Electric Arc Furnace Technology Research Articles

Flexibility options in a decarbonising iron and steel industry

The decarbonisation of the iron and steel industry is expected to significantly increase its electricity consumption due to higher levels of electrification and the partial shift to hydrogen as iron reductant. With its batch processes, this industry offers large potential for the application of demand response strategies to achieve electricity cost savings. Previous research has primarily focused on investigating the demand response potential for currently operating manufacturing processes and partly for future low-carbon processes. This study aims to consolidate this knowledge and apply it to a modelling analysis that investigates the demand response potential of two new low-carbon technologies: the hydrogen-based direct reduction of iron with electric arc furnace technology (H2-DRI-EAF) and the blast furnace basic oxygen furnace technology retrofitted with carbon capture (BF-BOF-CCUS). A cost optimisation approach is applied to plant configurations with varying parameters relevant for flexibility, such as electrolyser and storage sizes, and in the context of future electricity prices. Multiple price profiles are selected to encompass uncertainties on the development of the power system. The potential for a H2-DRI-EAF plant is 3–27 times higher than for a BF-BOF-CCUS, with electricity costs savings potentials of 35% and 3%, respectively. The study finds that electricity prices have the most significant impact on the profitability of investing in electrolyser overcapacities, which enable operating costs reduction. Therefore, the profitability of these investments are strongly dependent on future power system configurations.

Energy Intensity of Steel Manufactured Utilising EAF Technology as a Function of Investments Made: The Case of the Steel Industry in Poland

The production of steel in the world is dominated by two types of technologies: BF + BOF (the blast furnace and basic oxygen furnace, also known as integrated steel plants) and EAF (the electric arc furnace). The BF + BOF process uses a lot of natural resources (iron ore is a feedstock for steel production) and fossil fuels. As a result, these steel mills have a significantly negative impact on the environment. In turn, EAF technology is characterised by very low direct emissions and very high indirect emissions. The raw material for steel production is steel scrap, the processing of which is highly energy-consuming. This paper analyses the energy intensity of steel production in Poland as a function of investments made in the steel industry in the years 2000–2019. Statistical data on steel production in the EAF process in Poland (which represents an approximately 50% share of the steel produced, as the rest is produced utilising the BF + BOF process) was used. Slight fluctuations are caused by the periodic switching of technology for economic or technical reasons. The hypothesis stating that there is a relationship between the volume of steel production utilising the EAF process and the energy consumption of the process, which is influenced by investments, was formulated. Econometric modelling was used as the research method and three models were constructed: (1) a two-factor power model; (2) a linear two-factor model; and (3) a linear one-factor model. Our findings show that the correlation is negative, that is, along with the increase in technological investments in electric steel plants in Poland, a decrease in the energy consumption of steel produced in electric furnaces was noted during the analysed period.

Evaluation of recycled MgO-C bricks and dead-burned dolomite fines in setting slag foaming in the electric arc furnace

Abstract Production cost reduction for the Electric Arc Furnace (EAF) technology is strongly dependent on the efficiency of the electrical energy being introduced into the metal bath. Besides EAF technology, the slag foaming process is currently applied to some other equipment for steel production aiming to save energy, productivity improvements, enhance the refractory service life and inhibit steel re-oxidation. In this way, this study involved the recycling options of Crushed MgO-C spent refractories removed from the EAF without complex and costly beneficiation, with emphasis on its application as a slag conditioner, since its composition presents high MgO content. The experiments were performed in a laboratory induction furnace and the temperature was controlled at 1700°C.The initial height of the slag was recorded and foaming briquettes added into the furnace. The experiments were carried out for 30 minutes. When the foaming process was finalized, an aliquot from the slag was collected to be analyzed by chemical analysis. Then, the metal with slag was tapped into a mold. The results indicated that the best viscosity was 0.39poise. The maximum height of foam formation was observed for a binary basicity greater than 1.2. The concentration of MgO in the slag is close to the saturation point.

Copper droplets agglomeration/coagulation in the conditions similar to industrial ones

AbstractThe studied copper droplets suspension in the liquid slag came from the direct-to-blister technology developed in the KGHM - Polska Miedź S.A. plants. A treatment by the stimulators and reagents was performed in the conditions delivered / ensured by the BOLMET S.A., Wiechlice. These conditions were similar to those usually applied to the industrial process. Particularly, this treatment was similar, to some extent, to that known for the electric arc-furnace technology employed in the Smelter and Refinery Plant, Głogów. An effectiveness of the newly developed and patented complex chemical/reagent for the copper removal from slag was tested during the treatment. The effect of the liquid slag stirring on the copper droplets self-cleaning was also analysed. The performed test confirmed the effectiveness of the studied complex reagent in agglomeration, coagulation and sedimentation of the copper droplets.

