Furnace Gas

Furnace Gas

Coke GasBlast Furnace GasConverter Gas

Power from Steel Production Gas

High levels of power requirementand rising energy costs represent amajor challenge for the steel industry.Gases created as a ‘free’ by-productduring steel production processesserve as an attractive energy sourceoption for efficient power generation.In addition to the economic benefit,using these gases as engine fuelreduced industrial CO2 emissionsand saves natural energy sources.

Benefits of Power from SteelProduction Gas

— Higher revenues from theutilisation of steel production gasas a fuel

— Reduced carbon emissions— Stable robust onsite powersupply

— Heat from engines can be usedin other processes

Different Gases from SteelProduction Processes

Steel production processes typicallydispose large volumes of specialitygases. Three different processstages – from coal to steel – providethree different gas types: coke gas,blast furnace gas and converter gas.

Coke Gas

A by-product of industrial cokeproduction from pit coal, coke gas iscreated by high-temperature drydistillation of coking coals in theabsence of oxygen. The gas mainlyconsists of hydrogen (50-60%),methane (15-50%) and a smallpercentage of carbon monoxide,carbon and nitrogen. With a calorificvalue of 5kWh/Nm3, coke gasconstitutes a high-value fuel foreffective power generation with GEJenbacher gas engines

Blast Furnace Gas

Blast furnace gas is a by-product ofblast furnaces where iron ore isreduced with coke into metallic (pig)iron. The gas has a very low heatingvalue of around 0.9kWh/Nm3, whichon its own is typically not highenough for combustion in a gasengine. There is the possibility toblend this gas with other off gases;you should contact your local Clarke Energy office to discuss thisin more depth.

Furnace GasClarke Energy is the authorised distributor and servicepartner for GE Energy’s gas engine division in a growingnumber of countries across the world. In addition toproviding high-efficiency, reliable gas engines we combinethiswith the expertise and resources to deliver unbeatableproduct support.

Whether your requirement is for the supply of a single gasengine generator or a complete turnkey power generationfacility, we can meet that need. Our ability to add value byoffering an end-to-end service, from initial proposal toreliable long-term maintenance, has led to us becoming amulti-national company with operations in ten countriesacross the globe. Our company prides itself on integrity,delivering only the highest quality products whilst providinga reliable accountable localised service.

Benefits of working with Clarke EnergyClarke Energy provides flexible solutions for your gasgeneration projects. Our services range from the supply ofa gas engine generator, through to the complete turnkeyinstallationofagaspoweredgeneration facility.ClarkeEnergyhas a dedicated, top-quality team of sales, engineering,projectmanagement, commissioningandmaintenancestaffto meet your needs. We also offer long-term maintenancecontracts backed up by a strong balance sheet, givingpeace of mind with respect to the long-term performanceof your GE gas generation equipment.

Coal

ConverterBlast furnaceIron ore

Coke oven battery

Coke gasComposition: 50 – 70% H2

25 – 30% CH4

LHV: ~5 kWh/Nm3

Blast furnace gasComposition: 5% H2

20% CH4

LHV: ~0.9 kWh/Nm3

Converter gasComposition: 60% CO

LHV: ~3 kWh/Nm3

Coke Pig Iron Steel

Steel Production Gas Schematic

Steel production Coke Gas Blast Converter gas type Furnace Gas Gas

Source Coke oven Blast furnace Converterbattery

Input Coal Coke & Pig IronIron Ore

Output Coke Pig Iron Steel

Hydrogen % 50 - 70% 5% —

Methane % 25 - 30% — —

Carbon — 20% 60%+monoxide %

Lower heating ~5.0 ~0.9 ~3value kWh/Nm3

Converter Gas

Converter gas is created from pigiron during the steel productionprocess. Steel-making technologycan be categorised into two differentprocesses: blow moulding or openhearth.

Within the blow moulding process,the pig iron is refined with oxygen orair, lowering the carbon proportionand providing enough process heatto maintain the steel liquid. With60% of the worldwide raw steelproduction, the Linz-Donawitz (LD)process, classified as a blowmoulding process, is the mostcommon production method togenerate raw steel.

On the other hand, the open hearthprocess extracts the oxygen of theadded scrap and ore, requiringadditional heat supply for the steel-making process. One of the mostcommon open hearth processes isthe electrical melting process.

Converter gas from the LD andelectrical melting processes can beused in GE Jenbacher gas engines.The gas consists of about 65%carbon monoxide, 15% carbondioxide, 15% nitrogen and smallamounts of hydrogen and methane.

Concept

Varying compositions, as well ascalorific values and the combustionbehaviour of the gases from steelproduction processes, put greaterdemands on engine design. ClarkeEnergy offers specially modified GEJenbacher gas engines that makeefficient use of these gases forcombined generation of heat andelectricity.

In general, the stable composition ofcoke gas makes it advantageous asan engine fuel. The high hydrogencontent of coke gas however,means the combustion process isvery fast, which increases thedanger of engine knocking orbackfiring. To avoid this risk, GE hascreated an engine control systemthat is able to fuel the GE Jenbacherengine with a very lean mixture and,at the same time, react very quicklyto variations in the engine load.

Converter gas, with its high carbonmonoxide content, has lowcombustion speedand is very harmful.GE has developed the specificJenbacher gas engine combustionsystem that allows burning the gasefficiently and reliably. Additionally,we offer a safety technology packagethat allows firm handling of harmfulgases such as carbon monoxide.

Both gases can be used to createhot water, steam and electricity. Thehot water and exhaust gases fromthe engines are fed into boilers. Theresulting steam can be used withinthe steel production processes.Electricity generated by the GEJenbacher engines can either beused on-site or sold to the publicgrid. Converter gas electricalefficiencies of up to 37% can beachieved, and coke gas efficienciesare even higher.

Advantages

— Independent power supply— Reduced energy costs, andgreater predictability and stability

— Efficient and economic combinedheat and electricity supply

— High electrical efficiencycompared to other powergeneration technology (i.e. steamor gas turbines)

— Best suited for an electricaloutput range of a few hundredkW up to 20-30MW

— Considerably low gas pressurerequired

— Alternative disposal of a problemgas while simultaneouslyharnessing it as an energy source

— Substitute to conventional fuels— Environmental benefits bygreenhouse gas reduction

Key Figures

Per tonne of coke that is produced,approximately 470Nm3 of coke gasare produced. 60% of this volume istypically needed for internalprocesses; the remaining part canbe used for power generation withGE Jenbacher gas engines resultingin approximately 400kWh

Per tonne of steel produced throughthe LD process approximately50Nm3 of converter gas are releasedwhich can burn in GE Jenbacher gasengines leading to approximately50kWh electrical power.

Our Competence

Clarke Energy has comprehensiveexperience with gas enginetechnology and has a large reservoirof knowledge with respect tohandling tricky gases such as steelproduction gas.

Substantial research has beencompleted on the steel gasapplication. Jenbacher installed itsfirst commercial gas engineapplications for coke gas in 1995and for LD converter gas in 2004.

About 30 GE Jenbacher gas enginesnow run on either coke gas or LDconverter gas. Underscoring GE’stechnical expertise, these unitsrecently reached a combined total ofmore than1million operating hours.In addition, by utilising these ‘free’waste gases compared to usingnatural gas for power generation,the GE Jenbacher technology-equipped sites have achieved CO2savings of about 2 million tonnessince commissioning.

Profusa coke gas project, Spain,12 x JMS316

Posco steel gas project, Mexico,1x JMS620

If you would like to find outmore about how ClarkeEnergy can help youdevelop your steelproduction gas project,please contact your localoffice for more details.

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Furnace Gas

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