ECO SOLUTIONS SAVING RESOURCES, CREATING VALUE
A COMPREHENSIVE RANGE OF
FUTURE ORIENTED ENVIRONMENTAL
SOLUTIONS FOR STEELMAKING PLANTS

primetals.com

ECO SOLUTIONSSAVING RESOURCES, CREATING VALUE

As a result of increasingly stringent
environmental regulations and theneed to save resources and reduceenergy consumption, environmental
protection has become more
important than ever.
ECO Solutions from Primetals
Technologies stands for a wide rangeof services and advanced technologies
that minimize the environmental
impact of steel production, improveenergy efficiency and optimize byproduct management. Primetals
Technologies offers expert consulting
services, advanced processes andholistic solutions along the entire ironand steel production chain that ensure
strict adherence to the emission
regulations and support producers toachieve substantial cost savings. The
objective is always twofold: to saveresources and to create value.

GAS
CLEANING

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ENERGYEFFICIENCYECO SOLUTIONS
Saving resources• Optimized use of raw materials• Reduced energy consumption• Significant reduction in particulate
and gaseous emissions• Efficient by-product treatment andrecycling
Creating value• Improved plant performance• Lower conversion costs• Reduced environmental taxes anddisposal costs• Increased energy recovery• Substantially improved working
conditions and safety

BY-PRODUCTRECYCLING

ECOCONSULTING

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ENVIRONMENTALLY ORIENTED PRODUCTION
AND LOWER ENERGY CONSUMPTION
For every metric ton of steel produced, 50 to 100 kilogramsof sludge and scale accumulate and approximately 20,000
MJ of energy are consumed. There is no question thatmodern dedusting systems in combination with energyrecovery technologies and by-product recycling are crucial.
However, the outlay for such technology should be nohigher than absolutely necessary. The most important goals
are high reliability, strict compliance with defined thresholdvalues, and minimum energy consumption and maximum
by-product recycling.

YOU EXPECT

Primetals Technologies offers the entire spectrum of gas
cleaning and energy efficiency technologies as well as
by-product treatment plants from a single source, always
in close collaboration with your company’s iron and steel
production specialists. This is our approach for creating
perfectly coordinated and economically viable solutions.

• A reliable partner with innovative, tailor-made solutions• Cost-efficient production and maximized productivity• Low consumption levels for energy and utilities• Maximum energy recovery

ECO SOLUTIONSFOR STEELMAKING• Short delivery times and consistently high availability• Solid production quality and expert solutions• Designs that meet future environmental and market
requirements at the lowest investment

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ADVANTAGES OF PRIMETALS TECHNOLOGIES ECOSOLUTIONS

3

Gas cleaning

Energy recovery

By-product recycling• Full compliance with agreed-upon limit values

4• Tailored ECO plants using comprehensive expertise• Future emission requirements already considered in theplant layout and design• More than 40 years of experience and profoundknowledge in environmental technologies

56Electrics and automation

Lifecycle services

Selected references

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DDS - DRY DEDUSTING SYSTEM FOR LD (BOF)
FOR HIGHLY EFFICIENT GAS CLEANING,
HIGH ENERGY EFFICIENCY AND MAXIMUMAVAILABILITYWET VS. DRY DEDUSTING SYSTEMS FOR LD (BOF) CONVERTERS - GREEN FIELD INSTALLATIONSWET SYSTEMDRY SYSTEM

30 mg/Nm³

10 mg/Nm³

100%

55%

Scrubbing water treatment plant (WTP)

yes

no

Investment costs

75%

100%

Total investment incl. WTP

100%

100%

Maintenance sensitive parts

scrubber, ID fan, pumps,
sludge handling

dust conveyors
ESP

high

high

Clean gas dust content (typical)
Energy consumption

Reliability of operation

Evaporation cooler

Cylindrically stopped electrostatic precipitator

Primetals Technologies’ solutions for converter offgas
cleaning and energy recovery focus on highly efficient gas
cleaning, high energy efficiency and maximum availability.
For around ten years now, the dry dedusting process has
become the state-of-the-art technology for maximum gas
cleaning efficiency and minimum energy consumption forprimary offgas in LD (BOF) converters.
The offgas is cooled in an evaporation cooler throughthe injection of a water-steam mixture. Fine cleaningof the waste gas takes place in the cylindrically shaped
electrostatic precipitator (ESP), which features design
solutions such as special electrodes, a dust extraction
system, pressure relief devices, etc.
As a result of the very low pressure drop inside thededusting plant, lower-power axial-type ID fans can beused (approx. 40% less than in conventional systems). With
its round casing design, the ID fan is also fully pressurepeak resistant.

ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE
Saving resources• Lowest dust emission levels of <10 mg/Nm³• Reduction of energy consumption by <45% (compared to
wet type)• No water treatment plant and sludge handling required- Overall capex lower than a wet dedusting system with awater treatment plant- Overall opex such as maintenance works and chemical
dosing system not required
Creating value• Lowest electric energy consumption of <5 kWh/t leads toreduction of conversion costs• Increased gas recovery up to 100 Nm3/t• BAT conformity and thus a future-proof systemcompared to wet dedusting system• Plant availability of >99%

<10 mg/Nm3
6

Primetals Technologies has the competence to combine
the lowest operating costs with the lowest emission
levels. Emission levels of <10 mg/Nm³ can be achieved at
operating costs of approximately €0.30/t.
The design of the dry dedusting system is based on
tailor-made and advanced engineering methods such as
numerical simulations as well as analytic and dynamic
process models.
CFD simulations for gas ﬂow and temperature distribution
are essential to correctly define the shape and size ofthe evaporation cooler in order to ensure complete andhomogeneous vaporization of the water and to avoid dust
build-up at the inner evaporation cooler.

