Steel Times International Digital February 2018

INNOVATIONS

ENVIRONMENT

MAINTENANCE

FUTURE STEEL FORUM 2018

Eight pages of the latest products and steel contracts

Tenova says DR-EAF process emits 40 to 60% less CO2 than the BF-BOF

How to choose the right bearings – key advice from bearings guru Timken

Sign up as a delegate for this year’s conference – turn to page 46 now!

www.steeltimesint.com Digital Edition - February 2018 - No.8

THE IMPORTANCE OF NEW TECHNOLOGIES – SANDVIK’S STEEL SURVEY

CONTENTS DIGITAL EDITION - FEBRUARY 2018

INNOVATIONS

ENVIRONMENT

MAINTENANCE

FUTURE STEEL FORUM 2018

Eight pages of the latest products and steel contracts

Tenova says DR-EAF process emits 40 to 60% less CO2 than the BF-BOF

How to choose the right bearings – key advice from bearings guru Timken

Sign up as a delegate for this year’s conference – turn to page 46 now!

www.steeltimesint.com Digital Edition - February 2018 - No.8

THE IMPORTANCE OF NEW TECHNOLOGIES – SANDVIK’S STEEL SURVEY

1

Picture courtesy of: Friedrich Kocks GmbH & Co KG “At KOCKS, our philosophy is simple: we believe in German engineering and high quality manufacturing standards. Solutions that meet the needs of tomorrow can only be developed in closed loop with our customers. KOCKS ensures short routes – especially with our clients. This gives us a competitive edge that cannot be overstated in today’s fast-moving world, and a focus on service which considerably exceeds normal standards.”

EDITORIAL Editor Matthew Moggridge Tel: +44 (0) 1737 855151 matthewmoggridge@quartzltd.com Consultant Editor Dr. Tim Smith PhD, CEng, MIM Production Editor Annie Baker Advertisement Production Martin Lawrence SALES International Sales Manager Paul Rossage paulrossage@quartzltd.com Tel: +44 (0) 1737 855116 Sales Director Ken Clark kenclark@quartzltd.com Tel: +44 (0) 1737 855117 Managing Director Steve Diprose stevediprose@quartzltd.com Tel: +44 (0) 1737 855164

IF YOU WOULD LIKE TO ATTEND THIS EVENT (JUNE 6-7 2018) SEE PAGE 38 OF THIS ISSUE.

Chief Executive Officer Paul Michael SUBSCRIPTION Elizabeth Barford Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 Email subscriptions@quartzltd.com Steel Times International is published eight times a year and is available on subscription. Annual subscription: UK £178.00 Other countries: £254.00

2 Leader

by Matthew Moggridge, editor.

26 Maintenance Defining housing strength.

4 Astounding Facts & Figures Industry facts and figures.

35 Furnaces Reducing NOx emissions.

2 years subscription: UK £320.00 Other countries: £457.00 ) Single copy (inc postage): £40.00 Email: steel@quartzltd.com Published by: Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, England.

Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855034 www.steeltimesint.com Steel Times International (USPS No: 020-958) is published monthly except Feb, May, July, Dec by Quartz Business Media Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER send address changes to Steel Times International c/o PO Box 437, Emigsville, PA 17318-0437.

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7 39 Europe Update Environment Painting a healthy picture for EU steel. 40% to 60% less CO .

2.

8 Innovations The latest product innovations.

46 Future Steel Forum 2018 Steel and Industry 4.0 conference.

22 Sandvik’s Steel Survey Don’t prioritise cost over quality.

48 China Update Cold weather inflates coal prices.

ISSN0143-7798

www.steeltimesint.com

Digital Edition - February 2018

2

LEADER

Optimism all round for European steelmaking

Matthew Moggridge Editor matthewmoggridge@quartzltd.com

I don’t know about you, but it takes me a while to get back into the swing of things after the Christmas break. I’ve stopped wishing people a Happy New Year via email, which is a start, but I’ve yet to hit the ground running, even though there’s two issues of the magazine to publish before the end of February – one print edition, which is now out, and this digital edition. Obviously, if you’re reading this, it’s out, but right now, at the time of writing, there’s a few days to go and I’m sitting here ranting to myself about having to write two leader articles in the space of a few days and wondering what I can say this time around.

Well, there’s a fair bit going on: ThyssenKrupp’s 20,000-strong workforce has finally approved the merger with Tata Steel as no forced lay-offs or plant closures have been promised, which is good news for the workers, but if Dr. Wolfgang Eder, CEO of Austrian steelmaker voestalpine, is right, there is a need for plant closures because 20% of Europe’s steelmaking capacity is surplus to requirements.

Conversely, ThyssenKrupp and Tata both argue that the merger between the two steel giants will help them tackle overcapacity in the European steel market

– without any forced lay-offs or major plant closures. Watch this space.

There is, however, a note of optimism within the European steel industry. Even EUROFER is painting a rosy picture, claiming that in Q3 2017 EU28 apparent steel consumption grew by 1.1% year-onyear and that apparent steel demand rose 1.9%. For 2018 output in the EU’s steelusing sectors is forecast to grow 2.2% and by 1.9% in 2019. That said, Dr. Eder was quoted in the Financial Times as saying, “We should not be surprised that the European steel industry is suffering.”

Other good news for the start of the year is that world crude steel production was up 5.3% for 2017 when compared with the previous year, and that Swedish steelmaker SSAB’s joint initiative with LKAB and Vattenfall – known as the HYBRIT initiative – will make fossil-free steelmaking a reality by 2035.

Voestalpine is optimistic for carbon-free steelmaking after announcing that it has gained approval from the Government of Upper Austria for the construction of the world’s largest pilot plant for CO2-free production of hydrogen.

It’s all good news, so I say Happy New Year.

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4 NEWS

ASTOUNDING FACTS

Pedal to the metal for REIDsteel

Dorset, UK-based REIDsteel designed, manufactured and supplied all of the steelwork, cladding and glazing for Thruxton Motorsports’ new two-storey hospitality centre near Andover.

The new £1.5 million centre’s design includes a grand atrium and entrance lobby to reflect the dynamism of motorsport and Thruxton’s rich heritage.

Toby Hill-Cousins, REIDsteel’s project engineer, said that the client wanted an innovative and modern hospitality centre to re-

Motor racing at Thruxton (top) and the new hospitality centre (this image).

flect its status as one of the most iconic motorsport and leisure venues in the UK. “We have designed, manufactured and supplied stadia for a wide range of clients over many years, including Premier League football clubs, and are delighted to help deliver this landmark project which will support the venue’s growth for years to come.”

The new centre will be officially opened in April as part of Thruxton’s 50th anniversary celebrations.

• Touching the terminals of a 9-volt battery to a wad of steel wool can spark a campfire.

Source: This Old House.com

• Steel-framed homes won’t crack, warp, twist, rot, split or settle. Source: AISI.

• Millions of tons of iron and steel are diverted from the waste stream to the recycling stream due to steel’s magnetic properties that make it the easiest material to separate from the solid waste stream.

Source: AISI.

• By 2050, steel use is projected to increase to be 1.5 times higher than present levels in order to meet the needs of our growing population.

Source: worldsteel.

“If you had teeth of steel, you could eat iron coconuts.” (proverb in Senegal). Source: Daily Express.

Digital Edition - February 2018

• Packing steel wool into gaps around pipes forms a barrier mice can’t chew through.

Source: This Old House.com

NEWS IN BRIEF 5

AND FIGURES...

Factories should be closed, says Eder

• Average world steel use per capita has steadily increased from 150kg in 2001 to 208 kg in 2015, making the world more prosperous.

Source: worldsteel

• The weight of crude steel made in the world in 2013 was about equal to 160,000 Eiffel Towers. Source: Daily Express.

• Steel door latches help keep your car doors closed during a crash. Source: AISI.

• Austrian steelmaker Voestalpine says that steelmaking accounts for just one third of its EUR11.3 billion revenues. The rest comes from specialist metal and engineered components for the automotive, aviation and rail industries.

• Producing one tonne of steel today requires just 40% of the energy it did in 1960.

Source: worldsteel.

• More than 22 billion tonnes of steel have been recycled worldwide since 1900 – resulting in significant energy and raw material savings.

Source: worldsteel.

• Henry Bessemer, a British inventor, invented the first technique to mass produce steel in the mid-1850s. Blowing air through molten pig iron to oxidise the material and separate impurities is known as the Bessemer Process.

Source: worldsteel.

• Canned foods are the most tamper-resistant food packaging option available today. Source: AISI.

In the light of capacity surpluses in Europe, voestalpine’s CEO, Dr. Wolfgang Eder, believes that European steelmakers should be closing factories to avoid being outflanked by overseas rivals.

Dr. Eder told the Financial Times that around 20% of Europe’s steelmaking capacity was surplus to requirements and that plants should be closed down.

Eder said that European steelmakers should focus strongly on quality rather than quantity.

Liberty establishes testing facility Liberty House has established a UKAS-accredited materials testing facility at Willenhall in the West Midlands.

The company claims that metals businesses across the country will benefit from the range of expertise available at the new laboratory, which provides mechanical, spectrographic and chemical testing and analysis and will specialise in fast turnaround services for businesses such as steel stockists, foundries, engineering operations and fabrication companies.

The lab is fully AKAS accredited.

Metal demand likely to slow in 2018 Metal demand in China in 2018 is likely to slow further as the government tries to discourage speculation in the property market and constrain infrastructure investment, according to an insight report by Wood MacKenzie.

“Even with slow growth, however, companies should continue to benefit from better margins by producing less, a result of efforts to rationalise capacity and meet stricter environmental standards,” said the company.

