Eco-efficient Solutions in the Finnish Metallurgical Industry

Transcription

1 Eco-efficient Solutions in the Finnish Metallurgical Industry Juho Mäkinen, VTT Business Solutions

2 Structure of the presentation 1. Metallurgical industry in Finland 2. Eco-efficient features in the Finnish metallurcigal industry 3. Harjavalta industrial park 4. Outokumpu flash smelting technology 5. Ferro-alloys technologies of Outokumpu 6. Extraction of iron with low carbon dioxide emissions

3 1. Metallurgical industry in Finland PRODUCERS OF STEEL AND COLOUR METALS IN FINLAND Steel billets, BOF Steel billets, AOD Steel billets, EAF Hot rolling mill Cold rolling mill Pipe factories Aluminium Tornio Kemi Cr Nickel and coarse copper Cathode copper, copper half-products Electrolysis Zinc Pori Stainless Tubular Products, Pietarsaari Pori Kokkola Raahe Orivesi Au Hitura Ni Oulainen Pulkkila Kuusakoski, Heinola METALLINJALOSTAJAT 09/2006 Harjavalta Hämeenlinna Challenges of Eco-efficiency Dalsbruk Koverhar Lappohja Imatra

4 2. Eco-efficient features in the Finnish metallurcigal industry Conservation of energy and intelligent use of non-fossile energy sources Minimizing the impact on the environment; air, water, soil 6 BAT s = Best Available Technologies ASM Historical Landmark Award for the Outokumpu Flash Smelting Process in 2002 About 50 % of the World copper and 30 % of nickel is produced by Flash Smelting

5 3. Harjavalta industrial park

6 The history of Harjavalta industrial area 1944 Copper smelter is moved from Imatra to Harjavalta 1945 The start up of the Outokumpu copper smelter SO2 and metal containing flue dust SO2 and metal containing flue dust CuFeS2 SiO2 Copper matte Blister copper Anode copper to electrolysis ELECTRIC FURNACE PS-CONVERTER ANODE FURNACE Fe2SiO4 slag to disposal Surplus energy not utilized The Harjavalta copper smelter before Flash Smelting

7 The history of Harjavalta industrial area continued Copper smelter is moved from Imatra to Harjavalta 1945 The start up of the Outokumpu copper smelter 1947 The start up of the Kemira sulfuric acid plant

8 The history of Harjavalta industrial area continued Copper smelter is moved from Imatra to Harjavalta The start up of the Outokumpu copper smelter 1947 The start up of the Kemira sulfuric acid plant 1949 The start up of Outokumpu copper flash smelter

9 Concentrate, silica sand SCREENING AND GRINDING PRESSURE FILTER Steam Bag filter CONCENTRATE DRYING Feed mixture Oxygen and air FLOW SHEET OF COPPER SMELTER Flue dust FLASH SMELTING FURNACE WHB Bag filter EP Acid plant Slag concentrate THICKENER Slag Matte Scrap, anode scrap Bag filter Silica sand, coke, reverts WHB EP SLAG GRINDING SLAG COOLING Air and oxygen CONVERTER Blister HEAT EXCHANGER Ni drying Ni Electric furnace bins SLAG CONCENTRATOR Waste slag Propane, air ANODE FURNACE Challenges of Eco-efficiency ANODE CASTING Cu-ANODE

10 The history of Harjavalta industrial area continued 1944 Copper smelter is moved from Imatra to Harjavalta 1945 The start up of the Outokumpu copper smelter 1947 The start up of the Kemira sulfuric acid plant 1949 The start up of Outokumpu copper flash smelter 1959 The start up of Outokumpu nickel flash smelter 1971 The start up of the oxygen plant 1995 The start up of AGA hydrogen plant 1995 The start up of Direct Outokumpu Nickel process (DON) 2000 OMG Harjavalta Nickel Ltd is founded 2000 Porin Lämpövoima Ltd starts the energy production 2002 OMG starts the nickel chemical production 2004 Boliden Harjavalta Oy is founded

