Stahl-Zentrum. Koksqualität und Hochofenleistung - Theorie und Praxis. Düsseldorf, 05. Dezember Peter Schmöle

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1 Koksqualität und Hochofenleistung - Theorie und Praxis Düsseldorf, 05. Dezember ThyssenKrupp Steel Europe

2 Coke quality and blast furnace performance Introduction Roles of coke Flooding effects Effects on blast furnace performance Conclusion 2 ThyssenKrupp Steel Europe

3 Integrated blast furnace plants in Germany Hot metal production in 2012: 25.9 Mill. t Duisburg: 51.6 % Dillingen: 15.0 % Salzgitter: 16.5 % Bremen: 11.2 % EKO: 5.7 % 3 ThyssenKrupp Steel Europe

4 Introduction Consumption of reducing agents in German blast furnaces Total: kg / t HM in 2012 Coke: kg / t HM in ThyssenKrupp Steel Europe

5 Introduction Consumption of reducing agents, ThyssenKrupp Steel Europe

6 Coke quality and blast furnace performance Introduction Roles of coke Flooding effects Effects on blast furnace performance Conclusion 6 ThyssenKrupp Steel Europe

7 Roles of coke Coke in the counter current reactor blast furnace Chemical roles Energy input Generation of reducing gases Regeneration of CO 2 (Boudouard - Reaction) Carburization of the hot metal Physical roles Gas distribution in the BF shaft Support of the burden column Vertical and horizontal drainage for liquid products 7

8 Roles of coke Quality parameters of coke I 40, I 10 CSR / CRI Medium grain size, grain structure, grain size distribution All physical coke quality parameters and their interactions are to be discussed regarding the impacts on the mass and gas flows

9 Roles of coke Quality parameters of coke Grain size distribution Grain size distribution I 40, I 10 CSR / CRI Voidage high small Gas permeability high low Drainage high low

10 Roles of coke Bad size distribution Grain size distribution I 40, I 10 CSR / CRI Gas permeability Gas permeability Liquid products Grain size distribution Grain size distribution Voidage Gas permeability Drainage small low low

11 Roles of coke Good size distribution, low I 40 Grain size distribution I 40, I 10 CSR / CRI Gas permeability Gas permeability Liquid products Grain size distribution Grain size distribution Voidage Gas permeability Drainage small low low

12 Roles of coke Good size distribution, high I 40 and low CSR Grain size distribution I 40, I 10 CSR / CRI Gas permeability Grain size distribution Gas permeability Liquid products Grain size distribution Voidage high small Gas permeability high low Drainage low

13 Roles of coke Good size distribution, high I 40 and high CSR Grain size distribution I 40, I 10 CSR / CRI Gas permeability Gas permeability Liquid products Grain size distribution Grain size distribution Good coke = excellent BF performance! Voidage Gas permeability Drainage high high high

14 Coke quality and blast furnace performance Introduction Roles of coke Flooding effects Effects on blast furnace performance Conclusion 14 ThyssenKrupp Steel Europe

15 Flooding effects Slag flooding Blast furnace as counter current reactor Flooding of slag influenced by Shaft gas composition, temperature, pressure and the resulting density Slag amount, density and viscosity Coke specific surface Coke bed voidage 15

16 Flooding effects Slag flooding Hans Beer, Gerhard Heynert: stahl und eisen 84 (1964), No. 22, p. 1353/1365 Holdup key figure log (f) Based on T. K. Sherwood et al: Flooding Velocities in Packed Columns, MIT, Industrial and Engineering Chemistry, Vol. 30 (1938), p. 765/69 Counter current flow key figure log (k) 16 ThyssenKrupp Steel Europe

17 Flooding effects Slag flooding Case 1 Case 2 % Gas volume m³ (STP) / t HM 1.300, ,00 0,00 Gas pressure bar (abs.) 4,00 4,00 0,00 Slag amount kg / t HM 250,00 250,00 0,00 Slag viscosity cp 1.500, ,00 0,00 Coke specific surface m² / m³ 90,00 90,00 0,00 Coke bed voidage m³ / m³ 0,35 0,35 0,00 Productivity Case 2 / Case 1 % 0,00 17 ThyssenKrupp Steel Europe

