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8/18/2019 HIsmelt 0208 Jamshedpur Conference
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Direct Smelting Technology
© HIsmelt Corporation 2008
Alternative Process for Ironmaking without Coke Alternative Process for Ironmaking without Coke
– – The HIsmeltThe HIsmelt®® Process & its relevance to IndiaProcess & its relevance to India
28th February 2008
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© HIsmelt Corporation 2008
Agenda
Introduction to Rio Tinto
HIsmelt Technology Overview
Kwinana HIsmelt Plant Update
Future Technology Developments
– CO2 Reduction Options
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© HIsmelt Corporation 2008
HIsmelt’s f it with Rio Tinto
Aluminium (RT Alcan)
Copper
Energy
Diamonds & Gold
Industr ial Mineral
Iron Ore
Technology & Innovation
Exploration
• Rio Tinto is a world leader in finding, mining and processing the earth’s
mineral resources
• The Group’s activit ies span the world…
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Rio Tinto Group’s Operations – Rio Tinto Iron Ore (RTIO) has a global presence
• Operations in 3 continents (Nth America, Sth America & Australia)
• Development projects in Africa and India
Operations
Projects
Markets supplied
IOC
Corumba Pilbara Iron
HIsmelt
Simandou
Orrisa
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© HIsmelt Corporation 2008
HIsmelt Technology OverviewHIsmelt Technology Overview
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© HIsmelt Corporation 2008
The Kwinana HIsmelt Plant: 0.8Mtpa Capacity
– A small footprint
2 5 0 m
3 0 0 m
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© HIsmelt Corporation 2008
Strong international interest in HIsmelt
China’s top three poli ticians have visited the Kwinana plant
– Hu Jintao, President of the PRC (Sept-07)
– Wen Jiabao, Premier of the PRC (April-06)
– Wu Bang Guo, Chairman of China’s NPC* (May-05)
~35 site visits by major Chinese steelmakers
– Two licences signed with Laiwu Steel and Huaigang
Site visits from major steelmakers including Indian, European,Japanese, Korean, North-American, ROW
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© HIsmelt Corporation 2008
The HIsmelt process is simple
Offgas
Raw Materials
Injection Lances
Oxygen Enriched
Hot Air Blast
Metal Bath
Slag NotchForehearth
Water cooled
panels
Ore & coal are injected into
the molten bath
Hot blast is injected into the
top-space
Metal flows out
continuously, slag is batch
tapped
Smelt Reduction Vessel (SRV)
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© HIsmelt Corporation 2008
Coal Flux Injection
Ore Preheater Injection
System
Oxygen Plant
Waste Heat
Recovery Unit
Stoves
Offgas
Scrubbers
Coolers
Offgas Duct
Hood
Flue Gas Desulphurisation
Hot
Metal Handling
Slag Pits
Water
Treatment
Smelt Reduction
Vessel
The HIsmelt process is innovative
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© HIsmelt Corporation 2008
HIsmelt’s Advantages for India
Flexibi lity in Raw Materials
Lower Capital & Operating Costs
Lower Environmental Impact
High Quality Iron Product
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© HIsmelt Corporation 2008
Indian Raw Material Flexibili ty
Iron ore
– Dry fines (-6mm) and slimes (ultra-fines) – used directly
– High phosphorus content possible
– No blending or agglomeration necessary
– Can be pre-heated / pre-reduced to increase process efficiency
Steel plant wastes
– Dry fine wastes and metallic fines – used directly – E.g. mill-scale, steel-making slag, reverts, coke breeze
Coal
– Non-coking coals – ground to -3 mm and dried
