2010 SEAISI Environmental & Safety Seminar November 22-24, Manila Energy Efficiency Measures and Investments - Proof of Benefits by Case Studies J. Kriechmair © Copyright Siemens AG 2009 Siemens AG 2010. All rights reserved. Technological innovations play a key role in increasing energy efficiency and avoiding GHG emissions Siemens makes a substantial contribution to environmental protection with its energy-efficient products and solutions and its renewable energy and environmental technologies. What does Siemens offer? Some examples: • Siemens Combined Cycle Power Plants: efficiency > 60 % • Over 6,400 wind turbines, peak performance 5,700 MW • High voltage direct current transmission technology: 2000 km transmission with minimum loss • Variable speed drives for frequency converters: 60 % energy reduction • COREX technology reduces CO2 emissions by 30 %, SO2 emissions 97 % • Breaking energy recovery applied at Subways • Optimizing HVAC at 6,500 buildings -> 2.4 million t CO2 reduction • For lighting: LEDs use 80 % less electricity than lightbulbs, 50 times longer service life © Copyright Siemens AG Page 2 17 – 19 June 2009 Metals Symposium 2009 Author: asdfjklö I IS MT Energy – including reducing agents – is a major source for costs of iron & steel production Production costs for hot rolled coil Energy is a major cost driver – example integrated steel plant ($/t) ~ 400 24% 145 10% Other 18% 36% Energy Cost Development and Forecast Index = 100 in 2004 Electricity Thermal energy (mainly from natural gas) 250,00 Forecast Forecast 200,00 Energy sources 150,00 72% 40% Reducing agents (mainly coke) Ferrous raw materials 100,00 50,00 Total cost Energy costs 1. Contains all credits for by-products Source: Company data; BCG analysis Page 3 November, 2010 Coking coal cost Electricity cost Natural gas cost Source: CRU Efficiency improvements one way to counter-balance energy cost impact Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Existing plants show considerable differences in energy intensities – a key to improvement potentials Typical energy intensities (in GJ per ton of output material) Typical energy intensities (in GJ per ton of output material) “Top performers” “Medium” ~3.5 Coking ~4.3 ~1.5 Sintering ~7.7 ~1.7 ~14.8 Iron-making (BF) “High saving potential”1 ~3.3 ~17.4 ~22.2 Steel-making (BOF) ~0.2 ~0.3 ~0.7 Casting ~0.1 ~0.2 ~0.3 (CC) Hot rolling ~1.6 ~2.1 ~3.6 (HSM) Cold rolling Finishing ~0.3 ~1.1 ~0.4 Top performers ~1.4 ~0.6 Additional energy usage for medium performers ~2.4 Additional energy usage for low performers Different plant preconditions (size, input materials etc.) to be taken into account when comparing different sites 1. Not accounting for outdated technology, such as open hearth and ingot casting Source: SVAI, BCG Page 4 November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Energy savings can be realized by existing, proven technologies Siemens MT green solution examples • COREX/FINEX • Reheating Furnace Process Optimization • Mill pacing • Top gas recovery turbine • Improved automation • Gimbal top charging system • Coke dry quenching • Process mgmt. system Auxiliary plants power plant • Drive efficiency and controlled drives • Roll gap lubrication LDG Scrap COREX FINEX Coking Coal Coke oven gas Coke Oxygen, etc. Molten steel Hot rolled products BFG Sinter Cold rolled products Ladle Furnace Coke oven Ore Hot metal Sintering plant Hot stove • • • • Blowers – VVVF Automation Waste gas recycling Waste heat recovery Blast furnace • Process Optimization • Stove heat exchanger Continuous Caster Basic oxygen furnace Reheating furnace Hot rolling Cold rolling Processing Lines RH • • • • • Balanced drive operation Dry dedusting Waste heat recovery BOF gas recovery Process Optimization ESP • Demand-driven utilization of ancillary unit • ISP/ESP1 Efficient Energy Supply, Net Optimization Energy Management & Control Systems, Cross Process Optimization Page 5 November, 2010 1. Endless Strip Production Johann Kriechmair •New technology MT MP IP DP, Siemens VAI Metals Technologies GmbH •Proven technology Confidential / Copyright by Siemens VAI Environmental improvements both by end- of-pipeand primary process technology Siemens MT green solution examples