Challenges for Sustainable Ironmaking at ArcelorMittal - ABM
Challenges for Sustainable Ironmaking at ArcelorMittal - ABM
Challenges for Sustainable Ironmaking at ArcelorMittal - ABM
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<strong>Challenges</strong> <strong>for</strong> <strong>Sustainable</strong> <strong>Ironmaking</strong> <strong>at</strong><br />
<strong>ArcelorMittal</strong><br />
September 2008<br />
<strong>ABM</strong> <strong>Ironmaking</strong> Conference<br />
05/10/2008 Confidential 0
The front cover – November 1989<br />
05/10/2008 1
The inside cover -<br />
Not in this millennium. Mini<br />
and major relines as well as<br />
changes in oper<strong>at</strong>ing and<br />
maintenance practices will<br />
keep the big ironmakers<br />
running into the next<br />
century<br />
05/10/2008 2
Today’s cover<br />
21ST CENTURY<br />
Look<br />
Inside<br />
Plan &<br />
Do<br />
SustainAbility<br />
05/10/2008 3
Outline<br />
• <strong>Ironmaking</strong> <strong>at</strong> <strong>ArcelorMittal</strong> – An unique footprint<br />
• Sustainability – Wh<strong>at</strong> does it mean to us<br />
• The <strong>Challenges</strong> – How are we meeting them now and<br />
into the future<br />
• Concluding Remarks<br />
05/10/2008 4
• <strong>Ironmaking</strong> <strong>at</strong> <strong>ArcelorMittal</strong><br />
An unique footprint<br />
• Sustainability<br />
Wh<strong>at</strong> does it mean to us<br />
• The <strong>Challenges</strong><br />
How are we meeting them<br />
now and into the future<br />
• Concluding Remarks<br />
05/10/2008 5
Global Iron and Steel Production Trends<br />
Global iron production (millions of tons)<br />
1400<br />
1200<br />
1000<br />
800<br />
600<br />
400<br />
200<br />
0<br />
Steel<br />
BF<br />
DRI<br />
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007<br />
05/10/2008 6
<strong>ArcelorMittal</strong>’s Global Footprint<br />
<strong>ArcelorMittal</strong> 2007 production 116,4 Mt<br />
05/10/2008 7
<strong>Ironmaking</strong> facilities are “integr<strong>at</strong>ed”<br />
05/10/2008 8
Production via the “oxide route” - 2007<br />
100<br />
Number<br />
80<br />
60<br />
40<br />
32,1 Mt<br />
90,5 Mt<br />
82,5 Mt<br />
96.5Mt<br />
20<br />
9,9 Mt<br />
0<br />
coke plant sinter plant blast<br />
furnace<br />
DRI<br />
Steel<br />
05/10/2008 9
Eqv Coke R<strong>at</strong>e kg/thm<br />
Equivalent Coke R<strong>at</strong>ekg/t<br />
900<br />
850<br />
800<br />
750<br />
700<br />
650<br />
600<br />
550<br />
500<br />
3.5<br />
2.5<br />
1.5<br />
Productivity Prod. t/m3/d<br />
450<br />
Work. Vol., m3<br />
400 5 , 0 0 0<br />
4 , 0 0 0<br />
3 , 0 0 0<br />
2 , 0 0 0<br />
1 , 0 0 0<br />
0<br />
0.5<br />
05/10/2008 10
60<br />
0.25<br />
50<br />
0.2<br />
Oven Volume, m3<br />
40<br />
30<br />
20<br />
0.15<br />
0.1<br />
Productivity kg/m3/h<br />
10<br />
0.05<br />
0<br />
0<br />
05/10/2008 11
700<br />
80<br />
600<br />
70<br />
500<br />
60<br />
Effective Gr<strong>at</strong>e Area, m2<br />
400<br />
300<br />
200<br />
50<br />
40<br />
30<br />
20<br />
Productivity t/m2/d<br />
100<br />
10<br />
0<br />
0<br />
05/10/2008 12
3,000,000<br />
2,500,000<br />
Actual 2007<br />
Budjet 2008<br />
Production (ton/year)<br />
2,000,000<br />
1,500,000<br />
1,000,000<br />
COREX<br />
COAL<br />
500,000<br />
0<br />
AMPL-DR-1<br />
AMPL-DR-2<br />
AMPL-DR-3<br />
AMLC-Midrex<br />
AMLC-HYL<br />
AMC-Mod-1<br />
AMC-Mod-2<br />
AMH<br />
AMSA-Saldanha<br />
AMSA-VDB<br />
AMSA-Dunswart<br />
AM-Acindar<br />
AM DR Plants<br />
05/10/2008 13
And highly vertically integr<strong>at</strong>ed<br />
05/10/2008 14
<strong>ArcelorMittal</strong> – An unique footprint<br />
Leadership<br />
Knowledge<br />
Technologies<br />
Vertical<br />
integr<strong>at</strong>ion<br />
Wide range of:<br />
Capacity Levels<br />
Raw M<strong>at</strong>erials<br />
Per<strong>for</strong>mance<br />
levels<br />
05/10/2008 15
• <strong>Ironmaking</strong> <strong>at</strong> <strong>ArcelorMittal</strong><br />