18 Flooding effects Slag flooding - Gas volume minus 10 % Case 1 Case 2 % Gas volume m³ (STP) / t HM 1.300, ,00-10,00 Gas pressure bar (abs.) 4,00 4,00 0,00 Slag amount kg / t HM 250,00 250,00 0,00 Slag viscosity cp 1.500, ,00 0,00 Coke specific surface m² / m³ 90,00 90,00 0,00 Coke bed voidage m³ / m³ 0,35 0,35 0,00 Productivity Case 2 / Case 1 % 7,89 18 ThyssenKrupp Steel Europe

19 Flooding effects Slag flooding - Gas pressure plus 10 % Case 1 Case 2 % Gas volume m³ (STP) / t HM 1.300, ,00 0,00 Gas pressure bar (abs.) 4,00 4,40 10,00 Slag amount kg / t HM 250,00 250,00 0,00 Slag viscosity cp 1.500, ,00 0,00 Coke specific surface m² / m³ 90,00 90,00 0,00 Coke bed voidage m³ / m³ 0,35 0,35 0,00 Productivity Case 2 / Case 1 % 3,49 19 ThyssenKrupp Steel Europe

20 Flooding effects Slag flooding - Slag amount minus 10 % Case 1 Case 2 % Gas volume m³ (STP) / t HM 1.300, ,00 0,00 Gas pressure bar (abs.) 4,00 4,00 0,00 Slag amount kg / t HM 250,00 225,00-10,00 Slag viscosity cp 1.500, ,00 0,00 Coke specific surface m² / m³ 90,00 90,00 0,00 Coke bed voidage m³ / m³ 0,35 0,35 0,00 Productivity Case 2 / Case 1 % 2,99 20 ThyssenKrupp Steel Europe

21 Flooding effects Slag flooding - Slag viscosity minus 10 % Case 1 Case 2 % Gas volume m³ (STP) / t HM 1.300, ,00 0,00 Gas pressure bar (abs.) 4,00 4,00 0,00 Slag amount kg / t HM 250,00 250,00 0,00 Slag viscosity cp 1.500, ,00-10,00 Coke specific surface m² / m³ 90,00 90,00 0,00 Coke bed voidage m³ / m³ 0,35 0,35 0,00 Productivity Case 2 / Case 1 % 1,06 21 ThyssenKrupp Steel Europe

22 Flooding effects Slag flooding - Coke specific surface minus 10 % Case 1 Case 2 % Gas volume m³ (STP) / t HM 1.300, ,00 0,00 Gas pressure bar (abs.) 4,00 4,00 0,00 Slag amount kg / t HM 250,00 250,00 0,00 Slag viscosity cp 1.500, ,00 0,00 Coke specific surface m² / m³ 90,00 81,00-10,00 Coke bed voidage m³ / m³ 0,35 0,35 0,00 Productivity Case 2 / Case 1 % 5,41 22 ThyssenKrupp Steel Europe

23 Flooding effects Slag flooding - Coke bed voidage plus 10 % Case 1 Case 2 % Gas volume m³ (STP) / t HM 1.300, ,00 0,00 Gas pressure bar (abs.) 4,00 4,00 0,00 Slag amount kg / t HM 250,00 250,00 0,00 Slag viscosity cp 1.500, ,00 0,00 Coke specific surface m² / m³ 90,00 90,00 0,00 Coke bed voidage m³ / m³ 0,35 0,39 10,00 Productivity Case 2 / Case 1 % 15,37 23 ThyssenKrupp Steel Europe