The energy input for the ESP can be reduced while
maintaining the required clean gas dust concentration witha new additional design package:• Dynamic high-voltage control according to actual
process conditions• Optimized electrostatic precipitator power input
through dynamic online dust monitoring system (Moreinformation about Precon system on page 24)• Separate power/voltage/current control for each single
field (saving typically >30%)

The ESP design has been optimized through the years
for the best dust removal efficiency and the easiest plantmaintenance possible.
All plant components, including the low-pressure axialtype ID fan, are designed for extra-long service life andmaximum availability.

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SUCESSFULLYINSTALLED
DEDUSTING
PLANTS

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WDS - WET DEDUSTING SYSTEM FOR LD (BOF)
A HIGHLY EFFICIENT DUST RECYCLING PROCESSCONE wet-type dedusting system with split tower solution

Wet-type waste gas cleaning systems are installed in the
majority of dedusting systems for LD (BOF) steel plants
around the world. Wet dedusting systems are consideredsimpler in terms of operation and control.
Primetals Technologies offers two wet dedusting
technologies:• BAUMCO® scrubber system with venturi technology• CONE scrubber system with annular gap technology

CONE scrubber unit

BAUMCO® SCRUBBER SYSTEM
Gases are accelerated in the convergent section at theventuri throat inlet and hit a transversely injected water
spray. The laminar water spray injected from the sides
forms a multiple self-regenerating filter so that even thefinest particles are collected. Highly effective droplet
separation downstream of the venturi scrubber ensuresincreased scrubbing efficiency and less wear of materials.
Additionaly a patented 45° spraying technology is available
to further improve the cleaning performance.

Both types are optimized to ensure maximum dedusting
efficiency and the lower energy requirements.
CONE SCRUBBER SYSTEM WITH ANNULAR GAPTECHNOLOGY
Gases are accelerated in the annular gap between the
inner and outer cone. Water is injected onto the inner coneto ensure uniform distribution. An intense mixture of gas
and water takes place over the length of the annular gap
and ensures optimum gas cleaning. Water and gas pass a
demister to remove water droplets.

BAUMCO® wet dedusting system

ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE
Saving resources• Total emission reduction to <30 mg/Nm³• Reduced energy consumption of 10–20 kWh/t

MAIN BENEFITS• High performance scrubbing• High system reliability• Low maintenance requirements• Space saving design as single or split tower solution

Creating value• Simplified plant control- and automation system• 25% lower investment costs (compared to dry dedusting
system)• All serviceable units externally mounted• Plant availability of >99%

• 45° spraying technology to boost cleaning performance• Highly reliable and robust design, special solutions for
reduced maintenance requirements

PATENT

45° SPRAYINGTECHNOLOGY33
SUCESSFULLYINSTALLED
DEDUSTINGSYSTEMS

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SDS - SECONDARY DEDUSTING SYSTEM FORSTEELMAKING PLANTS
EFFICIENT CAPTURE OF DUST EMISSIONS AT THE
POINT OF ORIGIN

PEAK COOLEREFFICIENT GASCOOLING DURING HOTMETAL CHARGING

Optimized hood design for maximum achivable suction flow

Fan house and stack

Secondary dedusting system for highly efficient emission control

Peak cooler

The main task of a secondary dedusting system is toefficiently capture dust emissions that occur during thehandling and processing of hot metal and liquid steel (e.g.,charging, tapping, reladling, desulfurization, deslagging).
The proper design and location of hoods is essential
to achieve the highest dust efficiency and ensure clean
ambient conditions inside and outside the steel shop.

PRIMETALS TECHNOLOGIES OFFERS A WIDE RANGEOF CAPACITIES FOR SECONDARY AND AUXILIARY
DEDUSTING PLANTSECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE• High flow capacity: 600,000–2,600,000 m³/h

• Total emission reduction of <3 mg/Nm³• Medium suction rates: 200,000–600,000 m³/h

• Cost savings of €480,000 per ton and year when using
the static cooler

The peak cooler from Primetals Technologies is amajor advancement in secondary dedusting. Peakcoolers absorb thermal heat that is released during
charging and allow shorter charging periods andincreased safety.

• Low suction rates: <200,000 m³/h

• Equalizing of temperature peaks• Thermal power control via traffic light guide; redindicates to the crane operator not to interrupt hot metal
charging• Design gas flow reduced up to 50%• Less cooling air required• Thermal power control via crane interlock so that with
fast-moving scrap the charging sequence is interrupted
and restored to an optimized charging speed• Recycling of by-products via oxide briquetting possible

MAIN BENEFITSThis solution reduces investment and operating costs.
Operational safety is increased and higher productivity isachieved through a higher charging speed.

