Update on North American Ironmaking Joseph J. Poveromo Quebec Cartier Mining Company Fred C.
Download ReportTranscript Update on North American Ironmaking Joseph J. Poveromo Quebec Cartier Mining Company Fred C.
Update on North American Ironmaking Joseph J. Poveromo Quebec Cartier Mining Company Fred C. Rorick Rorick, Inc ABM 2nd International Meeting on Ironmaking, 1st International Symposium on Iron Ore, September 12 – 15, 2004, Vitoria – Espirito Santo, BRAZIL TOPICS Blast Furnace ironmaking Alternative Ironmaking Processes Future Prospects Total Pig Iron Total Raw Steel 2000 1994 1988 1982 1976 1970 1964 1958 1952 1946 1940 1934 1928 1922 1916 1910 1904 1898 1892 1886 1880 1874 1868 1862 140000 120000 100000 80000 60000 40000 20000 0 Problems of North American Blast Furnace Sector External – EAF mini-mill competition, imports, environmental mandates Internal – limited capital for modernization, high legacy costs, poor profitability Consequences – reduction in hot metal, coke & sintering capacity – excess pellet plant capacity Response of North American Blast Furnace Steelmakers Non-technical – consolidation, reduce legacy costs, currency changes, markets Technical improve raw materials, upgrade existing facilities to: increase productivity, reduce reductant rate and extend lining life North American BF’s – Increased Productivity, Reduced Fuel Rates Key factors: fluxed pellets, improved acid pellets improved coke quality higher levels of natural gas, coal injection high levels of oxygen enrichment – lower cost oxygen-pipelines, on-site plants higher blast temperatures furnace upgrades: charging, cooling, casting Extend Lining Life to 8 – 12 years + Enhanced cooling and refractory systems - intensive plate cooling, copper staves Remote repair methods - gunniting, grouting, shotcreting Hearth life extension - North American carbon, coke quality Burden distribution equipment PW or MA tops on 25 of 41 furnaces Weighted (by Production Rate) Averages of Reductants by AISI BF’s (4) Hot Metal # of Reductant Usage, kg/tHM Production, Working Coke Coal Oil Gas Tar COG MT BF’s Lump Nut Total 1990 55 60 454 1 455 1 12 23 3 0 1995 61 51 402 8 410 34 2002 50 38 377 23 400 60 13 38 1 1 7 29 2 3 Increased Furnace Productivity Furnace Hearth Productivity Burden Dia., M T/M3/day Injectant AK Middletown BF 3 8.9 3.9 pellets,HBI gas Dofasco 4 BF 8.5 2.9 pellets oil Severstal NA C 8.8 3.1 pellets gas 13.5 2.5 sinter/pellets coal ISG. Sp.Pt. L BF ISG Sparrows Point Ispat Inland L Furnace 7 Furnace Hearth diameter, m Burden, kg/tHM Sinter Acid Pellets Fluxed Pellets Lump ore, siliceous ore, etc Reductant use, kg/tHM Large coke Small coke Coal Natural gas Top gas utilization, % Slag volume, kg/tHM 13.5 13.7 1040 534 0 48 228 0 1350 13 316 24 149 1 50.4 270 319 22 155 0 49.2 265 Waste Oxide Processing 7 Remaining sinter plants Direct BF charging: BOF slag, pellet chips Cold bonded briquettes, < 5% of burden DR options, Severstal RHF plant Landfill options Coke Supply Challenges US Coke Oven Capacity: 14 MTPY Expensive Imported Coke Maximize Injection of Coal, Gas, etc Use HBI – ISG Circored Plant ?? Rebuild Slot Oven Batteries Heat Recovery Cokemaking - Indiana Harbor Coke Corp - ISG Haverhill Coke Battery, 0.8 MTPY Development of Competitive Processes & Process Routes Smelting reduction – Corex, HIsmelt Direct reduction/scrap/EAF steelmaking route Hot metal/scrap/EAF steelmaking route Alternative (pig iron) iron/scrap/EAF steelmaking route Development of Alternative Ironmaking Processes o large scale ironmaking - avoid cokemaking, sintering steps preceding blast furnace – most