Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore...

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Energy Saving Technology for Iron & Steel Making Process

Transcript of Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore...

Page 1: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Energy Saving Technology for

Iron & Steel Making Process

Page 2: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

SPCOSPCO  ChronologyChronology

April 2001 Established with integration of the iron&steel plant Sales Divisions of NKK, SHI and Hitz

April 2002 Consolidated the three(3)companies Engineering Divisions of the        iron&steel plant and equipment

April 2003 Consolidated the Sales Department of KHI’s iron&steel plant business

April 2004 Consolidated the Engineering Division of KHI’s iron&steel plant business

Page 3: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Corporate ProfileCorporate Profile

● Established: April 01, 2001

● Capital: Japanese ¥ 1,995 million

approx. US$ 19 million

● Employee: 280 (as of April, 2006)

● Headquarters: Yokohama, Japan

Page 4: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Main productsMain productsIron making and smelting furnaces, Sintering machine, Continuous caster, Rolling mills, Strip processing line, and Others.

Almost all the steel making facilities can be supplied by Steel Plantech.

Page 5: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Energy Saving Technology Energy Saving Technology forfor

Iron & Steel making ProcessIron & Steel making Process

Page 6: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Iron & Steel Making Process FlowIron & Steel Making Process Flow

Iron ore Coal

Sintering plant Coke oven

Pig iron

Blast furnaceCrude steel

Basic oxygen furnace

Secondary refining

Continuous caster

Slab

Semi-finished products

Bloom

Beam blank

Raw material yard

Lime stone

Page 7: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Applicable Applicable SPCOSPCO’’s s Technology for CDMTechnology for CDM

Process Technology

- CDQ (Coke Dry Quenching Process)Coke oven

- Coke oven gas recovery

Sintering machine - (WHRS) Waste Heat Recovery System

- TRT (Top pressure Recovery Turbine system)Blast furnace

- Pig iron de-[P] & de-[S]

Rotary kiln - Sponge iron kiln heat recovery system

Basic oxygen furnace - OG (Oxygen converter Gas recovery system)

Electric arc furnace - Electric arc furnace energy saving

Lime calcining kiln - High efficiency lime calcining kiln

Rolling mill - Regenerative burner system

Page 8: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Technology for CDMTechnology for CDM

CokeCoke [ CDQ ][ CDQ ]: Coke Dry Quenching System: Coke Dry Quenching System

BFBF [ TRT ][ TRT ]: Top pressure Recovery Turbine System: Top pressure Recovery Turbine System

BOFBOF [ OG ][ OG ]: Oxygen converter Gas Recovery System: Oxygen converter Gas Recovery System

RollingRolling Regenerative Burner SystemRegenerative Burner System

Page 9: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

CCokeoke DDryry QQuenchinguenching ProcessProcess[ [ CDQCDQ ]]

Page 10: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Concept of CDQ ProcessConcept of CDQ Process

00

Hot coke

PrePre--chamberchamber

Cooling chamberCooling chamber

Dust

Dust catcher Boiler

Gas circulation blower

Quenched coke

Steam generated

00

Hot coke

PrePre--chamberchamber

Cooling chamberCooling chamber

Dust

Dust catcher Boiler

Gas circulation blower

Quenched coke

Steam generated

Page 11: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Material & Gas Balance Sheet For Reference

CDQ

Coke bucket hoisting crane

Conveyor

Dust catcherBoiler

Air fanMultiCyclone

Gas cooler

Gas bleeder line

CDQChamber

Hot coke950~1050 ゜C

Quenched coke≦180゜C

Circulating gas1300~ 1400 Nm3/t・coke140~160゜C

900~980゜C

160~170゜C

Flue

Circulating gas blower

Steam generated550~600 kg/t

Coke bucket

Coke car & Coke bucket

APSDischarging device

Charging device

Dust cooler

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CDM Credit by CDQ ProcessCDM Credit by CDQ Process

0

500

1,000

1,500

2,000

2,500

3,000

75 100 125 150 175 200

0

50

100

150

200

250

300

CER

( k$/

y )

C DQ

Prod

ucti

on (

k t- c

oke/

y )

C O2

Emi s

s ion

Red

ucti

o n (

k t-C

O 2/y )

P ow

er G

e ner

a ti o

n ( G

Wh /

y )

CDQ Capacity ( t/h )

Annual Availability: 95%

Grid Emission Factor: 0.558 t-CO2/MWh

Value of CO2 Credit: 10 $/t-CO2

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TTopop--pressure pressure RRecovery ecovery TTurbine Systemurbine System

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Blast FurnaceBlast Furnace

Raw material charging system

Blast furnace

Hot stove

Granulated slagsystem

Gas cleaning system

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Comparison Table Comparison Table betweenbetween DryDry--type & Wettype & Wet--typetype