Dry gas cleaning • DDS-Bag filter • Hot cyclones Residual treatment • Slag granulation Recycling • Sludge granulation • COREX • FINEX Wet gas cleaning • COG treatment Dry gas cleaning • CDQ dust removal • CDQ gas cleaning Residual treatment • Biol. waste water treatment Recycling • Coke dust power plant Auxiliary plants LDG Scrap COREX FINEX Coking Coal Dry gas cleaning • DDS-ESP Coke oven gas Coke Oxygen, etc. Molten steel Hot rolled products BFG Sinter Cold rolled products Ladle Furnace Coke oven Ore Hot metal Sintering plant Hot stove Blast furnace Dry gas cleaning • MEROS • DENOX New process • EPOSINT Page 6 November, 2010 1. Endless Strip Production Basic oxygen furnace Wet gas cleaning • SVAI CONE Dry gas cleaning • Pulse-Jet-Filters Residual treatment • Pelletizing / Briquetting Recycling • CONTOP • Zero waste concept Johann Kriechmair Continuous Caster Reheating furnace • OXITERM (De-oiling) Hot rolling Cold rolling Processing Lines • CWC -Coating Weight Control • Dynamic Air Knife ControlDAK • FAPLAC – Automatic Pickle Liquor Analysis and. Control •New technology technology MT MP IP DP, Siemens•Proven VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI SIMETAL Selective Waste Gas Recirculation System reduce coke demand and waste gas volume Sinter process has a significant energy demand, i.e. coke, and produces a high Challenge amount of waste gas Solution Environmental benefit Page 7 Reduction of waste gas volume up to 40% up to 10% less CO2 emissions Decrease sinter plant emission (SOx, NOx and dioxins) by recirculation November, 2010 Johann Kriechmair re-circulate part of the off-gas from selected wind-boxes back to the sinter process Decrease of coke consumption up to 10% due to heat and CO recirculation Typical customer benefit Higher sinter quality Increase production Less investment costs for waste gas cleaning plant MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI SIMETAL Gimbal Top - Blast Furnace Charging reduce coke rate, increase productivity Distributing burden materials to the furnace stock line Challenge with high operational flexibility enhance furnace operation minimize maintenance costs Simple, rugged, lever mechanism Solution Proven operation Improved distribution control Infinite charging flexibility Environmental benefit Reduced CO2 emissions due optimized furnace operation Reduction of fume emissions due to pressurized charging system Typical customer benefit *) Reduce fuel rates 15-25 kg/thm Increase production > 5% Improve service life Improve gas utilization > 50% Reduce heat load Increase furnace campaign > 40% *) when compared with bell-top Page 8 November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Blast furnace top gas pressure recovery turbines (TRT) generate electricity from top pressure recover the potential energy in highpressure furnace off-gas Challenge Achieve a safe level for clean-gas pressure “bump-less” transfer of system pressure during an unexpected TRT stoppage. Solution turbine construction suitable for BF offgas with the ability to control the turbine blades for varying gas inlet conditions inclusion of quick-acting valves for a change in operation Environmental benefits Page 9 Generate ~ 30-40 kWh/tHM electric energy from blast furnace top pressure November, 2010 Johann Kriechmair Typical customer benefit Reduced electrical energy purchased for the site or new energy sold into a local grid Ease of bringing the TRT ‘On-’ and ‘Off-’ line MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Blower House for Blast Furnace Key features and benefits High energy demand for blast furnace cold wind (up to 40MW and more) Existing facility with low efficiency Challenge No spare parts available Highest degree of efficiency Greenfield or Brownfield environment Solution Baosteel COREX® C-3000 Cost and energy saving due high equipment and system efficiency - High blower efficiency 85-90% Environmental benefit - Total energy savings up to 50% - Reduce CO2 emissions - Save water consumption Page 10 November, 2010 Johann Kriechmair Electro or turbine drive Customer-oriented compressor solution Compaction of high volume flows within a relatively small enclosure Modular and robust machine design Meets API Standards