Setting the course for tomorrow - stahl-online.de · Stahl-Zentrum . STAHL 2015. 20 | Schmoele ·...

Stahl-Zentrum

STAHL 2015

1 | Schmoele · 12.11.2015 · STAHL 2015 · © Stahlinstitut VDEh | Wirtschaftsvereinigung Stahl

The blast furnace – Fit for the future? Energy efficiency in steelmaking

Peter Schmöle Head of Competence Centre Metallurgy, ThyssenKrupp Steel Europe

Setting the course for tomorrow

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Introduction

Metallurgical efficiency

Conclusion

The blast furnace – Fit for the future?

Alternative “benchmark” process modes

Cross-industrial network

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Introduction Dominant position of the blast furnace route in the world, 2014

Electric steel 25.6%

Oxygen steel 73.9%

Scrap 31.7%

Blast furnace hot metal

63.8%

OH steel 0.5%

1665 1843 DRI / HBI

4.1%

Corex / Finex hot metal

0.4%

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Introduction … with increasing shares in the last years

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Inner volume: Volume between 1 m below chute in vertical position and taphole level

Introduction … and the biggest blast furnaces in Asia

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Introduction


Conclusion




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Metallurgical efficiency Energy consumption – Real vs. ideal case

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Ideal case: Process • at thermodynamic equilibrium

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Ideal case: Process • at thermodynamic equilibrium • without cooling losses


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Metallurgical efficiency Consumption of reducing agents – BF’s in Germany

Why?

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Metallurgical efficiency Sinter composition, TKSE

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Metallurgical efficiency Carbon and ash contents in BF coke, TKSE

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Metallurgical efficiency BF slag volume, TKSE

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The BF is operated at 96 to 93 % efficiency level. (State of the art – operation related to a non-realistic process at the thermodynamic equilibrium and w/o heat losses)

Metallurgical efficiency Conclusion

Since end of 1990th the cumulated reducing agents consumption increases caused by higher slag volumes lower C contents in coke change from oil / natural gas to pulverized coal injection.

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Introduction


Conclusion




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Alternative “benchmark” process modes Different auxiliary reducing agents, HBI charging

PC = Pulverized Coal

HBI = Hot Briquetted Iron

NG = Natural Gas

H2 = Hydrogen

PC HBI NG H2

Coke kg / t HM 295 235 367 392PC kg / t HM 200 127NG kg / t HM 100H2 kg / t HM 40

HBI kg / t HM 400

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Alternative “benchmark” process modes Energy input without energy for HBI production

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Alternative “benchmark” process modes Energy input with energy for HBI production

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From the energetic point of view it is cockeyed to cut the upper part of the BF, to shift the indirect reduction to an external process and to loose the sensible heat of the HBI in-between.

To report only the energy consumption and/or the CO2 emissions of the BF and to “forget” energy need and CO2 emissions for HBI production creates something like an perpetual motion machine.

Alternative “benchmark” process modes Use of HBI in the blast furnace

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Alternative “benchmark” process modes Auxiliary reducing agents with increasing hydrogen input

200 kg PC / t HM

100 kg NG / t HM

40 kg H2 / t HM

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With higher hydrogen input the energy need and also the energy export increase.

Charging of cold HBI is contra-productive from the energetic point of view.

Alternative “benchmark” process modes Conclusion

Shifting the reduction reactions from carbon to hydrogen causes lower CO2 emissions, but exploding CO2 abatement costs.

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Introduction


Conclusion




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Source: ThyssenKrupp Process Technologies

State of the art

Power plant Top gases

Electrical Energy

CO2 Today

Steel production

Blast furnace

Converter

Coke plant

Significant reduction of CO2 emissions and high value by-products

Methanol Synthetic fuel Fertilizer Alcohol Polyalcohol Polymers

Chemical use of top gases

Top gases

Future

Steel production

Power plant

Synthesis

Blast furnace

Converter

Coke plant

Cross-industrial network ThyssenKrupp project Carbon2Chem – Chemical use of gases

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Power plant

Iron ore

Oxygen

Integrated iron and steel works

COG, BFG, BOFG

Steel

Cross-industrial network ThyssenKrupp project Carbon2Chem – State of the art Electric power

Injection coal

Coking coal

Electric power

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Chemical raw materials

Renewable energy

Synthesis

Cross-industrial network ThyssenKrupp project Carbon2Chem – Future Chemical products

COG, BFG, BOFG

Power plant

Steel

Iron ore

Injection coal

Coking coal

Oxygen

Integrated iron and steel works

Electric power

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Introduction


Conclusion




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Blast furnace as world champion in energy efficiency No chances for further energetic improvements from the metallurgical point of view

Conclusion State of the art, potentials and new ideas

Rethinking the bounds Cross-industrial network of steelmaking, chemicals industry and energy sectors to create an integrated economic and ecological optimum

“Hydrogen blast furnace” Increasing energy consumption, lower CO2 emissions, non-competitive costs

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Conclusion Statements of clerical and political experts for energy efficiency

Chancellor Merkel, 2015: “The G7 leaders had committed themselves to the need to decarbonise the global economy in the course of this century”

Pope Francesco, 2015: “Climate change is a global problem”

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Conclusion To realise this decarbonisation of the global economy we need steel

Renewable energies

Energy transformation

Automotive lightweight design

Energy supply and distribution

Infrastructure

Sustainable construction

STAHL 2015 Conclusion … and blast furnaces

Steelmaking without fossil energy based blast furnaces ……

Steelmaking without fossil energy based blast furnaces ……

the touchdown will be a disaster!

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The blast furnace – Fit for the future! Energy efficiency in steelmaking

Peter Schmöle Head of Competence Centre Metallurgy, ThyssenKrupp Steel Europe

Setting the course for tomorrow

Setting the course for tomorrow - stahl-online.de · Stahl-Zentrum . STAHL 2015. 20 | Schmoele ·...

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