• Emergency air damper controlled via a temperature
controller protects the filter from thermal overload andprovides ambient air to dilute and cool the hot offgas

The advanced pulse-jet filter from Primetals Technologies
removes dust from the raw gas stream and assures highly
efficient dedusting and increased lifetime of filter bags.

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MAIN BENEFITS:• Energy consumption reduced by 25–45 kWh/t

A major process improvement is the patented Primetals
Technologies peak cooler technology. Peak coolers absorb
temperature peaks during hot metal charging and reduce
the need for additional cooling air. Hence, this innovativetechnology based on thermal energy storage leads toreduced dilution air demands and reduced offgas volume
flows.

The spark eliminator prevents sparks and slag particles
from damaging the filter bags. Particles with a higher
density are separated through an increased centrifugal
acceleration.

Saving resources

Creating value• Plant availability of >99%
• Clean working environment results in reduced
maintenance costs• Static cooler means less risk to operate with understoichiometric combustion conditions• Personnel is protected from high dust loads• Optimized design for suction hoods and required suction
rates through CFD modeling• Primetals Technologies has developed and applied thissolution especially for retrofit- and revamping projects
were high-performance secondary dedusting systems
have been successfully installed in many old steel making
shops

#1
SUPPLIER WORLDWIDE- with the most advanced technology- for new installations and- revamping projects alike

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SUCESSFULLYINSTALLED
DEDUSTING
PLANTS

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GAS RECOVERY FOR LD (BOF) CONVERTERS
AN ECONOMIC, ECOLOGIC AND COMPLETELYINTEGRATED SOLUTION

Gas holder

Integrated gas recovery solutions

Switch-over station for dry-type dedusting

LD (BOF) gas recovery is an economic and ecologic
solution for LD (BOF) primary waste gas treatment thatis completely integrated. The main equipment for the LD(BOF) gas recovery is the gasholder plus the pressure
boosters and distribution network. The technologicallymost complex part of the gas recovery system is the socalled switch-over station, where the gas is switched fromflare stack to gasholder.

Depending on the primary dedusting plant configuration,
Primetals Technologies can offer switch-over stations forthe wet-type and dry-type dedusting process with theirindividual specific requirements. In the wet-type dedusting
plants, the switch-over station features a three-way valve as
the main control valve plus a series of parallel safety valves
downstream. For dry-type dedusting plants, the switchover station is designed with special, high-temperatureresistant cup valves.

ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE

The main focus of the plant solutions for LD (BOF) gas
recovery is on high-calorific-value CO-gas-enrichment
efficiency, plant reliability and safety.

• Additional earnings up to €5/t

<1
kWh/t
REDUCED

ENERGYCONSUMPTION

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Switch-over station for wet-type dedusting

Saving resources• Reduced energy consumption to <1 kWh/t• Substitution of natural gas
Creating value• Recovered energy up to 100 Nm³/t of steel converter gas

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SUCESSFULLYINSTALLED GASRECOVERY
PLANTS

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COOLING STACKHIGHLY EFFICIENT ENERGY RECOVERY
FOR LD (BOF)

Partially assembled cooling stack in the workshop

Converter waste gas cooling is highly challenging due tothe tough operating conditions with high loads of abrasive
dust particles as well as high temperatures and the general
cyclic nature of this batch process.
Primetals Technologies ensures high plant availability andbest performance by applying state-of-the-art and provendesigns and materials along with most modern calculation
tools for dynamic simulation of process conditions such asheat flow, steam circuit, etc.
In most cases, today the LD (BOF) converter coolingstacks are used for steam generation. Major benefits ofthe evaporative-cooled cooling stack system include value
creation from waste, energy savings and reduced CO2
emissions.

Cooling stack

ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE

The system is typically designed for suppressed
combustion in combination with CO gas recovery at a postcombustion factor between 0.1 and 0.2. The adjustable skirt
is lowered during oxygen blowing to close the gap between
the converter mouth and cooling system to minimize indraftof false air. The suction pressure in the converter hood area
is controlled by downstream facilities based on closed-looppressure control.

Saving resources• Energy consumption minimized by <1 kWh/t (natural
circulation)
Creating value• Maximum energy recovery of 80 kg steam per ton ofliquid steel or 60 kWh/t of liquid steel

Heat is transferred from the waste gas through the heating
surface to the cooling water, thereby generating steam.

• With the value of steam assumed at €20/t, the cost of
steam turns into savings of €0.16 per ton of liquid steel

The steam is stored in a steam accumulator for constantfeed into the overall plant steam network. To minimize
operational costs, the cooling stack system can be
operated in assisted or natural circulation mode.

• Steam production can lead to additional earnings of up
to €2/t

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SUCESSFULLYINSTALLED
ENERGY RECOVERY PLANTS
Cooling stack 3-D model

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DEDUSTING SYSTEM FOR ELECTRIC ARCFURNANCE
MEETING ENVIRONMENTAL STANDARDS IN
ELECTRIC STEELMAKING

Primetals Technologies dedusting plant

Bag filter plant with stack

As a state-of-the-art system integrator for EAF dedusting
equipment, Primetals Technologies offers comprehensive
in-house solutions for primary and secondary offgas
treatment. These proven solutions are characterized
by effective cleaning and cooling of the offgas, andcompliance with stringent environmental emission
regulations.

ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE

EAF dry dedusting system bag filter plant and stack

AOD DEDUSTING
AOD dedusting systems are based on the same
highly efficient dedusting technology as EAF
dedusting systems. Both systems apply complete
combustion of the furnace offgas for zero carbon
monoxide emissions.

Saving resources• Total emission reduction of <5 mg/Nm³• Reduced energy consumption by <35 kWh/t• Clean working environment results in reduced
maintenance costs• Complete recycling of by-products via oxide briquetting

ECO SOLUTIONS – SAVING RESOURCES,CREATING VALUE

Creating value

Saving resources• EAF process calculation combining process knowledge
with environmental know-how• Combination with energy recovery system for up to
45 kWh/t• Total emission reduction of <5 mg/Nm³• Dynamic thermodynamic simulations• Plant availability of >99%

Primetals Technologies provides profound knowledge
about the whole process of electric steelmaking andrespective environmental technologies. Its know-how
comprises:• Reduced electric power consumption of<35 kWh/t• Fluid dynamics simulation to optimize environmental
efficiency• Clean working environment results in reduced
maintenance costs• Analytical calculation tools for dedusting equipment
developed by our specialists

Creating value

In order to address specific requirements regarding
reduction of dioxins or heavy metals in the EAF offgas,
Primetals Technologies has developed a package solution
based on activated carbon injection upstream of the bag
filter.

16

113
SUCESSFULLY• Upgrade with the modular waste heat recovery
system utilizes the thermal power of the offgas

INSTALLED
DEDUSTING
PLANTS

17

ENERGY RECOVERY FOR ELECTRIC ARCFURNANCESHIGHLY EFFICIENT WASTE HEAT RECOVERYSYSTEM

Fossil energy
Charging coal
Blowing coal
Natural gas

Recovered energy

56kWh/t

Electric energy

434kWh/t
490kWh/t

Offgas210kWh/t

0kWh/t70kWh/t
40kWh/t
Steel

Additional energy input
Combustibles in scrap
Electrode combustion
Fe, C, SI combustion

3-D plant layout of heat recovery system

Most electric arc furnace offgas systems are not thermally
optimized, so only nearly 30% of the energy input in theelectric arc furnace is used further.
Primetals Technologies provides electric arc furnace
operators with highly efficient energy recovery systems.
The integral energy recovery approach is based on a
modular dedusting system set-up. Basically, either the hot
gas line or the forced-draft cooler or both aggregates canbe exchanged by an adequate energy recovery system.
The modular energy recovery solutions have the samelayout as the standard dedusting solutions and cantherefore be easily exchanged.

685kWh/t
629kWh/t

Other losses
Slag			
Cooling water furnance shell
Radiation losses

46kWh/t
26kWh/t
17kWh/t

Reduced specific energy demand per ton of steel

The discontinuous steelmaking process leads to a variable
thermal energy output. Thermal energy storage systems
like steam accumulators or thermocline storage tanks
provide downstream consumers with a constant amount ofheat.
The electric arc furnace energy recovery system is basedon two steps, depending on the demand of energy to be
recovered.
In the first stage the water-cooled hot gas line is replacedby an energy recovery system.
In the second stage the secondary offgas cooling device(e.g., forced-draft cooler) is additionally replaced by anenergy recovery system.
The recovered energy can either be used for hot waterproduction (heating or cooling), steam generation
for internal or external steam consumers (processing
or secondary metallurgical devices) or for electricity
generation.
For greenfield minimills, energy recovery solutions andwaste heat utilization concepts are an integral part of thededusting line.

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20kWh/t
15kWh/t
50kWh/t

386kWh/t

ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE
Saving resources• Emissions minimized by 5 mg/Nm³ using a modular
system based on highly efficient EAF dry dedusting
solutions
Creating value• Energy recovery solution stage 1 and 2 up to 120 kg/t
liquid steel or 100 kWh/t liquid steel• With the value of steam assumed at €20/t, the cost of
steam turns into savings of €0.20/t of liquid steel• Up to 100 Nm³ per ton of steel converter gas for
additional earnings up to €5/t

ENERGY RECOVERY FOR AOD
AOD energy recovery systems are based on thesame highly efficient technology as EAF recovery
systems.
A two stage solution helps customer to optimize
waste heat recovery in accordance with waste heatutilization. Depending on the individual requirements
the first cooling stage for the AOD waste heatrecovery system can be realized either as hot wateror steam cooled equipment. Additionally the second
stage cooling equipment (e.g. forced draught cooler)
is replaced by an waste heat boiler or an heatexchanger.
ECO SOLUTIONS – SAVING RESOURCES,CREATING VALUE

up
to
11%
REDUCTION OF
ELECTRICAL
ENERGYCONSUMPTION

Saving resources• Emissions minimized by 5 mg/Nm³ using a
modular system based on highly efficient EAF dry
dedusting solutions
Creating value• Energy recovery solution stage 1 and 2 up to
110 kg/t liquid steel or 90 kWh/t liquid steel• With the value of steam assumed at €20/t, the costof steam turns into savings of €2.2/t of liquid steel

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BSSF TECHNOLOGY FOR SLAG PROCESSINGLOW EMISSION IN CLOSED SLAG GRANULATIONPROCESS, SHORT PROCESSING TIME, UNIFORMGRAIN SIZE AND LOW FREE LIME CONTENTRECYCLING OF BY-PRODUCTS
FERROUS BRIQUETTING

BSSF plant at Baosteel

Briquetting plant

Slag from steel production in LD (BOF) converters andelectric arc furnaces can, for example, be used as material
in road or railway track bed construction. In the Baosteel
Slag Short Flow (BSSF) granulation process developed by
Baosteel, the liquid slag is transferred to a granulation drum
where it is treated with injected water with a dwell time
between three and five minutes, which significantly reduces
the amount of unreacted free lime. The hermetically sealed
vessel and central vapor extraction system ensure that allemissions of dust and hazardous substances are avoided.

