Post on 05-Jun-2018
Presentation Outline
• Introduction: Si Friedrich• Overview of Program Planning: Si Friedrich• Program Analysis: Nancy Margolis• Ironmaking Focus Area: Larry Lehtinen• Other Focus Areas: Si Friedrich• Program Management: Si Friedrich• Recent Accomplishments: Si Friedrich
Snapshot of the U.S. Steel Industry• Ranks 5th of all manufacturing
industries in total energy use• Vital to the U.S. economy and
national defense• Few resources to invest in
R&D, particularly high-risk,long-term efforts on revolutionary technologies
• Significant improvements in energy efficiency over the last 20 years, but further gains needed to remain viable
Need for Industry/Government Partnership
• High energy intensity
• Reliance on coke
• High energy intensity
• Yield losses
• High energy intensity
• Yield losses
Energy Saving Opportunities for Steel
Steelmaking Reheating Forming/ FinishingIronmaking
EAFBOF
Energy Efficiency Challenges:
Key Processes:
ITP Program StructureIndustrial Technologies
Technology DeliveryAssessments, BestPractices
Advanced Process Systems
Chemical and Enabling Technologies
Metals & MiningMining, Steel, Metal Casting,Aluminum
Materials, Sensors, & AutomationGlass, Materials, Sensors
Chemical & Allied ProcessesChemicals, Forest Products
Industrial Energy SystemsCombustion, Supporting Industries, Tool Development
Portfolio & Financial Mgmt.
Golden Field Office, Regional Offices
Steel
EERE/ITP Mission & Goals Guide the Steel Program
EERE/ITP
• EERE:Increase the energy efficiency of industry
• ITP:By 2020, contribute to a 30% decrease in the energy intensity of energy-intensive industries
Steel Program
• Reduce the energy intensity of making iron and steel
• Improve steel industry productivity and reduce yield losses
• Help the industry maintain its competitive position
Petroleum
Petroleum
Chemicals
PaperPrimaryMetals
Nonmetallic MineralsWood
Mining
Energy-Intensive Industries
Energy Consumption
Ene
rgy
Inte
nsity
Other EERE
Mining
Energy Supply Solar
Wind
FreedomCar
Buildings
Fuel Cells
Hydrogen
Conventional Products
Energy Efficiency and Renewable Energy (EERE) Boundaries
Energy Flow
ITP BoundariesEnergy Flow
Cokemaking Ironmaking Steelmaking Casting Forming/Finishing
LEGEND
ITP
Analysis-Guided PlanningActivity
Project Selection & Execution
Assessment& Evaluation
• Program Goal Setting• Technology Area Planning
- Focus Areas- Project Solicitation
Supporting Analysis• Energy Footprints and
Other Energy Studies• Bandwidth Studies• Barrier/Pathway
Approach
• Expert Peer Reviews• GPRA• Milestone Tracking
• Corporate & PortfolioPeer Review
• Follow-Up Studies
Program Planning Inputs
Industry Input
ITP Strategic
Plan
Prioritized Focus Areas
Analytic Studies
Barriers/R&D Pathways
Industry Input: Steel Industry Partners
• Partners include– American Iron and Steel Institute (AISI)– Steel Manufacturers Association (SMA)
• Provide input to program direction and project selection
• AISI manages projects within the Technology Roadmap Program
Industry Input• Steel Industry Technology Roadmap
- Published by U.S. steel industry 1998 and updated 2001
- Identifies industry priorities for reducing energy intensity and increasing competitiveness
• Barriers and Pathways for Yield Improvements- Published 2003- Currently being used to solicit
proposals for the AISI Technology Roadmap program
Analytic Tools for Steel Program Planning
• Energy Bandwidth Analysis• Energy Footprint Analysis
Energy Benchmarking and Future Opportunities Study
Theoretical Minimum Energy Study
Alternative Ironmaking Study
Steel Industry Energy and Environmental Profile
Barrier/Pathway ApproachFootprint Studies
Industry Roadmaps
Bandwidth Studies
Documents & Data
FOCUS AREA
FOCUS AREA
FOCUS AREA
FOCUS AREA
Focus Area Barrier Pathways
FY FY FY FY FYPathway
Milestone Chart
