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New Siemens electric arc furnace for steel-making cuts CO2 emissions by up to 30%; Tyasa incorporating first unit in new mill

1 April 2012

Mexico-based steel-maker Tyasa is building a compact steel mill that incorporates a new electric arc furnace from Siemens that reduces CO2 emissions by up to 30% compared to conventional electric arc furnaces. The new system, which recovers energy from the hot exhaust gas, also reduces costs by around 20%. The Tyasa mill is scheduled to be completed by mid-2013.

Siemensarc
Rendering of the Simetal EAF Quantum furnace. Click to enlarge.

Electric arc systems are particularly well suited for making steel from scrap iron. The electric arc heats the scrap metal to more than 1,500 degrees Celsius so that it melts. Besides scrap metal, other materials such as pig iron and direct reduced iron can also be used. However, the process consumes vast amounts of electricity, produces lots of carbon dioxide, and can lead to fluctuations in the stability of the power grid.

The new Simetal EAF Quantum furnace combines proven shaft furnace technology elements with new processes in order to reduce carbon dioxide emissions while at the same time saving energy and costs. Unlike a conventional electric arc furnace, it is not necessary to raise the roof and retract the electrodes in order to charge the furnace. The other benefit of charging via a shaft is that the scrap is preheated by the offgas of the melting process, which significantly reduces energy requirements.

Because the amount of scrap that is added is relatively low compared to the existing liquid steel, this process is referred to as flat-bath operation. It considerably reduces the strain on the furnace and lessens the repercussions for the power grid.

In combination with the automated offgas stream redirection system and a special hood to capture dust and offgases during charging, process emissions are considerably lower in the steel plant. This reduces the cost and size of the dedusting system and the canopy installation substantially.

In addition, the furnace has a new tilting concept for the lower shell as well as an optimized, patented tapping system. This enables the plant operator to achieve very short tap-to-tap times of around 36 minutes.

The new furnace has a tapping weight of 100 tons and a production capacity of around 1.2 million tons of different grades of steel per year.

Siemens has also developed another electric arc furnace specifically for use with direct reduced iron. Called the Simetal EAF FAST DRI, this furnace allows electricity to be used for heating the metal and makes it possible to feed direct reduced iron into the system during tapping. This shortens tap-to-tap times and reduces specific energy consumption. As a result, the productivity of a 150-ton furnace can be increased by around 15%.

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Comments

This is really great news! It seems that Siemens is really series about turning to more sustainable directions; first the exit from nuclear technology and now entering sustainable means towards a greener future.

Serious of course and not series!

Elctric are furnaces are enlarged tool steel furnaces that reduce CO2 output, as if that made any difference, no matter how constructed.

If Siemens have improved them, so much the better.

All electric arc furnaces promote the recycling of steel waste, enhance sustainability, and reduce by tremendous amounts, the raw energy consumed producing steel from 2% ferrous oxide.

Only true, green, yammerheads delight in the non-use of nuclear energy, the cleanest and best use of resources.

Go try living in your cave and delite in the wonders of being a naked Noble Savage, without tools.

It would be a grand way to start culling the herd, of its most useless, moronic members.

Hey Stan,

Would you mind explaining what kind of nuclear free lunch you expect? In the US, this will come in the form of loan guarantees, right?

In the US, the nukes and their pet politicians do not want permission to operate a plant, they want a hand out/ a free lunch/ something for nothing etc.

Nice for the scrap iron/metal industry.

Unfortunately for the AGW set, a decreasing number of people care about CO2 anymore - according to the latest Pew Research Poll:

"Pew Poll: Global warming finishes 22nd of 22 'top policy priorities of 2012': 'A quarter of Americans now find climate change a top concern, down from almost 4 in 10 in 2007."

Lowering to COST of energy for manufacturing and residences is the far higher priority now. And there are good ways to do that, cleanly, sustainably - to the benefit of all mankind.

The nuclear industry wants a common sense approval process and loan guarantees,
– not unlike:
The banks
GE, GM, Fisker, Tesla
Solindra and all the solar cell makers
Acorn
All the oil companies, drilling, pipelines and refining
All the windmill makers
All the EV makers


The government does many things;
Turning venture capitalism into crony capitalism is one thing it does well.

The new religion (i.e $$$$) is what is driving the majority, specially most (if not all) business oriented endeavors.

Could the Siemens improved torch approach be used for coal fired power plants to reduce emissions?

The legitimate and proper goal for almost all people, for 40 hours a week and for almost all businesses IS to make $$$$.

This is not new.


The goal of politicians is also to make $$$$, but this is completely immoral and illegitimate.

But that’s only my opinion, the house and senate ethics committees apparently do not agree.

The Ex-National Airline (North of the Border) hired a $$$$ minded manager from South of the Border a few years ago.

This $$$$ gentleman, broke the large firm into many smaller units. Sold the small units for cash and got rid of most of the employees at the same time and collected about 10% in bonuses (over $140M).

The individual smaller units had (most of the time) the ex-owner, i.e.
the National Airline as sole client. The next move was to progressively transfer the contracts to lower labor cost countries and bankrupt the smaller units.

Many thousand trained employees are now unemployed and without a pension because their new employer went bankrupt. Share holders of the smaller units lost almost 100%.

Politicians do not want to touch the deals because it is private (legal) business.

The $$$$ manager (hero) went back (retired?) South of the Border with his $140M bonus + many more $$M in yearly revenue.

@ Stan Peterson:
Some 50 years ago when I received my engineering degree I was almost as impetuous and impulsive but not as foolish and contemptuous as you. I was enthralled at the prospects of nuclear energy; over the years I've grown a bit wiser and recognize this technology for what it really is.
In contrast to you, I never parroted the ignorant phrases of nuclear proponents.
One tragedy of life is the difference in time that a young fool has to pursue his goals as compared to an old fool. But maybe you will never get to be that old.

Research and innovation into nuclear power generation was stifled after pressurized water, solid fueled reactors were developed for the Nautilis submarine. This technology was transferred to the first power stations and the state of the art has mostly languished since then.

In the early days (50s, 60s) many alternate designs were proposed, and alternative prototypes were built, including molten salt reactors (MSRs), a potentially much safer and more efficient paradigm for generating power from fissile elements. Unfortunately, for various political reasons, this promising technology was de-funded during the Nixon administration, and we are stuck with expensive, inefficient solid fuel, pressurized water designs that take forever to approve and build and end up generating tons of spent fuel.

There is a better way. See:

http://energyfromthorium.com/

Nick,
"For various political reasons"... wasn't that because of some near-mishaps and people got scared?
-
But very unfortunate for humanity because the problems could have benn solved with some more engineering... and, of course, still could be.

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