An unique footprint<br />
• Sustainability<br />
Wh<strong>at</strong> does it mean to us<br />
• The <strong>Challenges</strong><br />
How are we meeting them<br />
now and into the future<br />
• Concluding Remarks<br />
05/10/2008 16
Sustainability<br />
“Meet the needs of the present without compromising<br />
the ability of future gener<strong>at</strong>ions to meet their own needs”<br />
Today<br />
Tomorrow<br />
05/10/2008 17
Sustainability <strong>Challenges</strong><br />
05/10/2008 18
The <strong>Ironmaking</strong> plant is integr<strong>at</strong>ed in<br />
to the plant m<strong>at</strong>erials, gas and energy<br />
network<br />
NEW COKE PLANT<br />
(SOL COQUERIA TUBARÃO)<br />
COKE PLANT<br />
SINTER PLANT<br />
FLUXES / OTHERS<br />
COAL<br />
PCI<br />
T.R.T<br />
BLAST FURNACE<br />
IRON ORE<br />
PELLETS<br />
# 1 # 2 # 3<br />
# 1<br />
# 2<br />
PIG IRON<br />
MOLDING MACHINE<br />
TORPEDO CAR<br />
DESSULFURIZATION<br />
LADLE TREATMENT (IR-UT)<br />
# 1<br />
SLABS<br />
# 2<br />
# 1 # 2 # 3<br />
BOF SHOP<br />
# 1 # 2<br />
VACUUM DEGASSING-RH<br />
# 3<br />
CONTINUOUS CASTING<br />
HOT STRIP MILL<br />
05/10/2008 19
Sustainability<br />
A vertical vision, integr<strong>at</strong>ed and holistic<br />
<strong>Challenges</strong><br />
Global Sustainability<br />
IRON & STEEL MAKING<br />
- Longevity<br />
- Knowledge capitaliz<strong>at</strong>ion<br />
- Advanced Monitoring<br />
- Total control<br />
- PCI boosting<br />
- Process efficiency<br />
- Compact upstream<br />
- …<br />
RAW MAT. & ENERGY<br />
- New raw m<strong>at</strong>erials<br />
(poor ores, charcoal…)<br />
- New fuel and power mix<br />
- Logistics<br />
PROCESS SUPPORT<br />
- Powerhousing<br />
- Offgases valoriz<strong>at</strong>ion<br />
- W<strong>at</strong>er tre<strong>at</strong>ment<br />
- Emissions ab<strong>at</strong>ement<br />
- …<br />
ARCELORMITTAL +<br />
OTHER INDUSTRIES<br />
[Cement, Power Plants,<br />
Mines, Ceramics…]<br />
- Byproducts<br />
- CO2<br />
- …<br />
Time<br />
PROCESS<br />
RESOURCES<br />
PERIMETRAL<br />
SYNERGY<br />
05/10/2008 20
• <strong>Ironmaking</strong> <strong>at</strong> <strong>ArcelorMittal</strong><br />
An unique footprint<br />
• Sustainability<br />
Wh<strong>at</strong> does it mean to us<br />
• The <strong>Challenges</strong><br />
How are we meeting them<br />
now and into the future<br />
• Concluding Remarks<br />
05/10/2008 21
Three Axes of Action<br />
05/10/2008 22
Knowledge Organiz<strong>at</strong>ion<br />
05/10/2008 23
Knowledge Organiz<strong>at</strong>ion<br />
To move globally <strong>at</strong> a fast pace we should do:<br />
Top Level<br />
System <strong>for</strong><br />
every Aspect<br />
MEANS & TOOLS:<br />
Taking the best<br />
knowledge of the<br />
company and<br />
dissemin<strong>at</strong>ing it<br />
A bottom up system:<br />
• Extensive benchmarking<br />
• Twinning concepts<br />
Example of SHARE (Decision support tool<br />
dynamic Benchmarking)<br />
05/10/2008 24
Knowledge Organiz<strong>at</strong>ion<br />
Capture our knowledge via expert systems ;<br />
Hot metal temper<strong>at</strong>ure<br />
<strong>ArcelorMittal</strong> Dunkerque BF #4<br />
05/10/2008 25
Knowledge Organiz<strong>at</strong>ion<br />
Increase our knowledge via st<strong>at</strong>e of art tools<br />
3-D Raceway and Raceway combustion model <strong>for</strong> PCI<br />
combustion and raceway gas distribution<br />
05/10/2008 26
Knowledge Organiz<strong>at</strong>ion<br />
Increase our knowledge via st<strong>at</strong>e of art tools<br />
3-D CFD Hearth Model <strong>for</strong> he<strong>at</strong> transfer analyses<br />
3-DTemp. field in the lining<br />
Thermal connection effects<br />
05/10/2008 27
Knowledge Organiz<strong>at</strong>ion<br />
Increase our knowledge via st<strong>at</strong>e of art tools<br />
- 3-D CFD Hearth Model <strong>for</strong> Hearth Drainage analyses<br />
Mixture of<br />
iron and<br />
slag<br />
Iron<br />
Slag<br />
& gas<br />
Side view<br />
