Update on North American Ironmaking - PowerPoint PPT Presentation

Loading...

PPT – Update on North American Ironmaking PowerPoint presentation | free to download - id: 7973f-NjBiY



Loading


The Adobe Flash plugin is needed to view this content

Get the plugin now

View by Category
About This Presentation
Title:

Update on North American Ironmaking

Description:

ABM 2nd International Meeting on Ironmaking, 1st ... ISG Sparrows Point Ispat Inland. L Furnace 7 Furnace. Hearth diameter, m 13.5 13.7. Burden, kg/tHM ... – PowerPoint PPT presentation

Number of Views:893
Avg rating:3.0/5.0
Slides: 25
Provided by: abmbra
Learn more at: http://www.abmbrasil.com.br
Category:

less

Write a Comment
User Comments (0)
Transcript and Presenter's Notes

Title: Update on North American Ironmaking


1
Update on North American Ironmaking
  • Joseph J. Poveromo
    Quebec Cartier Mining Company
  • Fred C. Rorick
  • Rorick, Inc
  • ABM 2nd International Meeting on Ironmaking, 1st
    International Symposium on Iron Ore, September 12
    15, 2004, Vitoria Espirito Santo, BRAZIL

2
TOPICS
  • Blast Furnace ironmaking
  • Alternative Ironmaking Processes
  • Future Prospects

3
(No Transcript)
4
Problems of North American Blast Furnace Sector
  • External EAF mini-mill competition, imports,
    environmental mandates
  • Internal limited capital for modernization,
    high legacy costs, poor profitability
  • Consequences reduction in hot metal, coke
    sintering capacity excess pellet plant capacity

5
Response of North American Blast Furnace
Steelmakers
  • Non-technical consolidation, reduce legacy
    costs, currency changes, markets
  • Technical
  • improve raw materials, upgrade existing
    facilities to
  • increase productivity, reduce reductant rate
    and extend lining life

6
North American BFs Increased Productivity,
Reduced Fuel Rates
  • Key factors
  • fluxed pellets, improved acid pellets
  • improved coke quality
  • higher levels of natural gas, coal injection
  • high levels of oxygen enrichment lower
  • cost oxygen-pipelines, on-site plants
  • higher blast temperatures
  • furnace upgrades charging, cooling, casting

7
Extend Lining Life to 8 12 years
  • Enhanced cooling and refractory systems
  • - intensive plate cooling, copper staves
  •  Remote repair methods
  • - gunniting, grouting, shotcreting
  •  Hearth life extension
  • - North American carbon, coke quality
  •  Burden distribution equipment
  • PW or MA tops on 25 of 41 furnaces

8
Weighted (by Production Rate) Averages of
Reductants by AISI BFs (4)   Hot Metal
of Reductant Usage, kg/tHM
Production, Working Coke Coal
Oil Gas Tar COG MT BFs
Lump Nut Total 1990 55 60 454
1 455 1 12 23 3
0 1995 61 51 402 8
410 34 13 38 1 1 2002
50 38 377 23 400 60
7 29 2 3
9
Increased Furnace Productivity
  • Furnace Hearth
    Productivity Burden Injectant
  • Dia.,
    M T/M3/day
  •  
  • AK Middletown BF 3 8.9 3.9 pellets,HBI
    gas
  • Dofasco 4 BF 8.5 2.9 pellets
    oil
  • Severstal NA C 8.8 3.1 pellets
    gas
  • ISG. Sp.Pt. L BF 13.5 2.5 sinter/pellets
    coal

10


ISG Sparrows Point
Ispat Inland
L Furnace 7
Furnace Hearth diameter, m
13.5 13.7
Burden, kg/tHM

Sinter
1040 228
Acid Pellets 534
0 Fluxed Pellets
0
1350 Lump ore, siliceous ore, etc 48
13 Reductant use, kg/tHM
Large coke 316
319 Small coke
24
22 Coal
149 155 Natural gas
1
0 Top gas utilization,
50.4 49.2 Slag volume,
kg/tHM 270
265
11
Waste Oxide Processing
  • 7 Remaining sinter plants
  • Direct BF charging BOF slag, pellet chips
  • Cold bonded briquettes, lt 5 of burden
  • DR options, Severstal RHF plant
  • Landfill options

12
Coke Supply Challenges
  • US Coke Oven Capacity 14 MTPY
  • Expensive Imported Coke
  • Maximize Injection of Coal, Gas, etc
  • Use HBI ISG Circored Plant ??
  • Rebuild Slot Oven Batteries
  • Heat Recovery Cokemaking
  • - Indiana Harbor Coke Corp
  • - ISG Haverhill Coke Battery, 0.8 MTPY

13
Development of Competitive Processes Process
Routes
  • Smelting reduction Corex, HIsmelt
  • Direct reduction/scrap/EAF steelmaking route
  • Hot metal/scrap/EAF steelmaking route
  • Alternative (pig iron) iron/scrap/EAF steelmaking
    route