Typical customer benefit Low operating and maintenance costs Extended operating range Prevention of wear due to optimized material selection MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI SIMETAL DDS BOF steelmaking plant primary dedusting Dry type converter waste gas treatment with low consumption figures Challenge Solution Environmental benefits Page 11 High dedusting efficiency clean gas dust content < 30 mg/Nm3 CO-gas recovery 70-90 Nm3/CO tsteel Low specific consumption figures 3 kWh/t – Low pressure loss because of advanced design – No waste water treatment plant November, 2010 Johann Kriechmair Typical customer benefit CO rich hot fumes with high dust content during oxygen blowing cycle Gas temperature up to 1600 °C Dust content up to 20 g Nm3 Suppressed combustion Cooling stack (steam or pressured water cooled) Evaporation cooler with dry dust separator Electrostatic precipitator (compact design) High plant availability Low specific consumption figures (50% in comparison wet dedusting) Clean gas dust content < 30 mg/Nm3 No water treatment plant Conform to best availade technology Dry dust separation MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI BOF Gas Recovery cut energy costs by utilization of steel making gas By-product of LD-process: 80 Nm³/t steel of CO-rich Challenge converter gas Solution BOF gas recovery is a completely integrated economic and ecologic solution for BOF primarywaste-gas treatment Typical customer benefit Baosteel COREX® C-3000 Environmental benefits Page 12 Reduction of CO2 emissions 0.032 t CO2/ t steel Substitution of fossil fuels Total emission reduction November, 2010 Johann Kriechmair Energy savings of 0.57 GJ/t steel Reduction of energy costs Higher degree of efficiency Short pay-back time MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI EAF Optimization Reduce energy consumption and tap-to-tap time Challenge Increasing demands to lower production costs and increase product quality Insufficient process standardization High productivity requirements with minimum operator personnel Solution Well proven automation system for high quality at low production costs Dynamic process models Modular-designed, expandable and upgradeable automation package Typical customer benefit Reduce energy consumption up to 3% Reduce tap-to-tap time due to standardized production practice up to 5% Reduction of OPEX by up to 5% Baosteel COREX® C-3000 Environmental benefit Page 13 Reduced CO2 emissions due to efficient carbon usage Lower consumption of raw materials and resources Efficient oxygen injection November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI SIMETAL SIMELT Electrode Control System Real improvement for electric arc furnaces Environmental benefit Page 14 Reduced CO2 emissions due to lower specific electricity consumption Reduced impact on utility grid and environment Lower consumption of resources November, 2010 Johann Kriechmair Challenge Dynamic control for fast electrode movement and stable arc conditions ensure precise and stable adjustment of all EAF operating points sustainable performance combined with low usage of resources and consumables Solution Modular and multifunctional digital control system based on SIMATIC S7 Proven, neural network optimized dynamic impedance control with add-ons, system analyzer and visualization Melt down recipes for high repeat accuracy and stable process conditions Typical customer benefit Reduced electrode consumption, ~ -5% Increased effective power efficiency (+10%) leads to reduced specific melting power (-4%) shorter power-on times (-12%) and reduced down times (<50%) resulting in higher productivity, e.g. +15% MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI SIMELT Foaming Slag Manager Real improvement for electric arc furnaces Challenge to introduce fully automated foaming slag process to detect and indicate the foaming slag height to ensure uniform distribution of the foaming slag in all furnace sections to control and optimize carbon injection Solution with SIMELT FSM the foaming slag process is fully automated Body sound sensors are the base for precise detection and slag height analysis sectional and electrode related slag detection with automatic