Top view<br />
05/10/2008 28
Energy / Environment<br />
05/10/2008 29
Energy / Environment<br />
IH No. 7 Blast Furnace<br />
Cleaning<br />
Stage<br />
Primary<br />
Final<br />
Axial Cyclone<br />
Cleaner<br />
Stream<br />
Axial Cyclone<br />
Flue Dust<br />
Wet<br />
Scrubber<br />
Sludge<br />
Zinc, %<br />
0.28<br />
3.08<br />
Recovery of<br />
Solid<br />
Wastes, %<br />
70.00<br />
30.00<br />
Recovery of<br />
Zinc, %<br />
17.50<br />
82.50<br />
Blast Furnace<br />
IH No. 7 BF<br />
CST No. 3 BF<br />
Monlevade New BF<br />
Fos No. 1 BF<br />
Fos No. 2 BF<br />
Dunkerque No. 4 BF<br />
Hearth Diameter, m<br />
13.7<br />
12.5<br />
9.5<br />
11.8<br />
11.8<br />
14<br />
Install<strong>at</strong>ion St<strong>at</strong>e<br />
Installed<br />
Installed<br />
To be installed in 2011<br />
Installed<br />
To be installed in 2010<br />
Installed<br />
05/10/2008 30
Energy / Environment<br />
Understanding of technologies to select best local choice<br />
EOS<br />
Emission Optimised Sintering<br />
LEEP<br />
Low Emissions & Energy<br />
optimized sinter Production<br />
EPOSINT<br />
Environmentally Process Optimized<br />
SINTering<br />
<strong>ArcelorMittal</strong><br />
sinter plant<br />
Sinter<br />
pot facility<br />
Metallurgical per<strong>for</strong>mance<br />
Environmental results<br />
05/10/2008 31
Energy / Environment<br />
A process – product synergy <strong>at</strong> <strong>ArcelorMittal</strong> Mines<br />
• Low Silica Fluxed Pellets<br />
• New (2008) Former (2007)<br />
• Pellet<br />
• Fe 65.61 65.19<br />
• CaO 2.14 2.24<br />
• MgO 0.86 1.43<br />
• Tumbler 95.6 95.3<br />
• Abrasion 3.9 4.2<br />
• Compression 319 285<br />
• LTD 90.7 91.5<br />
• R40 1.28 1.35<br />
• Pellet Plant<br />
• dolomite 41.3 73.1<br />
• limestone 17.4 5.0<br />
• oil (MJ/T) 231.6 219.4<br />
• carbon (MJ/T) 530.2 604.1<br />
• Oil + carbon (MJ/T) 761.8 823.5<br />
05/10/2008 32
Energy / Environment<br />
Our Tubarao plant is our benchmark in Energy Management<br />
05/10/2008 33
<strong>ArcelorMittal</strong> Tubarão Energy Model<br />
SUMMARY (MW equivalent)<br />
INPUT: 5.950(COAL)<br />
COKE: 2.950<br />
RECOVERIES: 2.505<br />
Gas<br />
380<br />
Furnaces in the Plant<br />
Outsourced Lime Plant<br />
Gas<br />
420<br />
T.R .T<br />
Zero consumption of oil<br />
Low NG consumption<br />
Gas<br />
55<br />
Coal<br />
4.700<br />
By Products Coke Plant<br />
(1.600: coke)<br />
He<strong>at</strong> Recovery Coke Plant<br />
(1.350: coke)<br />
He<strong>at</strong>, Gas, Tar, Steam<br />
870<br />
SUMMARY (1 kboe/day)<br />
(1boe =1,88MWh)<br />
INPUT: 76<br />
COKE: 38<br />
RECOVERIES: 32<br />
Coal<br />
1.250<br />
Blast Furnaces<br />
Kinetic<br />
Energy Gas<br />
20 620 Gas<br />
140<br />
COGENERATION<br />
Electricity, steam, mechanical energy,<br />
oxygen, nitrogen, argon, compressed air<br />
Steel Making<br />
Self-sufficiency in<br />
Electric Energy<br />
Sales of electricity<br />
Low consumption of<br />
fresh w<strong>at</strong>er<br />
Sales of coke<br />
05/10/2008 and other utilities<br />
34
Fuel Distribution System<br />
NATURAL GAS<br />
T.R.T<br />
STEEL MAKING PLANT<br />
GAS HOLDER<br />
BFG<br />
BFG FLARE 1, 2 , 3 and 4<br />
BFG<br />
BLAST FURNACE 1 , 2 and 3<br />
LDG<br />
GAS HOLDER<br />
LDG<br />
NG<br />
DISTRIBUTION<br />
STATION<br />
NG<br />
T<br />
66 MW<br />
VAPOR<br />
(26 t/h)<br />
G<br />
72 MVA<br />
72 MVA<br />
S<br />
CALCINAÇÃO 1 e 2<br />
TORPEDO CAR<br />
TAR STORAGE<br />
T<br />
66 MW<br />
G<br />
72 MVA<br />
S<br />
VAPOR<br />
(26 t/h)<br />
HSM<br />
SALES<br />
T<br />
68 MW<br />
VAPOR<br />
(50 t/h)<br />
G<br />
80 MVA<br />
IRON CASTING MACHINE<br />
T<br />
68 MW<br />
G<br />
80 MVA<br />
Futuro<br />
BRIQUET PLANT<br />
VAPOR<br />
(50 t/h)<br />
COKE PLANT<br />
TAR<br />
COG FLARE<br />
COG GAS<br />
HOLDER<br />
SINTER PLANT<br />
GAS MIXER<br />
STATION<br />
SHOP<br />
FOUDRI,<br />
PCI,RH<br />
COG<br />
COG<br />
STEAM<br />
05/10/2008 35<br />
MG<br />
PLANT
Fuel Recovery Index<br />