Steel Industry Bandwidth Analysis(106 Btu/ton)
11.7
0
2
4
6
8
10
12
14
Iron-Making
BOF Steel EAF Steel Reheating
Area of Opportunity
Today’s Actual Energy Use
Theoretical Minimum Energy
Requirement
8.5
Practical MinimumEnergy Requirement 9.0
Impact of highly variable loads not shown in area of opportunity
Steel Energy Footprint Analysis
Energy Supply 1672
•Fuels
•Purchased Electricity and Steam
Central Energy Generation/
Utilities 1672
Energy Distribution
1647
Energy Export ~0Electricity
Energy Losses
Steel Plant Boundary
Utility/ Power Plant 163
Recycle Energy
Electricity generation and transmission losses 339
Losses in boilers and electricity generation losses 25
Losses in pipes, valves, traps, electrical transmission lines 62
Losses due to equipment inefficiency (motors, mechanical drive, waste heat) 291
Losses from waste heat, by-products TBD
Process Energy Systems
Recycle EnergyBy-product fuels and
feedstocks, heatSteam,
heat
Energy Conversion 1529
• Process Heating (1392)(coke ovens, blast furnaces, reheat furnaces)
• Process Cooling/ Refrigeration (4)
• Electrochemical (5)
• Machine Drives (116)(pumps, compressors, fans, blowers, conveyors, grinders)
• Other (12)
Process Energy Use
1238
Distribution losses 45
Facilities/HVAC/Lighting 56
• Steam Plant (77)• Power Generation
(18)• Direct Fuel Supply
(1389)• Purchased
Electricity (163)
• Steam Piping• Fuel Piping• Transmission Lines
• Cokemaking• Ironmaking• Steelmaking• Ladle refining• Casting• Reheating• Forming• Finishing• Waste Handling
Energy Losses
Fossil Energy Supply
1509
Total Steel Industry Energy Supply: 2056 Trillion Btu
• Evaluates end-use and loss patterns to clarify best opportunities for energy efficiency improvements
• Losses occur in equipment and distribution systems supplying energy to process operations or converting energy to usable work
Steel Energy Savings Potential Bandwidth
Analytic Basis for Steel Program Priorities• Used analytic tools to identify the best opportunities for reducing energy intensity• Set focus areas based on gap between current use and theoretical need• Quantified potential energy savings in each focus area• Issued solicitations and selected projects in each focus area
Steel Focus Areas
CokelessIronmaking
Next GenerationSteelmaking
Advanced Process*
Power DeliveryModeling**
Trillion Btu
Semi-Fabrication
Rolling/Reheating
Casting
Ladle Metallurgy
Steelmaking
Ironmaking
0 100 200 300 400
1
3
2
*Retrofit technologies addressing all areas**Bandwidth does not reflect impact of highly variable loads
4
Summary of Steel R&D Focus Areas
Focus Area
1. Cokeless Ironmaking
2. Next Generation Steelmaking
3. Advanced Process Development
4. Power DeliveryModeling
Goal
Make high-quality iron without coke
Revolutionize the way steel is made from both ore and scrap
Maximize energy efficiency while improving productivity (undergoing shift to focusing on yield improvement)
Develop technology to nullify adverse impacts of large, varying loads
Focus Area 1. Cokeless Ironmaking
Barriers• Making high-
quality iron without coke
• Risk of scaling -up to pilot plant
• Quality of pilot plant product
Pathways• Make iron with
reductants other than coke, such as coal
• Evaluate ITmk3®process at pilot scale
• Test iron product ina commercial steelmaking facility
1.4 MMTCeCarbon Reduction
$172 millionCost Savings
60 trillion BtuEnergy Savings
2020Metric
Metrics
Issued the Ironmaking Challenge solicitation in FY02;projects selected based on formal Merit Review
Barrier-Pathway Approach and Project Selection
Cokeless Ironmaking R&D Pathways: Assumptions and TargetsEnergy• Up to 30% less energy-intensive than current BF-BOF
steelmaking routeMarkets• Commercial introduction in 2006• Market saturation in 20 years
Cokeless Ironmaking ExampleMesabi Nugget - Direct Ironmaking (CPS# 1846)
