BAT Guide for electric arc furnace iron & steel installations

236 Pages·2013·4.3 MB·English

Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

BAT Guide for electric arc furnace
iron & steel installations
Project TR-2008-IB-EN-03
Mission no: 2.1.4.c.3

Prepared by:
Jesús Ángel Ocio
Hipólito Bilbao
José Luis Gayo
Nikolás García
Cesar Seoánez
Iron & Steel Producers Association
Serhat Karadayı (Asil Çelik Sanayi ve
Ticaret A.Ş.)
Muzaffer Demir
Mehmet Yayla
Yavuz Yücekutlu
Dinçer Karadavut
Betül Keskin Çatal
Zerrin Leblebici
Ece Tok
Şaziye Savaş
Özlem Gülay
Önder Gürpınar

October 2012
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

Contents
0 FOREWORD ............................................................................................................................ 12
1 INTRODUCTION. ..................................................................................................................... 14
1.1 IMPLEMENTATION OF THE DIRECTIVE ON INDUSTRIAL EMISSIONS IN THE SECTOR OF STEEL
PRODUCTION IN ELECTRIC ARC FURNACE ................................................................................. 14
1.2 OVERVIEW OF THE SITUATION OF THE SECTOR IN TURKEY ...................................................... 14
1.2.1 Current Situation ............................................................................................................ 14
1.2.2 Iron and Steel Production Processes............................................................................... 17
1.2.3 The Role Of Steel Sector in Turkish Economy .............................................................. 18
1.3 RELEVANT ENVIRONMENTAL IMPACTS OF THE SECTOR. .......................................................... 18
2 PRODUCTION PROCESSES AND TECHNIQUES ........................................................................ 21
2.1 STORAGE AND HANDLING OF RAW MATERIALS ....................................................................... 21
2.2 SCRAP CHARGING ...................................................................................................................... 23
2.3 ARC FURNACE MELTING AND REFINING. .................................................................................. 23
2.4 SECONDARY STEEL MAKING ...................................................................................................... 24
2.5 CASTING ..................................................................................................................................... 26
2.6 SLAG TREATMENT, LANDFILLS ................................................................................................... 30
2.7 HOT ROLLING MILLS .................................................................................................................. 31
2.7.1 Process Overview ........................................................................................................... 31
2.7.2 Surface Rectification and Conditioning of Input ............................................................ 42
2.7.3 Reheating- and Heat Treatment Furnaces ...................................................................... 43
2.7.4 Descaling ........................................................................................................................ 45
2.7.5 Edging ............................................................................................................................ 46
2.7.6 Roughing ........................................................................................................................ 46
2.7.7 Strip Rolling/Finishing Train ......................................................................................... 47
2.7.8 Rod Rolling/Finishing Train .......................................................................................... 47
2.7.9 Plate Rolling ................................................................................................................... 48
2.7.10 Transport of Roll Stock between Rolling Stands ........................................................... 48
2.7.11 Cooling Lines ................................................................................................................. 48
2.7.12 Sheet and Plate Production ............................................................................................. 49
2.7.13 Plate Heat Treatment ...................................................................................................... 49
2.7.14 Roll Shop ........................................................................................................................ 49
2.8 Cold Rolling Mills ....................................................................................................................... 50
2.8.1 Process Overview ........................................................................................................... 50
2.8.2 Pickling of Low Alloy and Alloy HR Steel .................................................................... 52
2.8.3 Initial Annealing and Pickling of High Alloy HR Steel ................................................. 53
2.8.4 Cold Rolling of the Pickled Hot Rolled Strip ................................................................. 54
2.8.5 Annealing of Low Alloy and Alloy Steel ....................................................................... 57
2.8.6 Final annealing and Pickling of High Alloy Steel .......................................................... 59
2.8.7 Tempering of Cold Rolled Strip ..................................................................................... 60
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

