Slide 1: Big and Diffuse or Small and Sharp: State-of-the-Art Oxyfuel Based Melting and Heating
Big and Diffuse or Small and Sharp State-of-the-Art Oxyfuel Based Melting and Heating Presentation at SCANMET III Joachim von Schéele June 10, 2008
Slide 2: Oxyfuel Solutions: Energy Efficiency
Oxyfuel Solutions Energy Efficiency ¾ Low flue-gas losses due to low flue-gas volume ¾ Possible to use high flue-gas temp ¾ Radiating compounds, H2O & CO2 8 Molecules of Nitrogen Ballast! ¾ Possible to use high power input ¾ Possible to use Low Calorific Fuels Oxyfuel 18/06/2008 2
Slide 3: Chemical Energy Package - Injectors
Chemical Chemical Energy Energy Package Package -- Injectors Injectors Hi JET OXYGENJET CARBONJET LIMEJET • UP TO 5 MW BURNER WITH INNOVATIVE • UP TO 5 MW BURNER WITH INNOVATIVE • UP TO 5 MW BURNER MIXED SWIRL FLAME TECHNOLOGY. MIXED SWIRL FLAME TECHNOLOGY. • WITH INNOVATIVE MIXED SWIRL FLAME TECHNO
Slide 4: Combustion Technologies
REBOX® Oxyfuel Solutions Combustion Technologies Oxyfuel Combustion Technology Flameless – low NOX, high uniformity ¾ Energy savings ¾ Increased production ¾ Lowered emission Big & Diffuse DFI – for ultra fast heating Small & Sharp Only <800°C And the Newest: REBOX® HLL! 18/06/2008 4
Slide 5: Flameless Oxyfuel: Uniform Heating and Reduced NOx
Flameless Oxyfuel Uniform Heating and Reduced NOX Combustion extended in time and space — Volume combustion — Spontaneous reaction above self ignition temp. (>750ºC from safety point of view) Dilution of flame reduces flame temperature — Flame temperature is even with no peaks which minimizes therma
Slide 6: Flameless Oxyfuel: Oxyfuel Staged Combustion with 5% Primary Oxygen
Flameless Oxyfuel Oxyfuel Staged Combustion with 5% Primary Oxygen 0 350 700 mm Flameless Oxyfuel 0 500 1,000 mm 18/06/2008 6
Slide 7: Flameless Oxyfuel: Ultra Low NOx Levels
Flameless Oxyfuel Ultra Low NOX Levels NOX mg/MJ Dilution reduces flame Standard Oxyfuel ~100-200 temperature and provides Staged Oxyfuel 70-100 effective stirring of the highly radiating CO2 and H2O gases Flameless Oxyfuel <25 18/06/2008 7
Slide 8: Flameless Oxyfuel has Lower Flame Temperature, but Same Energy Content
Flameless Oxyfuel has Lower Flame Temperature, but Same Energy Content Flame mode Flameless mode 18/06/2008 8
Slide 9: Flameless Oxyfuel: Ultra Low NOx Despite Ingress Air
Flameless Oxyfuel Ultra Low NOX Despite Ingress Air 18/06/2008 9
Slide 10: Benefits of Oxyfuel in Vessel Preheating
Benefits of Oxyfuel in Vessel Preheating Benefits from higher heating temperature of a steel-making vessel: — No need to have too high tapping temperature from the EAF/BOF — Shorter heating cycles for less number of vessels needed — Only 75-80% flue gases due to less fuel and no nitrogen in combusti
Slide 11: Vessel Preheating with Flameless Oxyfuel
Vessel Preheating with Flameless Oxyfuel Vessel preheating using oxyfuel is common technology – using Flameless Oxyfuel is a Milestone in Preheating! ¾ Increased temperature uniformity in ladle Ladle preheating at ACERINOX ¾ Decreased fuel consumption ¾ Lower NOX formation ¾ Increased heating capaci
Slide 12: General Results from Installations
REBOX® Oxyfuel Solutions General Results from Installations Fuel and CO2 savings Up to 50% reduction Low NOX emission Levels continuously below 70 mg/MJ Less Scaling Up to 0.4%-units reduction Increased production capacity/flexibility Up to 50% higher throughput Car bottom furnace at SCANA Steel, al
Slide 13: Lower Fuel Consumption in a Reheating Furnace
REBOX® Oxyfuel Solutions Energy Efficiency Lower Fuel Consumption in a Reheating Furnace Air fuel AF w recu REBOX® Enthalpy in steel kWh/t 200 200 200 Transmission losses kWh/t 10 10 10 Flue-gas enthalpy kWh/t 290 140* 50 o Flue-gas temperature C 1200 850 1200 o Air preheating C 20 450 20 Thermal ef
Slide 14: Flameless Oxyfuel burners, Water-cooled & Ceramic
Flameless Oxyfuel burners, Water-cooled & Ceramic Ultra low NOX & Uniform heating — High flue gas circulation and lower flame temperature Dual mode burner – standard and flameless Separated jets – Supersonic Powerful: 0.5-5 MW — Oil, coal or gaseous fuels Easy retrofit & Compact rugged design — Quic
Slide 15: Retrofit Replacing Air-fuel
REBOX® Oxyfuel Solutions Retrofit Replacing Air-fuel 4 MW air-fuel installed, before REBOX® 18/06/2008 2.5 MW Flameless Oxyfuel Installed15
Slide 16: Typical Installation: Flameless Oxyfuel Burner
REBOX® Oxyfuel Solutions Typical Installation Flameless Oxyfuel Burner 18/06/2008 16
Slide 17: Typical Installation: Flameless Oxyfuel Burner
REBOX® Oxyfuel Solutions Typical Installation Flameless Oxyfuel Burner 18/06/2008 17
Slide 18: Use of a Low Calorific Fuel