Tata Steel fined after worker death

• For every tonne of scrap made into new steel, there are savings of more than 1,400kg of iron ore, 740kg of coal and 120kg of limestone.

Source: worldsteel.

Eight years after Thomas Standerline was crushed to death by an overhead crane, Tata Steel has been fined £1.4 million.

An investigation by the Health & Safety Executive (HSE) found that the steelmaker had failed to enforce its own safety procedures, despite having two previous incidents before Standerline’s death.

Source: Construction Enquirer.

Digital Edition - February 2018

EUROPE UPDATE

7

Painting a healthy picture for EU steel

The manufacturing industry and construction sector in the EU gained last year from an investment-led domestic upturn and improving exports. A healthy outlook for these steel users bodes well for EU steel demand this year and next. The supply side situation could, however, continue to be negatively affected by import distortions.

EU28 apparent steel consumption grew by 1.1% year-on-year in the third quarter of 2017. By contrast, the second quarter was characterised by a contraction in domestic deliveries from EU suppliers due to a sharp increase in third country imports. Overall, domestic deliveries rose by 4.4% year-onyear.

Imports grew by around 8% year-on-year over the first half of 2017, the trend turned negative in the third quarter of last year.

Total steel imports fell by almost 14% yearon-year.

This decline has occurred in the context of improving global steel prices – largely driven by the Chinese market – which narrowed the gap between EU domestic prices and imports. Other restraining factors include the moderation of imports, particularly from China, but also other countries affected by the imposition of anti-dumping and anti-subsidy measures imposed by the European Commission.

However, other third country suppliers have triggered increased exports to the EU, making up for this drop.

Similar market conditions are expected to have shaped the supply-demand situation in the fourth quarter of 2017.

EU28 apparent steel demand is estimated to have risen by 1.9% in 2017.

Axel Eggert, director general of EUROFER www.steeltimesint.com

said that prospects for the continued recovery of EU steel demand are positive.

“The expected strength of most steel-using sectors bodes well for the demand side of the EU steel market. The supply side situation could, however, continue to be negatively affected by import distortions.”

EU steel-using sectors 2017 was a strongly expansionary year for steel-using sectors in the EU. The performance across countries and steel-using sectors became increasingly synchronised over 2017. In particular, growth dynamics in Central Europe improved significantly compared with overall rather weak momentum in 2016.

Individual sectoral performances are varied. The steel tube sector posted the strongest year-on-year jump in production activity, followed by the mechanical engineering sector, electrical domestic appliances and construction. As had been anticipated, growth in automotive output moderated somewhat.

The outlook for 2018 and 2019 is positive, although activity in steel-using sectors will settle back into a more moderate pace of expansion owing to waning momentum in the tube sector and automotive industry. Underlying economic conditions remain supportive to a steady

pace of expansion in other sectors.

Output in the EU’s steel-using sectors is forecast to grow by 2.2% in 2018 and by 1.8% in 2019.

EU economic context The EU economy remained on a favourable growth track in the second half of last year. GDP growth was driven by robust investment, solid private consumption and strong exports.

Conditions look right for the EU economy, expected to maintain an abovetrend growth rate in 2018. Economic sentiment in the Euro zone and EU28 has been going from strength to strength over the course of 2017 and January this year saw a further increase in confidence.

Investment is expected to remain a key driver of growth, reflecting robust domestic and external demand. Private consumption will also continue to perform well. However, exports may be impacted by the enduring relative strength of the euro and an expected – though mild – moderation in global trade growth.

The EU economy is forecast to return to a more sustainable growth rate in 2019 as EU monetary policy tightening may begin to dampen investment growth.

EUROFER forecasts EU GDP growth of 2.2% in 2018 and of 1.9% in 2019. � Digital Edition - February 2018

8

INNOVATIONS

Free training for US military veterans Endress+Hauser, a global leader in measurement instrumentation, services and solutions for industrial process engineering, will provide training free of charge to military veterans on process instrumentation, as part of the 12week Academy of Advanced Manufacturing (AAM) programme offered by the Rockwell Automation and ManpowerGroup.

“We are very excited to be collaborating with Rockwell Automation on this project. Our customers continue to tell us they have difficulty finding skilled workers to fill the many open positions that are created by the large number of personnel retiring from the workforce,” said Jerry Spindler, customer and field service training manager, Endress+Hauser. “We are proud to be involved in helping to solve this skills shortage by providing quality training on our instrumentation. With the training classes, we not only get to help our

customers, we are helping those who have served our country.”

The technical curriculum being taught by Endress+Hauser will offer in-depth training on technology and instrumentation for monitoring and managing temperature, flow and pressure for machinery and equipment in industrial process industries.

The company will lend its time and expertise in process instrumentation to help train military veterans for careers in advanced manufacturing, while enhancing the technical talent pool and helping to bridge the skills gap that exists globally.

“We are pleased that Endress+Hauser is part of the ranks of the AAM, and are bringing their instrumentation and process automation expertise to the programme,” stated Joe Allie, business manager, global competency, Rockwell Automation.

According to a white paper published

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by ManpowerGroup, more than 21 million military veterans live in the United States and more than a quarter of a million service members are discharged every year. That number represents one of the largest sources of highly-skilled and loyal talent in the country.

Over the next decade, the United States manufacturing sector is estimated to produce up to 3.5 million highly-skilled, technology-based jobs.

Nearly 2.5 million manufacturing workers will be retiring by 2025. With skill shortages in the USA, this leaves up to 2 million manufacturing positions unfilled and forecasts a major challenge that needs to be addressed with a solution. The AAM programme is aimed at reducing these potential future challenges.

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10

INNOVATIONS

Primetals sells 10th Multipas simulator Chinese steel producer Shandong Iron and Steel Group Rizhao has ordered a multi-purpose annealing simulator (Multipas) from Primetals Technologies.

The system will be installed in the research centre of the steelmaker’s new iron and steel works, which is under construction south of Rizhao.

According to Primetals Technologies, Multipas is designed for use in steel production for product development and process optimisation in heat treatment plants.

Primetals claims it got the job because of ‘the universal usability of its annealing simulator’. The simulator is claimed to shorten the run-up phase of heat treatment plants and simplify their optimisation.

The Rizhao unit is the tenth order for a Multipas system. Commissioning is scheduled for September 2018.

Shandong Iron & Steel Group Rizhao was founded in 2009 and is a subsidiary of Shandong Iron & Steel Group. It was established as a key component of the Shansteel Rizhao Quality Products Base and as the end processor for materials.

The company is currently building a new integrated iron and steel works south of Rizhao on the coast of the Yellow Sea. A research centre is being built on-site for product development and process optimisation, which will also be equipped with rolling and annealing simulators.

In a Multipas annealing simulator samples of cold-rolled plates with dimensions of up to 500 mm x

Digital Edition - February 2018

Innovations 2.indd 5

20/02/2018 09:41:21

INNOVATIONS

11

Shandong Iron and Steel Group Rizhao has ordered a multi-purpose annealing simulator from Primetals Technologies

300 mm and a thickness of up to 3 mm are heated by conduction up to a temperature of 1,200°C by a maximum electric current of 8,000 amperes. Depending on the geometry of the sample, the heating rates are up to 100 kelvins per second.

Samples can then be cooled in different ways. The two main forms of cooling are gas jet with cooling rates of up to 100 kelvins per second and water quenching, which cools a sample with water at rates of up to 1,000 kelvins per second, enabling the microstructure to be ‘frozen’. The sample is then examined in the laboratory. A Multipas is also equipped with spray water, mist jet nozzles and fan cooling. A wide range of heating and cooling speeds is necessary in order to be able to simulate, on a small scale, all possible and future heat treatments in the large-scale plant.

Multipas systems are assembled in the Mechatronic Laboratory of Primetals Technologies in Linz, Austria. The lab conducts all functional tests and preliminary acceptance by the customer. It will be shipped to Rizhao at the end of June.

Specialists from Primetals Technologies will install and commission the simulator. This is the 10th order for a Multipas system, which has already been supplied to customers in Austria, Germany, South Korea and China.

For further information, log on to www.primetals.com

Digital Edition - February 2018

Innovations 2.indd 6

20/02/2018 09:41:26

12

INNOVATIONS

“MPM is making a significant contribution to the future development of the country,” said SMS group’s Oleg Vilents

Iranian pipe mill signs big contract with SMS group The Iranian Mahshahr Pipe Mill Company (MPM) of Chuzestan Province has signed a service and modernisation contract with SMS group.

Last year the large diameter pipe mill in Mahshahr was audited by SMS group and MPM with a view to assessing maintenance standards at the facility. The audit included production, maintenance, management, administration and compliance with occupational health and safety regulations.

Ehsan Shahrokhi, purchasing and procurement manager of MPM said that SMS group’s modernisation and maintenance concept will provide the mill with premium technology and sustainable growth. “This is a significant future-oriented step that will enable us to safeguard our competitiveness and increase our production performance,” he said.

Included in the concept is the overhaul of the mill’s complete pipe welding equipment . “Digital PERFECT arc welding power sources are to be used for the welding units,” according to SMS group. “These work with insulated gate bipolar transistor (IGBT) power

electronics and regulate the welding current by fully digital means.”

SMS claims that energy savings of up to 30% can be achieved compared with older welding techniques and that productivity can be increased by up to 20%. Process stability remains at consistent levels throughout.

The plan is to replace the mill’s X-ray testing units to ensure maximum pipe quality while boosting output capacity throughout the plant.

The mill’s ageing MX4 hydraulic control system will also be replaced with an Indra Motion MLC L75 control system.

