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AP42 Chapter 12 Reference 4P42 Section: 12.2 Reference: 6 Title: Final Technological Reporf On A Systems Analysis Study Of The Integrated Iron And Steel Industry, J. Varga and H. W. Lownie, Jr., Contract No. PH-22-68-65, U. S. Environmental Protection Agency, May, 1969. 5'h edition FINAL TECHNOLOGICAL REPORT I on i ‘I A SYSTEM ANALYSIS STUDY OF THE INTEGRATED IRON AND STEEL INDUSTRY (Contract No. PH 22-68-65) to ‘I DIVISION OF PROCESS CONTROL ENGINEERING ‘I NATIONAL AIR POLLUTION CONTROL ADMINISTRATION ‘m DEPARTMENT OF HEALTH, EDUCATION, AND WELFARE I May 15, 1969 J. Varga, Jr., Principal Investigator H. W. Lownie, Jr., Project Director BATTELLE MEMORIAL INSTITUTE Columbus Laboratories 505 King Avenue Columbus, Ohio 43201 505 KING AVENUE COLUMBUS, OHIO 43201 . AREA CODE 614,TELEPHONE 299-3151 . CABLE ADDRESS: BATMIN May 29, 1969 F1 I Mr. Norman Plaks Dr. Paul Kenline Division of Process Control Engineering Division of Economic Effects Research National Air Pollution Control National Air Pollution Control I Administration Administration 5710 Wooster Pike 1055 Laidlaw Avenue I Cincinnati, Ohio 45527 Cincinnati, Ohio 45237 Mr. N. G. Edmisten Division of Economic Effects Research I National Air Pollution Control Administration 1 411 W. Chapel Hill Street Durham, North Carolina 27701 I Gentlemen: Final Technological Report on I A Systems Analysis Study of The Integrated Iron and Steel Industry I (Contract No. PH 22-68-65) Two copies of the subject report are being sent to both Mr. Edmisten and I Dr. Kenline, and 96 copies to Mr. Plaks. For the companion Final Economic Report on Cost Analyses, two copies are being I sent to both Mr. Edmisten and Mr. Plaks, and 96 copies to Dr. Kenline. I Very truly yours, I H. W. Lownie, Jr. 1 Project Director HWL:.ils I 'I c 'I% M I TABLEOFCONTENTS 1 -Page 1 SECTION I INTRODUCTION AND SCOPE. 1-1 I PURPOSES OF THIS STUDY . 1-1 1 SCOPE OF THIS STUDY . 1-2 I SECTION I1 SUMMARY AND RECOMMENDATIONS . , . , 11-1 I THE NATURE OF THE INTEGRATED IRON AND STEEL INDUSTRY . 11-1 I Industry Efforts for the Immediate Future . 11-2 FUTURE PLANS OF THE INDUSTRY . 11-4 I AIR-POLLUTION-CONTROL RESEARCH AND DEVELOPMENT . 11-5 General Recommendations for Phase 11 Research on I Technical Aspects of Control of Air-Pollution Emissions From the Integrated Iron and Steel Industry . 11-5 Improved Control of Emissions From the 1 Manufacture of Metallurgical Coke . , . 11-6 Instrumentation for In-Plant Emissions Measurement and Control . 11-7 i Improved Characterization of Emissions From Process Segments . 11-8 Other Subjects of Research Interest . 11-9 I Specific Recommendations for Phase I1 Research on Technical Aspects of Control of Air -Pollution Emissions T From the Integrated Iron and Steel Industry . , . II-11 Project 1: Processes for Making Metallurgical Coke. 11-11 Project 2: Sulfur-Bearing Emissions from I Blast-Furnace Slag. 11-17 Project 3: Characterization of Emissions from Sintering Plants . 11-18 Project 4: Evaluation of Instrumentation for In-Plant I Emissions Measurement and Control. II- 19 Project 5: Development of Improved Flow Sheets and Material Balances for American Integrated Steelworks . II-20 I Project 6: Control of Wide-Area Emissions from Storage Piles . 11-21 Project 7: Design and Costing of Systems for Collection 1 and Control of Wide-Area Emissions Inside a Steelworks . 11-21 I 1 BATTELLE MEMORIAL INSTITUTE - COLUMBUS LABORATORIES A ~~~ ~~~~ ~~ ~ ~~~~~ ~ . TABLE OF CONTENTS (Continued) .Page SECTION I11 THE INTEGRATED IRON AND STEEL INDUSTRY ........... 111-1 CHARACTERISTICS ON A NATIONAL SCALE ............ 111-1 GEOGRAPHIC DISTRIBUTION OF THE INDUSTRY ..........111-32 Present Facilities ...................111-32 Current Modernization and Expansion .............III-32 Future Plans ..................... 111-40 MAKING OF IRON AND STEEL .................111-40 Raw Materials ..................... 111-41 Making Iron ..................... 111-42 Making Steel ..................... 111-43 Manufacture of Semifinished Products .............111-44 Manufacture of Finished Products ..............111-44 REFERENCES FOR SECTION 111 ................111-45 SECTION IV PROJECTIONS REGARDING STEEL-INDUSTRY GROWTH AND CHANGES IN PROCESS TECHNOLOGY ............ 1v-1 Anticipated Growth in Production and Consumption of Raw Steel .... IV- 1 Anticipated Growth in Production and Consumption of Pig Iron . .... 1v-5 Anticipated Growth in Consumption of Iron Ore ...... .... 1v-6 Anticipated Changes in Iron and Steel Process Technology . .... 1v-8 Processing of Iron Ore at or Near the Source of the Ore . .... 1v-8 Coke Ovens and Coke Production ........ .... 1v-9 The Ironmaking Blast Furnace ............. 1v-11 Electric-Furnace Pig Iron ............... 1v-13 Direct -Reduction Processes .......... ....1v-14 Basic-Oxygen-Furnace (BOF) Steelmaking ..... 