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12 The utilisation chain of sulphur starting from a copper mine to sulphur dioxide, sulphuric acid and ending at consumer s dinner-table Raw material acquisition Raw materials refining Copper deposit Copper flash smelting off gases Transporting Products making Sulphure chemicals using / Raw material acquisition Ilmenite deposit Bauxite deposit Surphurric acid plant Apatite mine Potassium mine Natural gas Raw materials refining Ilmenite Bauxite Sulphuric acid Phosphorous acid Potassium chloride Nitric acid Ammonia Sulphur dioxide Transporting Products making TiO 2 - plant FeSO 4 Al 2 (SO 4 ) 3 Fertilizer industry ClO 2 - making Products using TiO 2 Wastewater. treatment Barley growing Chemical pulp (bleaching) Transporting Products using Paint industry Cattle feed Food production Sugar- and starch industry Paper industry Domestic market / Consumer

13 Product and company diversity progress

14 Material and energy exchange of Harjavalta Industrial Park ADVANTAGES: Environmental and recycling benefits Better energy efficiency Better product diversity when different companies can concentrate to their own core know-how areas Marketing and logistic benefits Improved safety activity Image factors Cultural differences is a positive factor in cooperation

15 How to govern the eco-efficiency of the activities in an industrial park? There is no umbrella organization to govern the activities of individual companies in the park The overall supervision is carried out by the environmental authorities They have the final decision making power in environmental permissions and they also monitor the emissions from various sources in the park

16 4. Outokumpu Flash Smelting Technology

17 Theory of Flash Smelting - reactions Dissociation reactions endothermic (require energy) Oxidation reactions exothermic (produce energy) Oxidation reaction are not completed, the degree of oxidation depends on the amount of available oxygen. Iron sulphides are oxidized easier than copper sulphides.

18 Flash smelting furnace

19 Cu production by process 4.0 PRODUCTION, Mt Cu/a REVERBERATORY FSF OK FSF REVERB. CMT ELECTR. F. BLAST F. INCO MITSUBISHI ISA NORANDA

20 Sulfur Capture in Copper Smelters (Forecast) Japan FSF + FCF + Acid Plant FSF + PS + Acid Plant MITSUBISHI + Acid Plant SULFUR CAPTURE (%) Europe North America ISA + PS + Acid Plant Africa South America Australia Asia excl. Japan YEAR

21 Flash Smelters around the world Cu SMELTING Cu CONVERTING DIRECT TO BLISTER Ni SMELTING NOT IN OPERATION RÖNNSKÄR (SWEDEN) GLOGOW KOKKOLA HARJAVALTA (FINLAND) NORILSK (RUSSIA) HAMBURG (GERMANY) (POLAND) SALT LAKE CITY SAN MANUEL HIDALGO (USA) BAIA MARE (ROMANIA) PIRDOP (BULGARIA) HUELVA (SPAIN) SAMSUN (TURKEY) KHATOON-ABAD (IRAN) ONSAN (SOUTH KOREA) KOSAKA HITACHI ASHIO TAMANO LA CARIDAD (MEXICO) DAHEJ PASAR (PHILIPPINES) TOYO SAGANOSEKI (JAPAN) KHETRI GHATSILA CHUQUICAMATA CHAGRES (CHILE) FORTALEZA DIAS D AVILA (BRAZIL) KONKOLA (ZAMBIA) SELEBI-PHIKWE (BOTSWANA) (INDIA) JINCHANG YANGGU TONGLING GUIXI (CHINA) KALGOORLIE TENNANT CREEK OLYMPIC DAM MOUNT MORGAN (AUSTRALIA)

