mm2017 02 ENERGY ENVIRONMENTAL CARE

72
FEATURING 3
ENERGY &
ENVIRONMENTAL
CARE
papers from Primetals Technologies
at the ESTAD Conference 2017 in Vienna,
covering the topics of energy efficiency
and carbon dioxide reduction.
Metals Magazine 2/2017 | Technology | Energy & Environmental Care

73
“ Technology in harmony
with the environment
has become a
key challenge of
our times.”
The integrated iron- and

steelworks of voestalpine
Stahl, Linz, Austria

74
CARBON RECYCLING AT ITS BEST –

UTILIZATION OF BY-PRODUCTS FROM
PROCESS-GAS FERMENTATION
Paper number: 69
Principal author: Tobias Plattner
Technological solutions that allow process gases from

SINTER PLANT AND BASIC OXYGEN
the iron and steel industry to be utilized in other
FURNACE WASTE-HEAT UTILIZATION production facilities, such as in the chemical industry,
– NEW CONFIGURATION WITH ORC are becoming more and more attractive. With the
MODULES FOR POWER GENERATION* use of a microbiological process, it is now possible to
convert the available energy contained in carbon-
Paper number: 67 and hydrogen-rich offgases from coke ovens, blast
Principal author: Dr. Thomas Steinparzer furnaces, direct-reduction plants and LD (BOF)
converters into liquid-based energy sources.
The demand for increasing energy efficiency and
CO₂ reduction is one of the global megatrends of our LanzaTech and Primetals Technologies offer a unique
times. Although the steel industry suffers from a microbial fermentation system to produce chemicals,
volatile economic environment, steel plants welcome most commonly ethanol, from the process gas of
opportunities for sustainable cost reductions and are metallurgical plants. An integrated fermentation
committed to finding healthy solutions for the envi- system with additional downstream facilities is
ronment. Considerable efforts are therefore being made required to treat the fermentation product and waste
to cut electrical power and energy costs in integrated streams to generate a number of by-products that
steel plants, as these count among the biggest cost are usable for various applications such as for the
factors that can be influenced. In integrated iron- generation of electrical or thermal power. By returning
and steelmaking routes, the complex interrelationship the by-products to an integrated steelworks, the
between process energy demands, waste energy fermentation system can be operated as a zero-waste
utilization, the use of natural- and metallurgical gases, facility that compensates for portions of external
the requirements for steam- and heating systems as well input materials such as natural gas or carbon-based
as for power generation must be carefully analyzed. materials.
Potential energy sources, such as the sinter plant,
the cooling stack of basic oxygen furnaces (BOF)
and reheating furnaces, can be assessed in order
to develop a more fully integrated energy concept.
When the direct local use of waste heat is limited, the

best option is to convert the waste heat to mechanical-
electrical power in a Rankine cycle. Electrical power
generation is an especially attractive option for steel
plant operators since it can easily be connected to
the existing power grid of the steel plant. Such units
must be compactly designed as stand-alone systems
in order to fit into the existing steel plant layout, and
operational costs have to be kept to a minimum.
The objective of this paper is to demonstrate eco-

nomically feasible opportunities for energy recovery
in sinter coolers and basic oxygen furnaces. The focus
is placed on electrical power generation via ORC
(Organic Rankine Cycle) modules, while at the same
time achieving CO₂ reductions by utilizing waste heat
from the process. Typical plant arrangements of such
solutions are presented in the paper, as well as basic
economic calculations.
*This paper was written together with Turboden s.r.l., a

Mitsubishi Heavy Industries company that specializes in the
development, production and supply of Organic Rankine Cycle
modules. Example of a LanzaTech gas fermentation plant in China