A SHAPE automation system will control the forming process based on a continuous calculation of the optimum forming parameters. “This minimises any potential negative influences from the starting material and will support the operator,” says SMS. The technical assistance deal with MPM includes the examination of the company’s large diameter pipe mill in Khuzestan. “This entails not only identifying the necessary spare parts, but also optimising production sequences,” said

SMS, adding that numerous on-site employee training courses would also take place.

To improve preventive maintenance, SMS group’s technical services team will assist MPM in the deployment of an effective maintenance organisation with a view to improving the availability of the plant and the quality of finished product over the long term. IMMS is an integrated maintenance management system that combines tried and tested software and valuable information, building on decades of maintenance experience at the plant, the company claims.

Oleg Vilents, an SMS group maintenance consultant, said that once the various systems are in place, the plant will perform the same as a newly built steel plant.

“With it’s willingness to invest, MPM is making a significant contribution to the future development of the country,” he said.

For further information, log on to www.sms-group.com

Digital Edition - February 2018

Innovations 2.indd 2

20/02/2018 09:41:14

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14

INNOVATIONS

Three becomes one as labels companies merge Dura-ID Solutions is the name of a newly formed company following the merger of three label printing specialists: IML Labels & Systems, Longcombe Labels and Lead Marque Concepts.

The deal creates a combined company with just under 100 employees, five sites and annual revenues of £14 million.

All three businesses involved in the merger have reported a highly successful year of sales as three companies previously owned as separate entitities

by Goonvean Holdings.

The plan now is to ‘further revolutionise identification solutions across all

its key sectors’ and will continue to focus on supplying ‘high quality products and services’ to its client base.

According to Dura-ID, the full workforce has been retained and with sites dotted around the UK (Sheffield, Paignton, Mansfield, Cambridge and Aycliffe) the plan is to continue doing what the business has been doing over the past 80 years.

“We are very enthusiastic about the new opportunities that this merger will bring to our company,” said Shaun Higgins, who was managing director of IML Labels & Systems. “We are all looking forward to our unified future as

Dura-ID Solutions,” he added.

Longcombe’s managing director, Paul Harris, said, “This news comes from a keen interest in wanting to provide complete identification solutions for every industry, and as Dura-ID Solutions we can achieve that.”

The new company will continue to manufacture and supply specialist identification solutions and aim to make the transition period as smooth as possible for suppliers and clilents.

For further information, log on to www.dura-id.com

Dura-ID plans to revolutionise identification solutions across its key sectors

Digital Edition - February 2018

Innovations 2.indd 4

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20/02/2018 09:41:14

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16

INNOVATIONS

KCL’s Ken Loh (left) and Lars Fredin of Konecranes

Konecranes appoints distributor for China and Hong Kong With a view strengthening Konecranes’ presence in China and Hong Kong, KCL Lifttrucks has been appointed as a distributor for the Swedish crane manufacturer.

According to Konecranes, its new distributor will focus on sales and after-market services of mobile container handling machines and heavy duty lift trucks for all industries.

Ken Loh, managing director at KCL Lifttrucks, is enthusiastic for the company to be part of the Konecranes network: “I am excited to join Konecranes’ network as they continue their Swedish heritage of making lift trucks. When I enter the Markaryd and Lingang factories it feels like coming home;

seeing so many people with a passion to deliver reliable, high quality products with state-of-the-art technology. With this co-operation, our team with its deep know-how in container handling will be able to deliver breakthrough customer experiences.”

KCL employees are claimed to have ‘extensive experience of distributing lift trucks and container handling equipment’ in the region.

According to Konecranes, they are more than ready to start supplying high performing lift trucks.

“We are very happy to have KCL Lifttrucks Ltd joining us and strengthening our offering for the Chinese and Hong Kong market. We look forward to a long and successful partnership with

many satisfied customers” said Patrik Lundbäck, regional manager APAC for lift trucks at Konecranes.

Lars Fredin, senior vice president of BU Lift Trucks at Konecranes, said KCL will be a great resource to further strengthen the global market position of lift trucks and container handling equipment in the region.

“This will certainly bring many interesting opportunities for the future,” he said.

Konecranes’ existing lift trucks distributors in China will continue their business as usual, and work in close co-operation with KCL. For more information visit www. kclifttrucks.com

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INNOVATIONS

Flex EX2 wireless controls

Magnetek’s ‘next generation’ Flex EX2 Wireless Controls Magnetek, a leading supplier of digital power and motion control systems for the material handling industry, has announced the availability of its new Flex EX2 wireless controls. “These next generation rugged wireless controls are ideal for use in materials handling, overhead crane, and industrial applications,” says the company, adding that transmitters are available in four, six, eight, and 12-button style options, while receivers will be available in 4/6 and 8/12 styles.

Ben Stoller, director of radio controls, said that Flex EX2 wireless controls provide innovative and efficient performance, along with secure and dependable communications. “Backed

by Magnetek’s expertise and superior service, Flex EX2 is available with new and improved features to enhance safety and efficiency,” he said.

Magnetek claims that the Flex EX2 is versatile, feature-rich, and offers advanced software capabilities, including expanded frequency ranges, channel scanning schemes for anti-interference, drop detection, and remote pairing.

The transmitters feature an improved ergonomic design with a single thumbscrew for easy access to batteries and dipswitches, while retaining its IP66 rating for protection in harsh indoor and outdoor environments. Also available are a variety of accessories for additional protection and flexibility, including protective rubber transmitter boots, a retractable belt clip, and a charging cradle.

For further information, log on to www.magnetekmh.com Digital Edition - February 2018

Elevator rope tension measured by SP COLT Tensology has used Straightpoint’s (SP) Clamp-On Line Tensionmeter (COLT) to measure tension on eight 19mm diameter ropes that lift a hulking 50t capacity elevator at a major UK steel facility.

Tensology used the COLT, which measures tension up to 11,000 lbf (lb. force) / 5,000 kgf (kg force) and up to 1 in. / 25mm diameter, to verify that each of the eight newly installed ropes were under the same tension.

Any variance would have created a safety issue when the elevator was returned to work delivering materials to different levels of the steel-making factory.

The COLT was clamped onto the pre-tensioned wire ropes and the tension was directly displayed. Tensology would previously have used a statimeter to complete the task.

According to Barrie Mordue, director at Tensology, a provider of specialist services related to wire ropes: “The facility issued a contract to replace the system of ropes that was part of a complicated reeving system, including counterweights and other components. The statimeter has been used for such applications for many years, but it doesn’t provide a direct reading; users have to refer to a calibration graph. And it’s a two-person job to install it each time.”

Mordue singled out a state-of-theart Bluetooth load monitoring app among the COLT’s standout features.

The Bluetooth module transmitted tension data wirelessly to Tensology’s smart device running the app (available on Android or iOS), which also contains an infinite wire rope library.

Tension in each rope was measured and logged within a few seconds.

“The principle of the equipment is the same as more traditional methods, but it is more user-friendly and efficient. The product makes contact with the wire rope at three points.

Force is then applied to the rope at the centre connection point while an

auto-locking, magnetic handle mechanism secures it in place. Tension data is available in real time.”

The COLT offers an integral quick adjustment mechanism, meaning it can be used to measure wire rope diameters from 3/16 in. to 1 in. or 5mm to 25mm. It also features a computer numerical control (CNC) machined aluminium construction with high precision roller bearing pivot; high leverage tensioning arm; and IP67 / NEMA6 waterproofing rating.

Other applications to which it is suited include tower and stack guy wires; pre-tensioned cable barriers; bridges; winch rope; overhead electric transit wires; fall arrest systems; aircraft cables; and utilities equipment.

For further information, log on to www.straightpoint.com

Measuring rope tension

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DRIVING INGENUITY

1/10/18 9:45 AM

20

INNOVATIONS

Fives acquires tube and pipe know-how Global industrial engineering group Fives has acquired the intellectual property (IP) and know-how of Italy’s Imec Engineering’s Tube and Pipe Division.

According to Fives, the acquired portfolio covers Imec’s technological expertise in four areas: polishing, finishing, packaging and handling in the steel and energy sectors.

The acquisition will complement what Fives has to offer in terms of engineering, manufacturing, supply and installation of custom-engineered Abbey, Bronx, OTO and Taylor-Wilson equipment to process seamless and welded tube and pipe products.

From Fives’ perspective, the purchase of the IP and know-how of Imec is a key step towards enlarging the company’s stainless steel machinery offer as well as strengthening the global offer for mechanical, structural and automotive tubing markets.

“The acquisition will enable us to provide complete customised solutions to tube manufacturers worldwide and cement our position as a supplier of choice from start to finishing,” said Stefano Olcese, head of tube and pipe business for Fives.

For further information, log on to www.fivesgroup.com

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22

STEEL SURVEY

Don’t prioritise cost over

STEEL SURVEY

23

quality The importance of having new technologies available while at the same time keeping costs down was one of the key outcomes of a survey undertaken by Sandvik. In recent years, since the global economy has been challenging, those responsible for sourcing stainless steel may have been tempted to try and make budget savings by purchasing cheaper materials. Inevitably this will often prove to be a false economy in the long run and could result in costly operational failure in some cases. Here Hans Boudewijn* discusses the survey findings and gives his advice on key areas to consider when purchasing stainless steel.

Towards the end of 2017, Sandvik was keen to find out more about current industry trends, what the key factors are affecting customers today and what is most likely to influence their purchasing decisions.

This led to a survey being undertaken at the Stainless Steel World Exhibition, where customers from leading blue chip companies responded to questions on a range of topics including investment in infrastructure, cost cutting, plant upgrades and maintenance, safety and security and the adoption of new technologies.

The results revealed that the adoption of new technologies and the importance of innovation were very much at the top of the list with 65% of those questioned. In addition, it was no surprise that keeping costs down also came out as being highly important (62%) to customers, indicating that market conditions continue to be challenging and budgets are still being squeezed.