24 Flooding effects Slag flooding Change Productivity % % Gas volume m³ (STP) / t HM -10,0 7,9 Gas pressure bar (abs.) 10,0 3,5 Slag amount kg / t HM -10,0 3,0 Slag viscosity cp -10,0 1,1 Coke specific surface m² / m³ -10,0 5,4 Coke bed voidage m³ / m³ 10,0 15,4 24 ThyssenKrupp Steel Europe

25 Flooding effects Conclusion The blast furnace productivity is influenced by a lot of parameters like Gas volume, temperature, composition and pressure Slag amount, density and viscosity Especially coke quality Specific surface (Surface to volume ratio) Coke bed voidage 25 ThyssenKrupp Steel Europe

26 Coke quality and blast furnace performance Introduction Roles of coke Flooding effects Effects on blast furnace performance Conclusion 26 ThyssenKrupp Steel Europe

27 Effects on blast furnace performance Coke quality CSR, ThyssenKrupp Steel Europe 75 CSR [ % ] ThyssenKrupp Steel Europe

28 Effects on blast furnace performance A lot of influences 3,00 BF 1 Productivity [ t / 24 h & m³ IV ] 2,50 2,00 BF 2 BF 9 1, CSR [ % ] 28 ThyssenKrupp Steel Europe

29 Effects on blast furnace performance CSR and BF productivity 3,00 BF 1 Productivity [ t / 24 h & m³ IV ] 2,50 2,00 BF 2 BF 9 1, CSR [ % ] 29 ThyssenKrupp Steel Europe

30 Effects on blast furnace performance Shrinking of the steel profit - pool in favour of mining companies 100 Shares of profit pool HRC [ % ] Steel Coking coal Iron ore ThyssenKrupp Steel Europe Source: SBB, McKinsey, BCG

31 Effects on blast furnace performance Coke consumption, productivity and costs Costs [ EUR / t HM ] Costs [ EUR / t HM ] Hot metal production [ Mill. t HM / y ] Alternative measures to increase production Hot metal production [ Mill. t HM / y ] High quality coke: High productivity, low cost level Low quality coke: Low productivity, high cost level 31 ThyssenKrupp Steel Europe

32 Coke quality and blast furnace performance Introduction Roles of coke Flooding effects Effects on blast furnace performance Conclusion 32 ThyssenKrupp Steel Europe

33 Conclusion The blast furnace operation years of experience 1709: First coke based blast furnace in the world, Coalbrookdale, England HM production 2 t / d 2012: Highest hot metal production in the world, Pohang 4, South Korea HM production up to 17,000 t / d 33 ThyssenKrupp Steel Europe

34 Conclusion Quality parameters of coke I 40, I 10 CSR / CRI Medium grain size, grain structure, grain size distribution After 304 years of the coke blast furnace there exists no integrated coke quality parameter to describe the blast furnace performance!

35 Conclusion Quality parameters of coke It would be to simple to describe the coke quality only by the pragmatic experiences of old blast furnace operators: If the slag is billowing in front of the tuyeres the coke quality is not consistent with our standards! Oder auf gut Deutsch: Schlabbert Schlacke in den Formen, entspricht der Koks nicht unseren Normen! After 304 years of the coke blast furnace there exists no integrated coke quality parameter to describe the blast furnace performance!

36 Conclusion Coke quality and blast furnace performance Blast furnace performance depends on coke quality Postulation of a sufficient coke quality Coke production at a cost minimum from an integrated point of view Need for an integrated coke quality parameter Knowledge of the correlations between coking coal blend, coke quality and blast furnace performance After 304 years of the coke blast furnace there exists no integrated coke quality parameter to describe the blast furnace performance!

37 Conclusion Coke quality and blast furnace performance 37 ThyssenKrupp Steel Europe

38 Conclusion Coke quality and blast furnace performance 38 ThyssenKrupp Steel Europe

39 Conclusion Coke quality and blast furnace performance 39 ThyssenKrupp Steel Europe

40 Koksqualität und Hochofenleistung - Theorie und Praxis Düsseldorf, 05. Dezember ThyssenKrupp Steel Europe

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