Gas Fuel is produced <strong>at</strong> Coke Plant, Blast Furnace and Steel Making Plant.<br />
Recovery all th<strong>at</strong> Energy is our target to have a high productivity and low costs.<br />
Fuel Recovery Index (%)<br />
Foreseen<br />
Accomplished<br />
The Fuel Recovery Index has reduced in middle 2007 due to new energy fuel sources after the 7,5 Mt/y<br />
start up (new Blast Furnace and Steel Converter). It is <strong>for</strong>eseen th<strong>at</strong> in begin of 2009 after the new Hot<br />
Strip Mill furnace start up this index to be recovered to values above 95%.<br />
05/10/2008 36
Energy / Environment<br />
• And be a responsible part of the community<br />
- Clean W<strong>at</strong>er<br />
- Clean Air<br />
- Clean Earth<br />
05/10/2008 37
Profit / Innov<strong>at</strong>ion<br />
05/10/2008 38
Profit /Innov<strong>at</strong>ion<br />
Asset Longevity – Coke plant, novel Videofil<br />
and its use in b<strong>at</strong>tery age determin<strong>at</strong>ion<br />
ARCELORMITTAL COKE PLANTS<br />
• Methodology to estim<strong>at</strong>e the<br />
corrected age of a b<strong>at</strong>tery using<br />
• Geometry of the b<strong>at</strong>tery<br />
• Temper<strong>at</strong>ures<br />
• Gas leakages<br />
• Oven wall damages<br />
• Videofil ®<br />
– Flexible non-w<strong>at</strong>er cooled<br />
endoscope of 10 m length<br />
– Assess he<strong>at</strong>ing flues or chamber<br />
walls conditions<br />
– Determine the depth and extent<br />
of repair work<br />
CORRECTED AGE<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
0 10 20 30 40 50 60<br />
CALENDAR AGE<br />
05/10/2008 39
Profit /Innov<strong>at</strong>ion<br />
Asset Longevity - Advanced Monitoring tools <strong>for</strong> the BF hearth<br />
• Based on a dense network of<br />
thermocouples<br />
• Inverse thermal analysis<br />
estim<strong>at</strong>ed position of the<br />
1150°C isotherm<br />
• Model installed in:<br />
– Gent, Liege<br />
– Monlevade, Tubarao<br />
– Dunkerque, Fos, Florange<br />
– Bremen, Eisenhüttenstadt Dillingen<br />
– Gijon<br />
– Hamilton<br />
– Indiana Harbor<br />
Dunkerque-4<br />
05/10/2008 40
Profit /Innov<strong>at</strong>ion<br />
• BF Campaign Extension requires a long term commitment<br />
to every aspect of excellence from oper<strong>at</strong>ions, maintenance,<br />
training – <strong>ArcelorMittal</strong> Tubarao No. 1 BF experience<br />
05/10/2008 41
Tubarao No. 1 BF Equipment Control<br />
Critical points of furnace life<br />
Controlled by Process<br />
Refractories falldown<br />
Bells and rod wear<br />
and abrasion<br />
Shell cracks /<br />
Stave failure<br />
Diffuser corrosion<br />
Thro<strong>at</strong> corrosion<br />
Bricks failures<br />
and shell cracks<br />
05/10/2008 42<br />
Bricks failures<br />
Hearth wear
Tubarao No. 1 BF Equipment Control<br />
YEAR<br />
1987<br />
1988<br />
1989<br />
1991<br />
1992<br />
1994<br />
1996<br />
1998<br />
2000<br />
2001<br />
ITEM<br />
Start of the Blast Furnace life extension program<br />
Small Bell liner repair<br />
Large Bell liner install<strong>at</strong>ion<br />
Start of shaft grouting<br />
Trough wearing pl<strong>at</strong>es install<strong>at</strong>ion<br />
Small bell liner repair<br />
Start of gunning technique repair<br />
Small bell hopper repair<br />
Special cooling devices development<br />
Large bell line repair<br />
Small bell cup reline<br />
Stave cooling (pipes) system repair<br />
Large bell liner repair<br />
Small bell cup and line repair<br />
Start of second Blast Furnace life extension program<br />
Main activities th<strong>at</strong> CST has been<br />
working rel<strong>at</strong>ed to the equipment<br />
maintenance <strong>for</strong> extending the BF life<br />
05/10/2008 2003 Coke central feeding system<br />
43
Tubarao No. 1 BF BF – SHELL DEGRADATION<br />
Cracks Evolution<br />
Cracks Lenght<br />
6<br />
4<br />
2<br />
0<br />
1999 / 2<br />
2000/1<br />
2000/2<br />
2001/1<br />
2001/2<br />
