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Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Commercial & Ecological Competitiveness in
Steelmaking Process
Helmuth Ester / Surinder Baluja
Tata Sustainability Expo 2016 , 17th June 2016
1
Confidential·Allrightsreserved·©2014SMSGmbH
Development in Germany (Ruhr)
209.06.2016
Developments of Emissions in Germany
In the past ….Today
 Up to 20 kg of dust per ton of steel are
generated within each melting process
 Cleaning of exhaust air is governed by
numerous regulations
 Stress on energy recovery (Most Steel making
Plants in Germany are with energy recovery. In
India none of the steel making plant is presently
running with energy recovery)
ECO plants by SMS Group : Saving
Energy & Protecting Environment
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Introduction
Gas Cleaning
Assistance for
secondary
dedusting
systems
Hydro-hybrid
system
for existing BOF
shops
Energy recovery
for existing BOF
shops
TATA Sustainability Expo 2016 3
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Gas Cleaning Assistance
for secondary dedusting
systems
4TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Herkömmliches
Verfahren
Conventional
method
Gas Cleaning Assistance
COMPARISON
P
Mixer
Filter
ID fan
Gas Cleaning
Assistance
Manual setting
-
Always optimal flap
position operation due
to continous network
analysis
+
No network analysis
High negative pressure
for all process steps
resulting into high power
consumption
Constant network analysis resulting
into high efficiency due to
consideration of network
resistances for actual operating
conditiones
Always optimal negative
pressure operation
resulting into low power
consumption
5TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Scope of Supply for Existing Plant
ECO-DUST
PCsystemDedusting-PLC
Field
P
NewExisting
HMI
HMI
Model
Flexibly extendable
IBN functions
Emergency functions
6
Gas Cleaning Assistance
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Gas Cleaning Assistance
Summary
Highlights:
■ Optimal flap positions
■ Maximum suction power with minimum
energy consumption
■ Reacts flexible to every process step
■ Usable for all possible aopplications of Secondary
Dedusting Systems such as BOF, BF, EAF etc
Features:
■ Gas Duct Auto-Cleaning-Mode
■ IBN function
■ Damper functionality monitored on HMI
( a Secondary Ventilation System functions only
if all dampers are functioning)
7TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Gas Cleaning Assistance
Case Study
kWh
Energy Saving
8
JSW, Toronagalu SMS 3:
After implementation of GCA 1 out of 3
fans is switched off.
Power savings up to 35%
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 9
Gas Cleaning Assistance
TATA Sustainability Expo 2016
BENEFIT TO TATA STEEL
EXAMPLE:
Possible Approx. Power Savings in LD # 3 Secondary Dedusting System per
annum :
6000 MWh * * / annum
** Has to be checked with a study
Substantial power savings can be done in Secondary Dedusting Systems
throughout the plant like for LD # 1, LD # 2, Blast Furnaces etc. With very
minimal investment.
With installation of GCA approx. 20-40 % power savings can be done but it
depends upon the type and operation of plant.
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Hydro-hybrid system
for existing BOF shops
10TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Conventional wet type gas cleaning system
Hydro Hybrid System
11
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
 Typical clean gas dust content: 50 mg/m³
Wet scrubber (e.g. Baumco system)
Water treament plant
Electro Static precipitator (final cleaning)
after gasholder
Wet scrubbing tower
Conventional Technology
12
Hydro Hybrid System
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 13
From conventional system to Hydro Hybrid System
TATA Sustainability Expo 2016
Hydro Hybrid System
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 14
 Typical clean gas dust content: 10 mg/m³
Hydro Hybrid Filter System
Wet scrubbing
tower
Water treament
plant (hidden)
Wet-type ESP
Water treament
plant
 A new concept for wet-type BOF primary off-gas cleaning
Hydro Hybrid System
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 15
 Summary and advantages of the Hydro Hybrid System
 Much lower dust contents at system outlet.
 Less dust loads at the ID fans and
therefore maintenance for the fans.
 Reduction of operation costs is possible
by optimal tuning of wet scrubber and
ESP.
 Existing water treatment facilities of
scrubber do not need to be extended and
can be normally used for the wet-type
ESP.
 Suction capacity of existing ID fan can
be increased as system permits lower
pressure drop.
 Low investment cost in case of a revamp.
 Short down time required for hooking up.
300
200
100
2.0001.5001.000
TATA Sustainability Expo 2016
Hydro Hybrid System
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 16
 Advantages of the new process - Hydro Hybrid Filter system
 Upgrade of almost every
existing wet scrubber is possible
 Meeting existing and future
authority requirements
 No further ESP for fine cleaning
necessary (downstream of the
gas holder)
 Especially for TATA Steel it is
beneficial since in LD # 1 & 2
where high dust emission
problems is there, it can be
solved.
≤10 mg/m³
Hydro Hybrid System
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2014SMSSiemagAG
SMS Group
Energy recovery for
existing BOF shops
17TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 18
Energy Recovery – BOF shop
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
 Recovery of sensible heat energy from BOF Off Gas
19
Off-gas (2000° – 800°C)
has to be cooled down
BOF
converter
Energy Recovery – BOF shop
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
SMS SIEMAG HOT WATER UTILIZATION SYSTEM
(HWU SYSTEM)
Hot Water
Users (Absorption
Chillers)
20TATA Sustainability Expo 2016
Energy Recovery – BOF shop
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
up to 2000°C
180 TNm³/h
Cooling Stack: 56 m
Hot Water Cooling
up to 2000°C
180 TNm³/h
Cooling Stack: 56 m
Modified Hot Water
Cooling
Offgas Water
850ºC 130°C
Offgas Water
850ºC 130°C
 Energy Wasted to
Atmosphere
Chilling 4800 TR
( i.e 3.5 MWh Power
Savings )
15,5 MWh
Example
 250 Ton Converter
 TTT : 45 mins
22 MWh 22 MWh
Comparison : Conventional Hot Water Cooling
Vs
Modified Hot Water Cooling with Energy Recovery
Energy
Recovered
to generate
free chilling
21
Energy Recovery – BOF shop
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
SMS Siemag Steam Generation during BOF Gas Cooling
22
80 kg
steam / tls
Energy Recovery – BOF shop
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS GroupE
Options for steam utilisation
23
Power
generation
Power
generation
Cooling by
absorption
chilling
Cooling by
absorption
chilling
Steam injector
pumps for
VD / RH process
Steam injector
pumps for
VD / RH process
Steam netSteam net
Other
Applications
Other
Applications
TATA Sustainability Expo 2016
Energy Recovery – BOF shop
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 24
Energy Recovery – BOF shop
TATA Sustainability Expo 2016
BENEFIT TO TATA STEEL
EXAMPLE:
1. Possible Approx. TR generation from LD # 3 Primary Gas cooling System
per annum :
5000 TR * * / annum
** Has to be checked with a study
2. Possible Approx. Steam generation from LD # 3 Primary Gas cooling
System per annum :
200 X 103 tonnes* * / annum
** Has to be checked with a study
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group
Summary
25
• All three solutions will reduce the power consumption and
reduce the CO2 footprints for the present facilities in TATA Steel.
• Also TATA Steel will have environmental benefits with reduction
in dust emissions and efficient fume collection.
• Case wise Pay back solutions can be worked out
• Apart from the tangible benefits, the described solution is one of
our contributions for environmental protection & make the
World - A better place to live “ in our own small way. “
TATA Sustainability Expo 2016
Confidential·Allrightsreserved·©2016SMSSiemagAG
SMS Group 26
We thank you for your attention
TATA Sustainability Expo 2016

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