2009/industry2009. pg. 69 pdf
http://www.iea.org/textbase/nppdf/free/2009/industry2009. pg. 70 pdf
www.processeng.biz/ieafbc.org/upload/61_3_Shimizu_Slag.pdf
pg. 09
pg. 09
pg. 11
http://gcep.stanford.edu/pdfs/2RK4ZjKBF2f71uM4uriP9g/Mar pg. 17-19 k_Atkinson_ULCOS_GCEP_webversion.pdf
pg. 11
http://www.unido.org/fileadmin/user_media/Services/Energy _and_Climate_Change/Energy_Efficiency/CCS/Stee_sectoral_ pg. 25 %20report.pdf www.epa.gov/nsr/ghgdocs/ironsteel.pdf pg. 11
pg. 11
http://www.revuemetallurgie.org/index.php?option=com_article&access=stand ard&Itemid=129&url=/articles/metal/abs/2006/04/P168/P16 8.html
http://asiapacificpartnership.org/pdf/Projects/Steel/SOACTHandbook-2nd-Edition.pdf http://asiapacificpartnership.org/pdf/Projects/Steel/SOACTHandbook-2nd-Edition.pdf
pg. 20
pg. 21
www.teamorissa.org/Convention_%20Presentations_%20Sess ionwise/Session-1/Session1pg. 26 2%20Energy_Efficiency%20_PPT_2.pdf
asdi.curtin.edu.au/csrp/_media/downloads/SolveMay06_Gree nSteel.pdf
pg. 55
pg. 94
pg. 86
http://www.energystar.gov/ia/business/industry/downloads/ pg. 81-82 ENERGY_STAR_Iron_and_Steel_Guide.pdf
pg. 23
pg. 35
pg. 09
http://www.paulwurth.com/en/OurActivities/Ironmaking/Blast-Furnace-Top-Charging-Technology
steellibrary.com/BookContents/PR-353023%201%20View%20Abstract.pdf
pg. 09
http://www.processmetrix.com/product_details/Downloads/ TIP2_Brochure.pdf
pg. 70
http://is.industry.siemens.com/broschueren/pdf/metals/siem pg. 11 ens_vai/en/LDBOF-SteelmakingSolutions_en.pdf
pg. 79
pg. 11
pg. 84
http://www.millennium-steel.com/articles/pdf/2008/pp9698%20MS08.pdf
pg. 10
http://www.jfe-steel.co.jp/en/research/report/003/pdf/00316.pdf
pg. 09
pg. 09
http://www.bfi.de/en/fields_of_activity/heat_engineering_an d_energy_management/blast_furnace_hearth_monitoring.ht m
http://www.bfi.de/en/fields_of_activity/process_automation_ steelmaking/process_control_of_electric_arc_furnace.htm
www.iea.org/work/2010/india_bee/jain.pdf
pg. 21
http://www.unido.org/fileadmin/import/18465_NipponSteel. pg. 03 pdf
www1.eere.energy.gov/industry/steel/pdfs/improving_syste m_life.pdf
pg. 01
www1.eere.energy.gov/industry/steel/pdfs/dev_of_process.p pg. 01 df
www.crm-eur.com/F-PUBLICATIONS/media/18f_Trinidad.pdf
http://www1.eere.energy.gov/industry/bestpractices/softwar e_airmaster.html
http://www1.eere.energy.gov/industry/steel/pdfs/ironmaking pg. 31 _process.pdf
Link to Webpage 3
Page Number
http://www.algoma.com/company/environment/energymanagement/
http://asiapacificpartnership.org/pdf/Projects/Steel/SOACTpg. 41 Handbook-2nd-Edition.pdf
http://www.unido.org/fileadmin/user_media/Services/Ene rgy_and_Climate_Change/Energy_Efficiency/CCS/Stee_sect pg. 25 oral_%20report.pdf
http://www.azom.com/article.aspx?ArticleID=1770
www.kemco.or.kr/up_load/blog/ULCOS_Infodays_print.pd pg. 17-21 f
