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A Process Integration Approach to Assessing Possibilities for Improved Material Efficiency in Nordic ore-based Iron- and Steelmaking Systems
Luleå University of Technology, Department of Civil, Environmental and Natural Resources Engineering, Minerals and Metallurgical Engineering. Swerim AB.ORCID iD: 0000-0002-3662-8831
2019 (English)Licentiate thesis, comprehensive summary (Other academic)Alternative title
En processintegrationsstrategi för bedömning av möjligheter för förbättrad materialeffektivitet i nordiska malmbaserade järn- och ståltillverkningssystem (Swedish)
Abstract [en]

Iron- and steel production is a material- and energy intensive industrial activity. The production of one tonne of steel commonly results in some 400 kilograms of residual materials such as metallurgical slags, dusts, sludge and scales generated in the processes. Much work is continuously devoted to finding possible ways of using residual materials and minimising landfilled volumes. As these materials often contain considerable amounts of valuable elements such as iron, coal, manganese and calcium, it may be profitable to use them to replace virgin raw materials or to sell them as products that may be useful in other industries and/or processes. 

 

The thesis is based on case studies that exemplify how the use of process integration, through system analysis, can assist in assessing effects and opportunities for different concepts for increased material efficiency in Nordic ore-based steelmaking systems. The process integration approach taken for this research work was the simulation of a specific iron- and steel production system and the use of an optimisation tool for the evaluation of an extended system including the symbiosis between four steel plants.

 

Three different cases were studied including: system effects of increased magnesium oxide content in the lime raw material, investigation of the prospects for vanadium enrichment and slag reduction concept and a study of the logistics perspective for a joint residual material upgrading and recycling venture between four steel plants. The analysed cases present possibilities to improve the material efficiency by:

•      Enhanced recovery of residual materials;

•      Upgrading of residual materials to products;

•      Specific elements recovery;

•      Decreased use of virgin raw material;

•      Improved quality of residual materials;

•      Decreased amounts of materials placed in long-term storage or landfills.

 

From the results of the cases studied, the best scenarios and potential gains by enhanced material efficiency is presented. In the case of system effects of increased magnesium oxide content in the lime raw material, the issue was mainly to obtain maximum usage of metallurgical slags without compromising the quality of the main product. The calculated possibility of increased slag recirculation enabled further a decreased consumption of iron ore pellet and limestone. Regarding the investigation of the vanadium enrichment and slag reduction concept, the best scenario markedly increased the internal slag recirculation in order to enrich the vanadium content in the slag for ferrovanadium production. By the vanadium enrichment and recovery concept, considerable amounts of vanadium would be made useful instead of ending up in long-term storage. The study of a shared Nordic concept for residual materials upgrading and use demonstrated the potential for upgrading the materials to a direct reduced iron product for recovery in blast furnace. The concept showed high potential for significantly reducing the amount of material being long-term stored or deposited to landfill and thus a potential step towards achieving the zero-waste philosophy target.

 

None of the concepts for enhanced material efficiency studied in this thesis work has been implemented; however, they are still of relevance for the Nordic steel industry.

Place, publisher, year, edition, pages
Luleå: Luleå University of Technology, 2019. , p. 82
Series
Licentiate thesis / Luleå University of Technology, ISSN 1402-1757
Keywords [en]
Process metallurgy, Process integration, System analysis
National Category
Metallurgy and Metallic Materials
Research subject
Process Metallurgy
Identifiers
URN: urn:nbn:se:ltu:diva-76435ISBN: 978-91-7790-478-6 (print)ISBN: 978-91-7790-479-3 (electronic)OAI: oai:DiVA.org:ltu-76435DiVA, id: diva2:1362291
Presentation
2019-12-11, F531, LTU, Luleå, 10:00 (English)
Opponent
Supervisors
Available from: 2019-10-18 Created: 2019-10-18 Last updated: 2019-11-27Bibliographically approved
List of papers
1. Analysis of metallurgical processes and slag utilisation in an integrated steel plant producing advanced high strength steels
Open this publication in new window or tab >>Analysis of metallurgical processes and slag utilisation in an integrated steel plant producing advanced high strength steels
2012 (English)In: Scanmet IV: 4th International Conference on Process Development in Iron and Steelmaking, Luleå: MEFOS , 2012, Vol. 2, p. 415-424Conference paper, Published paper (Refereed)
Abstract [en]

Some elements in the raw materials used in iron- and steelmaking make it difficult to maintain or further improve the steel quality, but also adversely affect the composition of generated slags and other materials, thereby reducing their potential for internal recycling and/or other utilisation.A Process Integration (PI) approach was taken to analyse the dependence of the properties of a specific metallurgical slag on individual processes as well as on the interaction between processes. Analyses were made of how to obtain maximum usage of metallurgical slags without compromising the quality of the main product, i.e. crude steel. Based on a real case scenario, a number of approaches were studied with regard to the quality demands for maximised use of slags. The effects of changes in raw materials on blast furnace (BF) and basic oxygen furnace (BOF) processes were investigated. Altered composition of the raw materials affects material and BF reductant rate, generated slag amounts, slag recycling and material compositions, etc. In this study special attention was directed towards the magnesium oxide (MgO) contents in BF and BOF slags and, subsequently, the effects on phosphorus (P) refining in the BOF.The analysis of system effects of changed quality of lime raw material, i.e. limestone and consequently on-site produced burnt lime, show that an increased MgO content raises the MgO level, exceeding the set maximum permissible MgO content in both the BF and the BOF slag. The increased MgO content in burnt lime charged to the BOF will have a strong negative effect on the P refining capacity of the slag; therefore, burnt lime with an increased MgO content cannot be used without taking further measures if maximum P refining is required.Based on the results of the analysis, a number of approaches were further investigated in order to identify methods to preserve or decrease current MgO levels in generated slags and maintain, or further improve, slag utilisation potential without compromising the liquid steel (LS) quality. Analysed strategies were: diluting the MgO content in the BF slag by increased slag rate, decreased BOF slag recycling to the BF, increased P tolerance in BF produced hot metal (HM), lower MgO content in pellet mix or decreased use of dolomitic lime in the BOF. The most efficient approach to markedly increase the BOF slag recycling rate and simultaneously maintain the prerequisite MgO content in BF slag and LS quality is by increasing the tolerance of P in hot metal while at the same time excluding dolomitic lime in the BOF.

