ECO solutions – saving resources, creating valuesthai-german-cooperation.info/download/20141001_pdp_08_siemens... · ECO solutions – saving resources, ... SIMETAL RCB Temp 5 Process

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Siemens VAI – the life-cycle partner for the metallurgical industry

ECO solutions –saving resources, creating values

Confidential © Siemens VAI Metals Technologies GmbH 2014 All rights reserved.

Life-cycle Partner for the Metals IndustryPartnership for optimized performance

Life Cycle Technology Consulting

50+ years operation

InquiryIdea Construction Production

Plants, technologies, products and consulting for the entire value chain

Modernization

Energy Efficiency &Environmental Care

Innovation

Services

Electrics,Automation & IT

Life-cycleValue Drivers

October 2014 J. Kriechmair, I MT ECO IPPage 2


Plant life-cycle expertiseFrom ironmaking to finished products

Energy Efficiency & Environmental Care

Electrics/Automation

Services

Consulting

StripProcessingCold RollingHot RollingContinuous

CastingSteelmakingIronmaking

• Strip and plate

• Hot aluminium

• Converter andelectric steelmaking

• Secondary metallurgy

• Flat products casting

• Long products casting

• Beneficiation• Agglomeration• Smelting/

direct reduction

• Blast furnace

• Cold rolling • Cold

aluminium

• Processing lines

• Finishing lines

Long Rolling

• Long products rolling

Integrated plant solutions

J. Kriechmair, I MT ECO IPPage 3 October 2014


Integrated plant solutions

• Horizontally and vertically integrated technology know-how backed by state-of-the-art process configuration and automation solutions for all steps of a steel plant are the core competences of Siemens VAI.

• We provide customized solutions ranging from the original idea and basic studies to plant conception and technology and energy efficiency consulting as well as continuous optimization of plant productivity.

• With Siemens VAI as partner, our customers profit from the global presence and the integrated know-how of all disciplines within the Siemens group.

Integrated compact mill

Mini mill (flat and long)

Integrated plants

Consulting

Energy Efficiency & Environmental Care, Electrics/Automation, Services

StripProcessingCold RollingHot RollingContinuous

CastingSteelmakingIronmaking

Endless strip production (flat) WinLink (long)



Motivation for new and modernization businessand the introduction of innovative solutions

Stepwise improvement with technology / modernization packages along the whole value chain, and

References for innovative technologies (evaluated for specific projects, for reference)

Reduction of production cost

Extension of product mix

Environmentalfriendly & efficient production

Lifetime of machines, software or hardware

Increasing safety requirements

quality improvement

Hochofenbereich

Purchase

Natural Gas

Power Plant

SteamHeat Generation

Unmeasured, Losses

own other

Electricity

District Heat

Sale

Electricity Generation

Gas mixing station Blast Furnace

Steel Melting Shop

Kokereiverbrauch

Coking Plant

STAHLWERK

Oxygen Plant

Hot Rolling Mill

Cold Rolling Mill

Plate Mill

Other

508

61.4

336

849

13.573.4 86.9

38.4

1.2

10.7

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172

920

1056

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148

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External11.1



Increasing energy efficiency and environmental compatibility


Energy efficiency improvements Typical actions

BAT - Best Available Technology

Based on installed facilities and technology

KPIbenchmark

Maintenance

Energy recovery

Automation, process optimization

Plant updates & upgrades

KPIcurrent

situationEconomi-

-cally

feasible

KPItarget

Technically achievable

Improvementmeasures

BehaviorContinuous improvement

Relevant Key Performance Indicators (KPI): Specific energy cost, spezific energy consumption



Energy savings can be realized by existing, proven technologiesSiemens MT green solutions for EAF Route

Hotmetal

Ladlefurnace

Molten steel

Reheating furnace

Hotrolling

• Reheating Furnace Optimization

• Mill pacing• Drive efficiency and

controlled drives• Roll gap lubrication

EAFMidrex

Iron ore

Reduction gas(CO+H2)

Scrap

DRI/HBI

Alloys

• Hot Charging• Preheating of scrap• Ultimate furnace• Slag manager• Laser off-gas analyzer• Contact less temp. meas.• Electrode savings