2002/1<br />
2002/2<br />
2003/1<br />
2003/2<br />
2004/1<br />
2005/2<br />
2006/1<br />
2006/2<br />
2007/1<br />
6250 mm<br />
2007/2<br />
2008/1<br />
Accum.<br />
year<br />
05/10/2008 44
Tubarao No. 1 BF Productivity – t/d/m³ IV<br />
Sustained oper<strong>at</strong>ion with high production<br />
- Accumul<strong>at</strong>ed Production: 82.263.912 t<br />
- Accumul<strong>at</strong>ed Productivity: 2.068 t/d/m³ Inner volume<br />
3.5<br />
3<br />
2.5<br />
2<br />
t/d/m³<br />
1.5<br />
1<br />
0.5<br />
0<br />
Startup<br />
1983<br />
1984<br />
Nov 11, 1983<br />
1985<br />
1986<br />
1987<br />
1988<br />
1989<br />
1990<br />
1991<br />
1992<br />
1993<br />
1994<br />
1995<br />
1996<br />
1997<br />
1998<br />
1999<br />
2000<br />
2001<br />
2002<br />
2003<br />
2004<br />
2005<br />
2006<br />
2007<br />
2008<br />
Productivity<br />
05/10/2008 45
Tubarao No. 1 BF Total Fuel R<strong>at</strong>e<br />
(not equivalent)<br />
Sustained oper<strong>at</strong>ion with low fuel r<strong>at</strong>e<br />
- 1986 started tar injection,<br />
- 1996 started PCI injection<br />
Kg/thm<br />
600<br />
550<br />
500<br />
450<br />
400<br />
350<br />
300<br />
250<br />
200<br />
150<br />
100<br />
50<br />
0<br />
9,3 13,3 12,9 13,6 3,8 1,1 10,4 12,7 17,3 19,8 11,6 15,5 17,8 28,5 32,5 32,2 34,0 40,5<br />
69,0<br />
64,0 64,5<br />
73,8 70,7<br />
1983<br />
1984<br />
1985<br />
1986<br />
1987<br />
1988<br />
160<br />
140<br />
120<br />
100<br />
80<br />
60<br />
40<br />
20<br />
0<br />
1989<br />
1990<br />
1991<br />
1992<br />
1993<br />
1994<br />
1995<br />
1996<br />
1997<br />
1998<br />
1999<br />
2000<br />
2001<br />
2002<br />
2003<br />
2004<br />
2005<br />
2006<br />
2007<br />
2008<br />
SCR CR TAR PCR FR<br />
05/10/2008 46
Tubarao No. 1 BF Burden<br />
100%<br />
90%<br />
80%<br />
70%<br />
60%<br />
50%<br />
40%<br />
30%<br />
20%<br />
10%<br />
0%<br />
1983<br />
1984<br />
1985<br />
1986<br />
1987<br />
1988<br />
1989<br />
1990<br />
1991<br />
1992<br />
1993<br />
1994<br />
1995<br />
1996<br />
1997<br />
1998<br />
1999<br />
2000<br />
2001<br />
2002<br />
2003<br />
2004<br />
2005<br />
2006<br />
2007<br />
2008<br />
Sinter Lump Pellet<br />
05/10/2008 47
Profit /Innov<strong>at</strong>ion<br />
Design tools <strong>for</strong> longevity – the hearth<br />
• When submitted to he<strong>at</strong> transfer,<br />
the hearth refractory expands <br />
thermal stresses.<br />
• Finite Element Analysis <br />
optimize design to minimize<br />
stresses<br />
Block<br />
displacements<br />
Temper<strong>at</strong>ure<br />
distribution<br />
• Applic<strong>at</strong>ion <strong>for</strong> designs of future<br />
– Fos-2<br />
– Dunkerque-2<br />
– Gijon-B<br />
• Benchmark of all oper<strong>at</strong>ing<br />
hearths in the Group<br />
VonMises<br />
stress map<br />
Critical area<br />
(m<strong>at</strong>erial yield)<br />
05/10/2008 48
Profit /Innov<strong>at</strong>ion<br />
Know your process better<br />
• Measure actual pushing <strong>for</strong>ce, not calcul<strong>at</strong>ed<br />
from motor amperage<br />
– Typical pushing <strong>for</strong>ce curve shows:<br />
• A peak when coke cake start to move<br />
• A rapid decrease as coke cake clears from oven wall<br />
due to oven taper and keeps stable<br />
• A long and more or less fl<strong>at</strong> zone where only friction<br />
on the oven sole occurs<br />
Hard Pushing<br />
30<br />
25<br />
20<br />
Force (Tonnes)<br />
15<br />
10<br />
5<br />
0<br />
05/10/2008 49<br />
0 5 10 15 20 25 30 35 40 45<br />
Time (sec)
Profit /Innov<strong>at</strong>ion<br />
Know your process better<br />
SUPERMAGNAC<br />
Continuous assessment of the magnetic index of sinter = indic<strong>at</strong>or of sintering degree<br />
directly on the sinter strand<br />
over the whole bed width<br />
Sensor installed <strong>at</strong><br />
<strong>ArcelorMittal</strong> Gent<br />
Magnetic index (-)<br />
40<br />
35<br />
30<br />
25<br />
20<br />