Wet Type Dry Type

BF Inner Volume:1,500 m 3

BFG Volume:194 kNm 3/h

Top Pressure:2.0 kg/cm 2G

Inlet 1.70 kg/cm 2G 1.90 kg/cm 2GTurbinePressure Outlet 0.10 kg/cm 2G 0.10 kg/cm 2G

Turbine InletTemperature

60 ゜C 140 ゜C

Power generated 4,700 kW 6,300 kW

PC

G Wet-type Dust Collector

PC

G Dry-type Dust Collector

BFDC

SV

Turbine Generator

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CDM Credit by TRT ProcessCDM Credit by TRT Process

0

200

400

600

800

1,000

1,500 2,000 2,500 3,000 3,500

20

40

60

80

100

120

CER

( k$ /

y )

C O2

Emi s

s ion

Red

ucti

o n (

k t-C

O 2/y )

P ow

er G

e ner

a ti o

n ( G

Wh /

y )

BF Inner Volume ( m3 )

Annual Availability: 95%Grid Emission Factor: 0.558 t-CO2/MWhValue of CO2 Credit: 10 $/t-CO2BF Productivity: 2.0 t/m3/d BF Gas: 1550 Nm3/t

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Oxygen Converter Gas Recovery SystemOxygen Converter Gas Recovery System[ OG System ][ OG System ]

Page 18: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Iron & Steel Making Process FlowIron & Steel Making Process Flow

Iron ore Coal

Sintering plant Coke oven

Pig iron

Blast furnaceCrude steel

Basic oxygen furnace

Secondary refining

Continuous caster

Slab

Semi-finished products

Bloom

Beam blank

Raw material yard

Lime stone

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Basic Oxygen FurnaceBasic Oxygen Furnace

O2 Lance

Page 20: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Concept of OG System Concept of OG System

Converter

Skirt

Hood

Gas cooler

Dust Collector

Mist separator Flow meter

Induced draft fan

Stack

Three way valve

To gas holder

Water sealed check valve

By-pass duct

Page 21: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Operation Pattern of OG SystemOperation Pattern of OG System

TimeTime

Blowing Period

Tap to Tap

Gas Component

Gas FlowGas Flow

CO-rich Air CO-richCO-richAir CO2+N2 CO2+N2 CO2+N2

No-blowing Period

Operation Pattern

Gas Relief Recovery RecoveryGas Relief

Page 22: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

CDM Credit by OG ProcessCDM Credit by OG Process

0

500

1,000

1,500

2,000

2,500

500 1,000 1,500 2,000 2,500

0

50

100

150

200

250

CER

( k$ /

y )

C O2

E mi s

s io n

Re d

u cti

o n (

k t- C

O 2/y )

P ow

e r G

ene r

a tio

n ( G

Wh/

y )

Crude Steel Production ( kt / year )

Grid Emission Factor: 0.558 t-CO2/MWhValue of CO2 Credit: 10 $/t-CO2Gas Recovered: 100 Nm3/t-steelOG Gas Calorie: 2000 kcal/Nm3

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Regenerative Burner Regenerative Burner for for

Reheating FurnaceReheating Furnace

Page 24: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Combustion System with Conventional BurnersCombustion System with Conventional Burners

from Combustion Air blower

Exhaust Gas  300゜C

FuelBurner

Heated MaterialHot Furnace Gas 1,350゜C

Exhaust Gas1,000 ゜C

Dilution Air

750 ゜C

Recuperator

to Exhaust Gas Blower

Preheated Air 500 ゜C

1,050゜C25゜C

Page 25: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Concept of Regenerative BurnerConcept of Regenerative BurnerBurner-A(burning)

Burner-B(regenerating)

FurnaceMain Burner

Pilot Burner Regenerator

Exhaust Gas150 ゜C

Preheated Air1,150 ゜C

Switching Valve

to Exhaust Gas Blowerfrom Combustion air Blower

Heated Material

(every 30 seconds)

Page 26: Energy Saving Technology for Iron & Steel Making …...Iron & Steel Making Process Flow Iron ore Coal Sintering plant Coke oven Pig iron Blast furnace Crude steel Basic oxygen furnace

Comparison betweenComparison betweenRegenerative & Conventional Burners Regenerative & Conventional Burners

Burner Type

Regenerative Conventional

Rolling temperature 1050 - 1200 1050 - 1200

Combusted gas temperature ≧ 1350 ≧ 1350

Type of Recuperator / RegeneratorHoneycomb- or Ball-shaped Ceramic type

Metalic tube type

Dilution Air NA Necessary

Gas temperature of recuperator inlet 1250 ≦ 850

Preheated combustion air temperature 1150 500 – 600

Gas temperature of recuperator outlet 150 250 - 350

10 - 15 % fuel saving compared to modern conventional burner system