Michael Babel

Metallurgical Plants and Environmental Technology

SMS group GmbH

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Energy Recovery Systems behind EAF

Environmental Technology

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
Service
Maintenance & Optimization
Revisions & Studies
Revamp/Modification & Spare parts
Energy Management & Energy Monitoring Systems

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

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By-Products & recycling

Waste material SAF
Waste material briquettes
Combined EAF shredder Process

ARCCESS Process-Model
KJ Schneider EAF.XLS Version 01.11.2011

Prepared by:

Copy

File:

Date:

Project:

Potential for heat recovery in the EAF off-gas

Gunni ng 6 0 %S c r a p_ 4 0 %H M 9 1111. EA F

Gunung

LOSE
29.02.2012 Project-No.:
0
Process Calculation for 60% Scrap & 40 % Hot Metal - 120 t / 100 MVA AC-EAF

EAF Sankey Diagram

kWh/t

Burners30,4

kWh/t

Burners

Injection Carbon

93,5

kWh/t

8,5

kWh/t
kWh/t

Carbon 0,0
Lump Carbon:
Electrodes

Electrical
Energy

Sankey diagram for

139,3
Hot Metal

Sensible Heat

Exothermic
reactions
304,2
kWh/t

277,2

exoth. Reactions

Tapping weight

120 t

Charging material

60% scrap
40% HM

Total energy content 853 kWh/t

kWh/t

853,2

kWh/t

19,4 losses
kWh/t
Electrical
Heat Losses
93,1
kWh/t
Heat losses
Electrical Losses

Steel

off-gas

Offgas Sensible
391,9

kWh/t

91,0

kWh/t

Offgas sensible
Offgas
Offgas chemical chemical
206,4
kWh/t

Fe- losses
9,6
Slag 41,9
Slag
Fe - Losses

Recovery

35 %
%
35

80% of off-gas energy

Saturated
steam

kWh/t

kWh/t

The values indicated are rounded

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

26.06.2015

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Total

Recovery of energy from waste heat at melting units

Off-Gas heat

To steam drum

Boiling water
Inlet enthalpy
h = 1000 kJ/kg

Seamless tube

Water/steam mixture
Exit enthalpy steam h= 2800 kJ/kg

Energy absorption by phase change water to steam

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

Confidential All rights reserved 2014 SMS GmbH

Membrane tube wall

(tube-membrane-tube)

26.06.2015

Technical details Flow Chart

water

Steam generation plant

low-pressure circuit

Saturated
steam

high-pressure circuit

Accumulator
Water / steam
mixture

Steam drum

Circular
pumps

Feed water tank

LP
pumps

Energy Recovery at EAF

HP
pumps

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Feed
water

Typical set up

EAF plant with a two step Energy Recovery System

Bag house filter

250C

< 130C

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1,200 C

700 C

Step 1:
Evaporative cooled postcombustion chamber + duct

Step 2:
Additional
Waste Heat Boiler

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

26.06.2015

Further development
Compact Boiler for EAF future design
Heat
exchanger
bundles

Evaporative
cooled walls

Advantages of a compact set up

Postcombustion
zone

+ Option for energy recovery

+ Small layout footprint
+ Natural circulation
No energy consumption by pumps

1,200 C

+ Lower maintenance costs

Confidential All rights reserved 2014 SMS GmbH

No corrosion due to high wall temperature

Decreased abrasion due to low off gas
velocity

230C

Dropping of coarse
dust & slag
Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

26.06.2015

Four different cases for EAF

190 t EAF

100% Scrap

60% scrap,
40% hot metal

49% Scrap
51% DRIhot40%/cold60%

90% HDRI,
10% CDRI

Offgas
temp.

Energy
recovery

Offgas
temp.

Energy
recovery

Offgas
temp.

Energy
recovery

Offgas
temp.

Energy
recovery

250C

30 t/h
steam

250C

45 t/h
steam

270C

91 t/h
steam

270C

118 t/h
steam
26.06.2015

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120 t EAF

Power
generation

Air
separation

Fan or pump
drive turbine

Steam injector
pumps for
VD / RH process

Cooling by
absorption
chilling

Steam
accumulator
vessels

Steam net

ORC process

Water treatment
(e.g. desalination)

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Options for steam utilisation

Wide influence on ROI!

26.06.2015

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Environmental Technology, Example EAF

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

SMS reference

Roof elbow

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Swivel elbow

Combustion chamber

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

26.06.2015

10

SMS reference

Hot gas duct downstream

combustion chamber:

Confidential All rights reserved 2014 SMS GmbH

90- bend with dust hopper,

compensator and manhole

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

26.06.2015

11

SMS reference

Steam drum

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Accumulators

Pump station
Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

26.06.2015

12

Reference: Energy Recovery, Fuxin

Key Data

Technology
Aggregates

Energy Recovery at

Sizes
Melting Aggregates

Steam Generation

Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

FuXin
2010
2014

EAF, AOD, LF,

Gas Cleaning
AOD and EAF

1x 160-t EAF
1x 180-t AOD
1x 180-t LF
50 t/h (peak)

26.06.2015

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Customer
Order
Commissioning

13

Reference: Energy Recovery, Tisco

Key Data
Client
Order intake
Commisioning

Tisco
2012
2014

Technology
Furnance

X-Melt CONARC

Technical Data
Steam generation

two boiler units, up to

60 t/h

CO2 reduction

25,000 tons per year

Energy Recovery System

Stage 1
Stage 2
Metallurgical Plants and Environmental Technology - Energy Recovery at EAF

cools down to 600 C

cools down to 200 C
26.06.2015

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Planning & supply for new long product mill

14

Confidential All rights reserved 2014 SMS group GmbH

Environmental Technology