Place, publisher, year, edition, pages
Luleå: MEFOS, 2012
National Category
Metallurgy and Metallic Materials
Research subject
Process Metallurgy
Identifiers
urn:nbn:se:ltu:diva-40181 (URN)f3491715-b7d0-4fe1-8961-cbe9a7457b30 (Local ID)978-91-637-0859-6 (ISBN)f3491715-b7d0-4fe1-8961-cbe9a7457b30 (Archive number)f3491715-b7d0-4fe1-8961-cbe9a7457b30 (OAI)
Conference
International Conference on Process Development in Iron and Steelmaking : 10/06/2012 - 13/06/2012
Note
Godkänd; 2012; 20120614 (ysko)Available from: 2016-10-03 Created: 2016-10-03 Last updated: 2019-10-18Bibliographically approved
2. System analysis of slag utilisation from vanadium recovery in an integrated steel plant
Open this publication in new window or tab >>System analysis of slag utilisation from vanadium recovery in an integrated steel plant
2013 (English)In: Journal of Cleaner Production, ISSN 0959-6526, E-ISSN 1879-1786, Vol. 47, p. 43-51Article in journal (Refereed) Published
Abstract [en]

Vanadium in raw materials used in iron- and steelmaking, a particular challenge for Nordic steel producers, affects the composition of the generated slag from the steelmaking vessel, i.e. the basic oxygen furnace (BOF) adversely and reduces the potential for recycling and external utilisation. A process concept under development aims to enrich and extract the vanadium content of slag from the BOF, making use of the vanadium in the slag and also increasing the overall slag use potential. Applications of this concept affect slag compositions and internal material flows in the iron and steel production system, especially when recycling BOF slags as flux in the blast furnace (BF). This paper will present a case study, based on a Process Integration (PI) approach, using a designated system model to simulate the steel production system and the implementation of the process concept, thereby analysing how to obtain maximum usage of metallurgical slags without compromising the quality of the main product, i.e. liquid steel. Different approaches were studied to improve the environmental sustainability in the production system by maximising the material efficiency through vanadium recovery (as FeV alloy) and the use of slags, thereby minimising the stored/deposited slag amounts.

National Category
Metallurgy and Metallic Materials
Research subject
Process Metallurgy
Identifiers
urn:nbn:se:ltu:diva-7825 (URN)10.1016/j.jclepro.2012.09.002 (DOI)000319178200006 ()2-s2.0-84879904081 (Scopus ID)63f505d0-234d-4821-8efb-4257a2f9f79f (Local ID)63f505d0-234d-4821-8efb-4257a2f9f79f (Archive number)63f505d0-234d-4821-8efb-4257a2f9f79f (OAI)
Note
Validerad; 2013; 20120914 (ysko)Available from: 2016-09-29 Created: 2016-09-29 Last updated: 2019-10-18Bibliographically approved
3. Optimisation of a centralised recycling system for steel plant by-products: a logistics perspective
Open this publication in new window or tab >>Optimisation of a centralised recycling system for steel plant by-products: a logistics perspective
2013 (English)In: Resources, Conservation and Recycling, ISSN 0921-3449, E-ISSN 1879-0658, Vol. 77, p. 29-36Article in journal (Refereed) Published
Abstract [en]

This paper focuses on the optimisation of a recovery strategy for waste materials and thereby improved material efficiency in the iron and steel industry. A joint venture between four Nordic steel plants is considered in order to recycle materials otherwise mainly put to landfill, i.e. dusts and sludges from the steel production processes. Process integration (PI) was used to investigate the possibilities for recovering the materials by developing a system optimisation model of the steel plants and integrating a dedicated material upgrading process in the system. This work aims to develop a model suitable for analysing and finding a logistic solution needed to achieve a common recycling system by studying material supply, required material storage, shipping system and shipping frequency. The developed optimisation model is presented, using a case study of the steel production plants with the dedicated upgrading process and the logistics system. The prospect for shipping materials from the steel production sites to the material upgrading process site as well as the material supply to the upgrading unit is essential in the system analysis. A mathematical optimisation model based on mixed-integer linear programming (MILP) for the common system is presented. The integration of the dedicated material upgrading process show a system in balance regarding the materials generated and processed in the upgrading unit. Generated material amounts suitable for the upgrading process can be fully recovered thereby decreasing the landfilled amounts from the four steel production sites.

National Category
Metallurgy and Metallic Materials
Research subject
Process Metallurgy
Identifiers
urn:nbn:se:ltu:diva-10099 (URN)10.1016/j.resconrec.2013.04.012 (DOI)000323142200004 ()2-s2.0-84879093305 (Scopus ID)8d8e6968-fb26-4e2a-b826-0da8f5a7531f (Local ID)8d8e6968-fb26-4e2a-b826-0da8f5a7531f (Archive number)8d8e6968-fb26-4e2a-b826-0da8f5a7531f (OAI)
Note
Validerad; 2013; 20130617 (andbra)Available from: 2016-09-29 Created: 2016-09-29 Last updated: 2019-10-18Bibliographically approved

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