22 Flash Smelting & Flash Converting References 1/3 1. Outokumpu Oy, Harjavalta, Finland Cu smelting Outokumpu Oy, Harjavalta, Finland Ni smelting Furukawa Co Ltd., Ashio, Japan Cu smelting Outokumpu Oy, Kokkola, Finland Pyrite smelting Combinatul Chimico Metalurgic, Baia Mare, Romania Cu smelting The Dowa Mining Co Ltd., Kosaka, Japan Cu smelting Nippon Mining Co Ltd., Saganoseki, Japan Cu smelting Sumitomo Metal Mining Co Ltd., Toyo, Japan Cu smelting Hindustan Copper Ltd., Ghatsila, India Cu smelting Peko Wallsend Metals Ltd., Mount Morgan, Australia Cu smelting Hibi Kyodo Smelting Co Ltd., Tamano, Japan Cu smelting Norddeutsche Affinerie AG, Hamburg, Germany Cu smelting Nippon Mining Co Ltd., Hitachi, Japan Cu smelting Western Mining Corporation, Kalgoorlie, Australia Ni smelting Karadeniz Bakir Isletmeleri AS, Samsun, Turkey Cu smelting Peko Wallsend Metals Ltd., Tennant Creek, Australia Cu smelting Nippon Mining Co Ltd., Saganoseki, Japan Cu smelting BCL Limited, Selebi-Phikwe, Botswana Ni smelting 1973

23 Flash Smelting & Flash Converting References 2/3 19. Hindustan Copper Ltd, Khetri, India Cu smelting Rio Tinto Minera SA, Huelva, Spain Cu smelting Phelps Dodge Corporation, Playas, USA Cu smelting Gécamines, Luilu, Zaire Direct to blister 23. Kombinat Górniczo-Hutniczy Miedz, Glogow, Poland Direct to blister Korea Mining & Smelting Co Ltd., Onsan, South Korea Cu smelting Norilsk Mining & Metallurgical Co, Norilsk, Russia Ni smelting Norilsk Mining & Metallurgical Co, Norilsk, Russia Cu smelting Caraíba Metais SA, Camacari, Brazil Cu smelting Philippine Associated Smelting & Refining Co., Isabel, the Philippines Cu smelting Jiangxi Copper Corporation, Guixi, China Cu smelting Mexicana de Cobre SA, El Tajo, Mexico Cu smelting MDK G Damianov, Srednogorie, Bulgaria Cu smelting Codelco, Chuquicamata, Chile Cu smelting Jinchuan Non-ferrous Metals Co, Jinchang, China Ni smelting Magma Copper Co., San Manuel, USA Cu smelting 1988

24 Flash Smelting & Flash Converting References 3/3 35. Roxby Management Services Pty Ltd, Olympic Dam, Australia Direct to blister Compania Minera Disputada de las Condes SA, Chagres, Chile Cu smelting Kennecott Utah Copper Corp., Salt Lake City, USA Cu smelting Kennecott Utah Copper Corp., Salt Lake City, USA Cu converting Jinlong Copper Co Ltd., Tongling, China Cu smelting Indo-Gulf Fertilisers & Chemical Ltd, Gujarat, India Cu smelting Mineraç o Serra da Fortaleza Ltda, Fortaleza, Brazil Ni smelting WMC Resources Ltd, Olympic Dam, Australia Direct to blister Boliden Mineral AB, Rönnskär, Sweden Cu smelting Southern Peru Copper Corporation, Ilo, Peru Cu smelting 45. Southern Peru Copper Corporation, Ilo, Peru Cu converting 46. National Iranian Copper Industries Co., Khatoon Abad, Iran Cu smelting Yanggu Xiangguang Copper Co., China Cu-smelting 48. Yanggu Xiangguang Copper Co., China Cu-converting 49. KGHM Polska Miedz S.A., Glogów, Poland Direct to blister 50. Jiangxi Copper Corporation, Guixi, China Cu smelting 51. Konkola Copper Mines Plc., Zambia Direct to blister

25 Relative amount of copper produced in smelters ( pure FSF vs. others) Other smelters OK Flash % of primary Cu produced > 95 % % < 90 % > 95 % > 90 % < 90 % Sulfur recovery, %

26 5. Ferro-alloys Technology of Outokumpu

27 Outokumpu FeCr smelting process Based on pellets. Furnace charge is preheated in stationary shaft kiln. Smelting furnace is closed and sealed. CO-gas is cleaned and utilized in the plant and outside.

