Clean Ironmaking and Steelmaking Processes (eBook)

Preface 5
Contents 8
Abbreviations 12
List of Figures 23
List of Tables 32
Chapter 1: Clean Ironmaking and Steelmaking Processes: Efficient Technologies for Greenhouse Emissions Abatement 36
1.1 Introduction and Global Scenario 36
1.2 Main Approaches to the Problem 41
1.3 Technological Issues 48
1.4 Main Solutions 57
1.5 Conclusions 67
References 68
Chapter 2: Coke Making: Most Efficient Technologies for Greenhouse Emissions Abatement 73
2.1 Introduction 73
2.2 Wastewater Treatment 74
2.3 Coke Dry Quenching (CDQ) 84
2.4 Use of Coke Oven Gas 91
2.5 Coke Making Control Systems 113
2.6 Coal Stamp Charging Battery (CSCB) 116
2.7 High-Pressure Ammonia Liquor Aspiration System (HPALA) 121
2.8 Coal Moisture Control 121
2.9 Non-Recovery Coke Ovens 122
2.10 Variable Speed Drive Coke Oven Gas Compressors 129
2.11 Coke Stabilization Quenching 129
2.12 Single-Chamber System 130
2.13 SCOPE 21 131
2.14 Use of Biomass and Waste Materials 133
2.15 Conclusions 137
References 138
Chapter 3: Sintering: Most Efficient Technologies for Greenhouse Emissions Abatement 145
3.1 Introduction 145
3.2 Waste Heat Recovery in Sinter Plant 152
3.3 Exhaust Gas Treatment 155
3.4 Improved Process Control and Quality Assurance 165
3.5 Improved Ignition Oven Efficiency with Multi-slit Burners 168
3.6 Emissions Optimized Sintering (EOS) 170
3.7 EPOSINT Process, Selective Waste Gas Recycling 171
3.8 Improved Charging of Materials 173
3.9 Low Emissions and Energy Optimized Sintering Process 176
3.10 Sectional Gas Recirculation 176
3.11 Curtain Flame Ignition System 179
3.12 Utilization of Waste Fuels in Sintering 180
3.13 Charcoal in Sintering 181
3.14 Biomass in Sintering 187
3.15 Conclusions 193
References 195
Chapter 4: Blast Furnace: Most Efficient Technologies for Greenhouse Emissions Abatement 200
4.1 Introduction 200
4.2 High-Quality Ore 212
4.3 Pulverized Coal Injection 214
4.4 Top-Pressure Recovery Turbines 221
4.5 Increased Blast Furnace Top Pressure 224
4.6 Improved Hot Stove Process Control 224
4.7 Blast Furnace Process Control 227
4.8 Heat Recuperation from Hot Blast Stoves 233
4.9 Increased Hot Blast Temperature 234
4.10 Injection of Coke Oven Gas 235
4.11 Improved Recovery of Blast Furnace Gas 239
4.12 Injection of Oil 241
4.13 Natural Gas (NG) Injection 242
4.14 Plastic Waste Injection 249
4.15 Oxy-Oil Injection 254
4.16 Injection of Residues 254
4.17 Biomass Combustion in the BF 256
4.18 Charging Carbon Composite Agglomerates (CCA) 265
4.19 COURSE50 273
4.20 Top Gas Recycling Blast Furnace (TGRBF) 276
4.21 Slag Heat Recovery 287
4.22 Conclusions 295
References 297
Chapter 5: Basic Oxygen Furnace: Most Efficient Technologies for Greenhouse Emissions Abatement 307
5.1 Introduction 307
5.2 Use of Metallized Iron 312
5.3 BOF Heat and Gas Recovery 313
5.4 Energy Issues 319
5.5 BOF Bottom Stirring 323
5.6 Improved Process Monitoring and Control 325
5.7 Improved Ladle Preheating 327
5.8 In-Furnace Post-Combustion 328
5.9 Conclusions 329
References 330
Chapter 6: Electric Arc Furnace: Most Efficient Technologies for Greenhouse Emissions Abatement 334
6.1 Introduction 334
6.2 Raw Materials 347
6.3 Oxyfuel Burners 353
6.4 Flue Gas Monitoring and Control 357
6.5 Post-Combustion Optimization in Steelmaking 359
6.6 Foamy Slag Practices 363
6.7 Scrap Preheating 368
6.8 Shaft Furnace Scrap Preheating 370
6.9 Tunnel Furnace Preheating 375
6.10 Bottom Stirring/Stirring Gas Injection 377
6.11 Direct Current (DC) Arc Furnace 382
6.12 Waste Heat Recovery for EAF 383
6.13 Contiarc Furnace 391
6.14 Twin-Shell DC Arc Furnace 392
6.15 Post-Combustion of EAF Flue Gas 395
6.16 Process Optimization and Control 396
6.17 Conclusions 399
References 401
Chapter 7: Smelting Reduction: Most Efficient Technologies for Greenhouse Emissions Abatement 407
7.1 Introduction 407
7.2 Corex Process 411
7.3 FINEX Process 432
7.4 HIsmelt 436
7.5 Tecnored 438
7.6 Flash Ironmaking Technology 442
7.7 Conclusions 443
References 443
Chapter 8: Direct Reduced Iron: Most Efficient Technologies for Greenhouse Emissions Abatement 448
8.1 Introduction 448
8.2 MIDREX Process 453
8.3 Hyl-ENERGIRON Process 460
8.4 FASTMET and FASTMELT 469
8.5 ITmk3 Process 470
8.6 MXCOAL: MIDREX with Coal Gasification 472
8.7 SL/RN Process 477
8.8 Waste Heat Recovery for Rotary Kiln Direct Reduction 478
8.9 FINMET Process 479
8.10 Iron Carbide Process 479
8.11 CIRCORED 481
8.12 Redsmelt 481
8.13 Hydrogen Reduction 481
8.14 Conclusions 507
References 508
Chapter 9: Carbon Capture and Storage: Most Efficient Technologies for Greenhouse Emissions Abatement 514
9.1 Introduction 514
9.2 Energy Issues 524
9.3 Shift Reactions 531
9.4 Chemical/Physical Adsorption 532
9.5 Solid Adsorbents Capture 540
9.6 Membrane Separation 545
9.7 Cryogenics Separation 547
9.8 Carbonization 550
9.9 CHG Capture 556
9.10 Post-combustion 563
9.11 Chemical Looping 567
9.12 Conclusions 576
References 578
Chapter 10: Electrolysis of Iron Ores: Most Efficient Technologies for Greenhouse Emissions Abatement 583
10.1 Introduction 583
10.2 Molten Oxide Electrolysis 585
10.3 Electrowinning 594
10.4 Conclusions 602
References 603
Index 605