To clarify the influence factors and optimization direction of energy consumption of EAF steelmaking, this study established a complete mass and energy balance model, comprising infiltrated air and off-gas flowrate measurement model and radiative and convective heat loss model, to forecast power and oxygen consumption. The influence of power supply, oxygen supply, carbon injection, infiltrated air, and hot metal charging on the power consumption of EAF is discussed. The results show that optimizing production parameters will effectively reduce power consumption, especially improve the infiltrated air flowrate when there are sufficient combustible gases, which is conducive to energy conservation and emission reduction. Additionally, due to the intensive energy and carbon input in the upstream process of hot metal production, the energy consumption and carbon emissions of hot metal charging EAF are much higher than those of 100% scrap charging EAF.
Get full access to this article
View all access options for this article.
References
1.
ChenJ.An empirical study on China’s energy supply-and-demand model considering carbon emission peak constraints in 2030. Engineering. 2017;3:512–517.
2.
AgencyXN. The 14th five year plan for national economic and social development and the outline of long term goals for 2035 (Draft) have made great achievements in the 13th five year plan and opened a new stage in the 14th five year plan. 2021.
3.
C.I.a.S.I. Association. China Iron and Steel Industry Yearbook 2020.2021.
4.
bp. Statistical Review of World Energy. 2020. 2021.
5.
HasanbeigiAJiangZPriceL.Retrospective and prospective analysis of the trends of energy use in Chinese iron and steel industry. J Clean Prod. 2014;74:105–118.
6.
Fang-qinSJi-chengZHai-fengWet al.Climate change and decarbonization development of steel industry. Iron and Steel. 2021: 1–6.
7.
W. association. Steel Statistical Yearbook 2019.2020.
8.
ZhongwuLJiujuCTaoDet al.The macro-control on energy consumption, material consumption & waste emission of steel industry. Strateg Stud Chinese Acad Eng. 2015;17:126–132.
9.
ChenWYinXMaD.A bottom-up analysis of China’s iron and steel industrial energy consumption and CO2 emissions. Appl Energy. 2014;136:1174–1183.
10.
HasanbeigiAArensMCardenasJCRet al.Comparison of carbon dioxide emissions intensity of steel production in China, Germany, Mexico, and the United States. Resour Conserv Recycl. 2016;113:127–139.
11.
HasanbeigiAPriceLChunxiaZet al.Comparison of iron and steel production energy use and energy intensity in China and the U.S. J Clean Prod. 2014;65:108–119.
12.
ArensMWorrellESchleichJ.Energy intensity development of the German iron and steel industry between 1991 and 2007. Energy. 2012;45:786–797.
13.
TanXLiHGuoJet al.Energy-saving and emission-reduction technology selection and CO2 emission reduction potential of China’s iron and steel industry under energy substitution policy. J Clean Prod. 2019;222:823–834.
14.
SakamotoYTonookaYYanagisawaY.Estimation of energy consumption for each process in the Japanese steel industry: a process analysis. Energy Convers Manage. 1999;40:1129–1140.
15.
KirschenMRisonartaVPfeiferH.Energy efficiency and the influence of gas burners to the energy related carbon dioxide emissions of electric arc furnaces in steel industry. Energy. 2009;34:1065–1072.
16.
PfeiferHKirschenM.Thermodynamic analysis of EAF energy efficiency and comparison with a statistical model of electric energy demand. 7th European electric steelmaking conference; 2002. p. 1.
17.
QianFZhongWDuW.Fundamental theories and Key technologies for smart and optimal manufacturing in the process industry. Engineering. 2017;3:154–160.
18.
SunWWangQZhengZet al.Material–energy–emission nexus in the integrated iron and steel industry. Energy Convers Manage. 2020;213.
19.
BadrKKirschenMCappelJ.Chemical energy and bottom stirring systems–cost effective solutions for a better performing EAF. METEC InSteel-Con. 2011: 7–10.
20.
LeeBSohnI.Review of innovative energy savings technology for the electric Arc furnace. Jom. 2014;66:1581–1594.
21.
LongWWangSLuCet al.Quantitative assessment of energy conservation potential and environmental benefits of an iron and steel plant in China. J Clean Prod. 2020: 273.
22.
HayTVisuriV-VAulaMet al.A review of mathematical process models for the electric Arc furnace process. Steel Res Int. 2020;92.
23.
ÇamdaliÜTunçMKarakaşA.Second law analysis of thermodynamics in the electric arc furnace at a steel producing company. Energy Convers Manage. 2003;44:961–973.
