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HJK CE industry energy saving potentials
1.
HJK CONSULTING ENGINEERS Project Management – Technology – Operating
– Consulting Excellence
2.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS Typical Energy Balance Electric Arc Furnace SEP15 HJK Consulting Engineers ©®2015 2 EAF 120 ton (C‐steel scrap)
720 kWh/t Off gas: 220 kWh/t Slag: 50 kWh/t Furnace Shell CW: 60 kWh/t Steel: 385 kWh/t Radiation loss: 5 kWh/t Electric Energy: 390 kWh/t Coal injection: 90 kWh/t Natural gas: 80 kWh/t Fossil energy Combustibles in scrap: 35 kWh/t Electrode combustion: 15 kWh/t Iron combustion: 70 kWh/t Al, Si combustion: 40 kWh/t Additional energy input 54.2% 12.5% 11.1% 5.6% 9.7% 2.1% 4.9% 30.6% 53.5% 6.9% 8.3% 0.7%
3.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS Typical Energy Balance Billet/Bloom/Beam Blank CCM SEP15 HJK Consulting Engineers ©®2015 3 Heat content of liquid steel: 365 kWh/t 54.2% Spray cooling & exhaust stem:
139 kWh/t Radiation heat slab cooling channel: 91 kWh/t Further heat losses: 26 kWh/t Residual heat of slabs: 91 kWh/t Mould cooling: 18 kWh/t
4.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), to adjust according to individual plant findings SEP15 HJK Consulting Engineers ©®2015
4 Technology or Measure Potential Energy Saving Increase in productivity Potential CO2 emission reduction Cost (estimate) EAF controls Electric energy consumption ≤ 14% Natural gas consumption ≤ 6% ≤ 34 Kton Co2 p.a. Improved process control Electricity savings ≤ 30 kWh/t‐steel Increase ≤ 12% Electrode consumption ‐ ≤ 25% ≤ 18 kg Co2/t‐steel Oxyfuel burner / lancing Energy savings 2‐3 kWh/t‐steel per minute heating time reduction ≤ 24 kg Co2/t‐steel Retrofit CAPEX ≤ 5 USD/t Hot DRI/HBI charging Melting energy savings ≤ 150 kWh/t‐steel (DRI/HBI ≤ 600 oC) Foamy slag practices Net energy savings ≤ 8 kWh/t‐steel ≤ 11 kg Co2/t‐steel Retrofit CAPEX ≤ 16 USD/t Bottom stirring, gas injection Electricity savings from 12 – 24 kWh/t‐steel ≤ 12 kg Co2/t‐steel Retrofit CAPEX ≤ 1 USD/t CONSTEEL Electricity savings ≤ 60 kWh/t‐steel Increase ≤ 33% ≤ 36 kg Co2/t‐steel Retrofit CAPEX ≤ 8 USD/t Shaft Furnace (QUANTUM) Electricity savings ≤ 280 kWh/t‐ steel Increase ≤ 35% Electrode consumption ‐ ≤ 30% Retrofit CAPEX ≤ 10 USD/t
5.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), SAMPLE DISTRICT HEATING & COOLING SYSTEM SEP15 HJK Consulting Engineers ©®2015
5
6.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), SAMPLE HEAT RECOVERY STEAM GENERATOR SEP15 HJK Consulting Engineers ©®2015
6
7.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), SAMPLE STEAM GENERATION (simplified scheme) SEP15 HJK Consulting Engineers ©®2015
7
8.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), Typical Energy Balance Reheating Furnace SEP15 HJK Consulting Engineers ©®2015
8 Heat form fuel (100%) Net heat from steel (46%) Oxidation heat (3%) Recuperator Waste gas losses (24%) Exhaust gas (38%
9.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), Iron & Steel Production life cycle (simplified) SEP15 HJK Consulting Engineers ©®2015
9 Basic Oxygen Furnace (BOF) Blast Furnace (BF) Electric Arc Furnace (EAF) Sinter PlantCoking Plant Ladle Treatment (Continuous) Casting Hot Rolling / Plate Mill Pickling Cold Rolling Mill Finishing Mill Cold Rolled Sheet, Strip, Plate, Pipe & Tube Hot Rolled Sheet, Strip & Plate Bar, Rod, Wire, Structural Shapes, Pipe & Tube, Rail, Billet & Bloom Internal Scrap DRI/HBI Oxygen Electricity, Fuels Bar, Rod, Tubing, Structural Mill Scrap Scrap Scrap Scrap Scrap Mill Scale Mill Scale Mill Scale Mill Scale Mill Scale Molten Iron Oxygen Scrap Waste Oxides Fluxes Coal Coke Breeze Molten SteelMolten Steel Scrap, Slag to Recycle Slag to Reclaim Iron Ore, Pellets Coke Scrap Waste Oxides Sinter Dolomite, Limestone Injectants: Coal, Oil, Oxygen, Natural Gas External Scrap Goods made from steel