Period 1<br />
Profiles across strand width<br />
Period 2<br />
13<br />
11.4<br />
9.8<br />
8.2<br />
6.6<br />
Fe++ (w/w%)<br />
15<br />
0 100 200 300 400<br />
Distance to the pallet wall (cm)<br />
5<br />
Potential benefits through enhanced process regularity<br />
gains rel<strong>at</strong>ed to energy, quality, productivity, environment<br />
05/10/2008 50
Profit /Innov<strong>at</strong>ion<br />
Know your process better –liquid level in BF<br />
hearths<br />
1 ,2<br />
1<br />
S t<strong>at</strong>ic p su m e as u rem e n t <strong>at</strong> F o s B F # 1<br />
St<strong>at</strong>ic pressure evolution <strong>at</strong> Fos BF1<br />
•St<strong>at</strong>ic Pressure measurement<br />
P<br />
slag<br />
St<strong>at</strong>ic pressure (bar)<br />
0 ,8<br />
0 ,6<br />
0 ,4<br />
hot metal<br />
0 ,2<br />
N 2<br />
Q<br />
0<br />
1 2 :0 0 1 3 :1 2 1 4 :2 4 1 5 :3 6 1 6 :4 8 1 8 :0 0 1 9 :1 2<br />
Raw EMF signal<br />
•ElectroMotive Forces (EMF) on BF shell:<br />
- Extraction of liquid level component from the EMF<br />
signal <strong>at</strong> Cleveland BF6<br />
Estim<strong>at</strong>ed thermal component<br />
Estim<strong>at</strong>ed liquid level component<br />
Estim<strong>at</strong>ed thermal component<br />
•Strains on BF shell:<br />
-Estim<strong>at</strong>e of hot metal and slag levels from Finite<br />
Element Method <strong>at</strong> Fos BF1<br />
0<br />
05/10/2008 51<br />
(m)<br />
10<br />
9<br />
8<br />
7<br />
6<br />
5<br />
4<br />
3<br />
2<br />
1<br />
REFERENCE<br />
Slag arrival<br />
-00:05<br />
+00:05<br />
+00:15<br />
Intercast I<br />
Tuyeres<br />
level<br />
Taphole<br />
Bottom<br />
+00:25<br />
+00:35<br />
+00:45<br />
+00:55<br />
+01:05<br />
+01:15<br />
+01:25<br />
+01:35<br />
+01:45<br />
Intercast II<br />
+01:55<br />
+02:05<br />
+02:15<br />
+02:20<br />
+02:30<br />
+02:40<br />
+02:50<br />
+03:05<br />
+03:15<br />
+03:25<br />
+03:35<br />
+03:45<br />
+03:55
Profit /Innov<strong>at</strong>ion<br />
Know your process better –Burden distribution<br />
simul<strong>at</strong>ions<br />
• Use of Discrete Element Method (DEM)<br />
– enough amount to keep realistic,<br />
and comput<strong>at</strong>ion time reasonable<br />
• Can be used to valid<strong>at</strong>e single particle models<br />
• Compares well with painted bar measurements<br />
05/10/2008 52
Profit /Innov<strong>at</strong>ion<br />
Know your process better –Cohesive zone<br />
positioning<br />
• The internal st<strong>at</strong>e of the furnace<br />
(cohesive zone, temper<strong>at</strong>ure and<br />
velocity maps, reduction areas) is<br />
described by MOGADOR<br />
• It is valid<strong>at</strong>ed/calibr<strong>at</strong>ed by mean<br />
of a Multi-Point Vertical Probing<br />
Computed thermal map (left)<br />
vs. measured (right)<br />
• It is running on-line <strong>at</strong>:<br />
– Dunkerque 3, 4<br />
– Florange 3<br />
– Gent A, B<br />
– Bremen 2<br />
Comparison of<br />
measured vs.<br />
computed<br />
temper<strong>at</strong>ure<br />
05/10/2008 53
Profit /Innov<strong>at</strong>ion<br />
Push the limits ---Innov<strong>at</strong>ive concepts in production of DRI<br />
05/10/2008 54
Profit /Innov<strong>at</strong>ion<br />
Push the limits -Innov<strong>at</strong>ive concepts in production of DRI<br />
System Pressure Vs Oper<strong>at</strong>ing Parameter<br />
500<br />
450<br />
400<br />
350<br />
300<br />
250<br />
200<br />
150<br />
100<br />
50<br />
0<br />
System<br />
Pressure<br />
(mBarg)<br />
Productivity<br />
(Ton/oper. Hr)<br />
NG<br />
consumption<br />
(x100 Gcal/t<br />
(gross))<br />
Low S-Pressure<br />
High S-Pressure<br />
Metalliz<strong>at</strong>ion<br />
(%)<br />
Carbon (x100<br />
%)<br />
05/10/2008 55
Profit /Innov<strong>at</strong>ion<br />
Push the Limits - <strong>ArcelorMittal</strong> Tubarao Sinter plant Productvity<br />
t/d/m2<br />
45,00<br />
44,00<br />
43,00<br />
42,00<br />
41,00<br />
40,00<br />
39,00<br />
38,00<br />
37,00<br />
36,00<br />
35,00<br />