24.
ChirattananonSGaoZ.A model for the performance evaluation of the operation of electric arc furnace. Energy Convers Manage. 1996;37:161–166.
25.
BabosLMarteganiAD.Energy conservation and recovery in electric arc furnaces dedusting plants. Energy Convers Manage. 1982;22:347–355.
26.
TrejoEMartellFMicheloudOet al.A novel estimation of electrical and cooling losses in electric arc furnaces. Energy. 2012;42:446–456.
27.
KhodabandehEGhaderiMAfzalabadiAet al.Parametric study of heat transfer in an electric arc furnace and cooling system. Appl Therm Eng. 2017;123:1190–1200.
28.
YigitCCoskunGBuyukkayaEet al.CFD modeling of carbon combustion and electrode radiation in an electric arc furnace. Appl Therm Eng. 2015;90:831–837.
29.
KhodabandehERahbariARosenMAet al.Experimental and numerical investigations on heat transfer of a water-cooled lance for blowing oxidizing gas in an electrical arc furnace. Energy Convers Manage. 2017;148:43–56.
30.
Dal MagroFMeneghettiANardinGet al.Enhancing energy recovery in the steel industry: matching continuous charge with off-gas variability smoothing. Energy Convers Manage. 2015;104:78–89.
31.
KirschenMVelikorodovVPfeiferH.Mathematical modelling of heat transfer in dedusting plants and comparison to off-gas measurements at electric arc furnaces. Energy. 2006;31:2926–2939.
32.
KirschenMPfeiferHWahlersF-Jet al.Off-gas measurements for mass and energy balances of a stainless steel EAF. Elect Furn; Conference2001:737–748.
33.
KirschenMBadrKPfeiferH.Influence of direct reduced iron on the energy balance of the electric arc furnace in steel industry. Energy. 2011;36:6146–6155.
34.
BetriebsforschungsinstitutDKöhleGD-ISKühnIR.Application of models for electrical energy consumption to improve EAF operation and dynamic control. 2005.
35.
BekkerJGCraigIKPistoriusP.Modeling and simulation of an electric arc furnace process. ISIJ Int. 1999;39:23–32.
36.
KühnRGeckHGSchwerdtfegerK.Continuous off-gas measurement and energy balance in electric arc steelmaking. ISIJ Int. 2005;45:1587–1596.
37.
LiYZhuL.Cost of energy saving and CO2 emissions reduction in China’s iron and steel sector. Appl Energy. 2014;130:603–616.
38.
SunWWangQZhouYet al.Material and energy flows of the iron and steel industry: status quo, challenges and perspectives. Appl Energy. 2020;268.
39.
RdMRubénLGLópezFet al.The slag foaming practice in EAF and its influence on the steelmaking shop productivity. ISIJ Int. 1995;35:1054–1062.
40.
MatsuuraHFruehanR.Slag foaming in an electric arc furnace. ISIJ Int. 2009;49:1530–1535.
41.
ToulouevskiYNZinurovIY.Innovation in electric arc furnaces. Springer2010.
42.
WangXWeiYShaoQ.Decomposing the decoupling of CO2 emissions and economic growth in China’s iron and steel industry. Resour Conserv Recycl. 2020;152:104509.
43.
KipepeTPanX.Importance and effect of foaming slag on energy efficiency. Conference proceeding; 2014.
44.
SarmaBMathurPSelinesR.Heat transfer rates and mechanisms in EAF post-combustion. Iron Steelmaker. 1997;24:41–49.
45.
KöhleS.Recent improvements in modelling energy consumption of electric arc furnaces. Proc 7 Europ Electric Steelmaking Conf, Venedig, Italien2002: 29.
46.
PimmAJCockerillTTGaleWF.Energy system requirements of fossil-free steelmaking using hydrogen direct reduction. J Clean Prod. 2021;312.
47.
HuberJ-CRubyFFaralMet al.Pilot assessment of the airtight EAF process. Revue de Métallurgie. 2006;103:168–173.
48.
KirschenMPfeiferHWahlersF-Jet al.Mass and energy balances of stainless steel EAF). Proc 7th europ electric steelmaking conf; 2002: 29.
49.
CormosC-C.Evaluation of reactive absorption and adsorption systems for post-combustion CO2 capture applied to iron and steel industry. Appl Therm Eng. 2016;105:56–64.
50.
EkmekçiĪYetiskenYÇamdaliÜ. Mass balance modeling for electric Arc furnace and ladle furnace system in steelmaking facility in Turkey. J Iron Steel Res Int. 2007;14:1–6.
