Sustainable solution for steel industry - FASTMET® · PDF fileKobe Steel, Ltd. retains ......
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Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Kobe Steel, Ltd. (KSL)
August 1st, 2014
Sustainable solution for steel industry
- FASTMET® Process -
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Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 2
Contents
1. Corporate Profile of KSL and Iron Unit Division
2. KSL’s Service Capability
3. FASTMETⓇ Process
4. Contribution to Indian Steel Industry
5. Project Reference
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 3
Contents
1. Corporate Profile of KSL and Iron Unit Division
2. KSL’s Service Capability
3. FASTMETⓇ Process
4. Contribution to Indian Steel Industry
5. Project Reference
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Name: Kobe Steel, Ltd.
Founded : September 1, 1905
Net Sales : USD 17.92 billion*
Capital: USD 2.48 billion*
Related Companies: 206 subsidiaries
64 equity-valued affiliates
Employees : 36,018* *Consolidated (KSL + subsidiaries , excluding affiliates)
*Ex-rate: JP¥ 94.05 / USD
Kobelco Construction
Machinery
Other Businesses
Kobelco Cranes
Corporate Profile
Engineering
& Machinery
13%
Iron & Steel,
Welding
49%
Others
7%
Aluminum & Copper
16%
Construction
Machinery
16%
KSL is composed of ;
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Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 5
IPP Unit
Power Generation IPP
(1,400MW)
Aluminum & Copper
Business Unit
Aluminum forgings for
automobile suspensions
Welding Business Unit
Various welding rods
Aluminum & Copper
Business Unit
Copper alloy sheet for
lead frame
Machinery Business Unit
- Various types of compressors
- Rolling Mills
Engineering Business Unit
Iron making processes
Iron & Steel Business Unit
High Strength Steel Sheet /
Wire rod products for
automobile
Kobelco Cranes
Crawler Crane
Products of Kobe Steel
Unique Products, Technology and Service
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Processes owned by KSL
Molten Iron
Casted Pig Iron
DRI
Iron Nugget
Steaming Coal
Coal-Based DR
Plant FASTMET/ FASTMELT
ITmk3
EAF
DRI
Pellet Plant
Natural Gas
Shale Gas
Low-Grade
Iron Ore
BF Iron Ore
Scrap
Coking Coal
Beneficiation
Outline of Iron Making Processes
Gas-Based
DR Plant
Pellet
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Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 7
Business Foundation of Iron Unit Division
Knowledge & Experience Accumulated
in Engineering and Project Execution
Countries: 29
FTK/STK Plants: 51
FOB + SV: 25
Creation of
New Iron Making Technologies
Continuous R & D for New Iron Making Technologies
in cooperation with MIDREX Technologies Inc.
MIDREX® DR Process KOBELCO Pelletizing
System
FASTMET ® Process
Plant Supply: Since 1962 - Bangladesh Fertilizer Plant
Japan Standard Engineering Quality: Thoughtfulness and Seamless Engineering
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 8
Contents
1. Corporate Profile of KSL and Iron Unit Division
2. KSL’s Service Capability
3. FASTMETⓇ Process
4. Contribution to Indian Steel Industry
5. Project Reference
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
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: FTK/STK Projects : FOB + SV Projects
Engineering Business - Overall Past Record
1. Fertilizer (Bangladesh) 17. Phenol Acetone (Korea) 33. Cement (Japan) 49. Polyethylene (Nigeria) 65. Cement (Italy)
2. Bar Mill (Bangladesh) 18. Polypropylene (Singapore) 34. Fertilizer (Indonesia) 50. Pelletizing (Venezuela) 66. FASTMET (Japan)
3. Pelletizing (Japan) 19. Cement (Japan) 35. Fertilizer (Malaysia) 51. Meltblown (Netherlands) 67. Iron Ore Beneficiation (Iran)