• Direct Reduction Plant• Improved automation:

SIMPAX

EAF gas

LF gas

• Electrode optimization

Hot rolledproducts

• Dust abatement• Waste heat recovery • EAF gas recovery• EAF gas utilization• Ultimate Furnace

Efficient Energy Supply, Net Optimization

• Demand-driven utilization of ancillary unit

Energy Management & Control Systems, Cross Process Optimization

• Wast heat recovery



Environmental improvements both by end-of-pipe-and primary process technology Siemens MT green solutions for mini mills

Gas cleaning• DedustingResidual treatment• Dust granulation

• OXITERM (Deoiling)

Dry gas cleaning• Pulse-Jet-FilterResidual treatment• Pelletizing / Briquetting

•New technology•Proven technology

Dry gas cleaning• Pulse-Jet-FilterResidual treatment• Pelletizing / BriquettingRecycling• CONTOPNew process• Slag manager

Hotmetal

Ladlefurnace

Molten steel

Reheating furnace

HotrollingEAFMidrex

Iron ore

Reduction gas(CO+H2)

Scrap

DRI/HBI

Alloys

EAF gas

LF gas

Hot rolledproducts



Energy consulting offersfor energy efficient plant operation

Energy check Energy feasibility Detailed improvement

Elaborate

… to support quick and proper selection of feasible energy efficiency measures

Find Evaluatequick energy benchmark based on installed base, main raw materials

1 week on site + 1 month analysis

detailed investigation of energy saving potential

2-3 weeks on site + 2-3 months analysis

plant specific efficiency measures; feasibility

2-3 weeks on site / plant + 2-3 months analysis



Selected references of innovative solutions


SIMETAL EAF Heatopt

OffgasAnalyzing

SlagDetection

TemperatureMeasurement

MetallurgicalModels

Melt DownControl

Charging Crane Automation

Power Demand Control

Water LeakageDetection

Scrap Yard Automation

Suction / DamperControl

Heatopt



Prevention of events of damage or loss

The Event:• Carbon-Monoxide (CO) Boiling - dangerous situation for personnel and equipment

Your solution for prevention:• Slag detection - SonArc FSM, Offgas analyzing - Lomas, Carbon mass balance

The Event:• Water Leakage - dangerous situation for personnel and equipment

Your solution for prevention:• Offgas analyzing - Lomas, Humidity analyzing - Lomas, Hydrogen mass balance

The Event:• Arc radiation to panels - Furnace hot spot and overheating

Your solution for prevention:• Slag detection - SonArc FSM, Carbon mass balance



General System Arrangement

Holistic process modelSIMETAL EAF Heatopt8

Customer/Siemens expertise

Offgas parametersSIMETAL Lomas1 /

SAM2

Slag parametersSIMETAL FSD3 /

SlagMon4

Fossil energyinput settings

Electric energyinput settings

EAF

Input from EAF process

Process core fordynamic and conditionbased process control

Output to EAF process1 Lomas (Low Maintenance gas analyzing system)2 SAM (Single Air Measurement)3 FSD (Foaming Slag Detection)4 SlagMon (Slag Monitoring System)5 RCB Temp (Refining Combined Burner with temperature measurement)6 CSM (Condition-based Scrap Melting) 7 ECS (Electrode Control System)8 Heatopt (Holistic energy and transparency optimizing)

Temperaturemeasurement

SIMETAL RCB Temp5

Process diagram andcalculation modelsLevel 1 / Level 2

Furnace controlset points

Melt down control systemSIMETAL CSM6 / ECS7



SIMETAL Quantum Energy optimized steel production

Challenge• Low energy demand steelmaking• High productivity – low operational cost.• Low emissions

Solution

• Direct energy recovery due to integrated scrap preheating

• Charging, tapping and tap hole refilling under power on leads to constant current flow and less power consumption

• Highest output, even with weak power grids due to pure flat bath operation resulting in lowest flicker

Typical customer benefit

• Increased productivity• Energy consumption of 280 kWh/t• Tap-to-tap time of 33 min.• Increased productivity of 1.35 mio. t/a

with an 100 t EAF arrangement and a 3-batch process

• Up to 30% reduced electrode consumption

• Total conversion cost advantage of 20%

Environ-mentalbenefit

• Direct energy recovery due to 100% scrap preheating with smaller transformer installation