2.8.8 Finishing ......................................................................................................................... 61
2.8.9 Roll Shop ........................................................................................................................ 62
2.8.10 Wire drawing plants ....................................................................................................... 63
2.9 Continuous Hot Dip Coating Process ......................................................................................... 70
2.9.1 Galvanizing of Sheet (Zinc and Zinc Alloy Coating) ..................................................... 71
3 PRESENT EMISSION LEVELS AND RAW MATERIALS AND ENERGY CONSUMPTION ............... 82
3.1 Present consumption and emission levels ................................................................................ 82
3.1.1 Mass stream overview and input/output data ................................................................. 82
3.1.2 Environmental issues for electric arc furnace steelmaking process ............................... 86
3.2 Emissions to air .......................................................................................................................... 86
3.2.1 Primary and secondary emissions and treatment ............................................................ 86
3.2.2 Emissions from secondary metallurgy processes and continuous casting ...................... 91
3.2.3 Emissions from scrap preheating.................................................................................... 92
3.2.4 Emissions from slag processing ..................................................................................... 92
3.3 Emissions to water .................................................................................................................... 92
3.3.1 Waste water .................................................................................................................... 92
3.4 Solid waste and by-products. Landfills ...................................................................................... 95
3.4.1 Process residues such as wastes and by-products ........................................................... 95
3.4.2 Slags from production of carbon steel/low alloyed steel/high alloyed steel ................... 95
3.4.3 Dusts from off-gas treatment .......................................................................................... 97
3.4.4 Refractory bricks ............................................................................................................ 99
3.5 Noise emissions ......................................................................................................................... 99
3.5.1 Techniques concerning noise aspects ............................................................................. 99
3.5.2 Aspects of relevant noise sources ................................................................................. 100
3.5.3 Main noise sources ....................................................................................................... 101
3.6 Soil contamination ................................................................................................................... 103
3.6.1 Storage and handling of input materials ....................................................................... 103
3.6.2 Drainage water from the scrapyard .............................................................................. 104
3.7 Raw materials consumption .................................................................................................... 104
3.8 Energy consumption ................................................................................................................ 105
4 BATs FOR THE PRODUCTION PROCESSES ............................................................................ 106
4.1 General considerations ............................................................................................................ 106
4.1.1 Techniques to consider in the determination of BAT and BAT conclusions ............... 106
4.2 EAF process optimisation ........................................................................................................ 109
4.3 BATS ON AIR EMISSIONS ......................................................................................................... 112
4.3.1 Advanced emission collection systems ........................................................................ 112
4.3.2 Abatement techniques for primary and secondary emissions to air from electric arc
furnaces .............................................................................................................................. 115
4.3.3 Reducing of dust emissions from slag processing ........................................................ 127
4.3.4 Adopted BAT Conclusions .......................................................................................... 129
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

4.4 BATS ON EMISSIONS TO WATER AND WASTEWATER ............................................................. 134
4.4.1 Treatment of waste water from continuous casting ...................................................... 134
4.4.2 Closed loop water cooling system ................................................................................ 135
4.4.3 Adopted BAT conclusions ........................................................................................... 136
4.5 BATS ON SOLID WASTE AND BY-PRODUCTS. ........................................................................... 137
4.5.1 EAF dust processing for the recovery of heavy metals ................................................ 137
4.5.2 EAF slag processing ..................................................................................................... 139
4.5.3 Treatment of high alloyed and stainless steel EAF slags ............................................. 141
4.5.4 Adopted BAT conclusions ........................................................................................... 143
4.6 BATS ON RAW MATERIALS AND FUEL AND ENERGY CONSUMPTION ..................................... 144
4.6.1 Scrap preheating ........................................................................................................... 144
4.6.2 Near net shape strip casting .......................................................................................... 151
4.6.3 Adopted BAT conclusions ........................................................................................... 151
4.7 BATS ON NOISE AND VIBRATIONS ........................................................................................... 156
4.7.1 Techniques to prevent noise emissions ........................................................................ 156
4.7.2 Adopted BAT conclusions ........................................................................................... 157
4.8 BATS ON SOIL AND GROUNDWATER POLLUTION PREVENTION ............................................. 159
4.9 BAT CONCLUSIONS ON ENVIRONMENTAL MANAGEMENT AND MONITORING ..................... 159
4.10 BAT CONCLUSIONS ON DECOMISSIONING .............................................................................. 162
4.11 BATS ON PROCESSES ASOCIATED TO EAF: HOT ROLLING, COLD ROLLING, WIRE DRAWING
PLANTS AND GALVANIZING OF SHEET .................................................................................... 163
4.11.1 Hot Rolling Mill ........................................................................................................... 163
4.11.2 Cold rolling mill ........................................................................................................... 169
4.11.3 Wire drawing plants ..................................................................................................... 174
4.11.4 Galvanizing of Sheet .................................................................................................... 176
5 EMISSIONS CONTROL AND MONITORING. .......................................................................... 179
5.1 General principles of emissions monitoring. ........................................................................... 180
5.2 Monitoring of emissions to the air. ......................................................................................... 184
5.2.1 Emissions to air. ........................................................................................................... 185
5.2.2 Ambient air monitoring ................................................................................................ 186
5.2.3 Air dispersion modelling studies. ................................................................................. 187
5.3 Monitoring of emissions to water. .......................................................................................... 188
5.4 Waste. ...................................................................................................................................... 189
5.5 Soil and groundwater. ............................................................................................................. 190
5.6 Noise. ....................................................................................................................................... 190
5.7 Monitoring standards .............................................................................................................. 191
5.8 Reporting on environmental monitoring and control ............................................................. 192
5.8.1 Monitoring of process variables and environmental performance indicators ............... 192
5.8.2 E-PRTR ........................................................................................................................ 193
5.8.3 Reporting monitoring ................................................................................................... 196
6 EMERGING TECHNIQUES...................................................................................................... 201
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

