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Canadian and Us Steel Production by Mill Type

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Canadian and Us Steel Production by Mill Type CRADLE-TO-GATE LIFE CYCLE INVENTORY: CANADIAN AND US STEEL PRODUCTION BY MILL TYPE Based on reports by: MARKUS ENGINEERING SERVICES Ottawa, Canada March 2002 ACKNOWLEDGMENT This report was made possible through the support of Natural Resources Canada and the federal Climate Change Action Fund under its Technology Early Action Measures Program (TEAM). DISCLAIMER TM Although the ATHENA Sustainable Materials Institute has done its best to ensure accurate and reliable information in this report, the Institute does not warrant the accuracy thereof. If notified of any errors or omissions, the Institute will take reasonable steps to correct such errors or omissions. COPYRIGHT No part of this report may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the ATHENATM Sustainable Materials Institute. Text © 2002 ATHENATM Sustainable Materials Institute ATHENATM Sustainable Materials Institute 28 St. John Street, P.O. Box 189 Merrickville, Ontario Canada, K0G 1N0 Tel: 613-269-3795 Fax: 613-269-3796 Email: [email protected] CONTENTS 1 INTRODUCTION...................................................................................................................................... 1 1.1 REPORT STRUCTURE........................................................................................................................... 1 2 OVERVIEW OF THE CANADIAN AND US STEEL INDUSTRY................................................... 3 2.1 INTRODUCTION ................................................................................................................................... 3 2.1.1 Product Categories .................................................................................................................. 3 2.1.2 Plant Types............................................................................................................................... 3 2.2 THE CANADIAN STEEL INDUSTRY...................................................................................................... 4 2.3 THE UNITED STATES STEEL INDUSTRY.............................................................................................. 6 2.4 TECHNOLOGICAL DEVELOPMENTS..................................................................................................... 8 2.4.1 Iron-Making.............................................................................................................................. 9 2.4.2 EAF Process Developments..................................................................................................... 9 2.4.3 Steel Casting Technology....................................................................................................... 10 2.4.4 Cold Rolling and Finishing.................................................................................................... 10 2.5 ENERGY CONSERVATION AND ENVIRONMENTAL CONTROL ........................................................... 10 2.5.1 Energy Conservation.............................................................................................................. 10 2.5.2 Emissions to Air ..................................................................................................................... 11 2.5.3 Emissions to Water................................................................................................................. 11 2.5.4 Solid Wastes ........................................................................................................................... 12 3 STUDY APPROACH .............................................................................................................................. 14 3.1 INTRODUCTION ................................................................................................................................. 14 3.2 INTEGRATED CANADIAN PLANTS..................................................................................................... 14 3.2.1 The Reference Plant............................................................................................................... 15 3.2.2 Unit Processes........................................................................................................................ 15 3.2.3 Emission Factors.................................................................................................................... 25 3.2.4 Water Use and Emissions to Water....................................................................................... 26 3.3 CANADIAN MINI-MILLS ................................................................................................................... 29 3.3.1 Reference Plants..................................................................................................................... 29 3.3.2 Scrap Usage and Types.......................................................................................................... 35 3.3.3 Water Use and Emissions to Water....................................................................................... 39 3.4 COMBINED CANADIAN MILLS .......................................................................................................... 40 3.4.1 Energy Components ............................................................................................................... 40 3.4.2 Process versus Combustion Emissions to Air ....................................................................... 42 3.5 COMBINED US MILLS....................................................................................................................... 43 4 LCI RESULTS BY PRODUCT.............................................................................................................. 44 4.1 INTRODUCTION ................................................................................................................................. 44 4.2 LCI ESTIMATES ................................................................................................................................44 4.2.1 The Effects of Processing Steps and Yield ............................................................................ 45 5 BIBLIOGRAPHY .................................................................................................................................... 82 5.1 INTEGRATED MILLS.......................................................................................................................... 82 5.2 MINI-MILLS ....................................................................................................................................... 87 Appendices Appendix 1 Mass and Energy Balances - Exploration, Mining and Processing of Raw Materials Appendix 2 Mass and Energy Balances - Transportation of Raw Materials Appendix 3 Mass and Energy Balances - Primary Processes Appendix 4 Mass and Energy Balances - Finishing Mills Appendix 5 Mass and Energy Balances - Manufacturing of Finished Products Appendix 6 Flat Rolled Products: Energy and Emission Diagrams Appendix 7 Shapes Products: Energy and Emission Diagrams List of Tables Table 1 Characteristics of Major Canadian Steel Plants 5 Table 2 Canadian Steel Production in 2000 by Product Plant Type 6 Table 3 List of Major Steel Plants in USA 7 Table 4 Estimated Production of Molten Steel in 2000 by Process Type 7 Table 5 Shipments of Selected Products in 2000 by US Plant Type 8 Table 6 Annual Reference Plant Steel Production 15 Table 7 Major Raw Material/Energy Purchases and Credits - Reference Plant 16 Table 8 Net Contaminate Discharge by Canadian Integrated Plants, 2000 29 Table 9 Annual Steel Production: Reference Steel Plants 30 Table 10 Annual Material Consumption: Flat Rolled Reference Plant 32 Table 11 Annual Material Consumption: Shapes Products Reference Plant 34 Table 12 Net Contaminate Discharge by Canadian Mini-Mills, 2000 40 Table 13 LCI Estimates by Product: Canadian Integrated Mills 46 Table 14 LCI Estimates by Product: Canadian Mini-Mills 56 Table 15 LCI Estimates by Product: Combined Canadian Mills 62 Table 16 LCI Estimates by Product: Combined US Mills 72 List of Figures Figure 1 Sinter Plant Schematic 17 Figure 2 Coke Ovens Schematic 18 Figure 3 Blast Furnace Schematic 19 Figure 4 BOF Steelmaking Schematic 20 Figure 5 Reference Plant Flow Diagram 21 Figure 6 Reference Plant Gas Distribution 24 Figure 7 Energy and Mass Balances for Blast Furnace Stoves 24 Figure 8 Annual Production of Flat Rolled Steel: Reference Plant 30 Figure 9 Schematic of DRI/EAF Process Flow 31 Figure 10 Annual Production of Shapes: Reference Plant 33 Figure 11 Schematic of Shapes: EAF Process Flow 33 Figure 12 Basic Scrap Types and Flows 36 Figure 13 Estimated Scrap Recycle Quantities in 2000 37 Cradle-to-Gate Life Cycle Inventory: Canadian and US Steel Production by Mill Type 1 INTRODUCTION This life cycle inventory (LCI) study of selected Canadian and US steel building products was commissioned by the ATHENATM Sustainable Materials Institute1 to up-date our original studies of steel production. The original work was done over two years (1993-94) by Stelco Technical Services Limited as two distinct studies, an assessment of production in fully integrate mills and in scrap-based mini-mills. The results from these two studies were then combined to develop weighted average results by product, using the relative production levels of the two types of mills as the weights. In view of the environmental advances made by the steel industry over the past decade, it became
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