14
Development of Alternative Ironmaking
Processes
  • o large scale ironmaking - avoid cokemaking,
    sintering steps preceding blast furnace most
    efforts have failed except for Corex high
    capital cost?
  • o small scale ironmaking - provide iron
    units to EAF mini-mill sector only shaft
    furnace gas based plants ( Midrex, HyL ) so far
    successful in North America
  • o process waste oxides at both EAF and
    BF-based steel plants limited success
  •  

15
North American Direct Reduced Iron ( DRI )
Production
  • Main process route in Mexico gt 5 MTPY shaft
    furnace ( HyL, Midrex ) DRI
  • USA, Canada lt 2 MTPY DRI ( Ispat Sidbec, ISG
    Georgetown ) other facilities down due to high
    gas prices AIR, Corus Mobile
  • North America major importer of metallics HBI
    (Venezuela ) pig iron ( Brazil, Russia )

16
North American Shaft Furnace DRI Developments
  • Application of pellet coating techniques
    increase bustle gas temperature
  • Midrex OXY system
  • HyL self reforming, hot charging of DRI (
    HyTemp system )

17
EVOLUTION OF MIDREX FURNACE PERFORMANCE Ispat
Sidbec
  • DRI Reducing O2 Nat. Elec.
  • Production Gas Temp.Addition Gas
    Cons.
  • T/hr C Nm3/T Nm3/T
    kWh/T
  •  
  • 1970s 88.8 780 0.0 268.6
    135
  • 1980s lump ore 100.3 850 0.0 262.3
    120
  • 1990s coat pellets 110.2 918 0.0 257.9
    109
  • late90s, O2 inj. 121.5 1050 17.5 260.3
    99
  • 2000 OXY 129.2 961 30.2 265.8
    93

18
Coal-based Alternative Ironmaking
  • Iron Dynamics, Inc ( IDI ) hot metal process to
    feed SDIs EAF flat-rolled mini-mill, IDI is an
    RHF(rotary hearth furnace)/SAF (submerged arc
    furnace ) process start with briquettes of iron
    ore/waste oxides/coal, produce DRI in RHF, then
    melt DRI in SAF plant restarted late 2003
  • Mesabi Nugget Demonstration Plant of Kobe ITmk3
    pig iron nugget process

19
Coal-based Alternative Ironmaking
  • HIsmelt plant ( 0.8 MTPY pig iron ) in Kwinana,
    Australia JV involving Nucor
  • Nucor/CVRD JV to build mini-blast furnaces in
    Brazil to produce pig iron for Nucor EAFs in USA
  • RHF waste oxide plants built at EAF and BF/BOF
    plants all are currently idle

20
Role of Quebec Cartier Mining Company in North
American Ironmaking
  • QCM mines iron ore in Quebec-Labrador Trough,
    with pellet plant, port facilities at Port
    Cartier on St. Lawrence Seaway.
  • Mt. Wright mining, concentrating produce 13 MT
    mining and upgrade 2.4 MT of raw ore at 32 Fe
    to yield 1 MT of concentrate specular hematite
    at 66 Fe.
  • Produce pellets ( 8.7 MTPY ) in ( 2 straight
    grate machines, 464 m2 ) for BF and DR use
  • Ship to Europe, N. America, Asia

21
Chemistry of QCMs Mt. Wright concentrate and
pellets

Fe
SiO2 Al2O3 CaO MgO Mt. Wright concentrate 66.0
4.90 0.33 0.07 0.05
TiO2 P S Mn
0.18
0.015 0.005 0.025 Blast Furnace pellets Fe
SiO2 Al2O3 CaO MgO Fluxed
63.3 3.75 0.50 3.68 1.30 Low SiO2
Fluxed 65.1 2.50 0.40 2.25 1.50
Acid 65.1 5.20
0.45 0.60 0.25 DR grade pellets
67.8 1.65 0.35 0.50 0.30
22
US Steelmaking vs. Off-shore slabs
  • Advantages of existing blast furnace plants
  • fully depreciated plants
  • high labor productivity, lt 1 man-hour/ton
  • local coal, equity pellet plants
  • Off-shore slab plants added costs
  • capital recovery
  • ocean freight

23
AISI Actual 2002 ICSTI03 Forecast -
2015
  • Blast Furnace DR
    DS Blast Furnace DR DS
  • M tonnes of BFs
    M tonnes of BFs
  • USA 39.4 31 0.5
    lt0.1 33.0 25 1.0
    2.0
  • Canada 8.0 5 0.2
    0 8.0 5 1.0
    1.0
  • Mexico 3.5 3 4.6
    0 4.0 3 6.0
    0
  • -----------------------------------
    -------- -----------------------------------
    -----
  • 50.9 39
    5.3 lt0.1 45.0 33
    8.0 3.0
  • IDI (RHF/SAF), HIsmelt, ITMk3 Midrex,
    HyL or RHF waste oxide

24
Conclusion - Key North American Developments
  • Heat RecoveryCokemaking
  • Blast Furnaces high productivity, endless
    campaigns, high use of O2, pellets, HBI
  • Midrex, HyL DR higher productivity,
    metallization coated pellets, O2, hot discharge
  • Coal based alternative ironmaking IDI, ITmk3
    processes
About PowerShow.com