However, despite the desire to keep a tight rein on costs, key decision makers are not forgetting the safety and security of their staff and operations with more than half of those polled believing this to be a key priority for their businesses.

Overall the conclusions drawn from the survey demonstrate that although budgets are still extremely tight, investment in infrastructure was rated as important in conjunction with the adoption of new technology, and purchasers have indicated that improving techniques and processes

are critical to business improvement and growth.

Manufacturing is just one sector where market conditions have been difficult in the last decade and those responsible for sourcing and purchasing of all types of materials and have been increasingly under pressure to keep their spend to a minimum. It can be tempting to seek cheaper alternatives, but this can come at a price and may cause failure during an operation or process. This in turn could result in downtime of the equipment, and in some cases costly loss of production.

Ultimately, there is no substitute for going for the experienced and reputable original equipment manufacturer (OEM) every time to make sure a consistent and reliable performance is delivered, while at the same time using the latest and best technology.

Selecting inferior, cheap stainless steel products can present a number of problems for customers. An area that many may not think of in the first instance is the life cycle cost. Aside from failure in operation, purchasing inferior stainless steel will inevitably shorten the overall life cycle of the equipment. This in turn will lead to the need for premature replacement and result in unnecessary and additional costs for the user.

One of the main reasons people work with stainless steel is due to its resistance to aggressive liquids or elements and its ability to operate continuously despite the effects of such products. This is another area where

* Regional sales director for Sandvik Digital Edition - February 2018

24

STEEL SURVEY

About Sandvik Sandvik is a leading developer and manufacturer of products in advanced stainless steels and special alloys for the most demanding environments, as well as products and systems for nuclear applications.

For more information on Sandvik, visit https://www.materials.sandvik

inferior steel will ultimately provide a poor level of performance and will cause a range of problems for the customers’ operation.

In general, using inferior products in expensive and state-of-the-art plants and facilities also has the potential to cause problems with the rest of the equipment or system. For example, chemical and oil & gas facilities involve highly technical and finely balanced processes and any problems with the quality of materials in the equipment used will have a ‘knock-on’ detrimental effect on operations. A catastrophic failure could result in production being held up for weeks or even months in the worst case scenarios.

Products that are tested thoroughly and correctly will ensure the customers’ confidence in the products they are buying. Quality manufacturers have their own in-house facilities where products are extensively tested so customers can be supremely confident in the quality of the steel they are purchasing.

So what should specifiers look for when selecting steel products? Many would say that the most important consideration is the experience of the manufacturer.

Working with established companies who have an excellent reputation and proven track record with their customers is something that cannot be underestimated.

Good business relationships are usually built on trust in the product and service received.

Specification Close examination of the material specification and consideration of how it will perform to meet expectations is vitally important. In some situations, if the wrong product is selected for the required application, it will not perform correctly, so care should be taken with specification.

This is where the product manufacturer can provide invaluable help.

Leading manufacturers will always avoid making a product that will simply meet the required industry standard. Instead, adopting an innovative approach and embracing real technical creativity will always ensure the relevant specification is exceeded. Equipment designers will always build in a safety factor of plus one or two and in turn material manufacturers will adopt the same principle; and the result will mean that customers have total confidence

in the performance and reliability of what they are buying.

When purchasing stainless steel products, the customer needs to be confident that what they are buying is offering them the best possible performance, quality and consistency. When specifying a steel grade for a particular application, working with the manufacturer who possesses the required knowledge and expertise to help will ultimately provide the best result.

Avoiding cutting corners on quality and not basing the purchasing decision on cost will always deliver the best and most technically innovative solution in the long run.

Inevitably cost and keeping a firm grip on the budget is important to those responsible for purchasing stainless steel, but their desire for quality products that will deliver the best solution and the right level of support is clearly demonstrated in these survey results. � Full details of the survey results can be found by logging on to https://tinyurl.com/ y77ta2o8

INNOVATIVE TECHNOLOGIES

FOR THE METALS INDUSTRY CMI INDUSTRY METALS designs, installs, modernizes and services installations and machinery for the steel and non-ferrous industries throughout their whole life-cycle in order to improve the economic, technological and environmental performance of this equipment. CMI’s clients benefit from: a unique combination of expertise in engineering, maintenance and the management of international technical projects, a vast geographic and technological scope, and an ability to innovate in accordance with the concrete needs of its customers.

CMI Industry is established in North America, China, Europe, India and Russia. It can also rely on the worldwide network of the CMI Group.

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Re h e a t in g f u r n ace s § Pi c k l i ng § A c i d R eg enera ti o n § C o l d Rol l i ng St r ip Pr oce ssi n g (m e ch a ni c a l , c hem i c a l & ther m a l ) § A utom a ti on DESIGN

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ENGINEERING

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COMMISSIONING

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TECHNICAL

A S S I S TA N C E

&

TRAINING

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AFTER-SALES

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MAINTENANCE

Digital Edition - February 2018

MAINTENANCE

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DeďŹ ning housing strength Design engineers across industries rely on pillow block bearings for a variety of tough and unconventional applications. Having access to data that backs claims about housing strength performance is an integral part of choosing the right bearing to keep operations running smoothly.

By Florin Constantin*

What design considerations must be made when the application demands a pillow block installation on a non-horizontal orientation? What happens when bearing load is not applied through the base of the unit? The Timken Company answers these questions with physical testing, advanced modelling and real-world experience to facilitate the selection of pillow block bearings for specific applications.

Why strength matters The roller bearing is an essential component of countless industrial applications around the world. The reliability and repeatability of the processes where differing types of roller bearings provide functionality is of paramount importance for countless everyday operations.

For most industrial operations, designers seek to maximise uptime with the selection of components that offer extended service life. In most applications where rolling-

element bearings are applied, bearing static and dynamic load capacities are crucial parameters when estimating operating life.

Static load rating: The maximum load a bearing can withstand before permanent damage to the raceways or rolling elements; indicates a load being applied in a constant, unchanging direction under non-rotating conditions.

Dynamic load rating: The radial load under which a population of bearings will achieve an L10 of one million revolutions.

The load value is used to estimate bearing life based on the actual applied loads and speeds.

For pillow block (also known as plummer block, mounted bearing or housed unit) applications, the strength rating of the housing itself is a critically important performance attribute – and is why Timken performed an evaluation of housing strength and permissible load across its roller housed unit product line.

Solid block housings: One-piece housings that are factory-assembled, pre-greased and sealed, offering simple installation direct from shelf to shaft.

Split block housings: Twopiece housings that are split in the middle with bolts fixing the two halves. These allow for simpler installation, and replacement of the bearings and seals without removal of the housings.

Industrial operators rely on these speciality bearings and housings for

supporting shafts, gears and other rotating or oscillating components in a variety of unconventional loading orientations.

Also, they often necessitate special design considerations. For instance: What changes in design must be made when the application requires a pillow block to be installed upside down? What if the bearing load is not applied through the base?

The equipment designer relies on housing static load carrying guidance to make the appropriate selection of pillow block bearing for a given application. Thus, it is critical that these decision makers have access to housing strength information to optimise the effectiveness of equipment.

Reliable housing strength data The demands of today’s operations require bearings to work harder and longer. This means the housing must work harder, too.

Applications that generate more than one loading orientation on bearings require housings that can bear the same loads, hence the need for consistent housing strength data when designing equipment.

In these types of applications, housings handle extreme forces in varying directions and allow the bearing to be mounted in positions where the load may not be applied directly through the base.

These orientations are most common in large conveyor systems and in extreme applications like industrial crushing machines or hammer mills.

Spherical roller bearings are commonly used in general industrial applications, providing dependable performance and capacity in supporting radial loads with limited axial loading.

*Principal application engineer, The Timken Company

Digital Edition - February 2018

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MAINTENANCE

3-D contact definition between housing and rigid pin

Fixed boundary condition at bolt positions

Fixed boundary condition at flange ends

Solid block housing

Rigid pin - fixed displacement with reaction force output

Half symmetry boundary conditions

Fig 1. In this example, the material is defined as AISI 1035 cast steel, with tensile test data gathered from different found-

A common question when seeking replacement mounted bearings is: What kind of load can be applied to my bearing?

Answering this question is critical to selecting an appropriate bearing for the application. The geometries of mounted roller bearing housings can be complex and varied in shape, based on the size and type of bearings they support, making it complicated to estimate housing strength.

The Timken testing methodology for generating housing strength data combines advanced modelling techniques and experimental testing, all backed by real-world experience for the purpose of providing answers for customers.

ries to improve data relevancy

Fig 2. Stress is concentrated near lubrication holes in this housing

Fig 3. Strain contour plot

Digital Edition - February 2018

Housing strength testing methodology Loads can be applied to pillow block bearings in virtually limitless ways. Testing every housing to failure in every loading orientation is impractical, requiring a consistent modelling technique to maximise available useable data.

Timken developed a method of generating breaking strength data based on laboratory testing, advanced modeling calculations and the company’s history in the metallurgical engineering field.

Finite element analysis (FEA) is combined with experimental testing to create calibrated models that calculate the limiting static strength of the bearing housing.

Housing strength design rules were then established and appropriate strength values published.

Modelling/Finite Element Analysis (FEA) is deployed primarily to account for the diversity in mounted bearing housing shapes and complexities. For housing strength, FEA is desirable over simplified analytical expressions’ limits in accounting for complex shapes.

FEA can account for the interaction between complex housing geometry and non-linear material properties when calculating stress and strain.