REBOX® Oxyfuel Solutions Use of a Low Calorific Fuel Air/BFG Flame: For Coke Oven Gas, Blast Furnace Top - Diffuse Gas, BOF Gas, and other in-house gases. - bad definition Used individually or in different - T = 1,300°C combinations. - efficiency <5% Combusting Low Calorific in-house gases with oxyg
Slide 19: Use of a Low Calorific Fuel: Burner Design
REBOX® Oxyfuel Solutions Use of a Low Calorific Fuel Burner design – Flameless Oxyfuel using a Low Calorific Fuel ¾Separate Jet Flameless technology ¾Ceramic self-cooled design ¾Dual-fuel and mixed fuel capability ¾Flame and Flameless mode for cold and hot furnace operation Ø 300mm stone For 400-600
Slide 20: Flameless vs. Conventional
REBOX® Oxyfuel Solutions Flameless vs. Conventional Rotary hearth furnace at ArcelorMittal Shelby, all equipped with flameless oxyfuel Total Heating Time at Ovako Hofors Works using different combustion technologies 18/06/2008 20
Slide 21: Example of Installation: Walking Beam Furnace at Outokumpu, Degerfors
REBOX® Oxyfuel Solutions Example of Installation Walking Beam Furnace at Outokumpu, Degerfors. Conversion into all flameless oxyfuel operation. Linde Turn-key delivery in 2003 Combustion system with flameless burners, furnace upgrade, new flue gas system, flow train, control system Furnace data Dime
Slide 22: Example of Installation: Soaking pit furnaces at Ascométal
REBOX® Oxyfuel Solutions Example of Installation 13 Soaking pit furnaces at Ascométal, Fos-sur-Mer and Les Dunes. Conversion into all flameless oxyfuel. Linde Turn-key delivery in 2005-2008 Combustion system with flameless burners, furnace upgrade, new flue gas system, flow train, control system Fur
Slide 23: Example of Installation: Rotary hearth furnace at ArcelorMittal Shelby
REBOX® Oxyfuel Solutions Example of Installation Rotary hearth furnace at ArcelorMittal Shelby. Conversion into all flameless oxyfuel. Linde Turn-key delivery in 2007 Combustion system with flameless burners, furnace upgrade, new flue gas system, flow train, control system Furnace data Dimension: 15
Slide 24: Direct Flame Impingement (DFI) Technology
Direct Flame Impingement (DFI) Technology Heat Firing Directly Onto a Moving Material flux [kW/m2] DFI Oxyfuel the local heat flux could be as high as 800-1000 kW/m2 18/06/2008 24
Slide 25: DFI Oxyfuel in a Stainless Strip Annealing & Pickling Line at Outokumpu
DFI Oxyfuel in a Stainless Strip Annealing & Pickling Line at Outokumpu Outokumpu Nyby Works, Sweden DFI Oxyfuel installation in 2002 by Linde 4 MW installed power 120 oxyfuel flames, four burner rows 2 meter long unit at entry of strip annealing furnace Furnace throughput capacity increased 50%, fr
Slide 26: DFI Oxyfuel in Metal Coating Lines: ThyssenKrupp Steel
DFI Oxyfuel in Metal Coating Lines ThyssenKrupp Steel at Finnentrop and Bruckhausen 3 m of recuperative zone removed to fit DFI Compact DFI unit: L 2.8 x W 2.8 x H 1.2 meter 12 days line stop 18/06/2008 26
Slide 27: DFI Oxyfuel in Metal Coating Lines: ThyssenKrupp Steel
DFI Oxyfuel in Metal Coating Lines ThyssenKrupp Steel at Finnentrop and Bruckhausen 5 MW power input 80-90% thermal efficiency Totally 120 oxyfuel flames, in 4 burner rows Option for 2 more burner rows (+ 2 MW) 18/06/2008 27
Slide 28: DFI Oxyfuel Example of Installation: Galvanizing lines at ThyssenKrupp Steel
REBOX® DFI Oxyfuel Example of Installation Galvanizing lines at ThyssenKrupp Steel, Finnentrop and Bruckhausen. DFI boosting. Linde Turn-key deliveries in 2006 and 2007 Combustion system with Direct Flame Impingement in 4 Burner Row Units, flow train, control system Furnace data Dimensions: 2.8 m lo
Slide 29: DFI is solutions in one - more capacity, clean strip
“DFI is 3 solutions in one – more capacity, clean strip and no extension of line” 120 0,84 109 t/h 100 0,82 Energy input GJ/ton Old + 10m longer furnace Old + 10m longer furnace 82 t/h 0,8 Capacity ton/h 80 Booster 0,78 Old furnace 60 Old furnace 0,76 With DFI 40 0,74 With DFI 20 0,72 0 1 2 0,7 The
Slide 30: Direct Flame Impingement (DFI) Technology
Direct Flame Impingement (DFI) Technology Here DFI for ΔT 200°C at max production rate (ton/h), but can be used for much higher ΔT, for example 500°C 18/06/2008 30
Slide 31: Direct Flame Impingement (DFI) Technology: other applications
Direct Flame Impingement (DFI) Technology DFI oxyfuel could be used not only for strip heating relating to annealing and coating of different kinds. ¾ Agglomeration – for example, ignition of sinter beds and agglomeration of briquettes ¾ Iron-making ¾ To change material properties ¾ Press hardening
Slide 32: Summary
Big and Diffuse or Small and Sharp State-of-the-Art Oxyfuel Based Melting and Heating Summary: In the steel industry, flameless oxyfuel should be applied for heating in all types of furnaces and vessels, with temperatures above 800-900°C. Flameless oxyfuel leads to great benefits in terms of lower f