• Optimized environmental compliance due to revolutionary design of offgas-processing



Integrated Offgas System leads to lowest direct emmissions

Features:

Special hood to cover dust and offgas emissions

Combined primary and secondary offgas-pipes with automated offgas-stream modification / deviation to adapt offgas-processing to the melting process

Advantages:

Maximized leak tightness

Full fills future environmental compliance and regulations

Minimized canopy installation



Optimized Shaft Design and Retaining System leads to best preheating conditions

Features:Hosting scrap during preheating

Trapezoidal shaft design

Modular cooling panel structure

Improved tightness

Water cooled finger system shaped like excavator shovels

New scrap impact absorber technology

Advantages:Optimized scrap distribution and scrap fall

Improved offgas-routing for improved heat transfer and increased preheating efficiency

Avoiding scrap sticking and blocking inside shaft

Improved life time



Key Features and Advantages - Tapping Concept

Features:

Special designed shell transfer an

moving concept with closed roof

Fixed roof and no tilting of gantry

Spare shell concept

Advantages:

Reduced furnace movements

Higher reliability

Less maintenance cost



Shell Design / FAST avoids Power-off time

Features:Furnace movements reduced to shell movements with minimized tilting angle of 4°

FAST - Furnace Advanced Slag-free Tapping

Integrated siphon system

Pure flat bath operation

Advantages:Charging, tapping and taphole refilling under power on / under arcing

Nearly no power off time

Lowest flicker and net disturbances

Improved safety



Movement Concept enables fast shell exchange

Features:New designed shell transfer and exchange concept

Safety concept

Self-sustaining hydraulic for shell tilting

Advantages:Fast shell exchange

Reduced power off / delay time



First reference at Talleres y Aceros S.A. de C.V. in Orizaba, Mexico

Febuary 2013

TYASA

• 1.4 mio melt shop with

Quantum, Twin LF, Twin VD

and CCM

• Contract signed 12-2011

• Commissioning start mid

2014



SIMETAL SIMELT electrode control systemReal improvement for electric arc furnaces


• Reduced CO2 emissions due to lower specific electricity consumption

• Reduced impact on utility grid and environment

• Lower consumption of resources

Challenge

• Dynamic control for fast electrode movement and stable arc conditions

• ensure precise and stable adjustment of all EAF operating points

• sustainable performance combined with low usage of resources and consumables

Solution

• Modular and multifunctional digital control system based on SIMATIC S7

• Proven, neural network optimized dynamic impedance control with add-ons, system analyzer and visualization

• Melt down recipes for high repeat accuracy and stable process conditions


• Reduced electrode consumption, ~ -5%• Increased effective power efficiency

(+10%) leads to reduced specific melting power (-4%)

• shorter power-on times (-12%) and reduced down times (<50%) resulting in

• higher productivity, e.g. +15%



SIMELT Foaming Slag ManagerReal improvement for electric arc furnaces


• Reduced CO2 emissions due to lower carbon and energy consumption, e.g. up to 10.000 t CO2/year at 100 t EAF

• Savings in specific electric energy consumption up to 3%

Challenge

• to introduce fully automated foaming slag process

• to detect and indicate the foaming slag height

• to ensure uniform distribution of the foaming slag in all furnace sections

• to control and optimize carbon injection

Solution

• With SIMELT FSM the foaming slag process is fully automated

• Body sound sensors are the base for precise detection and slag height analysis

• Sectional and electrode related slag detection with automatic carbon injection


• Controlled and optimized foaming slag process

• Reduced specific electric energy (up to 3%) and carbon consumption (up to 25%),

• Shorter power-on times, 1 min or even more

• Increased productivity, 2% or more possible



Functional principle

SIMETAL – RCB Temp = contactless temperature measurement SIMETAL RCB (combined burner) with supersonic injection technology

burner flame

supersonic - oxygen /

inertgas - stream

water cooled

RCB

oxygen /

inert gas

optical

sensor

natural gas / oxygen



Reasons for RCB-Temp

Authentic and accurate measurement

• without movable parts => sensor system with long life cycle

• RCB-Temp lance in water cooled modular => easy maintenance and accessibility injection panel totally protected => no damages because of scrap fallings

