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Introduction
The steel industry is important politically and economically. Most industrial and developing nations want
to have a strong steel industry. Production is at historic highs and growing.
Steel is widely regarded as a high
performance , contemporary
engineering material continuously
being improved to meet new
market demands.
Improved production
technologies and increased
recycling rates are driving
improvement in per ton energy
consumption and air pollution
emissions.
Steel is the material of choice in
a growing number of applications ,
and markets for steel are
expanding.
Thailand use scrap recycling technology to produce steel, not from iron ore
Thailand current steel production technology
Source: http://www.steel.org/learning/flowline/index.htm
Steel users in Thailand pay cost of steel 10-25% higher than China company due to
1,000
965
920
875
900
23%
845
770
800
786
704
700
674
654
18%
708
645
630
675
600
736
664
656
625
719
663
626
569
571
575
553
500
..-07
..-07
..-07
HRC dom estic china
HRC Thailand Im port*
..-07
..-08
..-08
..-08
..-08
HRC China export
HRC East Asia Im port cfr
* HRC Thailand import = HRC China export + Freight rate for 3 year handymax charter hire at 29 USD/MT
transportation cost
Freight cost estimation
2,725 NM
(29.0 USD/tonne) FG
ore
ore
4,454 NM
(31.3 USD/tonne)
4,295 NM
(30.4 USD/tonne)
HRC production from BF-BOF route generates value added to Thai economy 240
USD/MT, equivalent to 38,432 million THB per year
Mar 08 price
Unit: USD/MT
188.6
Energy
312.2
Raw material
Salary
240.2
5
235.2
+
China
domestic
price
Raw
material
import
Value
added
Profit
gained
from
produce
quality
grade
Total
value
added
12 million tonnes of BF-BOF production will benefit to overall trade balance more than
300,000 million THB.
Steel demand - supply in 2013 in 3 scenarios
Import value
(Million THB)
Consumption
(Thousand tonnes)
22,000
700,000
(RHS)
20,000
590,688
600,000
18,000
494,786
16,000
400,000
364,522
12,000
12,547
306,863
316,809
15,575
272,040
274,912
300,000
12,000
8,000
6,000
500,000
(RHS)
14,000
10,000
3,574
12,661
13,876
12,590
200,000
12,139
4,000
3,026
100,000
2,000
2,500
2,500
2,500
-
2004
2005
2006
2007E
2013E
2013E
2013E
Base
case
Worst
case
Best
case
Steelmaking Basics
Steel is composed of iron and small amounts of other
components :
less than 2 % carbon
small amounts of alloying materials such as Mn , Mo , Cr , or
Ni
Steel products have a range of properties that are largely
determined by :
chemical composition (carbon and other alloys)
controlled heating and cooling of the steel
mechanical working of the steel in the finishing process
The major steelmaking processes include :
Cokemaking
Ironmaking
Basic Oxygen Furnace (BOF) Steelmaking
Electric Arc Furnace (EAF) Steelmaking
Finishing
Cokemaking
Coke is used for molten iron production in blast furnaces.
Coke is nearly pure carbon and is produced from coal.
Coke is essential to traditional integrated steel mills.
In the cokemaking process coal is heated
oxygen deficient atmosphere.
Cokemaking drives off hydrocabon gases in
the coal and concentrates the remaining
carbon in the coke.
Incandescent coke
in the oven
Ironmaking
Ironmaking is the process of converting iron ore (solid,
oxidized iron) into molteniron.
The primary raw materials for ironmaking are:
Iron ore,which contains 50 % to 70 % iron often requires
agglomeration processing before it can be used.
A reducing agent, usually coke, is burned to generate heat and to
draw the oxygen from the iron.
A slagging agents, usually lime, helps to remove sulfur and other
Sinter Plant
impurities.
Iron ore Agglomerating Processes can improve the iron content and/or physical properties of ore
Some examples include:
Sintering: iron ore fines, other iron-bearing wastes and coke dust are blended and combusted.