75
ENERGY & ENVIRONMENTAL

CARE HIGHLIGHTS OF
PRIMETALS TECHNOLOGIES
Energy efficiency
• Generation of up to 100 kg of steam per ton
of liquid steel from the LD (BOF) process with
waste-heat recovery
• Up to 25 kWh electric power generation per
ton of sinter with waste-heat recovery from the
shaft cooler
• Up to 11% energy savings of the total energy
input for minimills
• Up to 40% energy savings for electrostatic
precipitators with Precon
• Up to 30% reduced energy consumption for
secondary emission control with a dynamic
process-control system
Industrial implementation of an EAF waste-heat recovery system • Generation of up to 450 kg of steam per ton of
for steam generation at Acciaieria Arvedi S.p.A., Cremona, Italy blast furnace slag with the Dry Slag Granulation
process (DSG)
• Production of up to 0.23 kg ethanol per Nm³
WASTE HEAT RECOVERY FOR THE feed gas (CO/H₂) with the bio-fermentation of
EAF – INNOVATIVE CONCEPTS AND waste-gas from metallurgical plants
INDUSTRIAL IMPLEMENTATION
Emissions
Paper number: 70 • Less than 3 mg/Nm³ particulate emissions from
Principal author: Paul Trunner bag-filter systems
• Less than 0.1 ng/Nm³ I-TEQ PCDD/F (dioxins/
furans) emissions from any type of metallurgical
Over the last years, waste heat recovery in the steel
plant
industry has attracted ever-increasing attention. • Up to 98% SOx and 90% NOx reductions in
Environmental regulations and public funding, as well the waste gas from sinter plants with Meros
as required revamps of old dedusting systems, have technology
led steel plant operators to discuss and evaluate • Zero-waste water discharge with dry-type
possibilities for recovering waste heat. waste-gas dedusting/gas-cleaning solutions
• Up to 99% plant reliability and availability of
The development of a waste-heat recovery plant any type of ECO gas-cleaning plant
requires extensive knowledge and long-term • 65% lower specific CO₂ emissions in the
experience with the entire plant, including the direct-reduction route compared with the
integrated blast furnace route
water-steam cycle, the EAF (electric arc furnace)
• 65% reduction of specific CO₂ emissions in
process, dedusting systems and downstream
the direct-reduction route compared to the
waste-heat consumers. Primetals Technologies integrated blast furnace route
provides innovative and reliable waste-heat recovery • Up to 50% reduction of waste gas with Selective
solutions for the EAF, which are presented in Waste Gas Recirculation (SWGR) in sinter plants
this paper.
By-products
An innovative waste-heat recovery plant is also • Up to 3% raw material savings with the
introduced, which was installed at Acciaieria Arvedi briquetting and recycling of oxide fines
S.p.a., Italy. Waste heat is used to produce steam for (sludges, dust, scale)
two pickling lines located at a considerable distance • Up to 2% metal-yield improvement with the
valorization of steelmaking slags (metallic
from the EAF. The substitution of the existing gas-fired
oxide recovery)
boilers led to a decisive reduction of operating costs
• Up to 15% boost in cokemaking productivity
for the steel plant. Another heat-recovery plant was with the fine-coal-briquetting process
installed at the electric arc furnace of Höganäs in • 60% (and higher) upgrading of iron content of
Sweden, where hot water at high pressure is produced mining tailings via tailings beneficiation
and utilized for the local district-heating system. The
industrial implementations of waste-heat recovery
systems for the EAF are presented in detail, along
with the operational results achieved.

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72

Metals Magazine 2/2017 | Technology | Energy & Environmental Care

The integrated iron- and

Metals Magazine 2/2017 | Technology | Energy & Environmental Care

CARBON RECYCLING AT ITS BEST –

Technological solutions that allow process gases from

When the direct local use of waste heat is limited, the

The objective of this paper is to demonstrate eco-

*This paper was written together with Turboden s.r.l., a

Metals Magazine 2/2017 | Technology | Energy & Environmental Care

ENERGY & ENVIRONMENTAL

Metals Magazine 2/2017 | Technology | Energy & Environmental Care

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