http://www.google.com/url?sa=t&source=web&cd=1&ved =0CBkQFjAA&url=http%3A%2F%2Fwww8.cao.go.jp%2Fcstp %2Fenglish%2Fdoc%2Flow_carbon_tec_plan%2Fref_roadm ap2.pdf&rct=j&q=hydrogen%20in%20ironmaking&ei=xGITaXtK5GIOInKsZQG&usg=AFQjCNGKJti37yx8jzHY3O4l7tW9 0v-wpw http://www.ulcos.org/en/research/electrolysis.php
http://www.google.com/url?sa=t&source=web&cd=1&ved =0CB0QFjAA&url=http%3A%2F%2Fwww.ieabioenergytask38.org%2Fworkshops%2Fcanberra01%2Fscaife.ppt&rct =j&q=use%20of%20biomass%20in%20steelmaking&ei=FYf KTYrRBo-6Aa64ciuAw&usg=AFQjCNHqvAmrzBR3N9JIa93uOxfLY5iUjw
pg. 01
www.iea.org/textbase/nppdf/free/2007/tracking_emission pg. 127 s.pdf
http://www.google.com/url?sa=t&source=web&cd=2&ved =0CBgQFjAB&url=http%3A%2F%2Fissiran.iut.ac.ir%2Fimag es%2F6.pdf&rct=j&q=hot%20charging%20hot%20rolling&e i=g6uITd3rNZGIOIfKsZQG&usg=AFQjCNEP9lYRdkuMZVZgwLT1F2ruVAc0w
www.dsir.gov.in/reports/techreps/tsr070.pdf
http://www.beepg. 03 india.nic.in/industrial_sectors/documents/steel/Bokaro.zip
http://www.ieacoal.org.uk/publishor/system/component_view.asp?LogDo cId=82343&PhyDocID=7523
www3.ufpa.br/projetomineracao/docs/estrut/arq11social.pdf
pg. 80
http://www.lindegas.com/en/images/Energieeffizienz%20und%20minderun g17-10824.pdf
http://www.midrex.com/handler.cfm/cat_id/167/section/ global
http://www1.eere.energy.gov/industry/steel/pdfs/ironmak pg. 29 ing_process.pdf
http://www.selaslinde.com/production_programme/special_furnace_design s/reduction_gas_heaters/circored.php
pg. 09
http://www.teamorissa.org/Convention_%20Presentations _%20Sessionwise/Session-3/Session33%20Charge%20Intelligent%20Sinter_bhubaneswar_PPT3.pdf
http://www.industry.siemens.com/industrysolutions/metal s-mining/en/metals/ironmaking/corex/Pages/home.aspx
http://www.iea.org/textbase/nppdf/free/2008/etp2008.pd pg. 486 f
www.mhi.co.jp/power/news/sec1/pdf/2004_nov_04b.pdf
http://www.energystar.gov/ia/business/industry/downloa pg. 80 ds/ENERGY_STAR_Iron_and_Steel_Guide.pdf
www1.eere.energy.gov/industry/steel/pdfs/ironmaking_pr ocess.pdf
www.kobelco.co.jp/english/ktr/pdf/ktr_26/092-097.pdf
www.kobelco.co.jp/english/ktr/pdf/ktr_29/077-084.pdf
steeltrp.com/Briefing07slides/09-TRP9956_MIT-07IBS.pdf
www.metsoc.org/com2010/PDFs/Techprogram/sustainability.pdf
http://www.ulcos.org/en/research/advanced_direct_reduc tion.php
http://www.ulcos.org/en/docs/Ref03 - Electrowinning publ.pdf
pg. 01
pg. 82
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pg. 09
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http://www.ret.gov.au/energy/efficiency/Documents/Case pg. 02 %20Studies/iron-and-steel-strip-casting.pdf
pg. 88
pg. 70
pg. 72
http://www.energystar.gov/ia/business/industry/downloa pg. 95 ds/ENERGY_STAR_Iron_and_Steel_Guide.pdf
pg. 93
pg. 11
http://www.steelplantech.co.jp/english/kiji/receipt-orderecoarc-from-dongkuk-south-korea/
http://www.prestigethermal.com/traditionalwalking%20beam.htm
pg. 71
www.brain-c-jcoal.info/cctinjapan-files/english/2_3A3.pdf
Link to Flow Diagram
Page Number
Co-generation
