MASTER'S THESIS Energy System Analysis in the Swedish Iron and Steel Industry Ernesto Ubieto Master of Science (120 credits) Mechanical Engineering Luleå University of Technology Department of Engineering Sciences and Mathematics Energy System Analysis of the Swedish Iron and Steel Industry Ernesto Ubieto Udina Table of contents 1 INTRODUCTION ................................................................................................................. 7 2 OBJECTIVES ....................................................................................................................... 8 3 METHODOLOGY ................................................................................................................ 9 3.1 Methodology of System Analysis ............................................................................... 9 3.1.1 Scope of the Analysis ....................................................................................... 10 3.1.2 Boundaries of the Analysis ............................................................................... 11 3.1.3 Time frames ..................................................................................................... 11 3.1.4 Components of the System .............................................................................. 12 3.1.5 Connections within the system ........................................................................ 13 3.1.6 Limitations of the study ................................................................................... 15 3.1.7 Tracking CO2 emissions .................................................................................... 16 3.2 Methodology for Energy Benchmarking ................................................................... 17 3.2.1 Boundaries of our study: .................................................................................. 17 3.2.2 Energy Intensive Values for the process: .......................................................... 18 3.2.3 Determine values for Benchmark ..................................................................... 18 3.2.4 Limitations of the Benchmarking Study ............................................................ 18 4 INDUSTRY DESCRIPTION .................................................................................................. 19 4.1 The Iron and Steel Process: ...................................................................................... 19 4.1.1 Material preparation ........................................................................................ 20 4.1.2 Iron making ...................................................................................................... 22 4.1.3 Steel Making .................................................................................................... 24 4.1.4 Steel Manufacturing......................................................................................... 28 4.1.5 Process flowsheet overview. ............................................................................ 30 4.2 Alternative technologies in the Iron and Steel Industry ............................................ 31 4.2.1 Direct Reduced Iron ......................................................................................... 31 4.2.2 Smelting Reduced Iron ..................................................................................... 32 4.3 Future Technologies for the Iron and Steel Industry ................................................. 33 4.4 Reference Energy System for the Iron and Steel Industry ......................................... 34 5 SYSTEM ANALYSIS ........................................................................................................... 35 5.1 Iron and Steel Industry in Sweden ............................................................................ 35 5.1.1 Energy Use by the Iron and Steel Industry ........................................................ 35 5.1.2 Iron and Steel Producers in Sweden ................................................................. 36 5.1.3 Energy Efficiency in the Iron and Steel Industry ................................................ 37 2 5.2 Mapping Energy Flows in the Swedish Iron and Steel Industry ................................. 38 5.2.1 BF-BOF route: integrated plants from SSAB. ..................................................... 38 5.2.2 Rest of the plants Analyzed: DRI and EAF route ................................................ 46 5.3 Assumptions made in the analysis of the plants ....................................................... 49 5.3.1 Accuracy of the results presented .................................................................... 51 5.4 Adjusting the results for the Electric Arc Furnace route............................................ 52 5.4.1 National Energy Balance .................................................................................. 52 5.4.2 Mapping the BF-BOF route ............................................................................... 55 5.4.3 Mapping the DRI route ..................................................................................... 56 5.4.4 Mapping the EAF route .................................................................................... 57 5.5 Tracking CO2 emissions in the Swedish Iron and Steel Industry ................................ 62 5.5.1 Emission Factors in Sweden ............................................................................. 62 5.5.2 Electricity production in Sweden ...................................................................... 62 5.5.3 Imported Electricity: ........................................................................................ 63 5.5.4 Generation, transport and distribution:............................................................ 63 5.5.5 CO2 emissions in the Swedish Iron and Steel Industry ....................................... 64 5.6 Benchmarking.......................................................................................................... 66 5.6.1 Reference Values for Benchmarking ................................................................. 66 5.6.2 Energy intensity values for the Swedish industry .............................................. 68 5.6.3 Comparison between Sweden and Ecotech ...................................................... 69 5.6.4 Comparison with the IPPC results ..................................................................... 71 6 SYSTEM ANALYSIS RESULTS ............................................................................................. 72 6.1 National Energy Balance .......................................................................................... 72 6.2 Energy Potential Savings .......................................................................................... 73 6.3 Potential CO2 emissions savings ............................................................................... 75 6.4 Identification of key processes for energy savings improvements. ........................... 76 7 DISCUSIONS AND CONCLUSIONS ..................................................................................... 78 7.1 Conclusion from the System Analysis and the Benchmarking study .......................... 79 7.2 Future options for the Steel Industry. ...................................................................... 80 7.3 Future work needed ................................................................................................ 80 8 References ...................................................................................................................... 81 3 LIST OF TABLES AND FIGURES TABLE 1: IPCC VALUES FOR COKING PROCESS..................................................................................................................... 21 TABLE 2: IPCC VALUES FOR THE BF PROCESS. .................................................................................................................... 23 TABLE 3: REACTIONS IN THE BOF PROCESS ....................................................................................................................... 24 TABLE 4: REACTIONS IN THE BOF PROCESS. ...................................................................................................................... 24 TABLE 5: HOT METAL AND STEEL COMPOSITION.................................................................................................................. 25 TABLE 6: IPCC VALUES FOR THE BOF PROCESS .................................................................................................................. 25 TABLE 7: IPCC VALUES FOR THE EAF PROCESS. .................................................................................................................. 26 TABLE 8: IPCC VALUES FOR THE HOT ROLLING PROCESS ........................................................................................................ 28 TABLE 9: IPCC VALUES FOR THE COLD ROLLING PROCESS ....................................................................................................... 30 TABLE 10: ENERGY USE IN THE SWEDISH IRON AND STEEL INDUSTRY ........................................................................................ 35 TABLE 11: TOTAL STEEL PRODUCTION IN SWEDEN ............................................................................................................... 36 TABLE 12: SHARE OF TOTAL PRODUCTION ANALYZED ...........................................................................................................