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Examples for Oxygen

Applications in SteelProduction

ISKENDERUN, June 2012

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Contents

Why oxygen for reheating?

Oxygen applications in

reheating furnaces

Calculation and savings

with oxygen enrichment

Oxygen applications

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Fuel savings

Less exhaustgas

Reducedemissions

Product quality

Benefits of oxygen application

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Oxygen Combustion

Adiabatic flame temperature vs. oxidizer concentration

f

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Highercombustion

efficiency

fuel savings

Higher gas radiationof exhaust gas

(CO2+H2O)

(increased emissivity

e)

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Typical Energy demand to

Reheat Steel

Typical Energy Demandto Reheat Steel Air / Fuel

Preheate

d Air /

Fuel

Oxygen /

Fuel

Flameles

sSteelenthalpy [kWh/t

] 200 200 200Losses [kWh/t

] 10 10 10

Exhaustgasenthalp

y [kWh/t] 290 140 50Exhaustgastemper

ature [C] 1200 850 1200Air Preheating [C] 20 450 20

f l i

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fuel savings

Better heat transfer (lower temperaturedifference needed)

Air

O2

Flamein

Metalout

Offgasout

Lossesout

l h t

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Less exhaust gas

Because the amount of

nitrogen (from air) is

reduced

Possibility to use moreblast furnace gas, without

changing the off-gas

system

Off-gas situation is similar

of

natural gas + air and

blast furnace gas +ox en

less exhaust gas

d d i i

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Reduced emissions Less nitrogen in the burner

air results in less NOx

Depending on the flame

temperature and increase

of production, the NOx

formation must be

monitored Reduced CO2 emissions

because of the fuel savings

Better reaction rates

ensures less CO in the off-

reduced emissions

d t lit

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Product quality Temperature distribution in

each zone is not impaired

by oxygen enrichment

(Phase 2: Flamelessoxygen burners can

improve temperature

distribution)

More uniform temperature

distribution in the metal

because of a better heat

transfer

product quality

C t t

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Contents

Why oxygen for reheating?

Oxygen applications in

reheating furnaces

Calculation and savings

with oxygen enrichment

Oxygen applications

f

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Examples of

oxygenenrichment in

reheating

furnaces

furnaces

Reheatingfurnace

Enrichment

Energysavings

Production

increase

Trials Smederevo 25 % O2 12 % 8 %

Trials Gevelsberg 24 % O2 13 % 14 %

f

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Examples of

oxygenenrichment in

forging furnaces

Reduction ofthe time to heat

up the furnace

furnaces

Forgingfurnace

Steel

[kg/h]

Air pre-heating

[C]

Furnace temp.

[C]

O2-enrich-ment

Energysavings

Heat uptime

saving

Pusher type,natural gas 15 30 1200 23% 10% 14%

Pusher type,

natural gas 4500 100 1200 23% 22% 26%

Turning hearthtype,

natural gas 2300 390 1200 23% 46% 35%

f

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furnaces

Forgingfurnace

Steel

[t/h]

Air pre-

heating[C]

Furnac

e temp.[C]

O2-

enrich-ment

Energysavings

Pro-

ductionincrease

Pusher type,

natural gas 0.5 150 1280 22 % 10 % -

Pusher type,

natural gas 0.5 150 1280 23 % 22 % -Pusher type,

natural gas 0.5 150 1280 24 % 28 % -

Chamber

furnace,

coking gas3 20 1280 22 % 14 % -

Chamber

furnace,

coking gas3 20 1280 23 % 17 % -

Chamber

furnace,

coking gas

3 20 1280 24 % 35 % -

Pusher furnace,

C t t

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Why oxygen for reheating?

Oxygen applications in reheating

furnaces

Calculation and savingswith oxygen enrichment

Oxygen applications

Contents

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Calculation

When is enrichment economical

Estimated values for highest

oxygen / natural gas price ratio

based on off-gas temperature

Calculation based on

direct savings + about 50%

because of enhanced gas radiationA lot of other important factors

(furnace insulation, production cycle,

false air, geometry )

Good preheating can prevents

Off gastemperat

ure

ESTIMA

TEDmax.priceratio

O2 / NG

600 C 31 %

700 C 35 %

800 C 40 %

900 C 46 %

1000 C 54 %

1100 C 63 %