The heat fuses the fines into coarse lumps that can be charged in a blast furnace.
Pelletizing: iron ore is crushed and impurities removed. The remaining iron-rich
ore is heated with a binding agent to create durable, marble sized pellets.
Briquetting: crushed ore or fines are heated and compressed to produce briquettes.
Ironmaking
Blast Furnace
Traditional integrated steel plants use a large blast furnace to produce molten iron from iron
ore, coke and lime.
The blast furnace is a huge, steel stack lined with refractory brick,
where iron ore, coke and limestone are dumped into the top, and
preheated air is blown in through the bottom.
Blast furnaces account for more than 90 % of global iron
production.
Major issues for blast furnaces include:
Coke: Blast furnaces require coke, which has significant cost
and environmental issues.
Scale and cost: Blast furnaces are large and operate on a nearly
continuous basis.
Iron that emerges from the blast furnace contains greater than 4
% carbon and other impurities.
The iron is too brittle for most engineering applications and is
refined into steel.
Blast furnace
Blast Furnace
At 500 C
3Fe2O3 +CO -> 2Fe3O4 + CO2
Fe2O3 +CO -> 2FeO + CO2
At 850 C
Fe3O4 +CO -> 3FeO + CO2
At 1000 C
FeO +CO -> Fe + CO2
At 1300 C
CO2 + C -> 2CO
At 1900 C
C+ O2 -> CO2
FeO +C -> Fe + CO
Source: wwwchem.uwimona.edu.jm:1104/ courses/blast.html
Source: http://www.jfe-21st-cf.or.jp/
Ironmaking
Direct Reduced Iron (DRI)
Direct reduction produces molten iron using natural gas as a reducing agent
instead of coke.
Advantages of DRI:
Environmental: Can have lower
emission (including CO ) than
integrated plants that use coke ovens
and blast furnaces.
Higher iron content: Produces
about 97% iron compared to 93%
for blast furnace iron. This allows
electric arc furnace (EAF)
steelmakers to use lower quality
scrap as a feedstock.
Fuel choice: Uses natural gas,
which is more available than coking
coal in some regions.
2
Disadvantages of DRI
Fuel cost: Can have higher fuel costs (natural gas
versus coke).
Higher oxygen content: Produces iron with more
oxygen than blast furnace iron.
This increases steelmaking energy costs and limits
how much DRI can be charged in an EAF.
Source: http://www.eng.man.ac.uk/mech/merg/Research/datafusion.org.uk/applications/BOS-Corus.html
BOF Operation
Source: http://www.jfe-21st-cf.or.jp/
358.1
1.4
45.1
17.1
28.8
21.1
52.2
165.6
The major advantage of EAF steelmaking is that it does not require molten iron for its operation. By
eliminating The need for coke oven batteries and blast furnaces, EAF technology facilitated the
proliferation of scrap-based steelmaking and minimills.
EAF Steelmaking
Electric Arc Furnace
Although electricity provides most of the
energy for EAF steelmaking, supplemental
heating from oxy-fuel and oxygen injection is
used.
The recycling of scrap saves the consumption
of virgin raw materials and energy.
Finishing
Finishing is the process of transforming molten steel into finished product.
The basic finishing processes include:
Casting
Forming and rolling
Chemical treatment
Finishing processes can important product
characteristics that include:
Final shape
Surface finish
Strength, hardness, and flexibility
Current finishing technology research focuses
on:
Improving product quality
research production costs
Reducing pollution
Finishing - Casting
Casting is the production of solid steel forms from molten steel.
Casting begins when refined steel is poured into a tundish.
Which is small basin at the top of the caster.
An operator controls the flow of molten steel from the
tundish. The falling steel passes through a mould and begins
to take on its final shape.
The strand of steel passes through the primary cooling zone
where it forms a solidifier outer shell sufficiently strong
enough to maintain the strand shape.