4. Pelletizing (Japan) 20. Bar & Wire Rod Rolling (Nigeria) 36. Coal Liquefaction (Australia) 52. Spunbond (Korea) 68. Direct Reduction (Qatar)
5. Integrated Mill (Bangladesh) 21. Cement (Japan) 37. LPG Recovery (Algeria) 53. Direct Reduction (Egypt) 69. Pelletizing (Iran)
6. Fertilizer (Zambia) 22. Vinyl Acetate (Taiwan) 38. Aluminum Mill (Bahrain) 54. Caustic Soda (Indonesia) 70. FASTMET (Japan)
7. Acrylic Fiber (Korea) 23. Cement (Indonesia) 39. Wire Annealing (Nigeria) 55. Direct Reduction (Venezuela) 71. Pelletizing (Bahrain)
8. Pelletizing (Japan) 24. Cement (Jordan) 40. Cement (Malaysia) 56. Iron Ore Beneficiation (Iran) 72. Direct Reduction (Oman)
9. Pelletizing (Japan) 25. Sulfuric Acid (Zambia) 41. Polypropylene (Thailand) 57. Cement (Vietnam) 73. FASTMET (Japan)
10. Pelletizing (Japan) 26. Bar & Section Mill (Libya) 42. Cement (Jordan) 58. Spunbond (USA) 74. FASTMET (Japan)
11. Pelletizing (Japan) 27. Sulfuric Acid (Iraq) 43. Direct Reduction (Iran) 59. Spunbond (Indonesia) 75. Iron Nugget (USA)
12. Polypropylene (Brazil) 28. Cement (Japan) 44. Direct Reduction (Egypt) 60. Pelletizing (Venezuela) 76. Direct Reduction (Bahrain)
13. Continuous Bar Mill (Qatar) 29. Cement (Japan) 45. Steel Casting (Australia) 61. Direct Reduction (Egypt)
14. Direct Reduction (Qatar) 30. Cement (Japan) 46. Refinery (Ecuador) 62. FASTMET (Japan)
15. Pelletizing (Chile) 31. Cement (Jordan) 47. Cement (Egypt) 63. FASTMET (Japan)
16. Oil Gathering (Kuwait) 32. Pelletizing (Bahrain) 48. Direct Reduction (Venezuela) 64. Direct Reduction (Korea)
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Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
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1. Acindar
2. ArcelorMittal Montreal 1
ArcelorMittal Montreal 2
3. ArcelorMittal Hamburg
4. ArcelorMittal Lazaro Cardenas
5. ArcelorMittal Pt. Lisas 1-3
6. ArcelorMittal South Africa
7. Antara Steel Mills
8. Arfa Steel
9. Comsigua
10.DRIC 1-2
11. ESISCO
12. Essar Steel 1-6
13. EZDK 1-3
14. Ferrominera Orinoco
15. Global Steel Holdings
16. Hadeed A - E
17. HOSCO 1-2
18. IGISCO
19. IMPADCO
20. JSW Ispat Steel
21. JSW Steel
22. Jindal Steel & Power
23. Khorasan Steel
24. Khouzestan Steel 1-5
25. LGOK 2, 3
26. Lion DRI
27. LISCO 1-3
28. Mobarakeh Steel A - F
29. Nu-Iron
30. OEMK 1-4
31. Qatar Steel Co. 1-2
32. Jindal Shadeed
33. SULB
34. Tenaris Siderca
35. Sidor 1
Sidor 2 A - C
36. Tuwairqi Steel Mills
37. Venprecar
38. voestalpine
Midrex - Midrex DR Plants all over the world Since 1969, Midrex has built more than 70 Shaft Furnace Modules in 21 countries worldwide.
Note: Projects written in blue were implemented by KSL (main contractor) with Midrex
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Midrex DR Plants Overall Past Record
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 11
Comprehensive Project
Development Capabilities
Project
Management
ISO9001
Training
Service
Spare Parts
Supply
Plant
Diagnosis Marketing,
Consultation &
Finance Arrangement
Plant Design
&
Engineering
Shipment
Haulage
Commissioning
&
Operation
Procurement
&
Inspection Service
Construction
&
Site Management
Technical
Assistance
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
KSL fulfills Customer’s requirement from multiple aspects;
Project Design & Development Stage
Project Study (Scoping / Conceptual / Preliminary Design)
(Conceptual Layout, Preliminary Financial Analysis, Sample Test etc.)
Feasibility Study & Finance Arrangement
Project Execution Stage
Plant Construction (Engineering, Procurement & Construction)
Project Management & Supervision
O & M, Training Services
Provision of Aftermarket Service: Technical Assistance, O&M, Training Service and
Spare Parts Supply for the smooth and timely operation of the plant.