• reducing of wrong measurements => measurements very fast and precise

Profitable investigation

• high return of investment (ROI)

• low cost of installation

• short time of implementation

• can be installed during maintenance or non-operating time



Base: EAF standard 100t, operating time = 300 days/year35 min PON / 48 min TTT / 380 kWh/t / 900.000 t/year / 30 heats 2 RCB-Temp measurements per heat / 3 manual measurements per heat 20 sec inert gas flow per measurement with 1400Nm³/h RCB nozzle

Costs: saving potential: 1min PON & POff inert gas = 0,15 [€/Nm³]energy: 0,05 - 0,30 [€/kWh]cost of cartridge: 2 €/unitsaving fix costs: 1min per heat 50 €

A. cost reduction- energy savings = 488.571 €/a- sensor savings = 36.000 €/a- fix cost savings = 450.000 €/a- costs of inert gas = -31.500 €/a- sum = 943.071 €/a

savings > 1 €/t => Amortization < 0,5 year

B. raising productivity

2% higher productivity => 18.000 t/year

Reasons for RCB-Temp



SIMETAL EAF optimization Reduce energy consumption and tap-to-tap time


• Reduced CO2 emissions due to efficient carbon usage

• Lower consumption of raw materials and resources

• Efficient oxygen injection

Challenge

• Increasing demands to lower production costs and increase product quality

• Insufficient process standardization• High productivity requirements with

minimum operator personnel

Solution

• Well proven automation system for high quality at low production costs

• Dynamic process models• Modular-designed, expandable and

upgradeable automation package


• Reduce energy consumption up to 3%• Reduce tap-to-tap time due to stan-

dardized production practice up to 5%• Reduction of raw material expenses by

up to 5%



SIMETAL LF optimizationKey features and benefits


• Reduction of energy consumption and costs up to 3%

Challenge• Optimization of scheduled process steps• Support for heat pacing between steel

plant and caster

Solution

• Exact adjustment of steel bath temperature and analysis

• Cost optimizing process models for required materials for different treatment steps (de-oxidation, desulphurization, alloying, inclusion shape control)


• Reduce alloying material costs up to 5%• Elimination of return heats



SIROLL Furnace optimizationReduced fuel consumption – improved quality


• Reduced fuel consumption resulting in lower environmental emissions (CO, CO2, NOX, SOX)

Challenge

• Hot rolling operations need high-quality reheated slabs, billets, or blooms at the lowest possible cost, at the mill’s optimal production rate, with minimal impact on the environment

Solution• SIROLL Furnace Optimization delivers

optimally heated pieces to hot rolling operations while minimizing fuel consumption.


• Fuel usage reduced by 6 to 15%• Discharge temperature deviation from

target < 1% • Improved surface quality



DIFFERENT CHARGING ROUTES ARE POSSIBLE

VARIABLE DEGREE OF INTEGRATION WITH CASTER:1. COLD CHARGE @ GAS FURNACE (GF) + INDUCTION FURNACE (IF) & COLD CHARGE @ GF

Billets are cold charged into the gas fired furnace, heated to the non oxidizing target temperature andfinally heated to the proper rolling temperature into the induction furnace. Billets can also be heatedto proper rolling temperature into the gas fired furnace.

2. HOT CHARGE @ IF & HOT/COLD CHARGE @ GF + IF

Billets can be directly sent to induction furnace and heating to the proper rolling temperature or hotcharged into the gas fired furnace, equalized and finally heated to the proper rolling temperature intothe induction furnace. Billets can also be cold charged into the gas fired furnace, heated to the nonoxidizing target temperature and finally heated to the proper rolling temperature into the inductionfurnace.

3. HOT CHARGE @ GF + IF

Billets are hot charged into the gas fired furnace directly form CCM and finally heated to the properrolling temperature into the induction furnace

4. HOT CHARGE @ IF

Billets are directly send from the CCM exit to induction furnace and heated to the proper rollingtemperature. A 100% synchronization from CCM to RM is required.