51.
MapelliCBaragiolaS.Evaluation of energy and exergy performances in EAF during melting and refining period. Ironmak Steelmak. 2006;33:379–388.
52.
LiuFZhuRDongKet al.Simulation and application of bottom-blowing in electrical Arc furnace steelmaking process. ISIJ Int. 2015;55:2365–2373.
53.
WeiGZhuRDongKAIet al.Research and analysis on the physical and chemical properties of molten bath with bottom-blowing in EAF steelmaking process. Metallurg Mater Trans B. 2016;47:3066–3079.
54.
WeiGZhuRDongKet al.Influence of bottom-blowing gas species on the nitrogen content in molten steel during the EAF steelmaking process. Ironmak Steelmak. 2018;45:839–846.
55.
MachadoJGBrehmFAMoraesCAet al.Chemical, physical, structural and morphological characterization of the electric arc furnace dust. J Hazard Mater. 2006;136:953–960.
56.
JonesJABowmanBLefrankAP. Electric furnace steelmaking 1998.
57.
NikolaevAKornilovGKhramshinTet al.Application of static Var compensator of ultra-high power electric arc furnace for voltage drops compensation in factory power supply system of metallurgical enterprise. 2014 IEEE electrical power and energy conference; IEEE 2014: 235–241.
58.
DankwahJRKoshyPSahajwallaV.Reduction of FeO in EAF steelmaking slag by blends of metallurgical coke and end-of-life polyethylene terephthalate. Ironmak Steelmak. 2014;41:401–409.
59.
SadowayDR.New opportunities for metals extraction and waste treatment by electrochemical processing in molten salts. J Mater Res. 1995;10:487–492.
60.
MemoliFMapelliCRavanelliPet al.Evaluation of the energy developed by a multipoint side-wall burner-injection system during the refining period in a EAF. ISIJ Int. 2004;44:1511–1516.
61.
HuSZhuRDongKet al.Effect of oxygen flow rate and temperature on supersonic jet characteristics and fluid flow in an EAF molten bath. Can Metall Q. 2018;57:219–234.
KlemtBNyssenPMathyCet al.Dynamic control of EAF burners and injectors for carbon and oxygen for improved and reproducible furnace operation and slag foaming, EUR 23920. Brussels. 2007.
64.
EchterhofT.Review on the Use of alternative carbon sources in EAF steelmaking. Metals (Basel). 2021;11.
65.
SahajwallaVZahariaMRahmanMet al.Recycling rubber tyres and waste plastics in EAF steelmaking. Steel Res Int. 2011;82:566–572.
66.
WeiGZhuRWuXet al.Technological innovations of carbon dioxide injection in EAF-LF steelmaking. Jom. 2018;70:969–976.
67.
GandtKMeierTEchterhofTet al.Heat recovery from EAF off-gas for steam generation: analytical exergy study of a sample EAF batch. Ironmak Steelmak. 2016;43:581–587.
68.
JieminTFerriMBArgentaP.EAF technology evolution by continuous charging. Ironmak Steelmak. 2005;32:191–194.
69.
DuanJ-pZhangY-lYangX-m.EAF steelmaking process with increasing hot metal charging ratio and improving slagging regime. Int J Mine, Metall Mater. 2009;16:375–382.
70.
SampaioRSJonesJVieiraJ.Hot metal strategies for the EAF industry. Iron Steel Techn. 2009: 31–37.
71.
YangchunL. Discussion on Application of Hot Metal Charging Technology in EAF in China Steelmaking. (2002).
72.
GrantMGKaiserKCCantacuzeneSMet al.Optimization of oxygen steelmaking in nonconventional EAF operations. AISTECH-CONFERENCE PROCEEDINGS-. citeseer; 2005. p. 545.
73.
SuopajärviHUmekiKMousaEet al.Use of biomass in integrated steelmaking – status quo, future needs and comparison to other low-CO2 steel production technologies. Appl Energy. 2018;213:384–407.
74.
HeKWangL.A review of energy use and energy-efficient technologies for the iron and steel industry. Renew Sust Energ Rev. 2017;70:1022–1039.
75.
WangGC. Ferrous metal production and ferrous slags 2016.
76.
YangL-zJiangTLiG-het al.Discussion of carbon emissions for charging Hot metal in EAF steelmaking process. High Temp Mater Processes. 2017;36:615–621.
77.
WangS.Near-Zero Air pollutant emission technologies and applications for clean coal-fired power. Engineering. 2020;6:1408–1422.