Three-dimensional solid models of housings are prepared as a first step for incorporation into the FEA model. Based on the loading and geometry symmetry, a half model was created to reduce the size of the model and the subsequent solution time. These models were first solved to get a rough estimate of the breaking strength of the test parts to estimate experimental tooling requirements. The models were later www.steeltimesint.com

MAINTENANCE

Fig 4a.

Fig 4b.

Fig 4c.

Fracture of split housing bolt

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Fracture of split housing section

www.steeltimesint.com

Digital Edition - February 2018

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MAINTENANCE

Fig 5. FEA of split housing 3-D contact at all interfaces

Rigid constraints at roller positions

Cap bolts modeled with solid elements ductile damage defined at end

Split housing

Flange bolts modeled with beam elements Half symmetry boundary conditions

refined to include failure criteria validated through experimental results. (See Fig. 1) Cast iron is commonly used for mounted bearing units, desirable for its relative structural rigidity, strength under compression and corrosion resistance.

However, some applications require very high impact loads or non-horizontal mounting, where cast iron does not provide adequate strength. Cast steel offers a strong alternative.

It has approximately twice the yield strength as comparable cast iron and offers greater breakage resistance in tougher applications. Ductile iron also far exceeds cast iron in strength and can be advantageous for certain housing geometries.

Through FEA modelling, Timken is able to calculate and define accurate fracture strain and stress values. Breaking strength for cast steel housings is estimated with a non-linear elastic-plastic analysis with an isotropic hardening model. Based on the housing’s material properties, ductile damage data is entered into the FEA models to check the maximum strain of each element.

As the housing load is increased, the material hardens while elements elongate and exceed critical strain thresholds. The load on the housing reaches a maximum, followed by ductile fracture.

Typical strain patterns are illustrated in Fig. 2 and Fig.3. Simulated modeling that follows an established method, as outlined above, allows Timken to predict housing strengths, enabling the customer to create a more reliable and dependable design.

Modelling is only part of the process.

Testing is also used to verify the modeling assumptions and provide better and more realistic model parameters.

Digital Edition - February 2018

Physical testing FEA simulation assumptions were based on findings for housings loaded to the point of fracture. To determine these figures, Timken housings of different sizes were selected and loaded in a hydraulic press fitted with specialised universal tooling and then tested at a range of loads.

The universal tooling used for these experiments can break housings in 180-, 150- and 90-degree loading directions based on differing set-up configurations, reflective of the unconventional angles in which pillow blocks are installed in the real world.

Since the estimated load necessary for housing fracture in these simulations could exceed the bearing static limit, no bearings were used in this exercise. Instead, they were replaced with round bars. Various styles of solid block housings and split block housings were physically tested.

Each test was performed using properly controlled loading cycles. Hydraulic fluid was slowly metered into the load piston using a control valve. A computer recorded the values of the load cell throughout the test so the maximum loads could be determined.

Multiple replicates were tested in each of the loading directions. The results of the test indicated variability between the replicates in load magnitude as well as breaking location. For example, a four-bolt housing had three different failure locations when loaded in the 180-degree direction.

The attachment bolts through the base flange had to be supported in each test to prevent bolt breaking and force a housing break. This was necessary even when using Grade 9 quality bolts.

The housing break failures, as seen in Fig.6, were ductile in nature, as

demonstrated by the visible deformation in the housing before fracture occurred.

These results were consistent with the expectations for cast steel material and assumptions based upon FEA findings. Large plastic deformation was seen at the bolt attachment area on the flanges, though no ultimate fractures occurred there.

Breaking load, displacement and break location data were collected from each test.

The methodology for analysing and testing split housings was similar to that of solid housings. The testing showed that the gray cast iron housings had a more brittle failure mode with little deformation before fracture. Breaking loads were lower than the cast steel due to the material strength difference.

The ductile iron housings had larger strains than the gray iron at fracture, but not as great as the cast steel parts. (See Fig. 6.)

In the FEA, the gray cast iron housing failure criteria were defined using an extended fracture mechanics model. In comparison, the ductile iron housings used the same failure model as the solid block housings, but with a smaller fracture strain definition.

The split housings also introduced another failure mode, which was bolt fracture on some of the housings. To account for this, FEA models were enhanced to include bolt ductile damage failure criteria. (See Fig. 5) Housing strength test results The Timken methodology for determining housing breaking strength can help equipment designers and end users make informed decisions on the advantages and benefits of each of Timken’s housed units. Through this rigorous testing process, Timken established not just the strength of its materials, but also the unique applications in which its portfolio of mounted bearings and housings will best perform, backing housing strength estimates with conclusive data. www.steeltimesint.com

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Ductile iron housing - safe load 600

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Fig. 7 shows a comparison of housing safe loads for both cast iron and ductile iron relative to shaft size and angle of the applied load. This shows the importance of housing design and material selection in selecting the proper housing for a given application

www.steeltimesint.com

Digital Edition - February 2018

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MAINTENANCE

Failure modes may vary based on casting geometry, casting material, and cap bolt size and grade. Split housings enable a simpler assembly and can help reduce overall installation cost, but do not maintain the same overall strength of comparable single-piece, solid block housings. Solid cast steel housing strength values generally exceed the bearing capacity regardless of load direction. Using a conservative approach, published housing strength values for solid block housed units were established using minimum material properties.

Gray cast iron generally has a smaller load-carrying capacity at varying orientations than ductile cast iron. While gray cast iron can be a more cost-effective material than ductile iron, it may not be the appropriate choice for more demanding applications in non-horizontal load bearing applications.

Digital Edition - February 2018

Easy-to-use safe load guidelines for Timken split housings, where load is not applied directly into the base or if the base is unsupported (P0) have been developed.

The safe load is the maximum suggested load to be applied to the housing depending on the direction of the load.

The safe load guidelines for split housings account for the breaking strength of the housing and the breaking strength of the cap bolts.

A commonly accepted safety factor of five is used for the breaking strength of the split housing material, and a safety factor of three is used for the cap bolt breaking strength. Additional safety factors may be applied by the user for safety-critical applications.

The published safe load values assume the housing has been properly secured to the base structure and proper torque has been applied to the cap bolts.

Fig. 7 shows a comparison of housing safe loads for both cast iron and ductile iron relative to shaft size and angle of the applied load. This shows the importance of housing design and material selection in selecting the proper housing for a given application.

By using FEA results calibrated with experimental testing, Timken has created a methodology to predict housing strength without testing each unit.

Through this combination of advanced modelling and real-world experience, Timken is able to provide estimated housing strength of its mounted bearing offerings.

Actionable, accessible data is one more way Timken meets the increasing demands of heavy industry every day.

All specific data relevant to housing strength based on the Timken method is available within the company’s latest housed unit catalogue. �

www.steeltimesint.com

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FURNACES

35

Reducing N0x emissions

REBOX high level lancing (HLL) and flameless oxyfuel technology is claimed to offer flexible environment-friendly and fuel-efficient steel heating. By RĂźdiger Eichler MSc EUR Ing * Oxyfuel Technologies have been used in steel heating furnaces since the late 1980s.

The main targets then were increased production, fuel efficiency and reduced NOx-emissions.

During the period 1988 to 1991, it was realised that special efforts were needed to achieve reduced NOx-emissions under certain conditions. It was then when the concept of Flameless Oxyfuel Combustion was shown to be very efficient in suppressing NOx-formation.

Between 1991 and 1995 several pitfurnaces in Avesta Degerfors (Outokumpu) and Ovako Hofors were revamped from air/fuel combustion to 100% Oxyfuel combustion. Great results were achieved both in productivity increase, fuel savings and NOx-emissions reduction.

In 1995 the journey towards larger furnaces started when the first catenary furnace was equipped with REBOX Oxyfuel Technology. In 1997 it was followed by the first car bottom furnace and the first rotary hearth furnace. In 1998 the first green field rotary hearth and green field roller hearth furnaces were built for 100% Oxyfuel combustion.

The first already 100% Oxyfuel-fired furnace was revamped to 100% REBOX

Flameless Oxyfuel Technology in 2003. The results were not only NOx-reductions, but also further reduced energy consumption mainly due to increased overall temperature homogeneity.

In 2010, when the first REBOX High Level Lancing (HLL) installation was made in a 130MW walking beam furnace at SSAB in Borlänge, Sweden, 125 steel heating furnaces had been equipped with REBOX Oxyfuel Technology. Seven years later it is 170 steel heating furnaces spread from

China in the east to the USA in the west.

Recently (2016-2017) Linde realised two new green field projects, among others, one in Sweden and one in China, where one roller hearth furnace and four pit furnaces where built for 100% flameless oxyfuel combustion. Both turn-key projects included furnaces, combustion system, dampers, flow trains as well as other equipment for material handling.

Schematic of a REBOX Turn-Key 4 pit furnace system

* Senior specialist, combustion and steel, Linde Gas www.steeltimesint.com

Digital Edition - February 2018

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FURNACES

Oxyfuel combustion Oxyfuel combustion is the combustion of a fuel using industrial grade oxygen as oxidant, normally containing over 90% oxygen. Combustion air contains 21% oxygen and the rest is essentially inert gases where about 78% is nitrogen.

By excluding the inert gases from air, the volume of oxidant needed and the exhaust gas volume created is substantially reduced.

This is not only due to the reduction of inert gases, but also fuel savings resulting from a more efficient heating process. The reduced exhaust gas volume also makes it possible to introduce a higher power into a given

furnace volume and/or extend the length of fired zones. This makes it often possible to increase the specific rate of production from a given furnace and/or use low calorific fuels instead of high calorific fuels and still reach the same heating results in the same furnace.

The increased efficiency depends on the base for the comparison i.e. how much energy has been recovered from the exhaust gases in the air/fuel combustion scenario.