– From coke breeze (low volatile) high volatile thermal coal (40%)
– No blending, briquetting or coking required
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© HIsmelt Corporation 2008
Carboniser
– Char = Rich carbon source for SRV
– Offgas used for power generation
– Further investigation required
Circofer (after 2015)
– Future technology using full spectrum of coals
– R&D in progress with Outotec (formerly Outokumpu/Lurgi)
Higher Value from Indian Coals
Indian Coal
Fuel gas / Power generation
Char Carboniser
Air/Recycle Gas
Oxygen
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© HIsmelt Corporation 2008
Indian Coal Solutions: – Use of a carboniser will allow higher productivity to be achieved
with local coals
* Assumes use of: Local Indian coal containing 18% ash and 25-30% volatile matter; Imported coal containing 10% ash and 10% volatile matter
0
100
200
300
400
500
600
700
800
900
Preheater
100% Imported coal
Preheater
50% Imported coal
50% Local coal
Carboniser + Preheater
100% Local coal0%Indian Coal
(Imported)
50%Indian Coal
100%Indian Coal
+
Carboniser
Productivity
(ktHM pa)
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© HIsmelt Corporation 2008
Lower Capital Cost for Greenfield Expansions
-
2.0
4.0
6.0
8.0
China India USA China India USA
HIsmelt Blast Furnace
R e l a t i v e C o s t
Coke ovens
Power plant
Iron ore pretreatment
Core plant
2Mtpa Greenfield Facility Comparison
HIsmelt Blast Furnace
Source: Rio Tinto analysis; 2006
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© HIsmelt Corporation 2008
Lower Operating Costs: Lower input costs
Raw Material Prices - Reductants
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
High Vol
PCI Coal
Coking Coal
Coke
Purch. Coke Non-coking coals
Iron ore fines
Single source feeds okay
No need for blending yards
Graphs are indexed values only on a per tonne basis
Source: CRU averages (updated Jan 2008)
Reductants
Raw Material Prices - Iron Units
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
Fines
Lump
Sinter
Pellets
Iron Units
Relative price
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© HIsmelt Corporation 2008
Lower
Operating
Costs:
Compared
to
blast
furnaces
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
Blast Furnace HIsmelt 8m
R e l a t i v e I n d e x
Ore Coal Other
~10-20% lower
operating costs
Source: Rio Tinto analysis
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© HIsmelt Corporation 2008
Recycle Wastes
– Utilise iron ore slimes
– Steel plant wastes
– Other iron unit sources (e.g. steel-making slag)
No Toxic Emissions
– No dioxins, furans, phenols or tars
Reduced Overall Emissions
– Reduced CO2, SO2 and NOx – CO2 Emissions
Now in line with BF
Future plants (Circofer) reduced emissions
Circofer CO2 can be sequestered
Low Footprint
– Less land disturbance
– Power balanced0.0
0.5
1.0
1.5
2.0
2.5
CO2 SOx NOx Dioxines &Furanes*
Lower Environmental Impact
Emissions per thm
B e s t -i n- c l a s
s B F
HI s m el t
(t/thm) (kg/thm) (kg/thm) (ppm/thm)Source: Rio Tinto analysis
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© HIsmelt Corporation 2008
1420°C1430 - 1500°CTemperature
0.1 ± 0.05% #0.04 ± 0.02%Sulphur
0.02 ± 0.01% **0.09 ± 0.02% *Phosphorus
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© HIsmelt Corporation 2008
HIsmelt Kwinana Plant UpdateHIsmelt Kwinana Plant Update
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© HIsmelt Corporation 2008
Located in Kwinana, Western Australia
Capacity of 800,000tpa
High quality merchant pig iron
Experienced Joint Venture Partners:
– Rio Tinto 60%
– Nucor 25%
– Mitsubishi 10% – Shougang 5%
First HIsmelt Commercial Facility
