STAHL Setting the course for tomorrow. Energy efficiency in steelmaking The blast furnace Fit for the future?

Transkript

1 Setting the course for tomorrow Energy efficiency in steelmaking The blast furnace Fit for the future? Peter Schmöle Head of Competence Centre Metallurgy, ThyssenKrupp Steel Europe 1 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

2 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusion 2 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

3 Introduction Dominant position of the blast furnace route in the world, Electric steel 25.6% OH steel 0.5% 1843 DRI / HBI 4.1% Scrap 31.7% Corex / Finex hot metal 0.4% Oxygen steel 73.9% Blast furnace hot metal 63.8% 3 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

4 Introduction with increasing shares in the last years 4 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

5 Introduction and the biggest blast furnaces in Asia Inner volume: Volume between 1 m below chute in vertical position and taphole level 5 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

6 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusion 6 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

7 Metallurgical efficiency Energy consumption Real vs. ideal case 7 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

8 Metallurgical efficiency Energy consumption Real vs. ideal case Ideal case: Process at thermodynamic equilibrium 8 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

9 Metallurgical efficiency Energy consumption Real vs. ideal case Ideal case: Process at thermodynamic equilibrium without cooling losses 9 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

10 Metallurgical efficiency Consumption of reducing agents BF s in Germany Why? 10 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

11 Metallurgical efficiency Sinter composition, TKSE 11 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

12 Metallurgical efficiency Carbon and ash contents in BF coke, TKSE 12 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

13 Metallurgical efficiency BF slag volume, TKSE 13 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

14 Metallurgical efficiency Conclusion The BF is operated at 96 to 93 % efficiency level. (State of the art operation related to a non-realistic process at the thermodynamic equilibrium and w/o heat losses) Since end of 1990 th the cumulated reducing agents consumption increases caused by higher slag volumes lower C contents in coke change from oil / natural gas to pulverized coal injection. 14 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

15 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusion 15 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

16 Alternative benchmark process modes Different auxiliary reducing agents, HBI charging PC HBI NG H 2 Coke kg / t HM PC kg / t HM NG kg / t HM 100 H 2 kg / t HM 40 HBI kg / t HM 400 PC = Pulverized Coal HBI = Hot Briquetted Iron NG = Natural Gas H 2 = Hydrogen 16 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

17 Alternative benchmark process modes Energy input without energy for HBI production 17 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

18 Alternative benchmark process modes Energy input with energy for HBI production 18 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

19 Alternative benchmark process modes Energy input with energy for HBI production 19 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

20 Alternative benchmark process modes Use of HBI in the blast furnace From the energetic point of view it is cockeyed to cut the upper part of the BF, to shift the indirect reduction to an external process and to loose the sensible heat of the HBI in-between. To report only the energy consumption and/or the CO 2 emissions of the BF and to forget energy need and CO 2 emissions for HBI production creates something like an perpetual motion machine. 20 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

21 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input 40 kg H 2 / t HM 100 kg NG / t HM 200 kg PC / t HM 21 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

22 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input 22 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

23 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input 23 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

24 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input 24 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

25 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input 25 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

26 Alternative benchmark process modes Auxiliary reducing agents with increasing hydrogen input 26 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

27 Alternative benchmark process modes Conclusion Charging of cold HBI is contra-productive from the energetic point of view. With higher hydrogen input the energy need and also the energy export increase. Shifting the reduction reactions from carbon to hydrogen causes lower CO 2 emissions, but exploding CO 2 abatement costs. 27 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

28 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusion 28 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

29 Cross-industrial network ThyssenKrupp project Carbon2Chem Chemical use of gases Blast furnace Converter Coke plant State of the art Top gases Power plant Steel production CO 2 Electrical Energy Today Blast furnace Converter Coke plant Chemical use of top gases Top gases Power plant Synthesis Steel production Methanol Synthetic fuel Fertilizer Alcohol Polyalcohol Polymers Future Significant reduction of CO 2 emissions and high value by-products Source: ThyssenKrupp Process Technologies 29 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

30 Cross-industrial network ThyssenKrupp project Carbon2Chem State of the art Electric power Injection coal Oxygen Coking coal COG, BFG, BOFG Iron ore Integrated iron and steel works Steel Electric power Power plant 30 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

31 Cross-industrial network ThyssenKrupp project Carbon2Chem Future Chemical products Injection coal Oxygen Coking coal COG, BFG, BOFG Synthesis Iron ore Integrated iron and steel works Steel Electric power Renewable energy Chemical raw materials Power plant 31 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

32 The blast furnace Fit for the future? Introduction Metallurgical efficiency Alternative benchmark process modes Cross-industrial network Conclusion 32 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

33 Conclusion State of the art, potentials and new ideas Blast furnace as world champion in energy efficiency No chances for further energetic improvements from the metallurgical point of view Hydrogen blast furnace Increasing energy consumption, lower CO 2 emissions, non-competitive costs Rethinking the bounds Cross-industrial network of steelmaking, chemicals industry and energy sectors to create an integrated economic and ecological optimum 33 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

34 Conclusion Statements of clerical and political experts for energy efficiency Pope Francesco, 2015: Climate change is a global problem Chancellor Merkel, 2015: The G7 leaders had committed themselves to the need to decarbonise the global economy in the course of this century 34 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

35 Conclusion To realise this decarbonisation of the global economy we need steel Automotive lightweight design Infrastructure Energy transformation Sustainable construction Renewable energies Energy supply and distribution 35 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl

36 Conclusion and blast furnaces Steelmaking without fossil energy based blast furnaces the touchdown will be a disaster!

37 Setting the course for tomorrow Energy efficiency in steelmaking The blast furnace Fit for the future! Peter Schmöle Head of Competence Centre Metallurgy, ThyssenKrupp Steel Europe 37 Schmoele STAHL 2015 Stahlinstitut VDEh Wirtschaftsvereinigung Stahl