34,00<br />
33,00<br />
32,00<br />
31,00<br />
30,00<br />
29,00<br />
'01/12/2005<br />
1<br />
2<br />
3<br />
'26/12/2005<br />
'13/01/2006<br />
'30/01/2006<br />
'20/02/2006<br />
'09/03/2006<br />
'26/03/2006<br />
'12/04/2006<br />
'29/04/2006<br />
'17/05/2006<br />
'05/06/2006<br />
'23/06/2006<br />
'10/07/2006<br />
'28/07/2006<br />
'15/08/2006<br />
'02/09/2006<br />
'18/09/2006<br />
'07/10/2006<br />
'24/10/2006<br />
'12/11/2006<br />
'30/11/2006<br />
'05/01/2007<br />
'27/01/2007<br />
'18/02/2007<br />
'13/03/2007<br />
'01/04/2007<br />
'20/04/2007<br />
'16/05/2007<br />
'05/06/2007<br />
'25/06/2007<br />
'16/07/2007<br />
'05/08/2007<br />
'24/08/2007<br />
'14/09/2007<br />
'05/10/2007<br />
'26/10/2007<br />
'14/11/2007<br />
'17/12/2007<br />
'14/01/2008<br />
'06/02/2008<br />
'02/03/2008<br />
chute <strong>at</strong> the cooling<br />
Productivity (t/d/m²)<br />
horizontal rakes<br />
Target<br />
Burnt Lime Feeding +<br />
05/10/2008 56
Push the Limits - <strong>ArcelorMittal</strong> Tubarao Sinter<br />
plant Productivity<br />
t/d/m2<br />
45,00<br />
44,00<br />
43,00<br />
42,00<br />
41,00<br />
40,00<br />
39,00<br />
38,00<br />
37,00<br />
36,00<br />
35,00<br />
34,00<br />
33,00<br />
32,00<br />
31,00<br />
30,00<br />
29,00<br />
1<br />
2<br />
3<br />
'01/12/2005<br />
'26/12/2005<br />
'13/01/2006<br />
'30/01/2006<br />
'20/02/2006<br />
'09/03/2006<br />
'26/03/2006<br />
'12/04/2006<br />
'29/04/2006<br />
'17/05/2006<br />
'05/06/2006<br />
'23/06/2006<br />
'10/07/2006<br />
'28/07/2006<br />
'15/08/2006<br />
'02/09/2006<br />
'18/09/2006<br />
'07/10/2006<br />
'24/10/2006<br />
'12/11/2006<br />
'30/11/2006<br />
'05/01/2007<br />
'27/01/2007<br />
'18/02/2007<br />
'13/03/2007<br />
'01/04/2007<br />
'20/04/2007<br />
'16/05/2007<br />
'05/06/2007<br />
'25/06/2007<br />
'16/07/2007<br />
'05/08/2007<br />
'24/08/2007<br />
'14/09/2007<br />
'05/10/2007<br />
'26/10/2007<br />
'14/11/2007<br />
'17/12/2007<br />
'14/01/2008<br />
'06/02/2008<br />
'02/03/2008<br />
Anthracite<br />
Solid fuel sizing<br />
Productivity (t/d/m²)<br />
New Ore Mixer<br />
Precipit<strong>at</strong>or Dust<br />
Target<br />
Bed Height Control<br />
“IFE”<br />
Screen<br />
Rod Mill<br />
Sinter<br />
05/10/2008 Plant<br />
57<br />
Bin
Profit /Innov<strong>at</strong>ion<br />
Improve Value-in-use of raw m<strong>at</strong>erials along the supply chain<br />
At <strong>ArcelorMittal</strong> Mines<br />
Reduction of SiO2 content - new upgrading<br />
circuit<br />
Increasing the r<strong>at</strong>io of larger (12.5 x 16.0 mm)<br />
pellets<br />
Elimin<strong>at</strong>ion of pellet sticking - co<strong>at</strong>ing techniques<br />
Increasing reducibility - optimize grinding, coke<br />
breeze addition.<br />
At <strong>ArcelorMittal</strong> Canada DR/EAF plant<br />
Increase reducibility and reduced sticking<br />
index leads to productivity and<br />
metalliz<strong>at</strong>ion increase<br />
Reduced EAF slag weight and Increased<br />
yield<br />
05/10/2008 58
Profit /Innov<strong>at</strong>ion<br />
Enhanced use of lower cost m<strong>at</strong>erials – High PCI practice<br />
700<br />
600<br />
Coal Coarse coke Nut coke N<strong>at</strong>ural gas Oil Tar Others<br />
Reducing agent (kg/t HM)<br />
500<br />
400<br />
300<br />
200<br />
100<br />
0<br />
5 BF <strong>at</strong> almost<br />
200 kg/thm<br />
IH-BF6<br />
2006 yearly d<strong>at</strong>a<br />
Ga-BF5<br />
Ga-BF2<br />
Br-BF3<br />
BH-BFD<br />
BH-BFC<br />
Ga-BF4<br />
IH-BF5<br />
Ga-BF3<br />
As-BFA<br />
SA-BFN5<br />
VP-BFC<br />
VP-BFD<br />
SP-BFL<br />
Li-BFB<br />
As-BFB<br />
Fo-BF1<br />
Fo-BF2<br />
Dk-BF2<br />
IH-BF7<br />
Dk-BF3<br />
Br-BF2<br />
EHS-BF5<br />
Fl-P3<br />
Fl-P6<br />
Ge-BFB<br />
Dk-BF4<br />
Ge-BFA<br />
05/10/2008 59
Profit /Innov<strong>at</strong>ion<br />
Enhanced use of lower cost m<strong>at</strong>erials – A drive towards increased install<strong>at</strong>ions<br />
and improved practice<br />