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© HIsmelt Corporation 2008
Construction
– Started January 2003
– Completed April 2005
Hot commissioning / Initial operations
– May-September 2005
Operation – 3 year ramp-up period beginning in November 2005
– Ramp-up schedule:
50% nameplate by 2006
80% by 2007
100% by 2008
Path to Operation
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© HIsmelt Corporation 2008
Core technology is working well at commercial scale
SRV close to design rates, reached ~80tph (77% of nameplate)
– Flue Gas De-sulphurisation (FGD) capacity limited productivity to ~60%
– FGD capacity upgraded in July-07 and new production records were set:
1,700t in a day 9,600t in a week
30,000t in a month
Coal consumption has fallen to 810kg per tonne – on track for
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© HIsmelt Corporation 2008
Accumulated Hot Metal Product ion
0
20
40
60
80
100
120
140
160
180
200
220
S e p - 0 5
N o v - 0 5
J a n - 0 6
M a r
- 0 6
M a y
- 0 6
J u l - 0
6
S e p - 0 6
N o v - 0 6
J a n - 0 7
M a r
- 0 7
M a y
- 0 7
J u l - 0
7
S e p - 0 7
N o v - 0 7
T h o u s a n d
t o n n e s
Cumulative production – Improving as bottlenecks removed
Ave: 350 tpd
Max 42 tph
Ave: 450 tpd
Max 48 tph
Ave: 700 tpd
Max. 68 tph*
Ave: 830 tpd
Max. 65 tph
Ave: 1000 tpd
Max. 85 tph
•This maximum rate exceeded the capability limit of the FGD, and practical maximum production rate was 65 t/h until extra FGD capacity was added in 2nd quarter 2007
•Source: HIsmelt Operation
Flue Gas
Desulphurisation (FGD)
unit expansion
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© HIsmelt Corporation 2008
20
30
40
50
60
70
80
90
20 25 30 35 40 45 50 55
Total Oxygen Input (kNm3/hr)
H e a t T r a n s f e r t o
t h e B a t h ( % )
HIsmelt Process indicators are excellent
Heat Transfer Efficiency (%)Coal rate (t/thm)
0.0
0.4
0.8
1.2
1.6
2.0
2.4
2.8
0 20 40 60 80 100
Hot metal production (thm/h)
C o a l r a t e t / t h m
Target ~0.70t/thm
Campaign C2-1 (April-06 to May-06)
Campaign C2-5 (Nov-06 to Dec-06)
Campaign C3-4 (Aug-07 to Sept-07)
Increased rates transfermore energy to the bath
•Source: HIsmelt Operation
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© HIsmelt Corporation 2008
Key
Productivity = Average productivity when injecting ore (tonnes per operating hour)
Utilisation = Time that ore was injected (%)
Performance by Operating Period
– Productivity and Utilisation Steadily Increasing
48
53
77
72
62
6867
37
45
1923
16
2730
22
38 40
72
42
4945
62
80
46
7369
1348
1041
787
1350 1258 1335 1184 1105
15701712
738704692
0
20
40
60
80
100
120
140
Sep-05 Oct-05 Dec-05 Apr-06 Jul-06 Aug-06 Sep-06 Nov-06 Feb-07 Jul-07 Aug-07 Oct-07 Nov-07
Month Operating Period Commenced
%
&
tpoh
-5000
-4500
-4000
-3500
-3000
-2500
-2000
-1500
-1000
-500
0
500
1000
1500
2000
tHM/d
Productivity
Utilisation
Peak daily production
•Source: HIsmelt Operation
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© HIsmelt Corporation 2008
Commissioning issues being systematically eliminated
Reliability issues have limited Kwinana HIsmelt Plant production – E.g. 30+ interruptions to ore injection for December ’07
Significant causes of delays been: – Preheater - Refractory sub-optimally installed (rectified)
- Unreliable ore feed system (rectified)
– WHRU - Process control / reliability (rectified)
- Trips (50+) stop whole plant…• Integrated steam systems (Blower, Oxygen plant)
• Will be replaced with electric drives next plant
– Flue Gas Desulphurisation- FGD unit under-designed (rectified)
– Hot Metal Handling- Desulphurisation & Pig Casting integrated with the SRV
• Delays could quickly create a bottle-neck
