iron steel industry co2 - ukccsrc
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Sahaviriya Steel Industries UK
Iron & Steel Industry COIron & Steel Industry CO 22
CaptureCapture
Recent History of the Teesside PlantRecent History of the Teesside Plant
Iron & Steel making facility (Tata Steel) ceased production in February 2010, ending 160 years of steel making in the area
Wharf operations & coke making continued, but the rest of the facility was mothballed
SSI became owners of the facility on 25 March 2011
SSI UK currently directly employs c1800 employees
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SSI UK LocationSSI UK Location
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SSI UK SSI UK ––
Plant LayoutPlant Layout
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STEEL HOUSE
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CLEVELANDWORKS
LACKENBY WORKS
REDCAR WORKS
B.O.C.
River Tees
Ore Terminal
Coke Ovens
Blast Furnace
Sinter Plant
Steelmaking/Casting
South Bank Coke Ovens
Ownership retained by Tata
The ProcessThe Process
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Iron making Steelmaking
How is iron and steel made?
Coke Ovens
Sinter Plant
Redcar Blast Furnace
BOSPlant
Slab Casters
Redundant Bloom Caster
The Process The Process
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RAW MATERIALSDeep water berth dredged to 17.0mtrsVessels range from coasters to large capes
REDCAR COKE OVENSTwo batteries of 66 ovens/battery. 5.36m high. 27.3t coal/ovenCoking rate of 25.4 mm/h with a charge to push cycle time of 18h
SOUTH BANK COKE OVENSTwo batteries of 44 ovens/battery. 5.36m high. 25.5t coal/ovenCoking rate of 20.5 mm/h with a charge to push cycle time of
22h.
SINTER PLANT4.2m wide with 336m²
suction area
Annual production 4.0 Mt
The ProcessThe Process‐‐
IronmakingIronmaking
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Iron is produced at the Teesside site from a
single >10,000 tonnes/ day
Blast furnace
This unit has been upgraded with the addition of the
Pulverised Coal Injection
The Liquid iron product from this process is
transferred to the Basic Oxygen steelmaking
Plant by Torpedo ladles
Process Route Process Route Primary Steelmaking Primary Steelmaking ‐‐
Capacity 4.88mtpa (2 Vessels)Capacity 4.88mtpa (2 Vessels)
3 x 250 tonne convertersTypical charge
225 tonnes liquid iron and 45 tonnes scrapAverage tapped weight 240 tonnesVessels equipped with
Bath agitation
Smart lances
Sub‐lance (data collection)
Slag splashing and washing
Primary Steelmaking
Process Route Process Route ‐‐
Slab CastingSlab Casting Capacity Capacity ‐‐
3.6Mtpa (Grade/Mix dependant)3.6Mtpa (Grade/Mix dependant)
Two twin strand castersTwin tundishes9.8 m radiusSizes
225 & 250 mm thick
1000‐2030 mm wide
Slab Casting
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Tundish
change practice
Tundish
Tube Changer
Full slab tracking
Computer logging
SSI UK SSI UK ––
Restart of OperationsRestart of Operations
Major work programme and capital investment to bring the plant back into operation
Blast furnace restarted 15th
April 2012
First slab produced 18th
April 2012
First shipment left for SSI‐
Thailand 15th
May 2012
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Coke OvensCoke Ovens
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Process•The coal is loaded into the oven from the top.
•The oven is then heated from below driving off the volatile gasses.
•At the end of the heating phase the doors are opened and the Coke is then “pushed” out into the coke car.
•The coke car is then taken to the quench tower where the coke is quenched.
•The gas produced in the process is used around the site as a fuel source
Typical gas make up : -
CARBON MONOXIDE 6%
CARBON DIOXIDE 2%
HYDROGEN 62%
NITROGEN 2%
METHANE 26%
Blast Furnace ProcessBlast Furnace Process
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Process•Coke and iron ore are charged in layers at the top of the furnace.•Hot blast (Compressed air at @ 1400 ºC) is blown in at the bottom of the furnace causing a melting zone.•In this zone the coke breaks down creating CO which causes the final reduction of the iron ore.•As the blast passes up through the burden (solid material in the blast furnace) it reduces the burden travelling down the furnace.•At the top of the burden the compressed gasses, Blast Furnace Gas (BFG) is taken away for cleaning gad use in the process.
•The typical make up of the gas is : -CARBON MONOXIDE 23% CARBON DIOXIDE 21%HYDROGEN 2%NITROGEN 54%
PCI enhancement to Blast FurnacePCI enhancement to Blast Furnace
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PCI reduces the amount of coal used in the production of each unit of hot iron and enables higher oxygen enrichment thus reducing Nitrogen in the Gas produced.
BOS ProcessBOS Process
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Process•The vessel is charged with scrap @ 50 tonne.•The hot metal is then charged over the top and the vessel is raised to the vertical.•The oxygen lance is lowered and the “blow” started.•Pure oxygen is blown at the molten iron at supersonic speeds, causing the carbon to be freed to CO.•After the Carbon is removed from the Iron producing Steel the blow is stopped and the vessel is tilted and the steel “Tapped” off.•Typical make up of the gas coming of the BOS vessels is: -
Carbon monoxide 50 – 70%Carbon dioxide 10 – 20%Oxygen 0.5 – 2%Nitrogen and others 15 – 20%
BFG volumesBFG volumes
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Fig 1
Fig 2
Fig 1 Shows the fluctuations in BFG volume over 2 hours from 0900 4th March 2014. The range is 400kNm^3/h to 600kNm^3/h.
Fig 2 Shows the fluctuations in BFG volume over one month (Feb 14). The range is 400kNm^3/h to 630kNm^3/h. The figures lower than 400kNm^3/h are the blast shutting down and restarting.
BFG compositionsBFG compositions
06 September 2011 16
Fig 3
Fig 4
Fig 3 Shows the gas composition fluctuations of Hydrogen, CO2 and CO in the BFG over 2 hours.
Fig 4 Shows the gas composition fluctuations of Hydrogen, CO2 and CO in the BFG over one month.
BOS Gas BOS Gas
06 September 2011 17
Fig 5
Fig 5 Shows the change in make up of gas over the blow cycle which is approximately 16 minutes long.The blows are on average done twice an hour.Due to the oxygen content at the start and end of the blow the gas is flared for safety in a BOS gas collection process.
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