LD Slag Reduction Treatment Process
Quenching Self-tempering
pg. 38
Hismelt
Hisarna
Electric Arc Furnace Controls
pg. 03 and 04
pg. 05
pg. 77
Injection of Oil
pg. 10
Hot Charging
Sinter Plant Wind Boxes
Sinter Machine Cooler Waste Heat Recovery
Plastic Waste Use
www.pigiron.org.uk/getlibrarydoc.php?id=28 pg. 10 &docnum=1&type=pdf
Top Pressure Recovery Turbine Dry Type
Heating Hot Stove by BF and Coke Oven Gas
Steel Slag Use in Cement
pg. 02
Oxy Fuel Burners
Midrex
HYLIII
Finmet
Circored
Thin Slab Casting
Coke Dry Quenching
Corex
Finex
pg. 07
pg. 02
Coke Stabilization Quenching
pg. 12
Coke Oven Gas Injection
pg. 04
SL/RN
pg. 16 of 50
FASTMET
FASTMELT
ITmk3
Molten Oxide in Electrolysis
Plasma Injection
pg. 11
Slag Heat Recovery
Variable Speed Drive
Ajustable Speed Drives
ULCORED
ULCOWIN
Direct Current Electric Arc Furnace
Non Recovery Coke Ovens
Reduction of NOx by SCR Process
pg. 20
Selective Catalytic Reduction
pg. 01
pg. 02
Multi Slit Ignition Oven Burner
pg. 66
Wood Char for Sintermaking
pg. 03
Coke Moisture Control
pg. 04
Top Pressure Recovery Turbine Wet Type
BFG Preheating System
pg. 06
Dry Dedustring of BF Gas
pg. 07
pg. 55
Castrip
pg. 12
Dust Recycling in Rotary Hearth Furnace
pg. 12
Regenerative Burner
pg. 14
pg. 18
Sinter Dust Control
pg. 19
pg. 177
Integrated Casting and Hot Rolling
pg. 86
Endless Strip Production
SCOPE 21
pg. 70
Improvement in Feeding Equipment
pg. 23
Improvement of Oven Door and Frame Seals pg. 35
pg. 37
Increase Blast Furnace Top Pressure
pg. 50
pg. 51
Rotary Kiln Direct Reduction
pg. 58
Coal Based HYL Process
pg. 59
Coal Based Midrex Process
pg. 61
Natural Gas-Based Midrex with CO2 Removal pg. 63 System
MultiGas Analyzer
pg. 64
pg. 65
pg. 70
pg. 72
pg. 74
BOF Bottom Gas Stirring
pg. 75
Lancing
CONSTEEL Process
pg. 82
pg. 83
pg. 85
Hot DRI/HBI Charging to the EAF
pg. 87
Flameless Burners
Extended Universal Fuel Gas Measuring Device
pg. 42
ECOARC
pg. 92
Near Net Shape Casting
Variable Speed Drive COG Compressor
Battery Underfiring with Advance Diagnostics pg. 45 and Control
pg. 60
pg. 46
Control Modules for Sinter Plants
Quality Assurane in Sinter Plant
pg. 11
Rolling Strand Temperature and Water Control
pg. 22
Development of Oxygen-rich Furnace System pg. 05 for reduced CO2 and NOx emissions
Sustainable Steelmaking using Biomass and Waste Oxides
pg. 08
Suspended Hydrogen Reduction of Iron Oxide pg. 30 Concentrates
pg. 08
pg. 02
COURSE 50
Recuperator Hot Blast Stove Energy Saving Drives
pg. 71
Install Lubrication System
Bottom Tapping
Tecnored
Redsmelt
pg. 17 of 50
On-line Laser-ultrasonic Measurement system
pg. 03
pg. 02
pg. 07
Dios Process
pg. 02
Comet
pg. 02

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2010 Electric Arc Furnace

2010 Blast Furnace

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2007 Blast Furnace

2010 Smelting Reduction

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