• Hot metal for steelmaking in future plants
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© HIsmelt Corporation 2008
Key Plans for 2008
Optimise SRV to achieve 80 100tph
Focus on improving plant reliabili ty / availabili ty
Extend SRV campaign life
– Installation of slag zone coolers
– Installation of keyed SRV refractory bricks
Couple Preheater to SRV
– ~10% pre-reduction / Productivity increase
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© HIsmelt Corporation 2008
Future TechnologyFuture TechnologyDevelopmentsDevelopments
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© HIsmelt Corporation 2008
The Next Step: 2Mtpa – 8 metre diameter SRV
Major Changes from 6m SRV
– Hearth diameter from 6m to 8m
– Production from 0.8 to 2.0 Mtpa
– Redesigned hot air blast injection – improved process efficiency, simplermanufacture
– Two 6m offgas hoods – single larger hood not feasible to manufacture,
transport or erect
Minimal Changes to:
– Lances
– Forehearth
– Cooling Panels
– Refractory
Offgas DuctsOffgas
Chamber
Forehearth
8m SRV 6m SRV
SRV Access
Roof
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© HIsmelt Corporation 2008
Circofer Pre-reduction
add coal feed
& oxygen
Circofer
– Utilising full spectrum of coals & dramatically lowers CO2 emissions
* Circofer is a trademark of Outotec GmbH
Preheater
Hot Ore
Circulating
Fluidised Bed
SRV Offgas
Off Gas
850
°C
Iron Ore
Process Gas
950
°C
Coal Feed
Oxygen
DRI & Char
Circulating
Fluidised Bed
Iron Ore Cl e an e d , S
c r u b b e d & R e c i r c ul a t e d
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© HIsmelt Corporation 2008
Future developments wil l allow major reductions in GHG
low vol coal
ore
10% prd
oreSRV
ore
preheaterFGD
stack
HABwaste heat
recovery
CO2 Emitted
1.7-1.9 t/thm
Equal to world’s bestblast furnace
oxygen
ore
highvol
coal
80%
prd ore
& char
Circofer
CFBFGD
stack
waste heat
recovery
CO2
Scrubber
geo-sequestered CO2
(30-35% of total output)
HAB
SRV
CO2 Emitted
0.9-1.1 t/thm
5 0 % r e d u c t i o n
oxygen
ore
highvol
coal
80%
prd ore
& char
Circofer
CFB
geo-sequestered CO2
(90-95% of total output)
ox
SRV
CO2
Scrubber
CO2
Scrubber
rich gas
CO2 Emitted
0.1-0.3 t/thm
9 0 % r e d u c t i o n
HIsmelt Mark III (2012)
N2-Free + Sequestration
HIsmelt Mark II (2010)
Circofer HIsmelt Mark I (2008)
Kwinana Plant
•Source: HIsmelt Technology Development
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© HIsmelt Corporation 2008
Developments to 2015: Mk I Developments 2015-2020: Mk II Developments 2020+: Mk III
HIsmelt’s Technology Roadmap:
– Step change improvement in capacity and emissions
Geo-sequestered
CO2
6m SRV + Preheater
0.8Mtpa Capacity 8m SRV + Preheater
2Mtpa Capacity
8m SRV + Circofer
4Mtpa Capacity
Geo-sequestered
CO2
8m SRV + Circofer + CCS
4Mtpa Capacity
6m SRV
0.6Mtpa Capacity
8m SRV
1.6Mtpa Capacity
Current
Kwinana
Plant
Near net zero
emissions profile
6m SRV + Circofer
2Mtpa Capacity
6m SRV + Circofer + CCS
2Mtpa Capacity
•Source: HIsmelt Technology Development
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© HIsmelt Corporation 2008
The HIsmelt process is performing. Production achievements of:
– 30,000t in 30 days
– 9,600t in 1 week
Coal rates on track with design
Strong global interest in the technology
– The 3 top politicians in China have visited Kwinana
– Over 80 steel company visits
Increasing injection & product ion rates to nameplate capacity in 2008
Detailed engineering for 2Mtpa HIsmelt plant complete
Circofer pilot plant test-work nearing completion
– Pathway to lower CO2 emissions
Preparing to deliver raw material flexibi lity to India…
In Summary