carbon injection Typical customer benefit Controlled and optimized foaming slag process Reduced specific electric energy (up to 3%) and carbon consumption (up to 25%), Shorter power-on times, 1 min or even more increased productivity, 2% or more possible Baosteel COREX® C-3000 Environmental benefit Page 15 Reduced CO2 emissions due to lower carbon and energy consumption, e.g. up to 10.000 t CO2/year at 100 t EAF savings in specific electric energy consumption up to 3% November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Furnace Optimization Reduced fuel consumption – improved quality Hot rolling operations need high-quality reheated slabs, billets, or blooms at the lowest possible cost, at the mill’s optimal Challenge production rate, with minimal impact on the environment. Solution Environmental benefit Page 16 Reduced fuel consumption resulting in lower environmental emissions (CO, CO2, NOX, SOX) November, 2010 Johann Kriechmair Typical customer benefit SIROLL Furnace Optimization delivers optimally heated pieces to hot rolling operations while minimizing fuel consumption. Fuel usage reduced by 6 to 15% Discharge temperature deviation from target < 1% Improved surface quality MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI SIROLL Work-roll lubrication increase surface quality, reduce energy demand Energy is a main cost driver approximately 40% of conversion costs Challenge in rolling mills are energy charges Solution Baosteel COREX® Work-roll lubrication is dedicated to reduce roll wear and friction of the work rolls by application of lubrication media in finishing mill stands Less friction leads to reduced rolling force and thus energy consumption C-3000 Saving costs (roll wear and energy) Environmental benefit Page 17 Significant reduction of electrical energy demand - up to ~15% November, 2010 Johann Kriechmair Typical customer benefit Improve strip surface quality Extending the mill availability Extending the mill limits MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI SIROLL Endless Strip Production First casting-rolling plant for ultra-thin HRC Production of ultra-thin high-quality steel grades Challenge Reduction of power requirements and emissions Satisfy current and future market demands Fully continuous strip production Solution Outstanding production capacity Most compact line layout Baosteel COREX® C-3000 Environmental benefit Page 18 - 45% energy - 50% CO2 - 50% length (190 m) November, 2010 Johann Kriechmair Typical customer benefit High volume production of ultra thin strip High quality strip Lowest conversion costs from liquid steel to Hot rolled coil MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Real Endless Strip Production Advantages of Inductive Heating Only 10 Meter inductive heating leads to reduced scale losses compared to min. 200m tunnel furnace No Energy consumption during idle and maintenance periods Energy Consumption [kWh/t] 500 fuel gas electricity 400 caster Reduced maintenance costs compared to long tunnel furnaces 300 Optimized control of end rolling temperature 200 100 0 Conv.casting and Conv. Casting HSM 20°C *) and HSM 600°C *) Arvedi ESP CSP cast and roll 1200°C **) CSP real ***) operations Sources: *) VdEh paper, **) SMS paper,Johann ***) Nucor publication Kriechmair November, 2010 Page 19 MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI ESP Alternative production routes Melt shop Casting & Rolling EAF Downstream ESP, ISP, Combi-Plant Ultra compact MiniMill Flat ESP……. 0.8mm, High productivity ISP……...1.0mm, Demanding grades Combi…..Best of both Hot dip galvanizing Compact pickling tandem line Arvedi ESP ▲▼ EAF and ladle treatment Compact pickling and 3 stand tandem cold mill Arvedi ISP (Cremona Furnace) Arvedi ESP line BOF Double-wide casting and slitting Compact and parallel to Existing Hot Strip Mill Continuous casting Greenfield or Brownfield Capacity increase by shift of thin gauges to ESP BOF and ladle treatment Continuous casting Arvedi ESP line Page 20 November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI ESP Specific cash conversion costs Conversion Cost Specific Cash Cost Conversion Cash Cost Conversion Specific Cash Specific to Hot Rolled Coil SteelCoil Hot Rolled to