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Steel Production Gases

Coke Gas Gas Converter Gas Production Power from Steel Production Gas Gas

High levels of power requirement A by-product of industrial coke Gases and rising energy costs represent a production from pit coal, coke gas is major challenge for the steel industry. created by high-temperature dry Gases created as a ‘free’ by-product distillation of coking coals in the Clarke Energy is the authorised distributor and service during steel production processes absence of oxygen. The gas mainly partner for GE Energy’s division in a growing serve as an attractive energy source consists of (50-60%), number of countries across the world. In addition to option for efficient power generation. (15-50%) and a small providing high-efficiency, reliable gas engines we combine In addition to the economic benefit, percentage of , using these gases as engine fuel carbon and . With a calorific this with the expertise and resources to deliver unbeatable reduced industrial CO 2 emissions value of 5kWh/Nm 3, coke gas product support. and saves natural energy sources. constitutes a high-value fuel for effective power generation with GE Whether your requirement is for the supply of a single gas Jenbacher gas engines engine generator or a complete turnkey power generation Benefits of Power from Steel facility, we can meet that need. Our ability to add value by Production Gas Blast Furnace Gas offering an end-to-end service, from initial proposal to — Higher revenues from the reliable long-term maintenance, has led to us becoming a utilisation of steel production gas multi-national company with operations in ten countries as a fuel Blast furnace gas is a by-product of across the globe. Our company prides itself on integrity, — Reduced carbon emissions blast furnaces where ore is delivering only the highest quality products whilst providing — Stable robust onsite power reduced with coke into metallic (pig) a reliable accountable localised service. supply iron. The gas has a very low heating — Heat from engines can be used value of around 0.9kWh/Nm 3, which in other processes on its own is typically not high Benefits of working with Clarke Energy enough for combustion in a gas Clarke Energy provides flexible solutions for your gas engine. There is the possibility to generation projects. Our services range from the supply of Different Gases from Steel blend this gas with other off gases; a gas engine generator, through to the complete turnkey Production Processes you should contact your local Clarke Energy office to discuss this installation of a gas powered generation facility. Clarke Energy Steel production processes typically in more depth. has a dedicated, top-quality team of sales, engineering, dispose large volumes of speciality project management, commissioning and maintenance staff gases. Three different process to meet your needs. We also offer long-term maintenance stages – from coal to steel – provide contracts backed up by a strong balance sheet, giving three different gas types: coke gas, peace of mind with respect to the long-term performance blast furnace gas and converter gas. of your GE gas generation equipment.

Steel Production Gas Schematic

Steel production Coke Gas Blast Converter gas type Furnace Gas Gas Coke gas Blast furnace gas Converter gas Composition: 50 – 70% H 2 Composition: 5% H 2 Composition: 60% CO 3 Source Coke oven Blast furnace Converter 25 – 30% CH 4 20% CH 4 LHV: ~3 kWh/ Nm LHV: ~5 kWh/Nm 3 LHV: ~0.9 kWh/ Nm 3 battery

Input Coal Coke & Pig Iron

Output Coke Pig Iron Steel Coal Coke Pig Iron Steel

Hydrogen % 50 - 70% 5% —

Methane % 25 - 30% —— Iron ore Carbon — 20% 60%+ Coke oven battery Blast furnace Converter monoxide %

Lower heating ~5.0 ~0.9 ~3 value kWh/Nm 3 Converter Gas Concept Advantages Our Competence

Converter gas is created from pig Varying compositions, as well as — Independent power supply Clarke Energy has comprehensive iron during the steel production calorific values and the combustion — Reduced energy costs, and experience with gas engine process. Steel-making technology behaviour of the gases from steel greater predictability and stability technology and has a large reservoir can be categorised into two different production processes, put greater — Efficient and economic combined of knowledge with respect to processes: blow moulding or open demands on engine design. Clarke heat and electricity supply handling tricky gases such as steel hearth. Energy offers specially modified GE — High electrical efficiency production gas. Jenbacher gas engines that make compared to other power Within the blow moulding process, efficient use of these gases for generation technology (i.e. steam Substantial research has been the pig iron is refined with oxygen or combined generation of heat and or gas turbines) completed on the steel gas air, lowering the carbon proportion electricity. — Best suited for an electrical application. Jenbacher installed its and providing enough process heat output range of a few hundred first commercial gas engine to maintain the steel liquid. With In general, the stable composition of kW up to 20-30MW applications for coke gas in 1995 60% of the worldwide raw steel coke gas makes it advantageous as — Considerably low gas pressure and for LD converter gas in 2004. production, the Linz-Donawitz (LD) an engine fuel. The high hydrogen required process, classified as a blow content of coke gas however, — Alternative disposal of a problem About 30 GE Jenbacher gas engines moulding process, is the most means the combustion process is gas while simultaneously now run on either coke gas or LD common production method to very fast, which increases the harnessing it as an energy source converter gas. Underscoring GE’s generate raw steel. danger of engine knocking or — Substitute to conventional fuels technical expertise, these units backfiring. To avoid this risk, GE has — Environmental benefits by recently reached a combined total of On the other hand, the open hearth created an engine control system greenhouse gas reduction more than 1million operating hours. process extracts the oxygen of the that is able to fuel the GE Jenbacher In addition, by utilising these ‘free’ added scrap and ore, requiring engine with a very lean mixture and, waste gases compared to using additional heat supply for the steel- at the same time, react very quickly Key Figures for power generation, making process. One of the most to variations in the engine load. the GE Jenbacher technology- common open hearth processes is equipped sites have achieved CO 2 the electrical melting process. Converter gas, with its high carbon Per tonne of coke that is produced, savings of about 2 million tonnes monoxide content, has low approximately 470Nm 3 of coke gas since commissioning. Converter gas from the LD and combustion speed and is very harmful. are produced. 60% of this volume is electrical melting processes can be GE has developed the specific typically needed for internal used in GE Jenbacher gas engines. Jenbacher gas engine combustion processes; the remaining part can The gas consists of about 65% system that allows burning the gas be used for power generation with carbon monoxide, 15% carbon efficiently and reliably. Additionally, GE Jenbacher gas engines resulting dioxide, 15% nitrogen and small we offer a safety technology package in approximately 400kWh amounts of hydrogen and methane. that allows firm handling of harmful gases such as carbon monoxide. Per tonne of steel produced through the LD process approximately Both gases can be used to create 50Nm 3 of converter gas are released hot water, steam and electricity. The which can burn in GE Jenbacher gas hot water and exhaust gases from engines leading to approximately the engines are fed into . The 50kWh electrical power. resulting steam can be used within the steel production processes. Electricity generated by the GE Jenbacher engines can either be used on-site or sold to the public grid. Converter gas electrical efficiencies of up to 37% can be achieved, and coke gas efficiencies are even higher.

Posco steel gas project, Mexico, 1x JMS620

Profusa coke gas project, Spain, 12 x JMS 316 If you would like to find out more about how Clarke Energy can help you develop your steel production gas project, please contact your local office for more details.

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