The strand continuous to be shaped and cooled as it curves
into horizontal orientation.
After additional cooling, the strand is cut into long sections Continuous Casting
Molten steel is simultaneously cooled and
with a cutting torch or mechanical shears.
formed into long standards of steel.
The resulting steel forms often proceed to rolling or
forming while retaining significant heat, which reduces
downstream reheat costs.
Historically, casting was performed by pouring steel into moulds in a batch process that produced large
steel ingots. After cooling, the ingots were reheated prior to additional processing.
Continuous casting has replaced ingot casting at most steel making facilities because it produces large
quantities of semi-finished steel that is closer to its final shape. Continuous casting achieves dramatic
improvements in throughput while reducing reheating and hot rolling cost
Recycling Technology
Steel production uses large quantities of raw materials, energy and water. Steelmaking
processes, especially at integrated facilities, can generate large amounts of dust and gas.
Millions of tones of steel products reach the end of their useful lives each year.
The steel industry is a recognized leader in developing recycling efforts that minimize the
environmental footprint of steel production while reducing costs.
Steel recycling
Steel is the worlds most recycled
material.
In many countries, more than half of
all old cars, cans and appliances
EAF Steelmaking is based primarily
on the use of scrap steel.
Energy
Scrap-based steelmaking
dramatically reduces energy intensity
per tonne of steel.
On-site production of stream and
electricity is achieved using combined
Heat and Power (CHP) technology.
Common Systems
Steel production equires the heating, shaping and movement of large Quantities of materials.
In addition to the steelmaking processes discussed previously, the steel industry uses many
large and essential common systems.
Boilers
Almost all stream for steelmaking is
produced in boilers.
Stream is used for heating in the
finishing process,
space heating andfor machine drive.
Boiler fuel include by-product gases
(e.g., coke oven gas and blast furnace
gas) as well as conventional fossil fuels.
Motors
Steelmakers use some of the largest
motors in industry.
Electric motors are used in blast furnace
fans, rolling mills and numerous other
operation.
Maintaining motors and minimizing
power consumption is a priority for the
industry
Pump
The large quantities of cooling water
and liquids used in steelmaking require
large pumps.
Pumping systems require large drives
and sophisticated maintenance systems.
Compressed Air
Many control systems and small drives
use compressed air.
Compressed air systems demand
rigorous maintenance to assure effciency
and reliability.
Comparison of SO2 Emission between steel industry and the power plants.
Source
SO2 Emission *
Steel Industry
2.56 kg SO2 /tons
(0.6% S Coking coal)
Liquid Steel
Capacity
Total SO2Emission *
5,000,000 tons
Power Plant
(2.88%S Lignite)
0.0586 kg SO2 /
kWh
3,940,000,000 kWh
/year **
Power Plant
(0.45%S bituminous)
0.00914 kg SO2 /
kWh
3,940,000,000 kWh
/year **
Comparison of CO2 Emission between steel industry and the power plants.
Source
CO2 Emission *
Capacity
Total CO2Emission *
Steel Industry
5,000,000 tons
Power Plant
3,940,000,000 kWh
/year **
Comparison of emission per value added between ironmaking and electricity generation
Steel production
(5 m tpy)
Electricity generation
(600 MW)
38,432
4,909
CO2 (ton)
9,165,000
10,244,000
SO2 (ton)
12,800
230,884
238
2,087
0.333
47.03
Emission
SOX (ppm)
NOX (ppm)
Dust (mg/m3)
320
350
120
450
350
120
640
350
120
3,800
500
250
320
500
250
350
350
250
3.
800
250
250
4.
800
180
240
200
180
50
(27 57 in EU)
1. " IPP #
SPP
2.