• Oper<strong>at</strong>ing conditions<br />
– Eg: blast conditions increased kinetic power<br />
• Some new install<strong>at</strong>ions<br />
– <strong>ArcelorMittal</strong> Dofasco, Hamilton, Canada: BF#2, #3 and #4<br />
– <strong>ArcelorMittal</strong> Indiana Harbor, USA: BF#3 and #4<br />
– <strong>ArcelorMittal</strong> Kriviy Rih, Ukraine: BF #9<br />
05/10/2008 60
Profit /Innov<strong>at</strong>ion<br />
Enhanced use of lower cost m<strong>at</strong>erials – reduce transport<strong>at</strong>ion<br />
costs– use local sources<br />
Present Concentr<strong>at</strong>e Analysis, %<br />
Fe SiO2 Al2O3 LOI P<br />
48-49 10-12 4-6 12-14 0.6-0.8<br />
0.5<br />
mm<br />
05/10/2008 61<br />
Fe<br />
P
Lisakovsky de-P flowsheet<br />
Gravity Magnetic Concentr<strong>at</strong>e<br />
Present Concentr<strong>at</strong>e Analysis, %<br />
900 C<br />
Fe SiO2 Al2O3 LOI P<br />
30-60 min<br />
48-49 10-12 4-6 12-14 0.6-0.8<br />
Drying-<br />
Roasting<br />
Magnetic Separ<strong>at</strong>ion<br />
Tails<br />
3-10 % H 2 SO 4<br />
60 min, s/l = 1/1<br />
Leaching<br />
Final Concentr<strong>at</strong>e Analysis, %<br />
Fe SiO2 Al2O3 LOI P<br />
Dephosphorized<br />
Concentr<strong>at</strong>e<br />
Solid-Liquid<br />
Separ<strong>at</strong>ion/Washing<br />
59-61 6-8 4-5 0-0.5 0.05-0.2<br />
Neutraliz<strong>at</strong>ion<br />
05/10/2008 62
Profit / Innov<strong>at</strong>ion<br />
Use lower cost raw m<strong>at</strong>erials – innov<strong>at</strong>ive no coke sinter<br />
BOF Slag Fines:<br />
Metallic<br />
Non-Metallic<br />
Skimmer<br />
Hammer<br />
Mn Fines<br />
Mn Slag<br />
QCM<br />
Concentr<strong>at</strong>e<br />
Pellet Chips<br />
BF Sludge<br />
Low-Oil and Oily<br />
Mill Scale<br />
BF Stockhouse Dust<br />
BF Casthouse Dust<br />
Pre-Blend Site<br />
Blend Site<br />
IHE #2 Sinter Plant<br />
W<strong>at</strong>er Tre<strong>at</strong>ment<br />
Sludge<br />
Scale Breaker Sludge<br />
Sinter Plant<br />
Clean-Up<br />
In-Plant<br />
Fines<br />
BOF Grit<br />
BF Flue Dust<br />
BOF Filter Cake<br />
Dolomite<br />
Pellet Fines<br />
Cold Sinter<br />
Fines<br />
Purchased<br />
Millscale<br />
05/10/2008 63<br />
Mn Slag
Profit /Innov<strong>at</strong>ion<br />
Use lower cost raw m<strong>at</strong>erials – Reduce n<strong>at</strong>ural gas use with tail gas<br />
NG<br />
HyL<br />
Midrex<br />
Tail<br />
Gas<br />
CO2 Removal<br />
05/10/2008 64
Profit /Innov<strong>at</strong>ion<br />
• And Logistics Optimiz<strong>at</strong>ion<br />
05/10/2008 65
Concluding Remarks<br />
The New Cover – new st<strong>at</strong>ements<br />
21ST CENTURY<br />
Look<br />
Inside<br />
Plan &<br />
Do<br />
SustainAbility<br />
05/10/2008 66
We need a global overview to be<br />
sustainable<br />
GREEN RING<br />
Iron & Steel production is not alone<br />
We must work <strong>for</strong> a Global Environmental Integr<strong>at</strong>ion approach<br />
05/10/2008 67
The <strong>Ironmaking</strong> plant - Innov<strong>at</strong>ion ahead<br />
•SCOPE-21<br />
•Carbonyx<br />
•More low-caking<br />
coals<br />
NEW COKE PLANT<br />
•Advanced<br />
control of gas<br />
distribution<br />
•Enhanced micro<br />
pelletizing<br />
•HPS<br />
•Monitoring<br />
Techniques<br />
•Repair<br />
Techniques<br />
•Innov<strong>at</strong>ive<br />
Maintenance<br />
(SOL COQUERIA TUBARÃO)<br />
COKE PLANT<br />
SINTER PLANT<br />
FLUXES / OTHERS<br />
COAL<br />
PCI<br />
T.R.T<br />
BLAST FURNACE<br />
IRON ORE<br />
PELLETS<br />
# 1 # 2 # 3<br />
# 1<br />
# 2<br />
TORPEDO CAR<br />
•20+ years campaign<br />
•BFG Turbines<br />
•100% BFG<br />
rehe<strong>at</strong>ing<br />
•Novel reline<br />
methodology<br />
•Improved<br />
briquetting<br />
•Innov<strong>at</strong>ive<br />
engineered<br />
m<strong>at</strong>erials<br />
•Biomass<br />
Injection<br />
•Reduced Iron<br />
•Non-Coal<br />
charge<br />
m<strong>at</strong>erials<br />
•Charcoal<br />
•TGRBF<br />
05/10/2008 68
Muito Obrigado<br />
05/10/2008 69
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