V. G. Lisienko

Greenhouse-gas (CO2) emissions in the steel industry

The greenhouse gas CO2 is produced copiously in the steel industry. Three types of carbon-dioxide emissions may be distinguished: emissions in the technological processes, emissions in transit, and the overall emissions. The overall CO2 emissions characterize the sum of the process and transit emissions. A classification of processes in the iron and steel industry is proposed, in terms of the mechanism by which the CO2 is formed. Five major sources are identified: furnaces, converters, open-hearth furnaces, blast furnaces, and coke batteries. The overall CO2 emissions are determined for six combinations of processes whose final product is steel.

BAT According to Climatic Neutrality of Production of Steel Products

The purpose of this article is to estimate the best available technologies for values of the following technological numbers: fuel, ecological, depreciation, greenhouse and their sums. All these numbers have power dimension: t of conditional fuel/unit of production that allows to put them. The fuel technological number characterizes power consumption of production. The technological ecological number transfers a payment of the enterprise for environmental pollution to power units. The technological depreciation number transfers depreciation charges from rubles to power units. The technological greenhouse number translates a payment of the enterprise for emissions of greenhouse gases in power units. Technological numbers have through character – from extraction of raw materials before receiving finished goods. The best available technologies are characterized by the smallest sum of all technological numbers.

Application of the triad of blast furnace, oxygen converter, and electric arc furnace for reducing of carbon footprint

Carbon footprint is the mass of carbon formed in the full cycle of manufacturing one kind or another product. This carbon is included in greenhouse gases. During production of iron and steel are generated carbon monoxide and greenhouse gases: methane, and carbon dioxide. Methane and carbon monoxide burn to carbon dioxide by secondary energy resources. By this means, the carbon footprint by the production of iron and steel has determined by the weight of carbon dioxide formed in this production. As results of analysis of the processes of manufacture of iron and steel, it has revealed that the tandem of blast furnace with electric arc furnace is characterized by a lower value of integrated emissions of CO2 than the tandem of blast furnace with an oxygen converter. It was proposed to process of the cast iron made by one blast furnace, then in the oxygen converter, and, at last, in one or more electric arc furnaces. Moreover, the electric arc furnace is loaded by 30% of iron produced in blast furnace, and the remaining 70% are complemented by metal scrap. In the oxygen converter is loaded, the part of cast iron (75–85%), that remained after processing in the arc furnace. The converter is applied the metal scrap for full loading. Calculations of total emission of carbon dioxide for different triads of these units are made. Simultaneous use of oxygen converter with electric arc furnaces for cast iron smelting (obtained from one blast furnace) helps to reduce reliably the emission of carbon dioxide to 20% as it is follows from these calculations. This suggests that such a triad of used units conforms to green technology. Example of the use of mentioned triad is for a full load of the converter applied to metal scrap. The calculations total emissions of carbon dioxide for different triads of these units were performed. From these calculations it follows that the simultaneous use of oxygen converters after electric arc furnaces for smelting iron (obtained from one blast furnace), it helps to reduce the emission of carbon dioxide to 20%. This suggests that this triad of used units conforms to green technology. An example of using this triad is in the Magnitogorsk Iron and Steel Works, where along with the oxygen converter, electric arc furnaces with the use of locally produced electricity at burning fuel of secondary energy resources from units, in which the fuel is burnt. This practice can be recommended for a number of other metallurgical enterprises.

Comparative Analysis of the Influence of Fuel Injection on the Energy Intensity and Carbon Footprint of the Blast-Furnace Process

The data on the energy intensity, carbon dioxide emission, and end-to-end emission (carbon footprint) for the production of vanadium iron in coke-fired blast furnaces with injection of either natural gas or both natural gas and pulverized coal are presented. Energy intensity is represented by end-to-end process fuel number. Mean values, variance, standard deviation, range of variation of process fuel number, emission, and end-to-end emission of carbon dioxide are calculated using published data on the consumption of coke, natural gas, and pulverized coal in a blast furnace. It is shown that the process with injection of pulverized coal has better performance in terms of energy intensity. Carbon footprint is minimum when injecting natural gas only.

Types of greenhouse gas emissions in the production of cast iron and steel

Types of carbon dioxide emissions in iron and steel production are indicated. Production processes have been classified according to mechanisms of carbon dioxide formation. Mathematical models for calculation of carbon dioxide emissions for each type of process are found. Calculations results of carbon dioxide emissions of coke (BF + EAF) and cokeless processes (Corex, Midrex, HyL-3, Romelt) in combination with EAF are provided.

Simulation in selecting the heat treatment of oil and gas pipe

A method is proposed for determining the actual heat-treatment conditions of oil and gas pipe, with allowance for the heat transfer within the furnace chamber. High tempering of 13XΦA steel pipe of elevated operational reliability (strength group K52) is simulated. The precision in simulating the treatment parameters exceeds that achieved by standard monitoring methods. The actual onset of isothermal holding is determined. Corresponding correction of the tempering conditions permits 18-fold reduction in the rejection rate associated with furnace treatment (that is, in the quantity of pipe sent for repeated heat treatment).

Analysis of Energy Content and CO2 Emissions in Different Combinations of Coke-Using and Coke-Less Processes for Steel Production

Comparative estimates are made of energy content and emissions of carbon dioxide – a greenhouse gas – for different combinations of coke-using processes (blast-furnace – BOF, blast-furnace – electric-arc-furnace (EAF)) and coke-less processes (HyL-3 – EAF, MIDREX – EAF; ROMELT – EAF, COREX – EAF, direct alloying with vanadium (DAV), EAF operation on scrap) that are performed in the course of producing steel. These processes were compared as part of an energy-environmental analysis by examining both energy content and a parameter that characterizes the emission of the greenhouse gas CO2 – the technological greenhouse number (TGN). It was determined that the advantages in terms of energy content and CO2 emissions belong to EAF steelmaking with the use of scrap, the DAV process, the HyL-3 – EAF process, and the Midrex – EAF process. It should be noted that the steel obtained in the DAV process is alloyed with vanadium. In each case, the processes that do not involve the use of molten pig iron in steel production should be given the highest priority based on their ratings for energy content and greenhouse-gas emissions.

Simple approximation of total emissivity of CO2-H2O mixture used in the zonal method of calculation of heat transfer by radiation

The paper presents a new simple-to-use expression to calculate the total emissivity of a mixture of gases CO2 and H2O used for modeling heat transfer by radiation in industrial furnaces. The accuracy of this expression is evaluated using the exponential wide band model. It is found that the time taken to calculate the total emissivity in this expression is 1.5 times less than in other approximation methods.

Calculation of exchange areas in models of high-temperature radiant systems

A method based on the discrete transfer model is proposed for the determination of direct exchange areas in zonal calculations of radiant heat transfer. This algorithm proves faster than numerical integration in assessing the matrix of direct exchange areas corresponding to the interaction of surface and internal (volume) zones. As a test case, the precision and speed of the proposed method are compared with those of numerical integration in simulating the heat transfer within the IFRF experimental furnace.

Accelerated Method for Surface View Factor Evaluation Based on Error Estimation

An algorithm for choosing the number of quadrature nodes before calculation of a view factor is proposed. Simple criterion is introduced that allows one to estimate the error in the computed view factor. The algorithm allows one to save much computation time by always using the minimum number of nodes for each pair of surface zones and insures a desired accuracy. The algorithm is applied for model of a continuous furnace and is compared with a standard method which uses predefined number of nodes at each surface. The proposed algorithm is many times faster and also more accurate than the standard one.