Fuel savings normally are between 20% and 70% when converting a heating furnace to 100% Oxyfuel combustion. Alternatively, a low calorific fuel can be used instead and

180 160

REBOX furnace installations

140

still the same results can be achieved.

When nitrogen is removed from the process the increased partial pressure of the three-atomic gases CO2 and H2O in the furnace atmosphere will increase the heat transfer by radiation from hot gases to the product. At the same time the smaller volume of product gases potentially increase the flame temperature. This would result in higher thermal NOx from Oxyfuel combustion if required nitrogen is available, unless measures were taken to reduce the actual flame temperature.

120 100 80 60 40 20 0 Number of REBOX installations in steel reheat furnaces

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mg NO2/MJ

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%O2 dry NOx reductions with REBOX HLL in a walking beam furnace.

NOx emissions in mgNO2/MJ vs %O2 in exhaust with and without REBOX HLL

Digital Edition - February 2018

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With HLL

Reducing thermal NOx A reduction of thermal NOx is achieved by reducing peak flame temperatures. REBOX flameless oxyfuel combustion is especially designed to transform the combustion from a small volume into a much larger volume. This is made by furnace-internal recirculation to a point when dilution has reduced the speed of reactions until there is no longer a visible flame attached to the burner.

REBOX flameless oxyfuel combustion is only used above a furnace temperature at which the combustion will self-ignite. Normally about 800°C. That is why the REBOX flameless oxyfuel burners have a flamemode and a flameless mode unless they are accompanied by other burners capable of heating up the furnace to above 800°C. The NOx emissions from steel reheat furnaces equipped with REBOX flameless oxyfuel typically present NOx-emissions well below Swedish legislation in mgNO2/MJ of energy added. At the same time the energy www.steeltimesint.com

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With special alloys and gas-tight shaft seals, we protect our fans from corro-sive gases containing sulphur, hydrochloric acid, chlorine and fluorine.

efficiency and the furnace flexibility is very high. Heating of steel from ambient temperature to rolling temperature can be made by using under 1 GJ/ton of steel which translates into a process efficiency of 70%-80% or more depending on the fuel, the steel and the rolling temperature.

A semi-flameless technology REBOX high level lancing (HLL) is a flexible, semi-flameless technology for capacity increase, fuel savings and emissions reduction where the existing burners are equipped with additional lances for oxygen injection. The advantages are several. The old existing system can be kept and operated as it is and at the same time the capacity can be increased when required.

The fuel consumption as well as the NOx and CO2 emissions are reduced.

The diagram below shows NOx measurements from a walking beam furnace during operation with and without REBOX HLL operation. The NOx emissions are reduced by about 40% in this case.

While REBOX HLL can be used in any type of combustion, however, it has found its place mostly in large continuous side-fired furnaces with large doors for charging and discharging where a certain amount of exhaust gas volume is needed to keep a positive furnace pressure.

REBOX HLL can also be used to reduce furnace pressure and exhaust gas temperature in situations when the furnace is put to its limits due to a very high load.

Since the reduction of exhaust gases and the injection of oxygen change the gas circulation in the furnace in different ways, the REBOX HLL technology is separated into several sub-technologies where the angle of injection in relation to fuel and air flow differs. This means that, for special cases, oxygen might not always be injected next to a fuel injection point. However, in all cases the target is to increase the efficiency of the heating operation and reduce emissions. As an example, REBOX HLL lancing technology is used today to control temperature distribution along the length of 12m long slabs to optimise heating and rolling operations.

Conclusions REBOX Flameless Oxyfuel and REBOX HLL can be used for process optimisation and emissions reduction.

For further information, log on to www.linde-gas.com/rebox �

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39

ENVIRONMENT

40% to 60% less CO2 The steelmaking industry is characterised by an intensive use of fossil fuels, which leads to a significant environmental impact in the form of Greenhouse Gases (GHG), mainly as CO2 emissions. For the integrated steelmaking process, the primary source for reduction of iron oxides is coal; while for the DR-EAF route the source of reducing gases can be natural gas (NG), reformed gas, coke oven gas (COG), syngas from coal and hydrogen (H2). In general, based on the use of coal in the BF-BOF route as compared to NG with the DR-EAF route, by simple material balance, the DR-EAF route emits 40% - 60% less CO2 (depending on plant location and source of power generation) than the BF-BOF.

By Pablo Duarte* and Jorge Martinez**

THE carbon intensity of steel production varies significantly between the various steelmaking routes, ranging from around 0.4 tCO2/t crude steel for scrap melting EAFs, 1.7–1.8 tCO2/t crude steel for the integrated BF-BOF to 2.5 tCO2/t crude steel for coal-based DRI processes, depending on the local kgCO2/kWh factor. Indirect steel industry CO2 emissions, depending on power generated from hydraulic, renewables or nuclear, will gradually decrease as electricity decarbonises. In case the power is 100% generated from these sources, the scrap-EAF route would result in near zero-CO2 emissions.

Besides GHG emissions, there are a number of by-products and pollutants that can have severe environmental impact and which require special attention, specifically for the BF-BOF route.

Heat recuperator

Iron ore (3.2 - 18mm)

PG compressor

- High temp: >1050oC - Operating pressure: 6-8 bar

PG heater CO2 absorber Reactor

Make-up: Natural gas Reformed gas Syngas COG Hydrogen

In-situ reforming CO + 3H2 CH4 + H2 CH4 + CO2 2CO + 2H2

Humidifier O2 Tail gas

Hytemp system

Fuel

Cold DRI

HBI

Reduction Fe2O3 + 3CO Fe2O3 + 3H2

2Feo + 3CO2 2Feo + 3H2O

Carburisation 3Feo + CH4

Fe3C + 2H2

Hot DRI to EAF

Fig 1. Energiron ZR process: In-situ reforming

Typical BF-BOF steelworks

Typical DR-EAF mill

Input

Unit

Consumption CO2 Emissions

(kg/tLS)

Input

Unit

Consumption

CO2 Emissions

(Unit/tLS)

(kg CO2/tLS)

(kg CO2/tLS)

Coking coal (dry)

kg/tLS

430

1293

Natural gas

Gcal/tLS

2.22

526

PCI (dry)

kg/tLS

150

434

Dolomite

kg/tLS

32

15

Limestone to BF/Sinter

kg/tLS

120

53

TOTAL

TOTAL 541

1780

Credit for export power

380kWh/tLS

-165 TOTAL

Import power (incl. O2) 630kWh/tLS

1615

+315 TOTAL

856

Table 1. Carbon/CO2 emissions balance in BF-BOF and DR-EAF routes

* Commercial VP, Tenova HYL **Proposals manager, Tenova HYL www.steeltimesint.com

Digital Edition - February 2018

40

ENVIRONMENT

Coking coal 440kg/tLS 361kg C/tLS CO2 emissions 1,810kg/tLS

Iron ore PCI 150kg/tLS 118kg C/tLS

Sinter Coking plant

Coke

Power plant

Hot metal

Export power 330 kWh/tLS (@0.5kg CO2/kWh)

0.91 t HM 0.20 t scrap BOF

Liquid steel

ENERGIRON ZR direct reduction

Power 79kWh/tLS (0.5kg CO2/kWh) Oxygen 55Nm3/tLS

Blast furnace

Limestone 120kg/tLS

Natural gas 2.22 Gcal/tLS

Power 400kWh/tLS (0.5kg CO2/kWh)

Non-Selective CO2 emissions 306kg/tLS Hot DRI

0.92 t HDRI 0.20 t scrap

Dolomite 32kg/tLS Oxygen 36Nm3/tLS

1.0 t liq. steel

Selective CO2 emissions 235kg/tLS

EAF Liquid steel

1.0 t liq. steel

Power 100kWh/tLS (0.5kg CO2/kWh) Fig 2a. BF-BOF route for HRC production: Energy/CO2 emissions scheme

Fig 2b. DR-EAF ROUTE FOR HRC production: Energy/CO2 emissions scheme OTHER TECHNOLOGY 0

ENERGIRON ZR

Selective CO2 emissions kgCO2/tDRI 256 Captured and sold as by-product Non-selective CO2 emissions kgCO2/tDRI 159 ~ 500 Released to atmosphere Non-selective 100% Non-selective 38% Selective 62% Iron ore

Iron ore Fig 4. H2 use in the ENERGIRON DR process

Renewable energy - optimised electrolysers

CO2 removal NG + H2

H2O

O2 Fuel

CO2 (+H2S)

Fig 3.Selective CO2 removal in ENERGIRON ZR process

DR reactor

- NG PG - H2 O2 Heater - COG Fuel - Ref. gas - Syngas

The ENERGIRON DR process The ENERGIRON Zero Reformer (ZR) Process scheme (Fig. 1) is a major step in reducing the size and improving the efficiency of direct reduction plants. Reducing gases are generated by in-situ reforming of hydrocarbons within the reduction reactor, feeding NG as make-up to the reducing gas circuit and injecting oxygen at the inlet of the reactor [1]. The ZR process scheme is the only one that allows the direct use of NG as an iron ore reducing agent. ENERGIRON plants can also use conventional steamNG reforming equipment as an external source of reducing gases, which has long characterised the process. Other reducing agents such as H2, syngas from coal Digital Edition - February 2018

H2O

DRI

gasification, pet coke and similar fossil fuels, and coke-oven gas, among others, are also potential sources of reducing gas, depending on the particular situation and availability. In any case, the same basic process scheme is used regardless of the reducing gas source.

The Fe° formed in the process itself acts as the necessary, renewable and continuous catalyst for the reduction process. During start up, process gas is heated by the process gas heater and then H2 and CO are generated by partial combustion (with oxygen injection), thus starting the reduction of the iron ore.