Around the world, government regulations concerning
environmental care are becoming more stringent, also
in regard to regulations and restrictions for depositing
and storing dust and sludge generated in the iron- andsteelmaking process.
These by-products such as iron-containing dust, sludge,oxide fines and scales as well as, for example, lime dusts
become a valuable resource and recycling becomesa profitable activity within a plant. Up to 10% in massof the total steel output of by-product materials are
generated within an integrated steel plant with an ironcontent ranging from 50% to 65%. In DRI-based plants, alarge amount of oxide fines, DRI sludge and DRI fines are
generated, either as a result of the process itself or during
material and product handling.

The process is already in use at Baosteel and several other
Chinese steel producers, the Korean Posco group and theIndian company JSW Steel. The batch-wise operating BSSF
plants have short process times and a compact design.

Briquette productHowever, in many DRI-based plants there is no sinter plant
available for recycling, and the most effective way tomake use of the materials is in the direct reduction plant
as a partial pellet or lump-ore substitute. Not surprisingly,
the reuse of these by-products in direct reduction plants
is currently not state-of-the-art. Therefore, Primetals
Technologies has performed comprehensive studies andtests on briquetting iron-containing by-products. To verify
the physical stability and chemical reducibility of thebriquetted material, extensive laboratory tests (e.g., static
reduction tests) as well as field tests – so-called basket
tests – have been performed and proved to be successful.
ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE
Saving resources

They achieve a high level of slag and crude steel metal
separation, uniform granulation and a consistently highquality in the end products.

In many cases, these by-products may be used as feedmaterial input in sinter plants without further processing,or sold at low value in order to avoid the space-consuming
and sometimes costly option of depositing the materials inor outside the plant.

Primetals Technologies and Baosteel Engineering &Technology Group Co. Ltd., a subsidiary of the BaosteelGroup, are cooperating in the granulation of slag producedin LD (BOF) converters and electric arc furnaces.

• Reduction of raw material consumption and thus
operating costs due to recycling of by-products (lumpore, pellets)• Sinter, pellets or lump ore bring savings of up to 7%
Creating value• Minimization of landfill and transport costs

Primetals Technologies already offers solutions for slag
granulation from pig iron production in blast furnaces.

• Short payback period

Granulated slag

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GASFERM
GENERATION OF ADDED VALUE FOR STEEL MILLOFFGASES

3-D plant layout for a double train installation

100% process gas recovery and utilization

Recycling carbon emissions from steel mills provides animportant new source for fuel and chemical production
while simultaneously reducing a steel mill’s carbon
footprint. Offgases generated from iron and steel
production contain significant amounts of carbon
monoxide (CO), carbon dioxide (CO2) and sometimes
also hydrogen (H2). Governments around the world are
setting ambitious targets for reduction of stationary
carbon emissions from industrial installations such as thesteel industry, thereby adding significant costs to steel
production.

Microbial fermentation of carbon and hydrogen-richoffgases, such as coke oven gas, blast furnace top gas,
direct reduction gas and converter gas to produce ethanol
or other basic chemicals, substantially mitigates CO2
emissions while simultaneously reducing NOx, SOx andparticulate emissions. The fuels and chemical products
produced in this manner deliver superior economic returns.
Greenhouse gas emissions from ethanol are up to 80%
lower compared with conventional gasoline, and between
30% and 50% lower per MJ of energy recovered whencompared with combustion for electricity generation.

GasFerm is a new development in offgas recycling thatsimultaneously addresses the need to reduce the steel
industry’s carbon footprint while improving a steelmaker’s
economic competitiveness through promotion of thecircular economy.

This technology is developed by LanzaTech. Primetals
Technologies is partner for plant implementation for theiron and steel industry.

MAIN BENEFITS• Added value for carbon-rich co-generation gases• Fuels und chemicals can be stored and globally traded,
while electrical power cannot• Chemical co-production adds diversification to the steelbusiness• GasFerm is a closed-loop, zero-waste process

ECO SOLUTIONS –SAVING RESOURCES, CREATING VALUE
Saving resources• Minimum 30% reduction in carbon footprint vs. power
generation• Energy conversion efficiency is 60% compared withpower generation efficiency of 35% to 40%• No food-crop usage as in other ethanol processes
Creating value• Net profit of ethanol produced is up to two times higher
than electrical power generation• 11 liters of ethanol per ton of liquid steel produced• Project internal rate of return (IRR) in the range of 25% to30%• Production cost per liter of ethanol up to 25% lower thantypical process for bio-ethanol production

4,5l/Nm CO-Gas
ETHANOL• Produced biomass replaces coal in sinter or blast furnace(23 MJ/kg biomass)• 100% process gas recovery and utilization

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ELECTRICAL AND AUTOMATION SOLUTIONSConverter control room at Taiyuan ISCO, China

Blast furnace control room

LD (BOF) PROCESS OPTIMIZATIONPRECON

With LD (BOF) Optimization and Dynacon, Primetals
Technologies offers two well-proven automation solutions
for high product quality at low production costs.
Depending on the available measuring devices, one or
the other system will be applied: Whereas Dynacon uses
continuous offgas measurement data for dynamic control
and automatic stop of oxygen blowing, conventional LD(BOF) Optimization improves temperature and carbon
hitting rates based on sublance measurement.