Technology Description:• One-step ironmaking production replaces three-step operation• Produces iron feedstocks to all existing iron and steel making furnaces
(basic oxygen, electric arc and foundries)Benefits
• Up to 30% energy savings• 21% reduction in CO2 emissions• Reduction in NOx, SO2, and PM emissions• Lower capital and operating costs
Status• Third production test starts March 2004
Partners: DOE, Ferrometrics, Cleveland-Cliffs, Kobe Steel, Steel Dynamics, and State of Minnesota
Cokeless Ironmaking: Management by MilestoneITP Milestones (CPS #1846)
Sept 02 Initiate R&D May 03 Pilot plant start-upJuly 03 Production Test 1 completedAugust 03 Began steel maker melt testsSept 03 Production Test 2 beganDec03 Production Test 2 completedMar 04 Begin Production Test 3June 04 Complete Production Test 3August 04 Complete melt testsSept 04 Disseminate R&Dresults
MYPP Milestones
Focus Area 2. Next-Generation Steelmaking:
Barriers• High energy use of making steel via multiple inefficient processes
• High cost of developing new technology
• Risk of scaling up to pilot plant
• Maintaining quality
Issued the Steelmaking Challenge solicitation in FY02; projects selected based on formal Merit Review
Barrier-Pathway Approach and Project Selection
Pathways• Integrate iron and steelmaking production processes
• Develop processes that are less capital-intensive
• Investigate novel combinations of existing technologies
0.1 MMTCeCarbon Reduction$14 millionCost Savings5 trillion BtuEnergy Savings
2020Metric
Metrics
Next Generation Steelmaking R&D Pathways: Assumptions and TargetsEnergy
• 10-20% less energy-intensive than cokemaking/blast furnace ironmaking/basic oxygen furnace steelmaking route
Markets
• Commercial introduction in 2012
• Adopted by 20% of the applicable U.S. market (~10 million tons steel/year)
• Market saturation in 20 years
Next Generation Steelmaking Projects• Novel Direct Steelmaking by Combining
Microwave, Electric Arc, and Exothermal Heating Technologies- Eliminates ironmaking- Produces steel directly from
an agglomerate of iron oxidefines and powdered coal
• Future Steelmaking Processes- Flexible, fossil-fuel-based process- Combines series of process units to
continuously melt, refine, and cast steel
Focus Area 3. Advanced Process Development
Barriers• Costly yield
losses throughout the processing chain
• Energy inefficiency of major equipment
• Collaborative R&D with AISI members addressing improvement and energy efficiency
• Selected high-priority process improvement projects
Barrier-Pathway Approach and Project Selection
Pathways• Improve the energy
efficiency of hot processing steps
• Improve the yield of steel production processes
• Integrate technological advances into existing processes
4.6 MMTCeCarbon Reduction$332 millionCost Savings
129 trillion BtuEnergy Savings
2020Metric
Metrics
Advanced Process Development R&D Pathways: Assumptions and Targets• Metrics represent combined savings of about 25 technologies
(most initiated 2-3 years ago)• Projects address incremental improvements in ironmaking,
steelmaking, casting, rolling, fabrication, finishing, application• Focus area is currently undergoing shift to focus on yield
improvementEnergy Savings Target
(million Btu/ton)
0.1 - 0.20.2 – 0.30.2 – 0.3
1.7
Current Yield Loss (%)
2-67-96-819
Unit Operation
IronmakingBOF SteelmakingEAF SteelmakingApplications/Mtrl Properties
Advanced Process Development ProjectsIronmaking• Pulverized Coal Injection (PCI) Combustion Behavior
in the Blast Furnace During PCI at High Rates
Casting and Finishing• Automated Steel Cleanliness Analysis Tool• Hydrogen and Nitrogen Control in Ladle and
Casting Operations• Submerged Entry Nozzles that Resist Clogging
(Plant Trials)• Controlled Thermal-Mechanical Processing of
Tubes and Pipes