1v-15 Electric-Furnace Steelmaking ............. 1v-16 Mini Steel Plants .................. 1v-17 Sponge Iron for Steelmaking .............. 1v-18 Open-Hearth Steelmaking ........... ....1v-18 Continuous Casting of Steel .............. 1v-19 Pressure Pouring ................ IV-19 Vacuum Degassing i............. ....1v-20 Rolling ................. ....1v-20 Finishing .................... 1v-22 Heating Furnaces and Controls ......... ....1V-23 BATTELLE MEMORIAL INSTITUTE .COLUMBUS LABORATORIES i ‘I TABLE OF CONTENTS (Continued) . t Explosive Bonding .................iv-24 Electrical-Energy Consumption and Generation ........1v-25 1 SECTION V SOURCES OF AIR POLLUTION IN THE INTEGRATED E IRON AND STEEL INDUSTRY ......... ... v-1 Process Segments as Sources of Air Pollution . ......... v-1 ‘I Receipt. Storage. and Handling of Raw Materials ......... v- 1 Coking Process .................... v-2 I Coke-Oven Charging ........ ......... v-2 Coke-Oven Pushing ................. v-3 Coke Quenching ......... ......... v-3 .1 Coke Handling .......... ......... v-4 By-product Processing ....... ......... v-4 Preprocessing of Raw Materials ...... ......... v-5 I Sintering ........... ......... v-5 Pelletizing .................... V-6 Ironmaking ............. ......... V-6 I Charging ..................... v-7 Smelting ............ ......... v-7 Casting and Flushing ................ v-a I Pigging of Iron ......... ......... v-9 Other Ironmaking Processes ..... ......... v-9 Steelmaking ............ .........v-10 P Open Hearth ................... v-10 Basic Oxygen Furnace ....... .........v-12 Electric Furnace .................. V-13 Vacuum Degassing of Molten Steel ............ V-15 Continuous Casting ........ .........V-17 1 Pressure Casting ......... ......... V- 17 Steel Shaping ............ .........v-la Soaking Pits and Primary Breakdown . ......... v-18 1 Conditioning. Reheating, and Hot Rolling . .........v-ia Acid Pickling .......... .........V-19 Cold Rolling and Cold Forming .... ......... V- 19 I Annealing ........... ......... V-19 Steel Finishing .................... V-19 I FUEL AND ENERGY UTILIZATION ............... V-21 10-Year Summary of Fuel Usage .............. V-22 I Analysis by Applications ................. V-30 Firing of Coke Ovens ................V-31 Sintering of Dusts and Ores ..............V-33 1 Smelting of Iron Ores and Agglomerates .......... V-35 I BATTELLE MEMORIAL INSTITUTE .COLUMBUS LABORATORIES 1 1 . I TABLE OF CONTENTS (Continued) I .Page Steelmaking ................... V-37 1 Steam Raising ................... V-40 Heating of Steel in Process .............. V-41 Principal Findings ................. V-43 1 Some Facets of the Relationship Between Clean Air and the Fuel and Energy Aspects of the Steel Industry .......V-44 1 SOURCES AND AMOUNTS OF NOXIOUS EMISSIONS IN THE IRON AND STEEL INDUSTRY .............. V-47 1 Sulfur in Iron and Steel Plant Processes ............V-47 Making Coke ................... V-50 1 Sintering Machine .................V-52 Blast Furnaces ..................V-53 Open Hearth Steelmaking ............... V-54 I Basic Oxygen Furnace steelmaking ............V-56 Electric Furnace Steelmaking ............. V-60 Summary Balance of Sulfur for Iron and Steel Industry .....V-63 1 CO Balances for the Iron and Steel Industry ...........V-63 Coke-Oven Gas ..................V-65 Blast Furnace Top Gas ................V-65 1 BOF Process ...................V-66 Fluoride Emissions ...................V-66 1 Nitrogen Oxide Emissions .................V-67 References ...................... V-67 1 SECTION VI ANALYSIS OF APPLIED CONTROL SYSTEMS ............ v1-1 I Electrostatic Precipitators ................v1-3 Sinter-Plant Applications of Electrostatic Precipitators ..... v1-7 1 Blast-Furnace Applications of Electrostatic Precipitators .... v1-7 Open-Hearth Applications of Electrostatic Precipitators ..... v1-8 Basic-Oxygen- Furnace Applications of Electrostatic Precipitators . VI-9 1 Electric-Furnace Applications of Electrostatic Precipitators ...VI- 12 Wet Scrubbers ..................... VI- 12 Application of Wet Scrubbers in Sinter Plants ........v1-15 1 Applicationof Wet Scrubbers to Blast Furnaces .......VI- 16 Application of Wet Scrubbers to Open-Hearth Furnaces .....VI- 18 1 Application of Wet Scrubbers to Basic Oxygen Furnaces .....VI- 18 Application of Wet Scrubbers to Electric Furnaces ......v1-20 Fabric Filters .................... v1-20 I Application of Fabric Filters to Sinter Plants ........v1-21 Application of Fabric Filters to Open-Hearth Furnaces .....v1-21 Application of Fabric Filters to Electric Furnaces ......v1-21 1 Cyclone Dust Collectors .................v1-23 I BATTELLE MEMORIAL INSTITUTE .COLUMBUS LABORATORIES I . I I TABLE OF CONTENTS I (Continued) .Page
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