Stahl-Zentrum
STAHL 2015
1 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
The blast furnace – Fit for the future? Energy efficiency in steelmaking
Peter Schmöle Head of Competence Centre Metallurgy, ThyssenKrupp Steel Europe
Setting the course for tomorrow
Stahl-Zentrum
STAHL 2015
2 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Introduction
Metallurgical efficiency
Conclusion
The blast furnace – Fit for the future?
Alternative “benchmark” process modes
Cross-industrial network
Stahl-Zentrum
STAHL 2015
3 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Introduction Dominant position of the blast furnace route in the world, 2014
Electric steel 25.6%
Oxygen steel 73.9%
Scrap 31.7%
Blast furnace hot metal
63.8%
OH steel 0.5%
1665 1843 DRI / HBI
4.1%
Corex / Finex hot metal
0.4%
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4 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Introduction … with increasing shares in the last years
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5 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Inner volume: Volume between 1 m below chute in vertical position and taphole level
Introduction … and the biggest blast furnaces in Asia
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STAHL 2015
6 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Introduction
Metallurgical efficiency
Conclusion
The blast furnace – Fit for the future?
Alternative “benchmark” process modes
Cross-industrial network
Stahl-Zentrum
STAHL 2015
7 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Metallurgical efficiency Energy consumption – Real vs. ideal case
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8 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Metallurgical efficiency Energy consumption – Real vs. ideal case
Ideal case: Process • at thermodynamic equilibrium
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9 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Ideal case: Process • at thermodynamic equilibrium • without cooling losses
Metallurgical efficiency Energy consumption – Real vs. ideal case
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10 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Metallurgical efficiency Consumption of reducing agents – BF’s in Germany
Why?
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11 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Metallurgical efficiency Sinter composition, TKSE
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12 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Metallurgical efficiency Carbon and ash contents in BF coke, TKSE
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13 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Metallurgical efficiency BF slag volume, TKSE
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14 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
The BF is operated at 96 to 93 % efficiency level. (State of the art – operation related to a non-realistic process at the thermodynamic equilibrium and w/o heat losses)
Metallurgical efficiency Conclusion
Since end of 1990th the cumulated reducing agents consumption increases caused by higher slag volumes lower C contents in coke change from oil / natural gas to pulverized coal injection.
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15 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Introduction
Metallurgical efficiency
Conclusion
The blast furnace – Fit for the future?
Alternative “benchmark” process modes
Cross-industrial network
Stahl-Zentrum
STAHL 2015
16 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Different auxiliary reducing agents, HBI charging
PC = Pulverized Coal
HBI = Hot Briquetted Iron
NG = Natural Gas
H2 = Hydrogen
PC HBI NG H2
Coke kg / t HM 295 235 367 392PC kg / t HM 200 127NG kg / t HM 100H2 kg / t HM 40
HBI kg / t HM 400
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17 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Energy input without energy for HBI production
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18 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Energy input with energy for HBI production
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19 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Energy input with energy for HBI production
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20 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
From the energetic point of view it is cockeyed to cut the upper part of the BF, to shift the indirect reduction to an external process and to loose the sensible heat of the HBI in-between.
To report only the energy consumption and/or the CO2 emissions of the BF and to “forget” energy need and CO2 emissions for HBI production creates something like an perpetual motion machine.
Alternative “benchmark” process modes Use of HBI in the blast furnace
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21 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Auxiliary reducing agents with increasing hydrogen input
200 kg PC / t HM
100 kg NG / t HM
40 kg H2 / t HM
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22 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Auxiliary reducing agents with increasing hydrogen input
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23 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Auxiliary reducing agents with increasing hydrogen input
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24 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Auxiliary reducing agents with increasing hydrogen input
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25 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Auxiliary reducing agents with increasing hydrogen input
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26 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Alternative “benchmark” process modes Auxiliary reducing agents with increasing hydrogen input
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27 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
With higher hydrogen input the energy need and also the energy export increase.
Charging of cold HBI is contra-productive from the energetic point of view.
Alternative “benchmark” process modes Conclusion
Shifting the reduction reactions from carbon to hydrogen causes lower CO2 emissions, but exploding CO2 abatement costs.
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28 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Introduction
Metallurgical efficiency
Conclusion
The blast furnace – Fit for the future?
Alternative “benchmark” process modes
Cross-industrial network
Stahl-Zentrum
STAHL 2015
29 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Source: ThyssenKrupp Process Technologies
State of the art
Power plant Top gases
Electrical Energy
CO2 Today
Steel production
Blast furnace
Converter
Coke plant
Significant reduction of CO2 emissions and high value by-products
Methanol Synthetic fuel Fertilizer Alcohol Polyalcohol Polymers
Chemical use of top gases
Top gases
Future
Steel production
Power plant
Synthesis
Blast furnace
Converter
Coke plant
Cross-industrial network ThyssenKrupp project Carbon2Chem – Chemical use of gases
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30 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Power plant
Iron ore
Oxygen
Integrated iron and steel works
COG, BFG, BOFG
Steel
Cross-industrial network ThyssenKrupp project Carbon2Chem – State of the art Electric power
Injection coal
Coking coal
Electric power
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31 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Chemical raw materials
Renewable energy
Synthesis
Cross-industrial network ThyssenKrupp project Carbon2Chem – Future Chemical products
COG, BFG, BOFG
Power plant
Steel
Iron ore
Injection coal
Coking coal
Oxygen
Integrated iron and steel works
Electric power
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STAHL 2015
32 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Introduction
Metallurgical efficiency
Conclusion
The blast furnace – Fit for the future?
Alternative “benchmark” process modes
Cross-industrial network
Stahl-Zentrum
STAHL 2015
33 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Blast furnace as world champion in energy efficiency No chances for further energetic improvements from the metallurgical point of view
Conclusion State of the art, potentials and new ideas
Rethinking the bounds Cross-industrial network of steelmaking, chemicals industry and energy sectors to create an integrated economic and ecological optimum
“Hydrogen blast furnace” Increasing energy consumption, lower CO2 emissions, non-competitive costs
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34 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Conclusion Statements of clerical and political experts for energy efficiency
Chancellor Merkel, 2015: “The G7 leaders had committed themselves to the need to decarbonise the global economy in the course of this century”
Pope Francesco, 2015: “Climate change is a global problem”
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35 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
Conclusion To realise this decarbonisation of the global economy we need steel
Renewable energies
Energy transformation
Automotive lightweight design
Energy supply and distribution
Infrastructure
Sustainable construction
STAHL 2015 Conclusion … and blast furnaces
Steelmaking without fossil energy based blast furnaces ……
Steelmaking without fossil energy based blast furnaces ……
the touchdown will be a disaster!
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STAHL 2015
37 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl
The blast furnace – Fit for the future! Energy efficiency in steelmaking
Peter Schmöle Head of Competence Centre Metallurgy, ThyssenKrupp Steel Europe
Setting the course for tomorrow