ASSESSMENT OF AERMOD MODEL’S SENSITIVITY TO TERRAIN FEATURES FOR IDENTIFYING AIR POLLUTANTS RECEPTOR POINTS IN STEEL INDUSTRY

Steel production industries using electric arc furnace technology are among potential sources of particulate emissions containing heavy metals that could endanger human health. For this reason, the measurement of emitted pollutants, assessment of spatial distribution of these pollutants and identification of receptor points around these industries are important. One of the most widely used models in this regard is AERMOD model which is a permanent predictive model. Given the importance of the subject, we attempted to measure the output of particulate emissions from electric arc furnace flue in Iran Alloy Steel Company located about 25 kilometers northwest of the city of Yazd in the present study and assess the validity of AERMOD model in topographical conditions with and without application. In this research, samples of flue output particles were collected systematically and by US-EPA Method 5 isokinetic method and TCR-Tecora model of Particle Measuring Device ; and the amount of collected particles were calculated in laboratory. Also 24 hour meteorological data of synoptic stations of Yazd was used for the implementation of the model and Global maper13 software was used to create dem format required by models with different accuracies of 30, 50 and 90 meters. Then the model was implemented in two modes, including area flatness and applied topography and finally the results were compared with each other. The results indicate that the average concentrations of applied topography with 0.036 µg\m3 are higher compared to not applying topography. Also the maximum concentration in the mode of not applying AERMAP is 1 µg\m3 in contrast to the prevailing wind direction in West Side of Flue and in mode of applied AERMAP; the maximum concentration is 17.5 µg\m3 in line with the prevailing wind direction and in East and South-East of Flue. Also no significant difference was observed in the average concentrations predicted by models with the application of DEM with different accuracies. The result is that prediction will not be sufficiently accurate without the implementation of AERMAP. Also AERMAP can be implemented and modeling can be carried out using 90 meters DEM. Generally, pollution of particles containing emitted metals from electric arc furnace has no effect on important industrial and demographic applications of the region by considering the prevailing wind direction in modeling and applied topography.

A system dynamics analysis of energy consumption and corrective policies in Iranian iron and steel industry

Iron and steel industry is the most energy intensive industrial sector in Iran. Long time subsidized energy has led to low energy efficiency in this industry. The sudden subsidy reform of energy prices in Iran is expected to have a great impact on steel production and energy consumption. A system dynamics model is presented in this paper to analyze steel demand, production and energy consumption in an integrated framework. A co-flow structure is used to show how subsidy reform affects energy consumption in the long run. The main focus of this paper is on direct and indirect natural gas consumption in the steel industry. Scrap based Electric Arc Furnace technology has been evaluated as an energy efficient way for steel making. The energy consumption in steel industry is estimated under various steel production and export scenarios while taking into account new energy prices to see the outlook of possible energy demand in steel industry over next 20 years. For example it is shown that under reference production scenario, potential reduction in gas consumption forced by complete removal of energy subsidy and utilizing scrap could lead to 85 billion cubic meters of gas saving over the next 20 years.

8th European Electric Steelmaking Conference

This conference, organised by the Institute of Materials Minerals and Mining, took place on 9–12 May 2005 at the International Convention Centre in Birmingham, UK and was attended by over 300 delegates from 27 countries. The technical programme covered the full spectrum of electric arc furnace technology, new plant developments and environmental issues.

EAF technology evolution by continuous charging

Recent developments in electric arc furnace (EAF) based meltshop operation are reviewed, including the Consteel system which facilitates continuous scrap charging and preheating completed by hot metal charging. The benefits offered by these developments are quantified, backed by operational performance results from several facilities. The future will see increasing use of EAFs to produce high quality steels, often in innovative operational combinations alongside the blast furnace route.

Trade and Environment: An Empirical Analysis of the Technology Effect in the Steel Industry

The objective of this paper is to study the impact of free trade on global environmental quality by focusing on the technology effect, that is, the relationship between trade openness and the adoption/diffusion of clean technologies. The paper attempts to empirically verify the existence of the technology effect by looking at the relationship between trade policy regime, or openness, and the speed of clean technology diffusion in the steel industry. Focusing on a cleaner steel technology, the electric arc furnace (EAF), in 30 steel-producing countries over 25 years, the results show that EAF technology is diffused faster in countries that have more open trade policy regimes, thereby supporting the existence of the technology effect for the industry considered.

Scrap in Modern Electric Arc Furnace Technology

Scrap in Modern Electric Arc Furnace Technology