Coal Prep and Injection for Blast Furnaces Brochure

Highest CCoke SSubstitutionFlexibilizing FFuel MMixBoosting PProductivityFull PPlant SSolutionsTime ffor aa CChangeIron & steelworks managers face an enormous chal-lenge by volatile prices for raw materials and energy,by environmental obligations, such as, resources con-servation, carbon footprint, emissions trading etc. Thecrucial lynchpin in economically governing the busi-ness simply asks for bringing out the utmost in themeans available: fuel efficient operation and multipleutilization of all energy in the system. The sole solutionreads: detection and capitalization of the hiddenpotentials throughout the entire process. Improve yourdegree of efficiencyConvincing AArguments: Reduce CCosts aand CCarbon FFootprintDevelopment of reductant mixes per tonne of hot metalshows that blast furnaces (BF) are mainly fueled withcoke and coal, the latter varying by country. The useof oil and natural gas is predominantly limited to afew countries, i.e., Russia, Ukraine, NAFTA, wherethese are available at low cost. In the EU, oil and gashave to be highly payed for.Evaluation of energy prices shows that coke, too, rangesat high levels. Throughout the last 2 years, e.g., averagecoke price volatility was 17 %/a. Today, coke amountsto 11 % of the total costs for 1 t of steel. Its consump-tion decreased and this trend is expected to continue.Adding VValue bby IIncreasing PPCI RRatesJust a simple sample calculation assesses the potential hid-den in your plant: BF require typical coke rates of 500kg/tHM. Substitution by PC helps to drastically lower thisconsumption. Characteristic replacement ratios from 0.85to 0.95 depend on coal quality. PCI rates of 200 kg/tHMare just like that practicable, earning you a little fortune of180 kg coke/tHM plus the carbon footprint involved.What is more, state-of-the-art technology by Küttnerenables you to markedly increase PCI rates and ben-efit from lower raw material costs and higher productivity.How about reaching out for even higher injectionrates? Make it reality with Küttner as your reliable part-ner PCI has long been believed to be limited to ratesof well below 200 kg/tHM. Küttner PCI applicationsgive evidence that this is, by far, not the end of thestory, as the optimum BF working range shows.IT PAYS TO BUY PCI6330 eCOAL PREP & INJECTIONfor Blast FurnacesSOLUTIONS CAPITALIZING THE HIDDEN POTENTIAL OF BFEfficient PCI is obtained by convenient coal pretreat-ment as far as moisture and grain size are con-cerned, appropriate mixing of coal and hot blast,uniform distribution across all tuyeres, low nitrogeninput into the BF, and by maximizing the retentiontime of the coal in the tuyere. To reach this aim,Küttner provides you with both, the necessary equip-ment and process know how.GGrriinnddiinngg aanndd DDrryyiinnggProper coal grinding and drying is an indispensa-ble pre-requisite for exploiting the full potential ofPCI (pulverized coal injection). Moisture has to beremoved and grain size must be optimised to obtaina material well-suited for transport and chemicalreactions. Both happens simultaneously in the com-pact grinding and drying (GAD) plant, also achiev-ing a high degree of intermingling. PC is separatedin a filter and ready to be injected into the BF.Küttner places great emphasis on a design resistantto explosion, wear and corrosion. Another sustain-able advantage is the possible re-use of hot stoveoff-gas for coal drying.Always struggling to find the very solution which fitsyour requirements best, we choose between a vari-ety of vertical roller mills - hence, you can get allyour equipment at one stop.VVaarriioouuss LLaayyoouuttss ooff PPCC IInnjjeeccttiioonnKüttner offers 3 different layouts to serve customers´needs:• PCI with static distributor, our minimum-cost vari-ant, with normal transport gas loading and nor-mal accuracy for mid-distance transport;• PCI with distribution vessel for long distances and• PCI with lock hopper for short distances.The first two design comprise intermediate hoppers,whereas the latter two feature high transport gasloading and flexibility as well as single-line regula-tion. No matter whether equal distribution or individ-ual flow control is preferred, every design is individ-ually tailored to customers´ requirements. Integrationinto existing plants is, of course, possible.Injecting pulverized coal (PC) into blast furnaces (BF)is an effective process lowering the