The operating conditions of the ZR process are characterised by high

temperature (~1080°C) and high pressure (6-8 bar A at the top gas). The elevated pressure allows high productivity (of about 10 t/h x m²) and low reducing gas velocities (of about 2 m/sec), as compared to processes using lower operating pressure, for which the gas velocities are >5 m/sec, thus minimising dust losses through top gas carry-over. This lowers overall iron ore consumption, which in turn lowers overall operating costs. A distinct advantage of the ZR scheme is wider flexibility for DRI carburisation. DRI carbon levels up to 5% can be obtained, due to the prevailing conditions of high methane (CH4) concentration in the process gas and the high temperature of the bed (>860°C), which favours the diffusion of carbon into the iron matrix and the precipitation of Iron Carbide (Fe3C) [2]. Additionally, a unique characteristic of this process is the selective removal of both by-products of the reduction process: H2O and CO2, thus significantly increasing process control and efficiency. www.steeltimesint.com

41

ENVIRONMENT

11.0

250 200

7.0

CO2 Emissions (Nm3/t DRI

DRI Energy consumption (GJ/tDRI)

9.0

5.0 3.0 1.0 -1.0 -3.0

150

100

50

0 100% NG (@4.0%C)

NG (GJ/tDRI)

35% H2 (@3.5%C)

H2 (GJ/tDRI)

55% H2 (@2.5%C)

70% H2 (@1.8%C)

100% NG (@4.0%C)

35% H2 (@3.5%C)

Non selective CO2 (Nm3/t DRI)

%C Energy credit (GJ/tDRI)

55% H2 (@2.5%C)

70% H2 (@1.8%C)

Selective CO2 (Nm3/t DRI)

Fig 5. DRI Energy consumption and CO2 emissions with H2 use in the ENERGIRON DR process

CO2 emissions in BF-BOF versus DR-EAF This scenario is based on the comparison between the DR-EAF and the BF-BOF routes for manufacturing hot rolled coils (HRC).

The selected typical integrated steelworks comprises a coke oven plant, sinter plant and BF for generation of HM and a BOF steel plant with ladle furnace and thin slab caster or compact strip plant (CSP) for the production of HRC. Fig. 2a shows the schematic energy distribution of this facility [1], [3] .

The major gaseous fuel by-products, which are recovered in integrated steelworks, are: blast furnace gases (BFG), coke oven gases (COG) and basic oxygen furnace gases (BOFG). Energy balances of integrated steel plants show that a significant portion of the gaseous energies are used for power generation or even flared. Since only a minor part of the electrical power that could be generated from these gases can be used internally in the steelworks, most of the electrical power is exported.

Electricity generation has an impact on CO2 emissions depending on the location of the steel plant. Electric power generation is a composite of sourcing from natural gas, coal, hydraulic, eolic, nuclear, biomass, and so on. There are countries like Venezuela where power generation is based on ~0.3 kg CO2/kWh and others like India, where it is ~0.9 kg CO2/kWh.  For the selected integrated BF-BOF mill, the specific CO2 emissions are about 1810 kg of CO2/t of liquid steel (LS). For this analysis, the selected location has a carbon www.steeltimesint.com

CO2 Emissions - steelmaking routes (location: 0.5kg CO2/kWh; w/o CO2 off-taking/commercialisation 100%

BF-BOF DRI (w/NG) TO BF (competing technology)

90%

DRI (w/NG) TO BF ENERGIRON (1)

84%

DRP-EAF (competing technology)

59%

DRP-EAF ENERGIRON (1)

53%

DRP-EAF ENERGIRON 35% H2- as energy( (1)

33% 0

400

800 1200 CO2 Emissions (kg/t Liquid Steel)

1600

Fig 6a. CO2 emissions for the various steelmaking routes-w/o selective CO2 off-taking Fig 6b. CO2 emissions for the various steelmaking routes-w/o selective CO2 off-taking

CO2 Emissions - steelmaking routes (location: 0.5kg CO2/kWh; w/o CO2 off-taking/commercialisation BF-BOF

100%

DRI (w/NG) TO BF (competing technology)

90%

DRI (w/NG) TO BF ENERGIRON (2)

78%

DRP-EAF (competing technology)

59%

DRP-EAF ENERGIRON (2)

38%

DRP-EAF ENERGIRON 35% H2- as energy( (2)

28% 0

400

800 1200 CO2 Emissions (kg/t Liquid Steel)

1600

Digital Edition - February 2018

42

ENVIRONMENT

footprint of 0.5 kg CO2/kWh. Considering that the BF-BOF installation has an export power of about 330 kWh/tLS, the credit for this will be reflected in 165 kg CO2/ tLS, for net CO2 emissions of 1615 kg CO2/ tLS. The DR/EAF route is presented in Fig. 3b. The ENERGIRON ZR-based DR plant was selected as reference, for high-C DRI (94% Mtz and 4%C) production, which provides additional energy for secondary reduction of FeO in the BF, as 80% feed to the EAF, similarly to the scrap charge to BOF (~20%).

The DR/EAF route is presented in Fig. 3b. The ENERGIRON ZR-based DR plant was selected as reference, for high-C DRI production, with 94% Mtz and 4%C, as 80% feed to the EAF. The difference between BF-BOF vs. DREAF in terms of CO2 emissions is clear when analysing the conversion of: 3CH4 + 4Fe2O3

the DR-EAF mill is a net importer. By using the ZR scheme, more than half of the gaseous CO2 is selectively removed. This provides a strong potential for alternate disposal of this CO2, thus significantly reducing GHG emissions.

CO2 emissions in an ENERGIRON DR plant Regardless of whether using natural gas (CH4), syngas from coal gasifiers, or COG; unless H2 is used, the make-up of reducing gases to a DR plant (DRP) contains carbon, either in the form of hydrocarbons and/ or carbonaceous compounds – CO and CO2. Also, regardless of the DR process configuration, from the total carbon in the make-up, only 15-40% (depending on the carbon content in the DRI) exits the process

as combined carbon in the DRI [2]. By the principle of mass conservation, the balance of the carbon must exit the process, and for the case of a DR process, this takes place in the gaseous form as CO2. In this regard: - Because the ENERGIRON ZR process takes advantage of the catalytic effect of metallic Fe in the DRI and a high level of carbon is part of the DRI (in the form of Fe3C), a lesser amount of carbon is removed from the system in the form of CO2. This higher carbon level in DRI, as has been well-proven in practice and documented in various papers [2], is beneficial in the steelmaking process by providing chemical energy to the furnace, and for making the steelmaking process more efficient.

8Fe° + 3CO2 + 6H2O

Reduction of ores through DR drastically reduces CO2 emissions as compared to coal, for which all reductants are coming from C, in a ratio of 2/1;

Fig 7. Nucor Steel Louisiana DR plant with CO2 absorption and Sulfur removal system

3C + 2Fe2O3

4Fe° + 3CO2

The main observations to be made are related to the fact that while the integrated steel plant is a net exporter of electricity,

Digital Edition - February 2018

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ENVIRONMENT

Additionally, a distinctive feature of this technology is the selective removal of CO2.

- In the other DR technology, with integrated reformer, all carbon entering the process (with the exception of the low %C leaving the system as part of the DRI) is purged through the flue gases of the reformer, to preserve the overall carbon balance.

Eliminating total carbon input The result of the ENERGIRON scheme configuration is the inherent selective elimination of about 60% of total carbon input as CO2 (equivalent to about 260 kg CO2/t DRI), which when commercialised, significantly reduces the CO2 emissions of the DR plant. This is a clear advantage of this configuration when compared to any competing DR technology.

Use of H2 in the ENERGIRON DR plant In ENERGIRON DR plants, reduction with H2 is a common process characteristic. In ZR plants, the typical ratio of H2/CO is 3-4 and in an ENERGIRON DR plant with external reformer, this ratio is 4-5.

For this case, the H2 in the reducing gas entering the shaft, or reducing reactor, is as high as 60% in volume. In general, reduction with H2 is more efficient and faster from the kinetics point of view; about five times as compared to that based on

CO. This is one of the reasons for the high efficiency of the ENERGIRON process, with energy consumption as low as ~10.0 GJ/ tDRI, including: a DRI quality with high metallisation (96%), high carbon (4.2%) and inherent selective CO2 removal.

In this regard, and as indicated in point 3 above, the basic ENERGIRON configuration remains unchanged for any reducing gas make-up.

By replacing NG with H2, plant productivity is enhanced since in-situ reforming is lower with less energy requirements.

Renewable energy sources Use of high-efficiency electrolysers, like reversible high-temperature systems with foreseen power consumption figures as low as <4 kWh/Nm3 H2, makes it feasible to produce H2 from renewable energy sources, significantly impacting reduction of CO2 emissions. This H2 can be used directly in the ENERGIRON ZR scheme without any modification and instead, improving plant efficiency and productivity.

As indicated in Fig.4, the ENERGIRON ZR scheme remains unchanged with intensive use of H20, up to 70% as energy, and as make up reducing gas, keeping 1.8%C. The energy consumption for various cases of %H2 to DRP, as replacement of NG is indicated in Fig. 5, including respective CO2 emissions for the various cases.

43

Overall analysis for CO2 emissions The overall analysis for the BF-BOF route, as compared to DR-EAF configurations for the ENERGIRON ZR scheme (with or without selective CO2 commercialisation and/or sequestration) and to the competing DR technology, is shown in Fig 6a and Fig 6b, respectively. The analysis refers to a location producing 0.50 kg CO2/kWh (typical of that prevailing in some countries worldwide).

In general, the DR-EAF route is characterised by 38%-53% lower CO2 emissions than the BF-BOF route, depending on the possibility of using the removed CO2 for other applications and, specifically, the ENERGIRON ZR scheme route is 6%-20% lower than competing DR technology.