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Summary of KSL’s Service
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 13
Contents
1. Corporate Profile of KSL and Iron Unit Division
2. KSL’s Service Capability
3. FASTMETⓇ Process
4. Contribution to Indian Steel Industry
5. Project Reference
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 14
Issues of Indian Steel Industry
Indian Steelworks
Lump Iron Ore
Iron Ore Fine
Steel Products
Coal
Steel Mill Dust
Landfill
1) Difficulty of the security of Iron Ore due to the strict ban for iron ore mining.
2) High dependent on the import of coking coal.
For Indian steel industry, the security of iron and carbon sources are the most
important theme.
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 15
Ideas of solution for Indian Steel Industry
1) FASTMET is a solution for security of iron and carbon sources &
re-utilization of steel mill dust.
2) KOBELCO Pelletizing System can contribute to utilization of iron ore fine.
Indian Steelworks
Lump Iron Ore
Iron Ore Fine
Steel Products
Coal
Steel Mill Dust Landfill
Recycling
Dust FASTMET
KOBELCO
Pelletizing System
Iron Ore Fine
Treatment
Iron Ore Fine
Treatment
FASTMELT
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 16
History of RHF Process
Midland Ross
6 commercial plants in operation
KSL Kakogawa Demo Plant
Development of FASTMET Technology was started.
1990
1980
1970
KSL/Midrex
Midrex
Pilot Plant of Heat-Fast
Taken over
by Midrex
Acquired by KSL
2000
1) FASTMET® process was developed by KSL and Midrex as an alternative to Gas-based
Direct Reduction technology.
2) FASTMET® process is proven, and presently 6 plants are in good commercial operation.
Installed Facility
Licensor
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
1. Higher Process Reliability
(1) Rich Experience as a Plant Contractor
(2) Rich Experience as a Plant Operator
・ As a plant owner, Kobe Steel obtains rich know-how and
experiences for operation & maintenance
Advantage of FASTMET Process (1/2)
17
・ Proven process – History for around 20 years
・ 6 plants were supplied to 3 major Japanese steel mills
(3 plants: Supplied to Nippon Steel & Sumitomo Metal)
Stable Operation
Lower frequency of mechanical troubles than other RHF process
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Higher Performance
than Other RHF Process
FASTMET - HBI
Capacity (Dust Feed) 200,000 ton/year
Plant Availability 90%
Metallization 85%
DRI Fine Generation 10%
De-Zn Ratio > 90%
(Source: KSL in-house study)
18
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
4. Flexible Operation
・ BF & BOF Dust/Sludge
・ EAF Dust
・ Oily or High CaO contained dust
3. Raw Material / Fuel Flexibility
(1) Raw Material
(2) Fuel
・ Coke Oven Gas (COG)/BOF Gas
・ Producer Gas/Natural Gas
Easy plant start-up and shut-down due to the short process time
(Approx. 10 Minutes)
Advantage of FASTMET Process (2/2)
19
2. Lower Impact on Environment
・Recycling of steel mill dust
・Hot Briquette Iron (HBI) ⇒ Lower Fine Generation
・Lower NOx/SOx Emission
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Burner Fuel
- NG
- COG
- BOF gas
(subject to detailed study)
Rotary Hearth
Furnace (RHF)
Agglomeration
Material Bin
(Steel mill dust, Coal)
Briquetter Pelletizer
Off-Gas Handling System
Bag Filter Air Pre-Heater
Off-Gas Cooler
Stack
HBI
HDRI
CDRI
Crude Zinc Oxide is recovered at
the off-gas handling system.
Process Features
• DRI or HBI is produced with no sinter & no coking coal.
• High metalized DRI / HBI due to specially designed RHF (Metallization > 85%)
• High De-Zinc ratio > 90%.
Steel mill dust
Raw material
Products
Cold Briquette (CBQ)
Dryer
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Typical Process Flow of FASTMET
DRI
* Boiler system can be adopted to Off-Gas Handling System
in accordance with the customer’s requirement.
Thermal energy in the
off gas from the RHF
is captured and re-
used at the RHF.