EHS – Efficient Heating System



Challenge


Key Features of EHS

Solution

To balance the cost fluctuation and availability of energyTo increase the plant yield (e.g. less scale) and optimize opexTo grant stable and continuous rollingoperations for consistency of quality

EHS is classified as green technology, which supports the access to public incentivesOptimized use of alternative energy sources (i.e. residual converter gas, adaptation to electricity cost fluctuation) and CO2 reductionMinimal material oxidation, hence higher productivity

Combines in an intelligent protocol the use of different heating sources and routes (direct feed, hot/mixed or coldbillet charge + fossil fuel + IH)Ideal for intermittent production and frequent changes of size or steel gradeGreen technology (reduced CO2)

Flexible combination of different quantity and type of heating sources with different billet routesEvolved material flow management platform tomaximize productivity and process accuracyPreferential route with direct feed to IF, alternative routes with hot/mixed/cold billetcharge to low capacity RHF integrated by IH

IF RM

GF

From CCM

CCT

Reference temperatures °C• to rolling 1000-1100• hot billets from GF 870-920• hot billets from CCM 600-920• cold billets 20

CCM continuous casting machineCCT continuous casting cooling bedGF gas furnace (fossil fuel)IF induction furnaceRM rolling mill

SIROLL Efficient Heating System (EHS)An answer to modern trends in long rolling



IF RM

GF

CCME

CCT

CCME: continuous casting machine exit - CCT : cold charging table

GF: gas furnace - IF: induction furnace - RM: rolling mill

HOT BILLETS TEMPERATURE

600 – 920°C

1110-1700° F

COLD BILLETS TEMPERATURE

20°C / 68° F

BILLETS EXIT

TEMPERATURE

870-920°C / 1600-1700°F

BILLETS EXIT

TEMPERATURE

1000-1100°C

1830-2010°F

1. COLD CHARGE @ GAS FURNACE (GF) + INDUCTION FURNACE (IF) & COLD CHARGE @ GF

Billets are cold charged into the gas fired furnace, heated to the non oxidizing targettemperature and finally heated to the proper rolling temperature into the inductionfurnace. Billets can also be heated to proper rolling temperature into the gas firedfurnace.

2. HOT CHARGE @ IF & HOT/COLD CHARGE @ GF + IF

Billets can be directly sent to induction furnace and heating to the proper rollingtemperature or hot charged into the gas fired furnace, equalized and finally heated tothe proper rolling temperature into the induction furnace. Billets can also be coldcharged into the gas fired furnace, heated to the non oxidizing target temperature andfinally heated to the proper rolling temperature into the induction furnace.

3. HOT CHARGE @ GF + IF

Billets are hot charged into the gas fired furnace directly form CCM and finally heatedto the proper rolling temperature into the induction furnace

4. DIRECT CHARGE @ IF

Billets are directly send from the CCM exit to induction furnace and heated to theproper rolling temperature. A 100% synchronization from CCM to RM is required.

IF integration

EHS® , efficient combination of heating sources Hot Charge + IF & Hot/Cold Charge @ GF + IF



Variable Speed Drives (VSD) Demand driven utilization of pumps


• Energy savings between 60 and 70%, compared to conventional systems (depending on existing system)

• Reduced maintenance costs

Challenge

Drives are often continuously operatedwithout appropriate control:• Waste of energy• Low system performance • High stress on piping and valves

Solution

Feasibility study:• Optimization of the entire drive system• Demand driven, economic and flexible

operation • Generated energy fed back


• Operation of high-voltage motors on low-voltage distribution possible

• Drives can be operated to precise specifications

• Investments normally pay off in less than two years



SIMETAL Energy managerCuts peak loads and energy costs


• Reduction of specific energy demand• Reduced emissions due to leakage

detection

Challenge• Optimize complex energy network• Approx. 25% of total production costs are

energy related• Benefit of the liberalized energy market

SolutionFlexible energy-management modules:• SCADA • Energy Data Management • Energy prediction and optimization


• Identification of energy saving potentials• Energy demand forecasts • Reduction of energy load peaks and

flaring• reduce energy costs by ~3%

(pipe bound)