Unit
Air Total
suspended
particulate
mg/m
Sulfur
dioxide
ppm
Oxides of
nitrogen
ppm
Dioxins
ng/Nm
Typical value
Thailand Standard
MNRE*
Ministry of Industry
Non
Combustion
Source
Combustion
50 mg/m3 (JFE
Heat source
Steel - Chiba)
Oil or fuel oil
240
80 mg/m3 (JFE
Coal
320
Steel- Keihih,
Biomass
320
120 Fukuyama)
Other fuel
320
Smelt, melt, roll and
300
240
aluminium production
General production
400
320
200 (NSC)
Heat source
Oil or fuel oil
950
Coal
700
800
Biomass
60
Other fuel
60
General production
400
Heat source
160 (NSC) 260
Oil or fuel oil
200
(JFE Steel)
180
Coal
400
Biomass
200
Other fuel
200
0.1/1
General production
30
(New/Existing)
JFE Steel
Reduction Technique
Air Total
suspended 1. Electrostatic precipitator (<40 mg/Nm3) 95-99%
particulate 2. Bag filter (2-25 mg/Nm3)
3. Dry-type off-gas cleaning (5-10 mg/Nm3) up to 99%
4. Fine wet scrubber (40-80 mg/Nm3)
5. Cyclone (Efficiency 60-80%)
6. Regenerative activated carbon (RAC) 2-20 mg/Nm3
3
7. MEROS by Siemens (<10 mg/Nm )
Sulfur
dioxide
Oxides of
nitrogen
Dioxins
1. Wet desulferisation(<200mg/Nm )
2. Bag filter (225-500 mg/Nm3)
3. Dry-type off-gas cleaning (<50-500 mg/Nm3)
4. Suppression of PCDD/Fs
5. Regenerative activated carbon (RAC) 20-30 mg/Nm3, 95-98%
6. MEROS by Siemens (<50 ppm)
1. Regenerative activated carbon (RAC) 120-200 mg/Nm3, 40-65%
3
2. Selective catalytic reduction (SCR) (37 mg/Nm )
3. MEROS by Siemens (<50 ppm)
1. Bag filter (<0.1-0.4 ng/Nm3)
2. Suppression of PCDD/Fs (reduce 40-60%)
3. Regenerative activated carbon (RAC), (0.000001-0.1 ng-TEQ/Nm3-dry)
4. MEROS by Siemens (<0.1 ng/Nm3)
Unit
3
mg/m
Air Total
suspended
particulate
Sulfur
dioxide
Oxides of
nitrogen
Carbon
monoxide
ppm
ppm
ppm
Thailand Standard
Ministry of Industry
Non
Source
Combustion Combustion
Heat source
Oil or fuel oil
240
Coal
320
Biomass
320
Other fuel
320
Smelt, melt, roll and
300
240
aluminium production
General production
400
320
Heat source
Oil or fuel oil
950
Coal
700
Biomass
60
Other fuel
60
General production
400
Heat source
Oil or fuel oil
200
Coal
400
Biomass
200
Other fuel
200
General production
870
690
Typical value
MNRE*
120
30 (NSC)
800
Reduction Technique
Air Total
suspended 1. Enclose & Filtration (0.5 - 4.5 mg/m3)
particulate 2. Coke Stabilizer Quenching (6 - 12 g/t coke)
3. Cyclone (coal crushing) (0.055 kg/t(SOACT))
4. Rotoclone (coal crushing) (0.027 kg/t(SOACT))
5. Enclosure (1st coal pulverizer) (0.00009 kg/t(SOACT))
6. Enclosure (2nd coal pulverizer) (0.000044 kg/t(SOACT))
7. Scrubber (Pre-heater) (0.13 kg/t(SOACT)) [93%]
8. Wet ESP (Pre-heater) (0.006 kg/t(SOACT)) [99%]
9. Coke Wet quenching (<20 g/t coke)
10. Bag filer (0.045 - 0.19 kg/t coke)
11. Coke Dry quenching (<20 mg/Nm3)
Sulfur
1. Gas desulfurizer