10.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), Flow Diagram Integrated Plant Production SEP15 HJK Consulting Engineers ©®2015
10 Coke making Iron making BOF steel making Continuous casting Hot Strip Mill Heavy Section Mill Plate Mill Bar MillRod Mill Coal Coke Hot Metal Liquid Steel Gas Flare Power Plant Water Supply & Treatment Air Separation Plant PLANT UTILITIES Utilities Utilities Utilities Utilities Utilities BF Gas BOF Gas & Steam Coke Oven Gas Utilities Cast and Roll Iron Ore Scrap Strip Strip Billets Plate Bars Rod Source: www.energystar.gov
11.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures (samples), Samples on implemented Energy Savings ‐ Excerpt SEP15
HJK Consulting Engineers ©®2015 11 Enterprise Investment Savings Source Tenaris Dalmine Plant EUR 3.8 mill. (2007‐2008) – e.g. high efficiency & frequency controlled motors, energy waste, heat recovery, CHP power plant, etc. 14% reduction in electricity 6% reduction in natural gas (JUN08‐JUL09 vs JUN05‐JUL06 www.worldsteel.org Essar Hazira Plant Investment in HBI Cooling system Water consumption reduction 0.68 m3/ton MAY08 compared to 0.92 3/ton FEB08, savings: 250,000 USD www.worldsteel.org HADEED Upgrading natural gas quality Specific consumption savings: 0.97 MBTU/MT equivalent to 8.48% of original gas consumption www.worldsteel.org ThyssenKrupp German HRM Advanced burner technology, secondary de‐dusting systems Specific dust & NOx emission reduction from 1985 to 2005 (2 kg/ton 0.5 kg/ton crude steel produced) www.worldsteel.org Usage of slag in different industries like road making, cement, etc. Production cost of 01 ton Portland Cement generates about 1.2 ton CO2, usage of BF slag containing 50 wt.‐% GGBS generates 0.54 ton CO2 Market price BF granulated slag: 75‐ 79USD/ton; 65 EUR/m3, BOF 38‐40 EUR/ton www.euroslag.com
12.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures, ISO 50001 Energy Management System Model (Plan – Do –
Check – Act) SEP15 HJK Consulting Engineers ©®2015 12 CheckingChecking Monitoring, measurement & analysis Monitoring, measurement & analysis Nonconformities, correction, corrective & preventive action Nonconformities, correction, corrective & preventive action Internal audit of the EnMS INTERNAL ENERGY MANAGEMENT SYSTEMS Internal audit of the EnMS INTERNAL ENERGY MANAGEMENT SYSTEMS Management reviewManagement review Energy policyEnergy policy Energy planningEnergy planning Implementation & operation Implementation & operation Continuous improvement Source: www.iso.org
13.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures, Basic program energy saving audit & implementation SEP15 HJK Consulting Engineers ©®2015
13 Information collection Preliminary Energy Audit Detailed Energy Audit Energy Audit Report Implementation of Energy Conservation Measures Agreement to proceed Energy Services Agreement
14.
IRON & STEEL MAKING INDUSTRIES ENERGY SAVING POTENTIALS ‐ Technologies & Measures SEP15 HJK Consulting Engineers ©®2015
14 Independent, reliable & trustable consultancy service for YOUR long‐term success
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