Hochofenbereich

Purchase

Natural Gas

Power Plant

SteamHeat Generation

Unmeasured, Losses

own other

Electricity

District Heat

Sale

Electricity Generation

Gas mixing station Blast Furnace

Steel Melting Shop

Kokereiverbrauch

Coking Plant

STAHLWERK

Oxygen Plant

Hot Rolling Mill

Cold Rolling Mill

External

Plate Mill

Other



Actual Production 340 t/h184.000 t/m

Sequence lengthMax. production/day

11 Heats (11x260=2860t)27 Heats (6750t)/day

Yield >98%Casting speed 6.0 m/min at thickness 80mm

Breakout rate0,07 %No breakout for 650.000t6 breakouts in 2012

Cobble rate 0,06 %Q1/2011

Work Roll Lifetime 170 km at F5

Steel grades

Low & Medium CarbonHSLA S500API X70DP 600

Arvedi ESP – MasterplantReal Endless – Peformance data



Reference: ESP (Endless Strip Production)First casting-rolling plant for ultra-thin HRC

Only 10 Meter inductive heating leads to reduced scale losses compared to min. 200m tunnel furnace

No energy consumption during idle and maintenance periods

Reduced maintenance costs compared to long tunnel furnaces

Optimized control of end rolling temperature

0

100

200

300

400

500

Conv.casting andHSM 20°C *)

Conv. Castingand HSM 600°C

*)

Arvedi ESP CSP cast androll 1200°C **)

CSP realoperations

Ener

gy C

onsu

mpt

ion

[kW

h/t] fuel gas

electricity

caster

Sources: *) VdEh paper, **) SMS paper, ***) Nucor publication

***)



ESP Endless Strip ProductionSpecific cash conversion costs

16,5 €/t

17,5 €/t

1,8 €/t

9,0 €/t9,0 €/t9,0 €/t

44,9 €/t

Conventional

Personnel

6,8 €/t

14,4 €/t

2,2 €/t

5,0 €/t

28,4 €/t

ESP

8,3 €/t

18,3 €/t

2,4 €/t

7,9 €/t7,9 €/t7,9 €/t

37,0 €/t

Other Thin Slab

Other op. suppliesEnergiesMaterial costs (yield losses)

PersonnelOnly one caster operation groupNo slab strorage staff

Other op. Supplies (Maintenance)Minimum maintenance at 10 m inductive heaterIncreased work roll life time due to 2-step rolling

EnergiesUse of hot strand internal energy for first rolling stepNo heating during idle times at inductive heater

Yield lossesMinimum scale at 10m inductive heaterNo head and tail losses

*) Compare World Steel Dynamics 2009 : Sestao 54US$/t (37,8 €/t)

*



WinLink® combines two high-tech solutions: high-speed caster and RM with high availability

A high-speed billet casting strand directly feeds a rolling mill with high availability,casting and rolling procedures become continuously linked.The conventional billet reheating furnace is replaced by an induction furnace toequalize the billet temperature.

1. EAF/LF has a higher availability than the rolling mill.

2. To compensate this, WinLink® uses a 2-strand CCM:

• Strand #1 feeds the rolling mill

• Strand #2 can exploit the longer availability of meltshop, by producing saleable billets

3. Liquid steel is balanced among rolled products and saleable billets.

4. Strand #2 serves also as backup in case of rolling mill extended downtimes.

5. With WinLink® the full capacity of Meltshop may be provided.



Reference: WinLink® for production of long productsCompact plant layout

LFEAF

Billet casterInductive HeatingRolling MillWater treatment facility

23

4

56

7

Scrap yard1

Dispatch area8

1

2

3

456

78



Reference: WinLink® process for micro mills

CCM (2 strands)Billet formats- 130 mm strand #1- 110-150 mm strand #2

Rebar for sale

Long rolling mill- Main process- Induction Furnace- Double supported stands- Slitting process- Final handling of rebars

Billets for sale 110-150mm

400,000 t/y

300,000 t/y UP TO 100,000 t/y

Billet cooling bed- Process- Emergency

Patentpending!