dioxide
2. Coke Dry Quenching (200 mg/Nm3)
Oxides of
1. Reduce the flame temperature (450 - 700 g/t coke)
nitrogen
2. Low Nox firing systems
3. DeNOx by SCR
Carbon
monoxide
NH3
CO2
CH4
Unit
Air Total
suspended
particulate
mg/m
Sulfur
dioxide
ppm
Oxides of
nitrogen
ppm
Carbon
monoxide
ppm
Thailand Standard
Typical value
Ministry of Industry
MNRE*
Non
Source
Combustion
Combustion
50 (JFE Steel-Chiba,
Heat source
Fukuyama) 100-200 (JFE
Oil or fuel oil
240
Steel, Keihin, Kurashiki)
Coal
320
Biomass
320
120
Other fuel
320
Smelt, melt, roll and
300
240
aluminium production
General production
400
320
Heat source
30 (NSC)
Oil or fuel oil
950
Coal
700
800
Biomass
60
Other fuel
60
General production
400
Heat source
10 (NSC)
Oil or fuel oil
200
100 - 250 (JFE)
180
Coal
400
Biomass
200
Other fuel
200
General production
870
690
21.52 - 5823g/t HM
(European commission)
Pollution type
Air Total
suspended
particulate
Carbon
monoxide
Reduction Technique
Unit
Thailand Standard
Ministry of Industry
Non
Source
Combustion Combustion
3
mg/m Heat source
Air Total
suspended
Oil or fuel oil
240
particulate
Coal
320
Biomass
320
Other fuel
320
Smelt, melt, roll and
300
240
aluminium production
General production
400
320
ppm Heat source
Sulfur
Oil or fuel oil
950
dioxide
Coal
700
Biomass
60
Other fuel
60
General production
400
ppm Heat source
Oxides of
Oil or fuel oil
200
nitrogen
Coal
400
Biomass
200
Other fuel
200
Typical value
MNRE*
10 - 143 g/t LS
(EU commission)
120
8.2 - 55 g/t LS
(EU commission)
180
Pollution type
Reduction Technique
Air Total
1. Bag filter
suspended 2. Venturi scrubber
particulate 3. Electrical dust catcher
4. Dry de-dusting and suppressed combustion (<50 mg/Nm3)
5. Dry de-dusting and open combustion (20-50 mg/Nm3)
6. Scrubbing and suppressed combustion (15-50 mg/Nm3)
7. Scrubbing and open combustion (10-50 mg/Nm3)
Oxides of
nitrogen
$;N$"Q
Y
=" [Q
! <"N&#
iron oxide, alkali chlorides, heave metal oxide
\\
"!"<=>
[ ]>N #^_>`_&
50 150
mg/m3 QK #^_ <!"< Specific Dust Resistivity
(SDR) @!/? Sinter Basicity
'_>`N_ #
$'#+^
@_N$>"'?
;
}#'$"QK>+# NOx
* Activated coke { catalyst
Benefit :
Gas
(Nm3/t -coke)
Wet quenching
200 ~ 400
CDQ
Less than 3
!
Blast Furnace Gas (BFG) Dedusting
= BFG #^_>!"< 10-30 g/m3
"#$&;"= BFG 2 K '? First dedusting @! Second dedusting
Fist dedusting !>`N Dust catcher ><= !"<
=!"
? 300 mg/m3
Second dedusting 3 $'# '? Venturi Scrubber (VS), Ring Slit Washer (RSW) @! Bag Filter
!"<=$""N VS !? ! 15-20 mg/m3 +_& RSW @! Bag Filter !"="N? 2-5 mg/m3
!
Top gas pressure Recovery Turbine (TRT)
'&"[
Blast Furnace (BF) Gas +;>`N!#`]>Y
"N
! 40-60 kWh/ton-pig iron +Y"N TRT [Q
>`N>`
~`#]K
@_ 1974 @!
< TRT >`N< BF $>
6CO
7CO
5CO
1.5 .
280 .
750 .
54
55
1.5 .
5CO
1.4 .
6,7CO
1.3 .
56