Liquid SteelCoil Hot Rolled toLiquid Liquid Steel Conversion Cost Hot Rolled Coil ecific Cash Conversion Cost quid€/t Steel to Hot Coil Specific Cash Conversion Cost €/t 44,9Rolled 4,9 Liquid Steel to Hot Rolled Coil 1,8 €/t ,8 €/t 7,5 €/t 28,4 €/t 2,2 €/t 6,5 €/t 14,4 €/t 37,0 €/t 44,9 2,4€/t €/t 17,5 1,8 €/t €/t 28,4 €/t 2,2 €/t 18,3 €/t 28,4 17,5 €/t€/t 2,2 €/t 14,4 €/t 16,5 €/t 37,0 €/t 2,4€/t €/t 28,4 2,2 €/t 18,3 €/t 14,4 €/t 37,0 €/t * 2,4 €/t 37,0 €/t 28,4 €/t 2,4 €/t€/t 2,2 18,3 €/t 28,414,4 €/t 18,3 €/t€/t 2,2 €/t Personnel Only one caster operation group No slab37,0 strorage staff €/t 37,0€/t €/t Other op.2,4 Supplies (Maintenance) Minimum 37,0 €/tmaintenance at 102,4 m18,3 inductive heater €/t 18,3 €/t €/t Increased work roll life time due to 2-step rolling 2,4 €/t 18,3 €/t 8,3 €/t 8,3 €/t 8,3 €/t 8,3 €/t 14,4 €/t Energies 8,3€/t €/t 14,46,8 6,8 6,8 €/t €/t €/t 16,5 €/t 6,8 €/t Use internal energy for first €/t ,0 7,99,0 €/t€/t €/t€/t €/t 7,99,0 9,0 €/t 7,9 strand €/t of hot 7,9 €/t 7,97,9 €/t 7,9 €/t €/t €/t8,3 €/t7,97,9 7,9 €/t 7,9 €/t €/t 7,9 5,0 5,0 €/t €/t 5,0 €/t €/t 5,0 5,0 €/t 5,0 €/t €/t €/t6,8 €/t5,0 5,0 5,0 €/t 8,3step €/t rolling 7,9 €/t €/t 7,9 €/t 7,9 5,0 €/t €/t€/t 7,9 €/t €/t 6,8Other 7,9 7,9 Thin Slab No heating Slab idle times at inductive Other Thinduring Slab ESPThin Slab Other Thin ESP Conventional entional 5,0 5,0 €/t €/tOther 5,0 €/tESP ,0 €/t 9,0 €/t 9,0 €/t 7,9 €/t 7,9 €/t 7,9 €/t ESP Other Thin Slab5,0 €/t heater 5,0 €/t 5,0 €/t p.s Material supplies Personnel Personnel supplies op. Other Personnel Energies losses) supplies op. (yield Other costs Material Personnel Energies supplies losses) op. (yield Other costs Energies (yield losses) ESP Other Thin Slab Energies Other op. supplies Personnel Yield losses Conventional ESP Other Thin Slab ld losses) Energies Other op. supplies Personnel Minimum scale at 10m inductive heater Material costs (yield losses) Energies Other op. supplies Personnel No head and tail losses *) Compare World Steel Dynamics 2009 : Sestao 54US$/t (37,8 €/t) Page 21 November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Energy Manager Cuts peak loads and energy costs Optimize complex energy network Challenge Approx. 25 % of total production costs are energy related Benefit of the liberalized energy market Flexible energy-management modules SCADA Solution Energy Data Management Energy prediction and optimization Environmental benefit Page 22 reduction of specific energy demand reduced emissions due to leakage detection November, 2010 Johann Kriechmair Typical customer benefit Identification of energy saving potentials Energy demand forecasts Reduction of energy load peaks and flaring reduce energy costs by ~3% (pipe bound) MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Variable Speed Drives (VSD) demand driven utilization of pumps Miscellaneous costs Maintenance cost saving potential 10% Investment costs Pump groups are often continuously operated without appropriate control: additional investment costs for VSD Challenge Waste of energy High stress on piping and valves 10% Low system performance Maintenance costs 30% Bild 22% Energy costs Implementation of VSD in pump groups: Solution Life-cycle costs of pumps and saving potential: Environmental benefits Page 23 Reduced maintenance costs November, 2010 Johann Kriechmair Feasibility study Implementation Energy cost saving potential Energy savings (up to 50% per pump group – depending on existing pump control system) Analysis of cooling system Soft starter effect Typical customer benefit Water hammers are avoided Reduced stress on pipe system Operation of high-voltage motors on low-voltage distribution possible MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Contact Johann Kriechmair Vice President Development of Projects Siemens VAI Metals Technologies GmbH / Linz / MT MP IP DP Turmstraße 44 4031 Linz Phone: +43 – (732) 6592 3518 Fax: +43 – (732) 6980 3518 Mobile: +43 664 – 615 3175 E-mail: johann.kriechmair@siemens.com Page 24 November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI Thank you for your attention! Page 25 November, 2010 Johann Kriechmair MT MP IP DP, Siemens VAI Metals Technologies GmbH Confidential / Copyright by Siemens VAI