28 Outokumpu Tornio Works Full capacity after last expansion: FeCr Slabs Coil products of which: Hot rolled Semi-cold rolled Cold rolled tons tons tons tons tons tons Specialized in: Custom-made volume production in selected product areas Supplying cost efficiently high quality volume products Using best available technology New products from RAP line About employees

29 The most integrated stainless steel works in the world (Outokumpu Tornio works) Own chrome safe supply Stable FeCr quality Liquid FeCr and use of own CO saves primary energies FeCr-converter increase melting capacity and saves energy Hot slab charging in Hot Rolling Mill Short processing time and lower logistical costs Savings in product handling Integrated southbound and northbound logistics Terneuzen Mill close to main markets

30 Main principles of environmental management Improvement of material efficiency and utilization of byproducts Improvement of energy efficiency Continuous improvement: ISO and R&D as tools Utilization of best available technology (BAT) to keep the emissions at low levels Active co-operation with authorities Aim is to be the best in ecoefficiency

31 The ecological balance of Tornio FeCr -plant FeCr - PLANT ECOLOGICAL BALANCE 2002 EMISSIONS TO AIR DUST 0,20 kg CO NO 2 0,87 SO 2 0,38 IN ELECTRICITY 3469 kwh (12,18 GJ) COKE 507 kg LIQUID NATURAL GAS 0,06 OIL 0 LUMPY ORE 769 FINE CONCENTRATE 1532 QUARTZ 306 ELECTRODE PASTE 7 OTHER 15 OUT FeCr 1000 kg SLAG 1181 CO 708 Nm 3 (CO EQUALS 196 kg OIL) EMISSIONS TO WATER SOLIDS 13,8 g Cr 0,4 Zn 1,0 CN 0,7 OIL 0 DUMPING PLACE WASTE 35 kg

32 Specific CO 2 emissions at Outokumpu Tornio FeCr Plant, kg CO 2 /t FeCr FERROCHROMIUM PRODUCTION - CO2 EMISSION SPECIFIC EMISSION, CO2 kg/t FeCr YEAR

33 Effect of Technology development on CO 2 emission and power consumption in FeCr production - kwh / ton FeCr t CO 2 /t FeCr Base Case Pelletizing/ Sintering Pelletizing Sintering+Preheating+ Closed Furnace Full utilization of Furnace CO in addition CO2 Emission per ton FeCr Power consumption kwh/t HC FeCr

34 Without technology development the CO 2 emission level at Outokumpu Tornio FeCr plant would be more than 3-fold compared to the present actual figures CO2 EMISSIONS, tpa CO 2 emissions at Outokumpu Tornio FeCr plant with and without technology development CO2 EMISSIONS, REAL CO2 EMISSIONS WITHOUT IMPROVEMENTS YEAR

35 Effect of technology development on cumulative CO 2 emission reduction at Outokumpu Tornio FeCr plant CO 2 EMISSION REDUCTION IN FeCr PRODUCTION IN TORNIO CUMULAT CO2 EMISSION REDUCTION, tons CO YEAR

36 Outokumpu Technology s latests FeCr technology transfer project references Ferrometals 1998 South Africa Hernic 1999 South Africa Assmang 2001 South Africa Tubatse 2002 South Africa SA Chrome 2002 South Africa Hernic South Africa Donskoy GOK 2005 Kazakhstan IFM 2007 South Africa Xstrata Wonderkop 2007 South Africa Already now about 5-7 million tons less CO 2 emissions

37 Estimate of cumulative CO 2 emission reduction in FeCr production in South Africa achieved by utilization of Outokumpu technology CUMULAT. CO 2 EMISSION REDUCTION, t CO FeCr PRODUCTION Outokumpu Technology Technology Deliveries Effect on CO 2 emissions CO2 REDUCTION CALC. BY ELECTRICAL ENERGY SAVINGS DIRECT REDUCTION OF CO2 EMISSIONS YEAR Forecast

38 6. Extraction of Iron With Low Carbon Dioxide Emissions

39 Reduction of iron ores Conventional blast furnace reduction of iron oxides Pelletizing Sintering Coking Oxygen removed as CO 2 95 % of primary iron production Direct reduction by natural gas Oxygen removed as H 2O+CO2 3-4 % of primary iron production Direct reduction by hydrogen Oxygen removed as H 2O 1-2 % of primary iron production

40 View of Circored plant in Point Lisas, Trinidad

41 Circored : Gas Based Direct Reduction of Iron Ore Fines

42 Basic reactions in the bath