Based on the converter phase and actual process
conditions, Precon controls the level of possible energy
reduction without affecting overall dedusting performance.
All relevant process data are analyzed during operation,and the power reduction calculation is sent to the individual
high-voltage units of the ESP. Precon can be used for all
primary dry-type dedusting systems with electrostatic
precipitators in steel plants.

Both systems include advanced models in order to prepare,supervise, and dynamically optimize the converter process.
Exact pre-calculation of required materials, comprehensive
considering of all actual process parameters as well as
dynamic control of oxygen blowing enable thermal andmetallurgical control of converter steelmaking. Overheatingof the steel bath can be eliminated and reblows are
significantly reduced.
MAIN BENEFITS• Increased productivity and yield• Improved hitting rate for steel temperature and carbon
content• Reduced CO2 emissions due to lower reblow rate andavoidance of overblowing• Energy savings of up to 3%• Lower consumption of raw materials and resources

24

The electrostatic precipitator (ESP) is one of the main
components in dry-type dedusting plants, at the same time
it is also one of the main electrical consumer. Therefore
Primetals Technologies supply efficient high-voltage units
for ESP operation for best cleaning results. To reduce theenergy consumption of new or existing ESPs Primetals
Technologies provide a product for energy saving in
combination with highest efficiency:
MAIN BENEFITS• Energy savings up to 60%• Short payback time
• Optimized dedusting control of the electrostatic
precipitator• No dust concentration increase in the clean gas• Short implementation and commissioning time

HIGHEST PRODUCTION QUALITY AND COST-OPTIMIZEDOPERATION – SINTER OPTIMIZATIONENSURING SAFE AND COST-EFFICIENT OPERATION –BF OPTIMIZATIONThis system enables major cost savings and process
improvements without compromising raw material
selection, sinter quality, energy efficiency, and productivity.
Optimized raw mix calculation allows the production ofsinter material of the highest quality, while at the same timeeffectively reducing fuel consumption. Furthermore, thesystem provides a complete history of process parameters
including recipe, chemical and physical raw material
properties, and process measurements for a comprehensive
analysis of the sinter process. The result is smooth sintering
operation around the clock, an increased equipment
lifetime and reduced production costs.

The BF Optimization system was developed to operate
the blast furnace in a standardized way at stable operating
conditions. This closed-loop expert system corrects evensmall deviations by automatically executing the required
counteractions. This leads to cost-efficient operation andenergy-efficient production of hot metal (HM).

MAIN BENEFITS• Monitoring of process measurements and indicesbecomes more efficient• Process control practices become more uniform by using
fully closed-loop operation on the basis of all provided
expert system rules• Higher productivity (increase by up to 5%)• Stabilization of product quality (decrease of standard
deviation by 5-10%)• Reduced fuel consumption (decrease by up to 3%)

Stable process conditions are indicated by reduced
standard deviation of quality parameters such as hot
metal temperature or silicon content and result in reduced
fuel consumption of the blast furnace. Core modules areproduct quality and energy efficiency rules, the proceduresfor shutdown and start-up, the 3D hearth monitoring
package and the burden distribution model. At the sametime, data management and analysis tools provide processengineers with a sound information basis for further
process optimization.
MAIN BENEFITS• Reduction of fuel consumption by 5 kg/t
• Increased productivity (up to 3%) HM• Reduced standard deviation of HM temperature and Si
content (by 10%)• Stabilization of operation by avoiding critical situations• Easy to use system• Fast implementation into existing systems

25

PROCESS & TECHNOLOGY CONSULTING
INCREASE PLANT PERFORMANCE AND REDUCECONVERSION COSTS

Consulting trough out the whole metallurgical production chain

PROCESS AND TECHNOLOGY CONSULTING
You can profit from our integrated process know-how
and global presence. Process and technology consulting
help increase plant performance and reduce conversion
costs to support quick and proper selection of feasible
improvement measures.
Primetals Technologies offers technology-consulting
services that help operators to achieve and maintain highstandards in production excellence.

On the basis of decades of experience in the engineering,
installation, start- up and commissioning of steelmaking
plants worldwide, our specialists are skilled in identifying
potential for plant performance improvement in thecourse of a performance check. Detailed and individual
concepts are proposed to optimize processes and adapt
technological equipment to deal with different qualities ofraw material. By implementing these measures, operators
can ensure permanent production excellence and stay inline with environmental goals and remain cost effective.

