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THE STEEL INDUSTRY
Pages 5-22

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From page 5... ... The Office of Indus trial Programs has sponsored a number of projec t s relat ing t o energy us e b y the iron and s teel indus try. The s e projects and the ir goals are summ a rized in Table 2. Read the entire page →
From page 6... ... FIGURE 2 Outl ine configurat ions of the electric arc furnace re ference plants. Read the entire page →
From page 7... ... DAI fed ere Nlerence fumeca plelll Nf-nce plena FIGURE 3 Ene rgy consump t ion in the re ference plants. TABLE 1 Energy Los ses for Integrated Re ferenc e Plant Ene rgy Los s n Source Mcal/tcs A MBtu/tcs Coke oven and by-produc t plant 515 2 . Read the entire page →
From page 8... ... A mee ting was convened in Wash ington to rece ive and d i s cuss input from persons knowledgeable in the current was te and energy i s sue s fac ing the s teel indus try and on the s tatus o f techno logy relevant to these problems. Representat ives from the Office of Indus trial Programs par t i c ipated in the mee t ing , along with J . Read the entire page →
From page 9... ... 10 TABLE 2 Projec t s Spons ored by the Office of Indus tri al Programs Re lat ing to Energy Use in the I ron and S te e l Indus try Program Objec t ive Formcoke Develop environmentally acceptab l e c oke manufac tur ing proc e s s Coke p e l l e t proc e s s Deve lop environmental ly acceptab le c oke manufac tur ing proc e s s Blas t gas i f ication Produce low- t o medium-Btu gas us ing i dle bla s t furnace capac i ty Coke dry quench Modify coke oven batte r i e s to permi t recovery o f h e a t re s ident in coke Direc t sme l t ing Deve lop proc e s s for direct produc t ion of s te e l of iron wi thout a b las t furnace Cupola furnace Permit off-gas recovery and combus t ion in modification cupola operation Ho t inspec t i on Deve lop proc e s s for inspec t ion and c orrec t ion and s carfing o f flaws in hot s teel slab s to perm i t cont inuous proc e s s ing to flat rolled produc t Computer control Deve lop hierarchical computer control sys tem for energy management in integrated s te e l mills I ron par t i cle Develop mathematical mode l for e lectric furnace me l t ing operat ions op t imiz ing energy requirements for me l t ing direc t-reduced iron ore and s te e l s crap Electric arc Develop computer model using new control furnace mode l ing me thods S l o t forge furnace Develop and demons trate modificat ions to improve furnace e fficiency Fluidized bed heat Demons trate commerc ial-scale furnace of fluidized treatment bed heat treatment o f me tal parts Nitrogen-bas ed Develop and demons trate nitrogen-based carbur ization atmo sphere for carbur izat ion o f s t e e l parts High-temperature Deve lop s ens ors to ob tain real-t ime proc e s s s ens ors for on; l ine analysis and control Thin s tr ip cas t ing Deve lop twin moving mold and planar flow whe e l cas ting technique s for th in s tr ip s te e l Source: An As s e s sment of the Indus trial Energy Cons ervat ion Program (3) Read the entire page →
From page 10... ... Technically proven concep ts that are be ing adop ted by the indus try as financ ing permits 4. Technical ly unproven concepts C learly , the Office o f Indus trial Programs has no role to play in category 1 and 3 concepts . Read the entire page →
From page 11... ... and als o the use of BOF off-gases for s crap preheat ing • Use of Freon or o ther bottoming cyc l e s to recover heat l o s t from areas such as furnace wal l s and BOF hoods Re search s tarted at GRI in 1986 on a gas-fired sc rap me l ter w i th an integrated heat recove ry sys tem and on a gas-fired hot me tal trans fer sys tem with heat re covery . WASTE HEAT ENERGY An attrac t ive use of was te energy that has been deve loped but may ne ed a demons tration in the Uni ted S tates to ful ly document i t s advantage s i s scrap preheat ing w i th the o ff-gas from an electric arc furnace . Read the entire page →
From page 12... ... In 1985, the indus try continuously cas t 44 percent o f the raw s teel produc t i on and exhibited a raw-s teel- to-produc t yield of 83 percent . Po ten t ial Ene rgy S av inss Base line figure s of 25 GJ per me tric ton of raw s te e l for integrated produc tion and 13 GJ per me tric ton for EAF produc t ion are us ed here to analyze the e ffec t o f incremental yield improvements on ene rgy cons ervation for the indus try . Read the entire page →
