2015-06-26-Energy-Recovery-System_behind_EAF.pdf

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Energy Recovery Systems behind EAF

Michael Babel

Metallurgical Plants and Environmental Technology

SMS group GmbH

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Energy

■ Energy Recovery Systems

(EAF, BOF, SAF)

■ Gas Recovery

(BOF, SAF)

■ Process Gas Boiler /

Power Plant

■ Energy from hot slabs

■ Innovative melting

- Primary Energy Melter

- S/EAF®

Gas Cleaning Plants

■ Complete Gas Cleaning Plants

■ New Primary BOF Dedusting

(wet/dry)

■ Secondary Dedusting Systems

(Meltshops etc.)

■ Airwash System™

■ Rolling mill offgas treatment

■ DENOX-Systems

Water Treatment

■ Classic waste water treatment

■ Make-up water Technologies

■ Open & closed cooling cycles

■ Thermal process

■ Membrane process

■ Chemical supply

Service

■ Maintenance & Optimization

■ Revisions & Studies

■ Revamp/Modification & Spare parts

■ Energy Management & Energy Monitoring Systems

By-Products & recycling

■ Waste material SAF

■ Waste material briquettes

■ Combined EAF shredder Process

1

Environmental Technology

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ARCCESS Process-Model File:

Project:

Project-No.:

Gunni ng 6 0 %S c r a p_ 4 0 %HM 9 1111. EAF

EAF Sankey Diagram

29.02.2012

Process Calculation for 60% Scrap & 40 % Hot Metal - 120 t / 100 MVA AC-EAF

LOSE 0Prepared by:

© KJ Schneider EAF.XLS Version 01.11.2011 Date: Gunung

Copy

Steel

391,9 kWh/t

Slag 41,9 kWh/t

Fe - Losses 9,6 kWh/t

Offgas chemical 206,4 kWh/t

Offgas Sensible 91,0 kWh/t

Heat Losses 93,1 kWh/t

Electrical Losses 19,4 kWh/t

Total 853,2 kWh/t

Electrical Energy

277,2

kWh/t

Sensible Heat 139,3 kWh/t

Burners 30,4 kWh/t

Injection Carbon 93,5 kWh/t

Lump Carbon: 0,0 kWh/t

Electrodes 8,5 kWh/t

exoth. Reactions 304,2 kWh/t

Tapping weight 120 t

Charging material 60% scrap

40% HM

Total energy content 853 kWh/t

Sankey diagram for

Recovery

The values indicated are rounded

off-gas

80% of off-gas energy

Saturated

steam 35 %

Burners

Carbon

Exothermic reactions

Electrical losses

Heat losses

Fe- losses Slag

2

Hot Metal

Potential for heat recovery in the EAF off-gas

35 % Offgas sensible

Offgas chemical

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF 26.06.2015

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Water/steam mixture

Exit enthalpy steam h‘‘= 2800 kJ/kg

Boiling water

Inlet enthalpy

h‘ = 1000 kJ/kg

Off-Gas heat

To steam drum

Membrane tube wall

(tube-membrane-tube)

Seamless tube

Energy absorption by phase change water to steam

Recovery of energy from waste heat at melting units


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Energy Recovery at EAF 4

Technical details – Flow Chart

Saturated

steam

Accumulator

Steam drum

Feed water tank

Steam generation plant water

low-pressure circuit

high-pressure circuit

HP pumps

LP pumps

Circular pumps

Water / steam

mixture

Feed

water

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5 26.06.2015 Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

EAF plant with a two step Energy Recovery System

Typical set up

Step 2:

Additional

Waste Heat Boiler

< 130°C

700 °C

250°C

1,200 °C

Bag house filter

Step 1:

Evaporative cooled post-

combustion chamber + duct

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Compact Boiler for EAF – future design

Further development

230°C

1,200 °C

Postcombustion

zone

Evaporative

cooled walls

Dropping of coarse

dust & slag

+ +

+

+

Lower maintenance costs

Advantages of a compact set up

Option for energy recovery

Small layout „footprint“

No corrosion due to high wall temperature

Decreased abrasion due to low off gas

velocity

Natural circulation

No energy consumption by pumps

Heat

exchanger

bundles

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7 26.06.2015

Four different cases for EAF

49% Scrap

51% DRIhot40%/cold60%

90% HDRI,

10% CDRI

190 t EAF

100% Scrap 60% scrap,

40% hot metal

120 t EAF

Offgas temp.

250°C

Energy recovery

30 t/h steam

Offgas temp.

250°C

Energy recovery

45 t/h steam

Offgas temp.

270°C

Energy recovery

91 t/h steam

Offgas temp.

270°C

Energy recovery

118 t/h steam

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8 26.06.2015

Options for steam utilisation

Power

generation

Air

separation

Cooling by

absorption

chilling

Steam injector

pumps for

VD / RH process

Fan or pump

drive turbine

Steam

accumulator

vessels

Steam net ORC process Water treatment

(e.g. desalination)

Wide influence on ROI!

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9

Environmental Technology, Example EAF

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

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11 Metallurgical Plants and Environmental Technology - Energy Recovery at EAF 26.06.2015

SMS reference

Hot gas duct downstream

combustion chamber:

90°- bend with dust hopper,

compensator and manhole

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Reference: Energy Recovery, Fuxin

Key Data

Customer FuXin

Order 2010

Commissioning 2014

Technology

Aggregates EAF, AOD, LF,

Gas Cleaning

Energy Recovery at AOD and EAF

Sizes

Melting Aggregates 1x 160-t EAF

1x 180-t AOD

1x 180-t LF

Steam Generation 50 t/h (peak)

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Reference: Energy Recovery, Tisco

Client Tisco

Order intake 2012

Commisioning 2014

Technology

Furnance X-Melt® CONARC®

Planning & supply for new long product mill

Technical Data

Steam generation two boiler units, up to

60 t/h

CO2 reduction 25,000 tons per year

Energy Recovery System

Stage 1 cools down to 600 °C

Stage 2 cools down to 200 °C

Key Data

2015-06-26-Energy-Recovery-System_behind_EAF.pdf

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