LIFE CYCLE SERVICES FOR YOUR PLANT

OPERATIONALSUPPORTPLANT
UPGRADES

MAINTENANCESERVICES

BENEFIT FROM OVER 50 YEARSOF EXPERIENCELOW INVESTMENTS FOR
STATE-OF-THE-ART
TECHNOLOGY

ON-AND OFFLINE
MAINTENANCE AND REPAIRSERVICES

Decades of experience
worldwide in design,
manufacturing, and commissioning as well as consultingof metallurgical plants ensureeach client with innovative
modernizations and mechatronicsolutions for its processing chain.

With wide-ranging international
network of customer support
experts and worldwide repair
and maintenance workshops,
Primetals Technologies is yourideal single source partner for
maintenance services.

Comprehensive services formetallurgical plants, fromsupply of original manufacturer
components, spare and wear
parts to consulting, technicalassistance and training.

With a portfolio consisting of operational support, plant
upgrades, and maintenance services you can focus on yourcore business while Primetals Technologies assures yourplant’s optimum performance.
STEPS FOR QUICK AND PROPER SELECTION OF FEASIBLE IMPROVEMENT MEASURESFACT FINDING AND
BENCHMARKFIND• Quick benchmark based on the
installed base and main raw
materials• Analysis of existing facility• Debottlenecking and productmix
26

INVESTIGATION AND
EVALUATIONEVALUATE• Improvement potential• Feasibility of investment

DETAILED
IMPROVEMENTELABORATE• Detailed plant specific measuresand specifications

Fast, reliable, and experienced service and support for the
metallurgical industry Primetals Technologies strives to bea long-term life-cycle partner dedicated to your success.
We offer a full range of services across the entire life-cycleof your plant, including consulting and technical assistance,
directly from a single provider. Our service portfolio ranges
from a spare parts service available at just the right time
to advanced staff training and technical support, upgradesof components and plants to be technical up to date;also from repair service of key components for a longer
life-cycle, to online and offline maintenance. Our services
reduce cost, increase productivity, improve product quality,and ensure safety.

27

SELECTED MODERNIZATION REFERENCES

Ruukki Metals Oy
FINLAND
Secondary dedusting system
3x125 t LD (BOF) and hot metal
mixer

TRINECKE ZELEZARNY, a. s.
CZECH REPUBLIC

ArcelorMittal GENTBELGIUM

Revamp of secondary dedusting
system2x180 t LD (BOF)

Secondary dedusting system
2x 295 t LD (BOF)

voestalpine Stahl GmbH
AUSTRIAOAO Severstal
RUSSIAN FEDERATION

Secondary dedusting system for
LD (BOF)

Secondary dedusting system for3x380 t LD (BOF)

OAO „Novolipetskiy
metallurgicheskiy kombinat“
RUSSIAN FEDERATION
Wet dedusting system BAUMCO®
for 3x160 t LD (BOF)
Dry dedusting system for
2x180 t LD (BOF) in steelshop 1
LD (BOF) heat recovery system plus

U. S. Steel Kosice, s.r.o.
SLOWAKIA
Wet dedusting system for
2x180 t LD (BOF) in steel shop 2

U. S. Steel Kosice, s.r.o.
SLOWAKIA
Dry dedusting system for
2x180 t LD (BOF) in steelshop 1
LD (BOF) heat recovery system plus

TRINECKE ZELEZARNY, a. s.
CZECH REPUBLIC
Revamp of wet dedusting system
CONE
2x180 t LD (BOF)

Acroni d.o.o.
SLOVENIA
Dedusting system for
95 t AOD converter

Salzgitter Europlatinen GmbHGERMANY
Modernization of dry dedusting
system for 3x230 t LD (BOF)

AG der Dillinger Huettenwerke(Societe Anonyme des Forges etAcieries de Dilling)
GERMANY

Whether it is exchange of outdated equipment,
retro-fit of new equipment into existing steel shops
or expansion of existing plants to increase capacity,
in today’s business environment it is essential tominimize CAPEX for modernization projects while stillachieving the desired performance improvement.
This is particularly important for environmetal
plants with environmental regulations and authority
requirements becoming more and more stringent.
Primetals Technologies has developed over the years
modular design solutions that can be easily applied inexisting systems and processes with focus on:

BAOTOU I/S Group
CHINA

Secondary dedusting system for2x100 t LD (BOF)

With many years of project experience in the steel
industry, Primetals Technologies has developed a
special expertise for modernization and upgrade
solutions.

Conversion of wet dedusting
system for 2x210 t LD (BOF)
Acciaieria Arvedi S.p.A.
ITALY
Heat recovery system andprimary, secondary, auxilary
dedusting system for 125 t EAF
CSN - CIA SIDERURGICA
NACIONAL
BRAZIL
Secondary dedusting system
extansion for 3x240 t LD (BOF)

AperamBRAZILWet dedusting system BAUMCO®
for AOD converter

TATA Steel Ltd.
INDIA
Secondary dedusting system
extension for 3x160 t LD (BOF)

Nanjing Iron & Steel Group (Nisco)
CHINA
Revamping of wet dedusting
system for 130 t LD (BOF)• Gas cleaning improvement packages e.g. upgradefrom wet dedusting system to dry dedusting system• Secondary emission control systems e.g. retrofit
or expansion of secondary dedusting systems,
optimized suction hoods, static cooler etc.
• Energy efficency packages e.g. replacement ofwater cooled hot gas line by steam generation
section for EAF primary dedusting system

CIA. SIDERURGICA PAULISTACOSIPABRAZIL
Secondary dedusting system forsteelmaking plant

Whether it is a small technology package solution
or a major system modernization, Primetals
Technologies is the right partner for your project.

