Post on 08-Jul-2020
R&D vision- EAF environmental impact:
an opportunity, not more a problem
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Key factors for a sustainable development
The key is to develop a solution that will reduce production
cost and generate environmental benefits without
increasing complexity and not affecting productivity
Typical cost
subdivision
for
EAF steel
ValEAF 6th Seminar - Bardolino, September 24th 2015
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What about the environment ?
EU legislation related to the environmental issues
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Cost of regulation
Emissions Trading System
Source: ASSESSMENT OF CUMULATIVE COST IMPACT FOR THE STEEL INDUSTRY, Centre for European Policy Studies , 2013
Cumulative regulatory costs in 2012 represent for EAF products approximately: • 3% of the total cost of
production of EAF wire rods;
• about 7% of price-raw material margin about;
• a quarter of EBITDA.
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Reduction of production cost mostly company decision
* ODEX is the ratio between the actual energy consumption of the sector in year and the
effective consumption without energy savings En
erg
y e
ffic
ien
cy in
de
x (
OD
EX
)*
Emissions (i.e. GHG) egislation constrain
http://dataservice.eea.europa.eu/
Cost or cost-strain ?
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Main CSM RFCS in EAF: energy & environment area
Scrap managment Process control/ optimisation
Environmental impact C & FeO based material subtitution
7215-PP/027 Scrap continuous charging to EAF
7210-PR/200 Effects of operational factors on the formation of toxic organic micropollutants in EAF
RFSR-CT-2006-00035 Laser-Induced Breakdown Spectroscopy for Advanced
Characterisation and Sorting of Steel Scrap
RFSR-CT-2006-00033 Control of nitrogen oxide emission at the EAF
(CONOX)
RFCR‐CT‐2008‐00009
Upgrading and utilisation of residual iron oxide materials for hot metal
production (URIOM)
RFSR-CT-2005-00003 Control and optimisation of scrap charging and melting operation to increase steel recycling ratio (CONOPTSCRAP)
RFSR-CT-2009-00004 Sustainable EAF steel production (GREENEAF)
RFCS-CT-2007-00008 Cost and energy effective management of EAF with flexible charge material mix (FLEXCHARGE)
RFSP-CT-2014-00003 Biochar for a sustainable EAF steel production (GREENEAF 2)
RFSR-CT-2014-00008 Recycling of industrial and municipal waste as slag foaming agent in EAF (RINFOAM)
RFSR-CT-2006-00004 Improved EAF process control using on-line offgas analysis (OFFGAS)
RFSR-CT-2012-00006 Control of slag quality for utilization in the
construction industry (SLACON)
RFSR-CT-2014-00007 Optimization of scrap charge management and related process adaptation for EAF performances improvement and cost reduction
(OptiScrapManage)
RFSR-CT-2013-00030 Environmental impact evaluation and effective management of resources
in the EAF steelmaking (EIRES)
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Some innovation key area
Environmental impact
residual valorisation (i.e. slag, dust) heat recovery from off-gas and slag with low
environmental impact (i.e. HE with fast cooling) reduction of emissions (i.e. dioxine, NOx) Source:DIOX
Productivity (cost)
Repeatability (product quality)
new generation of sensors and process control systems allowing synchronized regulation of global and local working conditions process integration (EAF + LF + CC)
Source: FLEXCHARGE Flexibility
use of C based materials (i.e. biochar, plastics) use of scrap substitutes (i.e. DRI, scale) use of low quality scrap (charge optimisation)
Source: URIOM
ValEAF 6th Seminar - Bardolino, September 24th 2015
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New development: EAF configuration/process
All of new processes have been able to demonstrate some benefits. However there is no perfect solution that will meet the needs of all
steelmaking operations. Rather, steelmakers must prioritize their objectives and then match these to the attributes of EAF designs
↑cost EE ↑high cost NG ↓cost of C or biomass ↑permeable scrap
↓ cost EE ↓cost NG ↑cost of C (including C tax) ↑↗variability of scrap
Source: WSA EAF Expert Group
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Environment:
some more challenges
How to recover the maximum level of exergy from hot gases (from 1500 to 2500C or less) with high content of dust without drawback in the micro-pollutant emissions ?
How to use in an effective way the recovered energy (inside the plant vs. cross-sectorial approach) ?
How to transfer energy from high temperature solids (blocks of slag from 1 to 10 cm) to produce high temperature gas with high global efficiency and obtain/mantaining the by-product physical/chemical charactherists for the treated solid ?
How to reduce the ROI of technologies already available for material and energy recovery & utilization ?
How to transform the residuals in certified products ?
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New development: by-products
Steelmaking wastes must be considered a secondary raw material source for two main reasons: 1) tightening
environmental legislation makes the landfill disposal of wastes more expensive
2) the high content of iron and metal oxides makes wastes valuable raw material for EAF charge
60-120 kg/tonLS
10-30 kg/tonLS
15-50 kg/tonLS
25-50 kg/tonLS
5-10 kg/tonLS
ValEAF 6th Seminar - Bardolino, September 24th 2015
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New development: by-products
ValEAF 6th Seminar - Bardolino, September 24th 2015
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EAF fume duct and measurement points
New development: dioxine minimisation
ValEAF 6th Seminar - Bardolino, September 24th 2015
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New development: waste heat recovery
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Constrains
Opportunity
energy in off gas about
140kWh/tLS
New development: WHR for EAF off-gas
ValEAF 6th Seminar - Bardolino, September 24th 2015
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VISION
Today perception Tomorrow perception (..hopefully!)
Productivity
Quality
Efficiency
Flexibility
Environmental impact
Process integration
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Process integration
VERTICAL
INTEGRATION
HORIZONTAL INTEGRATION
ValEAF 6th Seminar - Bardolino, September 24th 2015
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Key actions for next years
• R&D&I centres: new idea – Efforts to improve the incremental progress and generate new
technologies & breakthrough – Methodologies, tools and indicators for sustainability assessment of
energy and resource efficient solutions in the steel industry
• Governments: support to innovation – Introduce financial support mechanism for early deployment of new
technologies to drive private financing of projects – Incentivise cross-sectorial collaborative initiatives
• Industry: work to reduce cost impacts – Take the risk to prove and optimise new systems at pilot/demo scale – Look at possible synergy both inside the plant and with nearby plants
• Associations: common industrial vision – Promote cross-sectorial collaborative initiatives (different industries) – Give the technologists a target: industry’s roadmap to 20xx ?
ValEAF 6th Seminar - Bardolino, September 24th 2015
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