Crane activity charging -teeming Crane activity Casting - Rolling

Cooling bed

Open Scrap Yard@ 0,6…0,65 t/m³

Approx. 300 m

Ultimate EAF 5200 LF 35 Billet CCM Rolling mill

Transformer 45 MVA Transformer 8 MVA Billet format 1x 130mm1x110- 150mm

Finished product(Rebar)

2x8 mm (Min.)40 mm (Max.)

Tap weight 35 Ton Heating 4°/min Casting speed 5.7 to 7.5 m/min Finishing speed 1.3 to 16 m/s

Treatment time 36 min Treatment time 25 to 36 min Machine radius 9 m Number of stands 18

Billets for Sale110x110-150x150mm

Finished Product forSale

EAF LF

CCM

Rolling mill

Patentpending!

WinLink® process for micro mills



120t Furnace

Potential for energy recovery for EAFs

EAF

Energy-Recovery

Drop Out Box Hot gas line Forced Draught Cooler Filter

Canopy

17 >250°C

32

44

14,5all figures are [MWth] average per heat



Different ways of energy recovery from EAF off gas

Continuous output

Batch process

Steam

Buffer storage(Steam)

G

Electricity

e.g.: 13 bar a e.g.: 50 bar a0

10

20

30

40

50

60

70

80

90

21:07 21:21 21:36 21:50 22:04 22:19Time [hh:min]

Disch

arge

d po

wer [M

W]

Buffer storage(Steam + extra heat)



Challenge

Continuous supply of steam or electricity for different consumers (e.g. secondary metallurgy) Cope with “dirty” conditions of the waste gasNo interference with production process

Solution

Replace water cooled hot gas line by a waste heat steam boilerInstall appropriate steam turbine for power generationUse advanced buffer systems for stable power supply (molten salt)

Heat Recovery @ EAF - utilize the full waste gas energy potential to produce steam or electricity



El. Power

G

Saturated Steam Turbine

Steam light Steam max Steam to Power

Offgas cooling

Energy storage

Output

Option

~600°C ~250°C ~250°C

Steam Accumulator

Saturated Steam

Partial Heat Recovery

Steam Accumulator

Steam Accumulator

Saturated Steam

Maximum Generation of Steam

Energy recovery from EAF off gasAlternative paths

El. Power

G

Molten Salt

Salt to Power

~600 °C

ORCOrganic Rankine Cycle

Steam Demand available ?



SIMETAL RecoSteelTypical customer benefit120 t scrap charged EAF

Chem. energy305 kWh/t

Steel396 kWh/t

Offgas210

kWh/t

Steam30 t/h @ 50 bar(a)

Slag,cooling89 kWh/t

120 t EAFC-Steel

Scrap charged

Typical reduction of electrical energy consumption ~ 10 % !

Heat recoverysteam generator

Efficiency: 82%

SteamTurbines

Recovered El. Energy5.8 MWel (39 kWh/t)

El. energy390 kWh/t



Heat Recovery @ EAF Benefits and typical saving potentials for a 120 t EAF

120 t/tap47 min TTT7,400 h/a

1.1 Mio t/a 39 kWh/t

Specific savingswith 5,8 MWel heat

recovery

42,9 GWh/a 3,21 Mio €/a

~75 €/MWh

5,8 MWrecovered

120 t EAF steel scrap based

Electric energy: 390 kWh/t

Fossil energy:

Blowing coal: 75 kWh/tNatural gas: 51 kWh/t

Additional input:

Off gas: 210 kWh/t

Steel: 396 kWh/t

Other losses:Slag: 46 kWh/tCooling water 43 kWh/t

Charging coal: 44 kWh/t

135 kWh/t

695 kWh/t

Customer benefit

Avoid dew-point corrosion, due to higher cooling water temperaturesReduction of CO2 emissionsIncreased process efficiency (less energydemand per ton of steel)



Johann Kriechmair

Executive Manager

Siemens VAI Metals Technologies GmbHMT ECO IP

Turmstraße 444031 Linz

Tel.: +43 (732) 6592 3518Mobil: +43 (664) 615 3175

E-Mail:

[email protected]

siemens-vai.com


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ECO solutions – saving resources, creating valuesthai-german-cooperation.info/download/20141001_pdp_08_siemens... · ECO solutions – saving resources, ... SIMETAL RCB Temp 5 Process