consumption ofexpensive fuels. Increasing injection rate gains higherproductivity and envirofriendly and ecofriendly opera-tion. Chosing the best available technology furtherhelps to profitably exploit latent potentials.OXYCOAL+ / COAL PREHEATING: PROVENMEASURES TO STEP UP PCI PERFORMANCEUUllttrraa-DDeennssee FFllooww PPrriinncciipplleePCI in accordance with Küttner´s ultra-dense flow prin-ciple offers a series of convincing advantages:• markedly increased transport gas loading,• low N2 input into BF,• low wear of piping.You have already PCI? Well done Anyway, you havenot yet reached the top of the flag pole We can pro-vide you with another two add-ons tuning injection ratesand making the most out of pulverized coal injection.CCooaall PPrreehheeaattiinnggInjecting pulverized coal into the BF is the more effec-tive for productivity, the higher the carbon burn-out atthe end of the raceway. Coal preheating promotes thisburn-out as it drastically reduces the time required forheating up the PC from ambient to gasification temper-ature. This is ascribed to two facts: coal was driedbefore entering the BF and pyrolysis has already startedoutside the furnace.In order to make use of this potential, Küttner offers aspecial heat exchanger. Furthermore, why not optimiz-ing your overall energy budget by recycling the wasteheat from other aggregates for this purpose?OOxxyyccooaall+is a registered trademark by Küttner representing theingenious technology stepping up PCI and boosting BFproductivity. The basic idea is to coaxially inject part ofthe oxygen from the cold blast together with the coal.A coaxial lance serves for the transport of both, coal inthe inner and oxygen in the outer channel, to the race-way, where it is blown in at high pressure.Oxycoal+ benefits are threefold: it increases injectionrate without increasing oxygen rates, lowers ignitiontemperature and improves the process. Oxygen shroud-ing of the pulverized coal positively effects the temper-ature difference in the tuyere and optimizes the process-es in the raceway.Why not asking our experts for a model calculationusing your operating parameters? This will disclose anyhidden potential for PCI ready to be exploited in yourblast furnace We can also figure out further potentialsand payback. You will be pleased to hear thatOxycoal+ demonstrably succeeds in stepping up PCIrates by 20 - 25 kg/t hot metal.Ultra-dense flowprincipleFlow principleswith varyingdensityImprovement in the BF racewayobtained by PCI & OxyCoal+at Dillinger HütteAG, GermanyPreheating ofcoal with low-temperautrewaste heatCUSTOMISED SOLUTIONSGIVING A BOOST TO BFVASD, Austria, invested in PCI implementation simul-taneously supplying two BF with only one line. Theychose GAD plus PCI design with static distributor.HKM, Duisburg, Germany, invested in GAD plusPCI with distribution vessel. This line set world recordin maintaining ultra-dense flow of 80 kg PC per kgof transport gas and across a distance of not lessthan 850 mChina Steel Corp., Taiwan, retrofitted the old PCIsupplying their BF No. 4 from dilute to ultra-denseflow system. They decided in favour of PCI designwith static distributor. Compared to former figures,they increased coal injection rates by 35 kg/t of hotmetal. Advanced injection rate control representsanother benefit obtained by this revamp.TKSE, Germany, BF 1 is another world record hold-er in Küttner PCI technology: Having been employ-ing PCI with lock hopper since 1987, they provelong lasting continuity of this investment The stationwas extended by the then new add-ons Oxycoal+(1990) and Coal Preheating (2000). GAD PPros aat oone gglance• Recycling of waste gas to drying energy• Dew point control• GAD operation under inert conditionsPCI PPros aat oone gglance• High retention time in tuyere• Flow accuracy & uniform distributionacross tuyeres• Low gas consumption• Low N2 input into BF• Ultra-dense flow• Low wear of pipingOverall PPros aat oone gglance• All equipment at one stop• Highest flexibility• Added value by individual service• Entire process control available inhouse• Corresponding materials handlingHKM,GermanyVertical rollermill in coalGAD plantCSC, TTaiwaneffectivelytuned theirBF No. 4 byswitching toUltra-DenseFlowThyssenKruppSteel EEurope,GermanyHeatexchangerfor preheatingpulverizedcoal at BF 1Highest CCoke SSubstitutionFlexibilizing FFuel MMixBoosting PProductivityFull PPlant SSolutionsTime ffor aa CChangeIron & steelworks managers face an