28

29

REFERENCE HIGHLIGHTSDRY DEDUSTINGSYSTEM FOR
LD (BOF)DRY DEDUSTINGSYSTEM FOR
LD (BOF)DRY DEDUSTINGSYSTEM FOR
LD (BOF)WET-DEDUSTINGSYSTEM FOR
LD (BOF)SECONDARY
DEDUSTING
FOR LD (BOF)

Customer
THYSSENKRUPP CIA.
SIDERURGICA DO ATLANTICOType of plant
Dry dedusting system

CustomerShougang Jintang United SteelType of plant
Dry dedusting system

CustomerU. S. Steel Kosice, s.r.o.
Type of plant
Dry dedusting system

Customer
SSAB Oxelösund, Sweden
Type of plant
Wet dedusting system

Customer
OAO “Severstal”
Type of plant
Secondary dedusting system

Customer
TATA Steel Port Talbot
Type of plant
LD (BOF) gas recovery system

OUR SOLUTIONOUR SOLUTIONOUR SOLUTIONOUR SOLUTIONOUR SOLUTIONOUR SOLUTION

Thyssen Krupp expanded to
the Americas and set up agreenfield steel plant in Santa
Lucia near Rio de Janeiro, Brazil.
Primetals supplied state of theart dedusting systems for theentire steel shop. The LD (BOF)
primary dedusting features aheat recovery system with steam
generation, the first dry typededusting system in all Southand North America plus a gas
recovery system.
The plant was commissioned in2010.

In preparation for the Olympic
games 2008 in Beijing Shougang
was requested to relocate theirsteel production outside of the
Beijing area. Shougang set up
a 10 m.p./a. steel plant with five
300 t LD (BOF) converters in
two phases. Primetals supplied
dry dedusting systems tomeet the strict environmental
standards. A highlight wasa special control system for
management of simultaneousgas recovery on three converters
into one single gasholder.

US Steel made a big
modernization of its steel shop
No. 1 in Kosice (Slovakia). Of thethree original converters one
was removed. The other twolines were completely revamped
including new suppressed
combustion system cooling stackfor heat recovery, dry dedusting
systems and the required
secondary dedusting systems.
In 2013 a gas recovery system
was added.

In order to meet the ever-increasing
municipal emission limits in the
primary offgas during converter
steelmaking, SSAB (Oxelösund,Sweden) installed the latest wetdedusting system (WDS) from
Primetals Technologies. The original
Baumco scrubber tower wasconverted to a Primetals CONE
scrubber system, which represented
the best solution in terms ofinvestment costs, required installation
time and dedusting performance.
The plant was successfully put in
operation in December 2015.

In order to reduce the pollution
situation and to reduce
operational downtimes causedby heavy emissions in the steel
shop in Cherepovets, Severstal
decided to install a secondary
dedusting system in theconverter steel shop.

Although equipped with asuppressed combustion primarydedusting system, the steel shopof TATA Steel Port Talbot (former
CORUS), did not feature a gas
recovery system until Primetals
was awarded the contract toinstall the energy recovery
system. Primetals and TATA Port
Talbot jointly developed the
project according to the highest
safety standards in Europe andwith smallest impact on ongoingplant operation.

TECHNICAL DATATECHNICAL DATATECHNICAL DATATECHNICAL DATATECHNICAL DATATECHNICAL DATA

No of converters:
2 pcs

No of converters:
5 pcs

No of converters:
2 pcs

No of converters:
1 pc

No of converters:
3 pcs

No of converters:
2 pcs

Converter size:
330 tons

Converter size:
300 tons

Converter size:
180 tons

Converter size:
210 tons

Total suction volume:
2.500.000

Converter size:
300 tons

Converter offgas flow:
150.000 Nm³/h

Converter offgas flow:
150.000 Nm³/h

Converter offgas flow:
105.000 Nm³/h

Converter offgas flow:
100.000 Nm³/h

Filter type:Bag filter

Gasholder volume:
80.000 m3

Dust content of cleaned gas:
20 mg/Nm³

Dust content of cleaned gas:
20 mg/Nm³

Dust content of cleaned gas:
20 mg/Nm³

Dust content of cleaned gas:
30 mg/Nm³

Total surface:
28.100Primetals designed and supplied
the retrofit system in the existing
steel shop for the three 380 t LD(BOF) converters. The system
was commissioned successfullyin 2013.

GAS RECOVERYSYSTEM
FOR LD (BOF)

Converter tap weight:
380 tons

30

31

Primetals Technologies Austria GmbHA Group Company of Mitsubishi Heavy Industries

Turmstrasse 44
4031 Linz
Austriaprimetals.com
Brochure No.: T02-2-N193-L4-P-V5-EN
Printed in Austria© 2023 Primetals Technologies Ltd. All rights reserved
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in this document contains merely general descriptions or
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contract or an offer to enter into a contract to any extent and is
not binding upon the parties. Any obligation to provide and/or
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These estimates and assumptions have to be analyzed on acase-to-case basis and might change as a result of further
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