R&D vision- EAF environmental impact: an opportunity, not more a...

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


3

3

What about the environment ?

EU legislation related to the environmental issues


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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.


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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 ?


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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)


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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


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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


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New development: by-products


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EAF fume duct and measurement points

New development: dioxine minimisation


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New development: waste heat recovery


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Constrains

Opportunity

energy in off gas about

140kWh/tLS

New development: WHR for EAF off-gas


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VISION

Today perception Tomorrow perception (..hopefully!)

Productivity

Quality

Efficiency

Flexibility

Environmental impact

Process integration


16 16

Process integration

VERTICAL

INTEGRATION

HORIZONTAL INTEGRATION


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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 ?


18 ValEAF 6th Seminar - Bardolino, September 24th 2015

R&D vision- EAF environmental impact: an opportunity, not more a...

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