enormous chal-lenge by volatile prices for raw materials and energy,by environmental obligations, such as, resources con-servation, carbon footprint, emissions trading etc. Thecrucial lynchpin in economically governing the busi-ness simply asks for bringing out the utmost in themeans available: fuel efficient operation and multipleutilization of all energy in the system. The sole solutionreads: detection and capitalization of the hiddenpotentials throughout the entire process. Improve yourdegree of efficiencyConvincing AArguments: Reduce CCosts aand CCarbon FFootprintDevelopment of reductant mixes per tonne of hot metalshows that blast furnaces (BF) are mainly fueled withcoke and coal, the latter varying by country. The useof oil and natural gas is predominantly limited to afew countries, i.e., Russia, Ukraine, NAFTA, wherethese are available at low cost. In the EU, oil and gashave to be highly payed for.Evaluation of energy prices shows that coke, too, rangesat high levels. Throughout the last 2 years, e.g., averagecoke price volatility was 17 %/a. Today, coke amountsto 11 % of the total costs for 1 t of steel. Its consump-tion decreased and this trend is expected to continue.Adding VValue bby IIncreasing PPCI RRatesJust a simple sample calculation assesses the potential hid-den in your plant: BF require typical coke rates of 500kg/tHM. Substitution by PC helps to drastically lower thisconsumption. Characteristic replacement ratios from 0.85to 0.95 depend on coal quality. PCI rates of 200 kg/tHMare just like that practicable, earning you a little fortune of180 kg coke/tHM plus the carbon footprint involved.What is more, state-of-the-art technology by Küttnerenables you to markedly increase PCI rates and ben-efit from lower raw material costs and higher productivity.How about reaching out for even higher injectionrates? Make it reality with Küttner as your reliable part-ner PCI has long been believed to be limited to ratesof well below 200 kg/tHM. Küttner PCI applicationsgive evidence that this is, by far, not the end of thestory, as the optimum BF working range shows.IT PAYS TO BUY PCI6330 eCOAL PREP & INJECTIONfor Blast FurnacesA globally acting group of companies has developedfrom the engineering company once founded in 1949by Dr. Carl Küttner. Nowadays, their main focus is onbuilding turn-key plants for the metal producing and pro-cessing industry, especially in the fields of process andsmelting technology as well as of materials handling.Complying with the strong demand for holistic solutionsby the ferrous industry, all comprehensive experiencegained in the numerous projects in the field of iron andsteel metallurgy is concentrated in our PCI team. Wecommit ourselves to providing our customers with integrat-ed solutions - all available at one stop.Küttner is supplier of world leading technology for theinjection of pulverized coal into the blast furnace. Weoffer the whole range from coal grinding and drying,preheating up to injection including our innovativeinhouse developments ultra-dense flow PCI, Oxycoal+,Preheating. Equipment and technology optionally extend-ed on materials handling is always individually tailoredto fully meet the distinct requirements of our customer - aswe are well-known for.You are not sure whether the investment under consider-ation will be reasonable for your company? You want tolearn more about the Pros & Cons? You want to knowwhether and where latent capacity exists ready to beexploited? Backed up by long-lasting experience in iron& steelmaking and continuously updated by never stoplearning, Küttner is also your partner should you be look-ing for assessment of the hidden potential in your plantsand processes.Our scope of services further comprises the design andengineering, delivery, assembly, as well as the start-upand commissioning of the entire plant including controlsystem and data processing. Küttner is also your essentialally in modernisation, revamps and upgrades. Partneringwith Küttner means relying on an experienced team ofexperts combining process know-how with sophisticatedequipment design.Worldwide personnel of Küttner-Group counts more than550 employees, their owners themselves being activewithin the company.KÜTTNER GMBH & CO. KG6330 eKüttner GmbH & Co. KG Tel. +49 (0)201 7293 0 team-ht1@kuettner.comAlfredstr. 28, 45130 Essen Fax +49 (0)201 7293 107 www.kuettner.comOxycoal+ is a registered trademark of Küttner GmbH & Co. KG, Essen, Germany