6.1.1 CO2 capture and storage .............................................................................................. 201
6.1.2 Ceramic filters for the abatement of both particles and nitrogen oxides from gas streams
203
6.1.3 Contiarc furnace ........................................................................................................... 205
6.1.4 Intermetallic bag filter to minimise emissions of dust, PCDD/F and heavy metals ..... 206
6.1.5 Recovery of old tyres in EAF ....................................................................................... 206
6.1.6 Recycling of (BOF and EAF) slags as a flux agent in electric steelmaking ................. 207
7 Bibliography ......................................................................................................................... 209
ANNEX 1. CHECK-LISTS TO BE USED IN THE ASSESSMENT OF THE PERMIT APPLICATION ....... 213
ANNEX 2. BEST AVAILABLE TECHNIQUES (BATS) ASSOCIATED EMISSION LEVELS .................... 217
ANNEX 3. EU REGULATION 333/2011 AFFECTING SCRAP METAL MANAGEMENT ................... 225

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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

GLOSSARY AND ABBREVIATIONS

UNITS
Term Meaning

kWh kilowatt-hours
billion thousand million (109)
°C degree Celsius
cm centimetre
d day
g gram
GWg gigawatt hours
h hour
hPa hectopascals
J joule
K kelvin (0 °C = 273.15 K)
kcal kilocalorie (1 kcal = 4.19 kJ)
kW kilowatt
kWh kilowatt-hour (1 kWh = 3.6 MJ)
m metre
Mt megatonne
MW megawatts electric (energy)
c
MW megawatt
Nm3 normal cubic metre (at 101.325 kPa, 273 K)
ppb parts per billion (1 ppb = 10-9)
ppm parts per million (1 ppm = 10-6)
ppmv parts per million (by volume)
s second
t metric tonne (1000 kg or 106 g)
t/d tonnes per day
trillion million million (1012)
t/yr tonnes per year
vol-% percentage by volume
wt-% percentage by weight
W watt (1 W = 1 J/s)
yr year
μg microgram
μm micrometre (1 μm = 10-6 m)
μs microsiemens
Ω ohm, unit of electrical resistance

LIST OF CHEMICAL ELEMENTS
SYMBOL NAME
Al aluminium
As arsenic
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

C carbon
Ca calcium
Cd cadmium
Cl chlorine
Cm curium
Co cobalt
Cr chromium
Cu copper
F fluorine
Fe iron
H hydrogen
Hg mercury
K Potassium
Mg Magnesium
Mn Manganese
Mo Molybdenum
N Nitrogen
Na Sodium
Ni Nickel
O Oxygen
P Phosphorous
Pb lead
Pt platinum
S sulphur
Sb antimony
Se selenium
Si silicon
Sn tin
Te tellurium
Ti titanium
V vanadium
W tungsten
Zn zinc

ACRONYMS AND DEFINITIONS

Acronym Definition
AC Alternating current
AISI American Iron and Steel Institute
AOD Argon oxygen decarburisation
AOX Absorbable organically bound halogens in water
AS Activated sludge
ASK Ammoniumsulphide Kreislaufwäscher
BaP Benzo(a)pyrene
BF Blast furnace
BOD Biochemical oxygen demand
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

BOF Basic oxygen furnace
Borneff 6 Sum of six PAH (Fluoranthene, Benzo[b]fluoranthene,
Benzo[k]fluoranthene,Benzo[a]pyrene, Indeno[1,2,3-cd]pyrene
and Benzo[g,h,i]perylene)
Bq Bequerel
BTX Benzene, Toluene, Xylene
c. circa
CAS Chemical abstracts service
CAS-OB Composition adjustment by sealed argon bubbling
CCF Cyclone converter furnace
CCGT Combined cycle gas turbine
CCM Continuous casting machine
CCPP Combined cycle power plant
CCS Carbon capture and storage
CDQ Coke dry quenching
CEN European committee for standardisation
CFD Computational fluid dynamics
CHP Combined heat and power
COD Chemical oxygen demand
COG Coke oven gas
COS Carbon oxysulphide
CRI Coke reactivity index
CSQ Coke stabilisation quenching
CSR Coke strength after reaction
CV Calorific value
DAV Daily average
dBA A-weighted decibels
DC Direct current
DCI Direct carbon injection
DH Dortmund-Hörder
Diffuse emission Diffuse emissions occur during regular operation such as coal and
coke handling, transport of coal and coke, coal blending beds,
ascension pipes, coke pushing, coke quenching; if not captured
they can be released by the roof, roofhatch, window or from
stored material. Minimisation is possible only by prevention
and/or further treatment after transferring them into ducted
emissions (i.e. by capturing them)
DIOS Direct iron ore smelting reduction
DOC Dissolved organic carbon
DR Direct reduction
DRI Direct reduced iron
DSC Direct strip casting
DSI Direct sample induction
EAF Electric arc furnace
ECO Economiser
ECSC European Union for Coal and Steel
ECU European Currency Unit
EINECS European inventory of existing commercial chemical substances
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