Steel Quality and Downstream Processing• Clean Steels – Advancing the State of the Art
• Life Improvement of Pot Hardware in Continuous Hot Dipping Processes
• Constitutive Behavior of High-StrengthMultiphase Sheet under High Strain RateDeformation Conditions
• Appropriate Resistance Spot Welding Practice for Advanced High-Strength Steels
• Ultra-Low Carbon High-Strength Steels for Enhanced Stretch Formability and Dent Resistance
Advanced Process Development Projects
Environmental• Nitrogen Removal in EAF Steelmaking
by Direct Reduced Iron Fines Injection
• Recycling and Reuse of BOF/BOP Steelmaking Slags
• Inclusion Optimization for Next Generation Steel Products
• Low-NOx Heating Alternative for Round Shapes, Steel Substrate (Strip), and Coil Box Transfer Bars
Advanced Process Development Projects
Focus Area 4. Power Delivery Modeling:
Barriers• The random
nature and large size of electric loads contributed by electric arc furnaces and rolling mills
• Enhancing the Operation of Highly Varying Industrial Loads− Assessing opportunities to address large, non-conforming
electric loads from steelmaking operations
Barrier-Pathway Approach and Project Selection
Pathways• Develop short-term
load forecasting and intelligent control of electric load dispatching that can be integrated with regional steel mill operators
0.4 MMTCeCarbon Reduction$102 millionCost Savings18 trillion BtuEnergy Savings
2020Metric
Metrics
Power Delivery Modeling R&D Pathways: Assumptions and TargetsEnergy• Highly varying loads disproportionately impact control area
regulation requirements with clear cost consequences• Highly varying loads increase load-following requirements but
the cost consequences are not clear
Markets• Commercial• Adopted by 10% of the 150 grid areas in the U.S. (those
heavily populated with steel mills)• Market saturation in 10 years
Program Management Resources• Headquarters Project Management:
Simon Friedrich
• Analytical SupportNancy Margolis, Energetics with industry experts
• Golden Field Office- Project Manager:
Debo Aichbhaumik(formerly of Weirton Steel)
- Contract Administrator- Financial Accounting
Program Review and Assessment• Rigorous evaluation process for program and projects:
- Annual portfolio review (most recently September 2003)- Quarterly milestone review (most recently January 2004)- Ongoing project management by the field office
• Annual analysis of expected benefits (in accordance with Government Performance and Results Act) serves multiple purposes:- Up-front program planning and project selection- Benefits projection and project justification
Key MilestonesMilestone Expected Completion
Cokeless Ironmaking• Begin production in Mesabi Nugget pilot plant 5/03• Complete Mesabi Nugget demonstration 8/04Next Generation Steelmaking• Complete lab-scale microwave steelmaking test 9/04• Complete lab-scale future steelmaking test 3/05Advanced Process Development• Initiate near-term yield improvement program 11/04• Complete thermo-mechanical processing project 6/05• Begin pilot-plant demo of direct flame impingement 2/05• Complete steel cleanliness project 9/04Power Delivery Modeling• Assess results of power delivery modeling program 10/04
FY03-04 Accomplishments
• Mesabi Nugget Direct Ironmaking- Pilot plant has successfully completed
two continuous operation trials- Iron nuggets successfully used by an
EAF steel maker
FY03-04 Accomplishments• Novel Direct Steelmaking
by Combining Microwave, Electric Arc, and Exothermal Heating Technologies- Experimental development and
feasibility analysis- 85% of work completed
FY03-04 Accomplishments
• Hot Strip Mill Model- Commercially available- Simulates hot strip mill operations
and predicts final mechanical properties
• Laser-based Ultrasonic TubeWall Thickness Gauge- Commercially available - Has tested close to 1,000,000 tubes
at a Timken mill