Electric-Arc Furnace Sample Clauses

Electric-Arc Furnace. The electric-arc method uses high-current electric arcs to melt DRI and steel scrap (or steel scrap alone) and convert them into liquid steel of a specified chemical composition and temperature. The major charge material of electric-arc steelmaking is scrap steel, and its availability at low cost and proper quality is essential. The electric-arc furnace (EAF) is a squat, cylindrical vessel made of heavy steel plates; it has a dish-shaped refractory hearth and three vertical electrodes that reach down through a dome-shaped, removable roof.51 To produce 1,000 kg of crude steel, the main inputs for the DRI-EAF route are: 710 kg of steel scrap (account around 75% of EAF steel cost); 586 kg of iron ore; 150 kg of coal; 88 kg of limestone; 2.3 GJ of electricity. An EAF can be charged with 100% steel scrap.52 Recycling this steel accounts for significant energy and raw material savings: over 1,400 kg of iron ore, 740 kg of coal, and 120 kg of limestone are saved for every 1,000 kg of steel scrap made into new steel.53 To date, steel is mainly produced via BF-BOF and scrap-EAF routes. A big difference between the two steelmaking processes, besides the inputs needs and savings previously analysed, is the capital investment costs involved: whilst a typical integrated (i.e. BOF-route) steel mill today costs ~€980 per tonne of installed capacity, a medium-size EAF-route mini-mill today costs under €270 per tonne in terms of the initial capital outlay.54 Beside these just listed, there are also relevant differences on the energy required that is summarized in the following table.55 Table 17: Energy required of key processes in Iron and Steel industry. Process Electric energy (kWh/t) Thermal energy (kWh/t) min max min max BF-BOF route (sum of the processes below) 73 405 3,517 9,117 - Coke production 6 64 906 1,306 - Sintering pelletising 25 44 358 561 - Blast Furnace 31 236 2,236 6,783 - BOF 11 61 17 467 EAF route 403 747 22 517 As the table shows, for BF-BOF route the highest consumption is of thermal type, related to the furnaces and the peak of thermal consumption is in BFs. On the opposite, EAF reduces widely the thermal energy consumption and does not increase proportionally the electric energy consumption, thus making it less energy-intensive and preferable, when possible, due to availability of scraps and the quality of the final product. The main differences of the two technologies that have just been analysed are summarized in the table below: 51 xxxxx://xxx.xx...
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Electric-Arc Furnace if there are sufficient quantities of scrap available, the first step of transforming iron ore into pig or sponge iron can be skipped entirely. Scrap can simply be heated and cast in an Electric Arc Furnace, saving the raw materials and energy involved in transforming raw materials. The CO2 intensity of recycling depends on the electricity generating mix, but is typically around 0.4 tonnes of CO2 per tonne of steel produced. (IEA, 2009) However, as explained earlier, the ultimate limit on EAF-recycling is the availability of scrap metal. According to modelling conducted under the IEA’s BLUE scenario – which assumes CO2 emissions are cut by 38% from 2006 levels by 2050 – recycling would only be able to represent 54% of world steel production. (IEA, 2009) Steel production from scrap currently makes up of the order of 30% of world production. BF/BOF is the most CO2-intensive steel-making process but difficult to substitute because the only alternatives, DRI and EAF, also have limitations – the first requiring cheap supplies of natural gas in order to be affordably CO2-competitive and only able to process relatively pure iron ore; and the second being largely designed for either sponge iron or the re-processing of scrap steel, supplies of which are limited by available gas-based DRI plants and the varying availability of scrap steel. Table B1 Summary of the characteristics of main steel production methods energy inputs average CO2/t steel potential raw materials share of world production (approximate) other features BF/BOF coke 2.0 iron ore 65% (100%) scrap (10- 30%) DRI/EAF gas or 1.1 – 2.5 iron ore 5% requires access to cheap coal (100%) gas supplies in order to scrap (20– 50%) be CO2-competitive; only works with relatively pure iron ore feedstock EAF electricity
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