ISSN 1831-9424 (PDF) ISSN 1018-5593 (Printed) EU Efficient use of resources Efficient use of resources in steel plant through process integration (Reffiplant) in steel plant through process integration (Reffiplant) EUR 28457 EUR Research and Innovation EUR 28457 EN EUROPEAN COMMISSION Directorate-General for Research and Innovation Directorate D — Industrial Technologies Unit D.4 — Coal and Steel E-mail: [email protected] [email protected] Contact: RFCS Publications European Commission B-1049 Brussels European Commission Research Fund for Coal and Steel Efficient use of resources in steel plant through process integration (Reffiplant) Valentina Colla Scuola Superiore di Studi Universitari e di Perfezionamento Sant’Anna Piazza Martiri della Libertà, 33 IT-56127 Pisa, ITALY Erika Alcamisi, Ismael Matino Scuola Superiore di Studi Universitari e di Perfezionamento Sant'Anna Piazza Martiri della Libertà 33, IT-56127 Pisa, ITALY Lea Romaniello ILVA S.p.A. Viale Certosa 249, IT-20251, Milano, ITALY Mansour Saiepour Tata Steel UK Ltd Millbank 30, GB-SW1P4WY London, UNITED KINGDOM Ida Heintz, Johan Riesbeck, Jonas Zetterholm, Katarina Lundkvist, Mats Brämming Swerea MEFOS AB Arontorpsvagen 1, SE-971 25 Luleå, SWEDEN Anita Wedholm, Katarina Kylefors SSAB EMEA AB SE-613 80 Oxelösund, SWEDEN Yuhang Lou, Kokil Jain, Steve Doyle Process Integration Limited Station House, Stamford New Road, Altrincham, Cheshire WA14 1EP, UNITED KINGDOM Grant Agreement RFSR-CT-2012-00039 1 July 2012 to 31 December 2015 Final report Directorate-General for Research and Innovation 2017 EUR 28457 EN LEGAL NOTICE Neither the European Commission nor any person acting on behalf of the Commission is responsible for the use which might be made of the following information. The views expressed in this publication are the sole responsibility of the authors and do not necessarily reflect the views of the European Commission. 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TABLE OF CONTENTS 1 FINAL SUMMARY .......................................................................................................... 5 1.1 WP 1: Preliminary investigations required for the development of solutions for resource efficiency ....................................................................................................................... 5 1.2 WP 2: Water management ................................................................................... 7 1.3 WP 3: Waste minimization ................................................................................... 7 1.4 WP 4: Integrated process optimization .................................................................. 9 1.5 WP 5: Implementation and assessment of Process Integration solutions for resource efficiency ....................................................................................................................... 11 1.6 WP 6: Coordination and Reporting ....................................................................... 12 2 SCIENTIFIC AND TECHNICAL DESCRIPTION OF THE RESULTS ......................................... 15 2.1 Objectives of the project .................................................................................... 15 2.2 Description of activities and discussion ................................................................. 15 2.2.1 WP 1: Preliminary investigations required for the development of solutions for resource efficiency ...................................................................................................... 15 2.2.2 WP 2: Water management ........................................................................... 34 2.2.3 WP 3: Waste minimization ........................................................................... 52 2.2.4 WP 4: Integrated process optimization .......................................................... 61 2.2.5 WP 5: Implementation and assessment of Process Integration solutions for resource efficiency ...................................................................................................... 74 2.3 Conclusions ...................................................................................................... 80 2.4 Exploitation and impact of the research results ..................................................... 80 2.4.1 Publications / conference presentations resulting from the project .................... 80 3 LIST OF FIGURES ....................................................................................................... 82 4 LIST OF TABLES ........................................................................................................ 84 5 LIST OF ACRONYMS AND ABBREVIATIONS .................................................................... 86 6 REFERENCES ............................................................................................................. 88 7 APPENDIX A - Benchmarking documents - D1.4 ............................................................. 90 7.1 Benchmarking on water, by-products and waste ........................................................... 90 7.2 By-products and waste benchmarking ......................................................................... 98 8 Appendix B - Internal Process Constraints Tables ......................................................... 102 9 Appendix C - Water treatment Process models ............................................................ 106 10 Appendix D – List of potential solutions for water and energy efficiency (D2.1) ................ 118 11 Appendix E - Case studies on BF gas wash system ....................................................... 120 12 Appendix F – List of potential solutions for waste minimization (D3.1) ............................ 126 13 Appendix G - By - products and waste treatment models .............................................. 128 14 APPENDIX H - Holistic simulation models for MOO (D4.1) .............................................. 138 14.1 Holistic simulation models - water ..................................................................... 138 14.2 Holistic simulation models - by-products and wastes ............................................ 154 15 APPENDIX I - Site-specific PI-based solutions for resource efficiency (D4.2) .................... 160 15.1 PI-based solutions - water ................................................................................ 160 15.1.1 CASE STUDY No1: reuse of CCO1 blow down water for off-gas cleaning of BOF1 ... .............................................................................................................. 160 15.1.2 CASE STUDY No2: reuse of blow down water from CCO2/3/4 for the off-gas cleaning of the BOF2 ................................................................................................. 166 15.1.3 CASE STUDY No3: reuse of blow down water from RIV1 in TUL1 .................... 170 15.1.4 CASE STUDY No4: contaminants reduction and water reuse of coke-making area wastewater .............................................................................................................. 176 15.1.5 CASE STUDY No 5: Lagoon 1 Water Reuse in BF Gas Wash Systems ............... 178 15.1.6 CASE STUDY No 6: Pond A Water Reuse in BF Gas Wash Systems .................. 182 15.1.7 CASE STUDY No 7: Recycling of BF GW HC overflow water with suitable treatment .............................................................................................................. 184 15.1.8 CASE STUDY No 8: HPM-Ancholme System Water Recovery & Control ............ 192 15.1.9 CASE STUDY No 9: Efficient usage of spray-on water used at the CC at SSAB in Luleå .............................................................................................................. 196 15.1.10 CASE STUDY No 10: BF gas treatment system at SSAB in Luleå ..................... 198 15.2 PI-based solutions – by products and wastes ...................................................... 202 15.2.1 CASE STUDY No2: Optimization of the reuse of by-products or wastes ............ 208 15.2.2 CASE STUDY No3: reuse of sludge in briquette production ............................. 212 15.2.3 CASE STUDY No4: material recirculation at SSAB Luleå ................................. 214 16 APPENDIX L - Divulgation material and guidelines for analysing, developing and testing process integration solutions for the steel industry (D4.4) .................................................... 218 3 17 APPENDIX M – Other deliverables from WP4 ................................................................ 228 17.1 D4.3 Tools for total site analysis for testing process integration solutions ............... 228 17.2 D4.5 Training course on the tools for total site analysis devoted to engineers and process operators with guidelines for customization .......................................................... 228 18 APPENDIX