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
2ndaryCombustion
CO gas
Zn
Retention Time 8 - 16 分
Burner
Heat
Discharger
Feeder
DRI
1200 - 1400 1000 -1200
Heat
700 - 1200
Cooling
Heat
Hearth
Crude ZincOxide
2CO + O2 = 2CO
2
Zn + CO2 = ZnO + CO
CH4 + 2O
2 = CO
2 + 2H
2O
CombustionAir
CH4 etc
FeO + CO = Fe + CO2
Fe2O
3 + 3CO = 2Fe + 3CO
2
ZnO + CO = Zn + CO2
CO2 + C = 2CO
Fuel
min
Reduction Mechanism
21
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Direct Reduced Iron (DRI)
Hot Briquetted Iron (HBI)
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Advantage of Hot Briquette Iron (HBI)
1) Versatile Usage: Due to the small surface specific area, HBI is much less
likely to be re-oxidized and overheating than DRI and can
be flexibly fed into BF and BOF according to the conditions
from actual operation of iron and steel works:
- Substitute for Scrap fed into BOF
- Reduction of Iron ore / Cokes in BF
2) Easy Transportation/Storage: HBI can be stored and shipped without special precautions.
3) Fines Losses: HBI has less fines losses during handling and shipping.
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Fuel GJ 3.3
Electricity kWh 120
Labor man/shift 5~6
Others $ 30 DRI t 0.71
(Unit: per ton of dust)
Assumptions (DRI Product) :
Plant Capacity: 190,000t
Feed (Dust) : T.Fe 51%, Fe2O3 48%, Gangue 9%, ZnO 2%, C 15%, S 0.2%
Final Product : DRI (Electricity Consumption is 140kW/t of dust in case of HBI.)
Typical Unit Consumption
23
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Lower Impact on Environment
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Items Figures
Dust <0.03g/Nm3
NOx (O2 15%) <60 ppm
SOx (O2 15%) <10 ppm
<Typical Emission Figures>
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Rich Experience of FASTMET
25
Client Name Feed Rate
(ton/year) Raw Material
Start
Operation
Nippon Steel & Sumitomo Metal No.1
(NSSMC No.1) 190,000 BOF Dust April, 2000
Kobe Steel 14,000
BF Dust
BOF Dust
EAF Dust
April, 2001
Nippon Steel & Sumitomo Metal No.2
(NSSMC No.2) 190,000 BOF Dust January, 2005
Nippon Steel & Sumitomo Metal No.3
(NSSMC No.3) 190,000 BOF Dust December, 2008
JFE 190,000 BF Dust
BOF Dust April, 2009
Kobe Steel J/V with NSSMC
(Nittetsu Shinko Metal Refine) 220,000
BF Dust
BOF Dust
EAF Dust
October, 2011
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 26
Contents
1. Corporate Profile of KSL and Iron Unit Division
2. KSL’s Service Capability
3. FASTMETⓇ Process
4. Contribution to Indian Steel Industry
5. Project Reference
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Issues of Indian Steel Industry
Contribution to Indian Steel Industry
27
Security of iron and carbon sources are the most important theme.
Difficulty of the security
of Iron Ore
(Ban for iron ore mining)
High dependent on the
import of coking coal
FASTMET HBI/DRI: Substitute for Iron source & Coking Coal
- Iron ore & coking coal consumption can be reduced (for BF).
- Cost for raw material can be saved.
- Stable raw material supply can be secured.
Solution for Indian Steel Industry by FASTMET
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 28
Contents
1. Corporate Profile of KSL and Iron Unit Division
2. KSL’s Service Capability
3. FASTMETⓇ Process
4. Contribution to Indian Steel Industry
5. Project Reference
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
FASTMET Plants in Operation
JFE
KSL
29
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Nippon Steel & Sumitomo Metal
(NSSMC )
No.1
NSSMC
No.2
FASTMET Plants in Operation
30
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.
Nittetsu Shinko Metal Refine
Co., Ltd.
(JV between NSSMC & KSL)
FASTMET Plants in Operation – HBI Plant
31
NSSMC
No.3
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 32
Direct Reduced Iron (DRI)
Dryer Raw Material Bin
Briquetter Pelletizer
Bag Filter Off Gas Cooler Heat Exchanger
Stack
Hot Metal
Mixer
Iron Ore Reductant
Binder
BOF/EAF Pig caster
Typical Process Flow of FASTMELT®
Agglomeration
Off-Gas Handling System
Raw material
Rotary Hearth
Furnace (RHF)
DRI-Melter
Process Concept: FASTMET® + DRI-Melter
• Hot Metal can be produced from iron ore fines without coking coal.
• FASTMELT® is a combination of proven FASTMET® and DRI-Melter
• It is easier to treat iron ore compared to steel mill dust.
Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 33
Thank you very much for your kind attention!