efforts have failed except for Corex – high capital cost? o small scale ironmaking - provide iron units to EAF mini-mill sector – only shaft furnace gas based plants ( Midrex, HyL ) so far successful in North America o process waste oxides at both EAF and BFbased steel plants – limited success North American Direct Reduced Iron ( DRI ) Production Main process route in Mexico > 5 MTPY shaft furnace ( HyL, Midrex ) DRI USA, Canada: < 2 MTPY DRI ( Ispat Sidbec, ISG Georgetown ); other facilities down due to high gas prices: AIR, Corus Mobile North America major importer of metallics: HBI (Venezuela ); pig iron ( Brazil, Russia ) North American Shaft Furnace DRI Developments Application of pellet coating techniques; increase bustle gas temperature Midrex – OXY+ system HyL – self reforming, hot charging of DRI ( HyTemp system ) EVOLUTION OF MIDREX FURNACE PERFORMANCE DRI – Ispat Sidbec Nat. Elec. Production Gas Temp.Addition Gas T/hr C Nm3/T Nm3/T Cons. kWh/T 1970’s 1980’s lump ore 1990’s coat pellets late90’s, O2 inj. 2000 OXY+ Reducing 88.8 100.3 110.2 121.5 129.2 780 850 918 1050 961 O2 0.0 0.0 0.0 17.5 30.2 268.6 262.3 257.9 260.3 265.8 135 120 109 99 93 Coal-based Alternative Ironmaking Iron Dynamics, Inc ( IDI ) – hot metal process to feed SDI’s EAF flat-rolled mini-mill, IDI is an RHF(rotary hearth furnace)/SAF (submerged arc furnace ) process – start with briquettes of iron ore/waste oxides/coal, produce DRI in RHF, then melt DRI in SAF – plant restarted late 2003 Mesabi Nugget Demonstration Plant of Kobe ITmk3 pig iron nugget process Coal-based Alternative Ironmaking HIsmelt plant ( 0.8 MTPY pig iron ) in Kwinana, Australia – JV involving Nucor Nucor/CVRD JV to build mini-blast furnaces in Brazil to produce pig iron for Nucor EAF’s in USA RHF waste oxide plants – built at EAF and BF/BOF plants; all are currently idle Role of Quebec Cartier Mining Company in North American Ironmaking QCM mines iron ore in Quebec-Labrador Trough, with pellet plant, port facilities at Port Cartier on St. Lawrence Seaway. Mt. Wright mining, concentrating: produce 13 MT; mining and upgrade 2.4 MT of raw ore at 32 % Fe to yield 1 MT of concentrate: specular hematite at 66 % Fe. Produce pellets ( 8.7 MTPY ) in ( 2 straight grate machines, 464 m2 ) for BF and DR use Ship to Europe, N. America, Asia Chemistry of QCM’s Mt. Wright concentrate and pellets Mt. Wright concentrate Fe SiO2 Al2O3 CaO MgO 66.0 4.90 0.33 0.07 0.05 TiO2 P S Mn 0.18 0.015 0.005 0.025 Blast Furnace pellets Fluxed Low SiO2 Fluxed Acid Fe 63.3 65.1 65.1 SiO2 Al2O3 CaO MgO 3.75 0.50 3.68 1.30 2.50 0.40 2.25 1.50 5.20 0.45 0.60 0.25 DR grade pellets 67.8 1.65 0.35 0.50 0.30 US Steelmaking vs. Off-shore slabs Advantages of existing blast furnace plants: fully depreciated plants high labor productivity, < 1 man-hour/ton local coal, equity pellet plants Off-shore slab plants – added costs capital recovery ocean freight AISI Actual – 2002 Blast Furnace DR M tonnes # of BF’s USA Canada Mexico * ICSTI’03 Forecast - 2015 DS* 39.4 31 0.5 <0.1 8.0 5 0.2 0 3.5 3 4.6 0 ------------------------------------------50.9 39 5.3 <0.1 Blast Furnace DR** DS M tonnes # of BF’s 33.0 25 1.0 2.0 8.0 5 1.0 1.0 4.0 3 6.0 0 ---------------------------------------45.0 33 8.0 3.0 IDI (RHF/SAF), HIsmelt, ITMk3 ** Midrex, HyL or RHF waste oxide Conclusion - Key North American Developments “Heat Recovery”Cokemaking Blast Furnaces – high productivity, “endless campaigns”, high use of O2, pellets, HBI Midrex, HyL DR – higher productivity, metallization: coated pellets, O2, hot discharge Coal based alternative ironmaking – IDI, ITmk3 processes