From page 13... ... The remaining 40 percent w i ll be produced in electric arc furnaces . Th i s produc t i on rat io and the basel ine figures given proje c t a n annual energy consump t ion by the dome s t i c s teel indus try of 1, 760 , 000 GJ or 1 . Read the entire page →
From page 14... ... The major me thod of us ing sc rap is an electric arc furnace, which accounted for about 34 perc ent of s te e l produc tion in 1985 . If elec tric furnac e s teel produc tion could b e increased t o 50 pe rcent o f the to tal produc tion, 0 . Read the entire page →
From page 15... ... The major e l ement o f concern i s copper; the copper content o f typ ical types o f purchased s crap is l i s ted in Tab l e 4. Currently many of the produc ts produc ed in electric furnace shop s are s imple shapes such as reinforc ing bar and angles, for which copper, nickel, and molybdenum are no t a major concern . Read the entire page →
From page 16... ... The program dealing with s crap re finement cons i s ted o f • Physical separation -- -- A projec t t o improve physical s eparation initially looking at the e ffec t of magne tic flux and improved sight ing methods, to be done by Inland S teel Company wi th input from the Ins titute of S crap I ron and S teel • Hydrome tal lurgical separat ion -- -- W ork on leaching o f s c rap with various reagents , to be done at Idaho Nat ional Laboratory • Pyrome tal lurgical s eparation -- -- Examination o f the thermodynami c s, kine t i c s , and feas ib i l i ty of sulfide treatments for removing c opper , to be done by Carnegie-Me llon Univers i ty ; consideration o f o ther nove l me thods , such as formation o f comp lex hal i de vapor spec ies and novel fluxes, to be done by Argonne National Laboratory • Res i dual elements -- -- E xaminat ion of the ent ire que s t ion o f res idual elements, such as max imum coppe r leve l s, what o ther elements are of conc ern, res idual l evels of elements in various scrap forms, what can be achieved by scrap b lending, and the economics of improved physical s eparat ion and o ther new treatments, to be done by an appo inted task force As of December 1986 this program has no t been implemented. The greater us e o f s crap in s teelmaking i s po tent ially a s ignificant method of reducing energy consumption by indus try . Read the entire page →
From page 17... ... Overall , the energy consump tion for p o l lution abatement in the i ron and s te e l indus try cons t i tutes only a small frac tion of the total energy us ed in thi s indus try . In general, l e s s than 2 percent o f total energy consump t ion is u t i l ized in p o l luti on-abatement ac tivities, w i th by far the large s t part of this be ing for movement of relatively high-temperature o ff-gas es from the var ious s te e lmaking proces ses . Read the entire page →
From page 18... ... The s e materials frequently contain mois ture in the 30 to 40 percent range, and the abil i ty to fur ther dewater the s e material s would reduce the heat requi rements when they are recyc led. The po tential energy reduct i on in this area is s igni ficant; even though dewater ing proc e s s e s have been extens ively s tudied, a further review o f dewater ing techniques i s probab ly warranted . Read the entire page →
From page 19... ... As a result of i t s revi ew o f pub lished informat ion and dis cus sion w i th individuals knowledgeab l e about the s tatus o f techno logy app l icab l e to the indus try, the comm i ttee recommends that the fo llowing areas be considered for inc lus ion in res earch and deve lopment programs of the Office of Indus trial Programs : 1. Re search and development tasks ident i fied as a part o f the S tee l Ini t i a tive should be incorporated in OIP ' s program, even i f spec ial additional funding i s no t appropriated by Congress. Read the entire page →
From page 20... ... 3. An As s e s sment o f the Indus trial Energy Cons ervat ion Program , Volume 2: Final Report . Read the entire page →
From page 22... ... S ince the pe trochemical indus try p o s s e s s e s a s trong technology base, i t has addres sed energy conservation mainly on its own ; only a few proj e c t s relating t o this industry have been undertaken by the O f f i c e o f Indus trial Programs . The re sults o f a previous review of OI P ' s projects for the chemical indus try are s umma r ized in an ear l ier report (2) Read the entire page →

From page 5...

... The Office of Indus trial Programs has sponsored a number of projec t s relat ing t o energy us e b y the iron and s teel indus try. The s e projects and the ir goals are summ a rized in Table 2.

THE STEEL INDUSTRY Pages 5-22

THE STEEL INDUSTRY
Pages 5-22