ELPI Electrical low pressure impactor
ELV Emission limit value
EMS Environmental management system
EMAS Eco-Management and Audit Scheme
EN ISO 14001 European norm (EN) published by the International Organisation
for Standardisation (ISO) concerning environmental management
standards.
EOF Energy optimised furnace
EOS Emission optimised sintering
EPA Environmental Protection Agency (US)
ESP Electrostatic precipitator
ESCS Electrostatic space cleaner super
ETP Electrostatic tar precipitator
FF Fabric filter
Fine dust Fine dust in the sense of this BREF shall mean fine particulate
matter smaller than 10 micrometer
Fugitive emissions Fugitive emissions happen during irregular operation from
leakages at the battery, e.g. because of leakage of vessels, oven
doors, flanges etc. or at the byproduct plant. For minimisation the
first option is prevention by good maintenance. PAH compounds,
like benzo(a)pyrene (BaP), and benzene play an important role
with regard to fugitive emissions
FTIR Fourier transform infrared spectroscopy
GSA Gas suspension absorber
HBI Hot briquetted Iron
HCB Hexachlorobenzene
HHAV Half-hourly average
HM Hot metal
hPa Hectopascals
IISI International Iron and Steel Institute
I-TEQ International Toxicity Equivalents
IUPAC International Union of Pure and Applied Chemistry
KOBM Klöckner Oxygen Blowing Maximillanshuette
kW Kilowatt
LD Linz-Donawitz
LD-AC Linz-Donawitz-Arbed-CRM process
LEEP Low emission and energy optimised sintering process
Leq Equivalent Continuous Sound Level
LIBS Laser-induced breakdown spectroscopy
LIDAR Light detection and ranging
LPG Liquefied petroleum gas
LS Liquid steel
LTE lance tuyère equilibrium
L weighted sound power level
WA
LWS Loire-Wendel-Sprunck process
MEA Monoethanolamine
MEEP Moving electrodes Electrostatic Precipitator
MEROS Maximised emission reduction of sintering
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Eşleştirme Projesi TR 08 IB EN 03
IPPC – Entegre Kirlilik Önleme ve Kontrol
T.C. Çevre ve Şehircilik Bakanlığı

MHF Multiple hearth furnace
MLSS Mixed liquor suspended solids
NG Natural gas
NMVOC Non-methane volatile organic compounds
OBM Oxygen-bottom Maxhuette process
OCP Open circuit process
PAH Polycyclic aromatic hydrocarbons
PCB Polychlorinated biphenyls
PCDD/F Polychlorinated dibenzo-p-dioxins/dibenyofurans
PCI Pulverised coal injection
PLC Programmable Logic Controllers
PM , PM Particulate matter smaller than 10 or 2.5 micrometer according to
10 2,5
the definition of the Directive 2008/50/EC on air quality
POM Polycyclic organic matter
POP5 Persistent organic pollutants
PTFE Polytetrafluoroethylene
Q-BOP Oxygen-bottom Maxhuette process
RAC Regenerative activated carbon
RAFT Raceway adiabatic flame temperature
RDM Reverse dispersion modelling
RH Ruhrstahl-Heraeus
RHF Rotary hearth furnace
SCN Thiocyanate
SCOPE 21 Super coke oven for productivity and environment enhancement
in the 21st century
SCR Selective catalytic reduction
SI Shatter index
Split view Where a ‘split view’ is explicitly mentioned it means that there
was not a consensus in the Technical Working Group elaborating
the corresponding BREF document on the best available
techniques and associated emission/consumption levels
presented.
SR Smelting reduction
SRF Smelting reduction furnace
SS Suspended solids
STP Standard temperature and pressure
TEA Triethanolamine
TEQ Toxic equivalent quantity
TEF Toxic equivalent factor
TBM Thyssen blowing metallurgy process
TOC Total organic carbon
TWG Technical working group
UHP Ultra high power operation
ULCOS Ultra Low CO2 Steelmaking. EC funding research programme to
reduce CO2 emissions from steelmaking
VDI Verein Deutscher Ingenieure
VOC Volatile organic compounds
VOD Vacuum oxygen decarburisation
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