Commercialisation of CO2 from ENERGIRON DR plants Selective CO2 from ENERGIRON DR plants is already a reality, so what next? Since 1998, CO2 gas from the CO2 absorption system of ENERGIRON plants has been used as a by-product by different off-takers, providing additional income and OPEX reduction. It is important to note that this is dependent on the iron ore composition, natural gas analysis and the absorbing solution used in the CO2 absorption system. In the case of amines absorbing solutions, both CO2 and H2S are removed and thus the CO2 stream from the DR plant may contain some H2S

SOLIDS Emissions Source Iron ore fines/TSP

fugitive emissions in MH transfer points, coating area

By-products Iron ore fines -5mm

screening before DR shaft feeding

Iron ore & semi-metallised fines

sludge from de-dusting systems in MH and scrubbing systems in DR plant

DRI fines -6mm

sceening of cold DRI before shipping

GASES Emissions NOx

PG heater (flue gases), incinerator for CO2 stream, package boiler

SO2

PG heater (flue gases), incinerator for CO2 stream, package boiler

CO

PG heater (flue gases), incinerator for CO2 stream, package boiler,

BD stack (QCW), BD de-gasifier (PCW)

By-products CO2 CO2 from selective rmoval (absorption) system Sulfur

From CO2 stream from selective removal system

AQUEOUS EFFLUENTS

Effluents Bleed-off

Clarifier/settling pond or filtering system

Note (1): In case of CO2 cleaning through SulferoxÂŽ technology, SO2 is converted to elementary sulfur as slurry by-product

Table 2.

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Digital Edition - February 2018

44

ENVIRONMENT

in the range of 200 ppm. For H2S removal, there are some possibilities:

CO2 is being sold to Infra for further use in beverages.

− Passing the CO2 stream through an incinerator for conversion of H2S to SO2, in which case the CO2 will have no further use,

Emirates Steel in Abu Dhabi For the two ENERGIRON plants, each of 2.0 Mt/yr of hot DRI plus the Micromodule of 0.2 Mt/yr of cold DRI, a common CO2 capture facility is being implemented as part of the collaboration between Masdar, ADNOC and Emirates Steel. The CO2 will be utilised for enhanced oil recovery (EOR) operations.

− Delivering the CO2 stream as it is, as a valuable by-product to gas companies for further treatment and commercialisation, or − Passing the CO2 stream through a sulfur removal system, like Sulferox® for CO2 purification and immediate commercialisation as a higher value byproduct.

The current scenario of CO2 from ENERGIRON DR plants is as follows: Ternium DRI plants at Monterrey, Mexico ZR plants of 0.7 Mt/yr cold DRI and 1.0 Mt/ yr hot DRI – since the late 1990s the raw CO2 output is being sold to Praxair, which after further cleaning, distributes the gas to the food and beverage industries.

Nucor Steel, Louisiana, USA The largest DR ZR module ever built in the world of 2.5 Mt/yr DRI, includes a Sulferox® system for desulfurisation of the CO2 stream, yielding pure CO2, which will be commercialised as a valuable byproduct of the DR plant.

ENERGIRON DR plants as characterised by the minimum emissions, aqueous, gaseous and particles. Fig. 8 depicts the Ternium ZR DRP, which is located in the middle of the city of Monterrey, complying with the strictest environmental regulations.

Ternium DRI plant at Puebla, Mexico DR module of 0.7 Mt/yr cold DRI, and clean

By-products and emissions in an ENERGIRON DRP Emissions, effluents and by-products in an ENERGIRON DR plant can be summarised in Table 2.

An important observation is that most of the outputs from the ENERGIRON plant may be considered as by-products, due to their further recovery and use, which differentiates this technology from others. − DRI fines: are normally cold briquetted in most plants and used/ delivered as DRI briquettes. − Iron ore fines: iron ore fines from screening and sludge are normally disposed of as by-product; however, Tenova HYL has developed in conjunction with Diproinduca a system for the recycling of these fines, which will significantly increase the overall yield of the ENERGIRON DRP. − CO2: an important and valuable product from an ENERGIRON DR plant is the CO2, which can be commercialised and used for various applications, as mentioned in point 8 above.

Fig 8. ENERGIRON DR plant at Ternium Monterrey steelmaking facilities

Digital Edition - February 2018

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ENVIRONMENT

− NOX: Nitric oxide (NO) and nitrogen dioxide (NO2) are referred to as nitrogen oxides (NOX). These gases are formed when fuel is burned at high temperatures. The emissions are not dependent solely on the amount of nitrogen in the fuel but also on the air-fuel mix ratio. High temperatures, typically enhanced by air preheating, and oxidation-rich conditions generally favour NOX formation in combustion. While in competing DR technology a significant amount of air is preheated in the reformer, in the ENERGIRON DR technology this is minimal or non-existent. − SO2: Sulfur dioxide is one of a group of highly reactive gases known as “oxides of sulfur.” In a DR plant, the main sources of sulfur (which is converted to SO2) are iron ore and fuel gases. For the ENERGIRON DR plants, additional sulfur comes from sulfur injection to the reducing gas to prevent metal dusting in the process gas heater.

This sulfur is converted to H2S during the reduction process and mainly released in the tail-fuel gases. For competing technologies, recycling the top gas from the shaft to the reformer might create the

problem of catalyst poisoning.

In general, for ENERGIRON DR plants: − The amount of total solids wastes is lower than any other DR technology because of low gas velocities inside the ENERGIRON shaft furnace. This is due to higher operational pressure, which is reflected in the low amount of carry-over particles in the gases. − The ENERGIRON plant has been designed with intrinsic energy recovery systems, meaning there is no need for combustion air preheating in the main thermal equipment (reformer, process gas heater); the NOX is below environmental limits. − SO2 can be further minimised since most of the sulfur, in the form of H2S is captured in the CO2 absorption system and removed as elemental sulfur through systems like Sulferox®, while producing clean, pure CO2.

Table 3 lists the conventional methods for controlling emissions in an ENERGIRON DRP.

Solids

Pollutant

An ENERGIRON DR plant complies with the strictest environmental regulations worldwide without the need of specific process requirements and/or additional equipment for treatment of heavy hydrocarbons in natural gas, sulfur in iron ore and/or de-NOX systems.

To illustrate specific compliance with strict environmental regulations, actual data are indicated in Table 2. It can be noted that no particular methods and/or additional equipment are necessary to fulfill local regulations. �

1. REFERENCES [1] Technical and economic aspects of production and use of DRI in integrated steel works. PE Duarte, K Knop, E Zendejas.

Millennium Steel 2004.

[2] High-carbon DRI with ENERGIRON DR technology. P. Duarte, J. Becerra. Stahl und Eisen (2015) No 11.

[3] Decrease of GHG emissions through the Carbon Free Emissions ENERGIRON DR Scheme in Integrated Mills. P. Duarte, J. Becerra. METEC and INSTEELCON® 2011.

Method

Iron ore fines

Use of dry bags as dust collectors

DRI fines

Use of dry bags (with proper nitrogen inertisation, where required) and wet

scrubbing system

Use of ultra-low NOx burners

NOx

Note: NOx emission can be further reduced ( 8ppmV) by using the SCR system in the PGH flue gases

Sulfur removal in the CO2 absorption system

Gases

SO2

45

Note: SO2 can be reduced to the minimum by using the Sulferox® Technology

CO

None

CO2 (selective)

Selectively removed by chemical absorption based on Amines (α-MDEA)

Table 3. Emission control methods used in the ENERGIRON DR plant

Gaseous pollutants

Particulate

Minnesota environmental

Achieved value

regulation

in ENERGIRON plant

Specific method

0.014 grains/dscf

0.01 grains/dscf

None

SO2

15lb/hr, 24-hour average

14.1lb/hr

None

NOx

96ppmv@3% O2

85ppmv (maximum)

152ld/hr 24-hour average

75lb/hr

Just use of low NOx burners

CO

32lb/hr, 24-hour average

16.6lb/hr

None

VOC

2lb/hr, 24-hour average

0

None

Table 4 Specific environmental requirements as compared with emissions of the ENERGIRON DR plant in USA

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48

CHINA UPDATE

Cold weather means high demand China’s National Development and Reform Commission (NDRC) has requested that Qinhuangdao port cap thermal coal prices following increased demand because of abnormally cold weather.

By Zhai Yu*

Wood Mackenzie has heard that Qinhuangdao (QHD) port started to cap thermal coal prices for FOB 5,500 kcal/ kg coal at RMB750/t from 5 February, following a request from China’s National Development and Reform Commission (NDRC). Colder-than-normal weather in January has resulted in strong thermal coal demand and a subsequent increase in prices. Spot thermal coal prices for FOB Qinhuangdao 5500 kcal/kg reportedly reached RMB780/t recently. We believe such high prices, and their potential to rise even further, prompted intervention from the NDRC. The price cap will have an impact from now until mid-March. Demand for thermal coal will fall in February during the Chinese New Year holiday. But supply will also fall for the same reason. After the holiday period, demand will quickly return and restocking by power companies will add additional demand. Without the price cap, we do not expect prices for FOB QHD 5500 to drop below RMB750/t until the middle of March, when the need for heating coal disappears.

The price cap will be difficult to implement. The measure impacts thermal coal prices, but it is only the power

industry that has called for coal prices to be restricted. As electricity tariffs are fixed, high coal prices resulted in big losses for the power companies in 2017. Non-power industries aren’t so bothered by coal price fluctuations as their product prices are market-driven and can adapt accordingly.

For example, the cement industry increased its prices by over 30% in the second half of 2017. As the NDRC has asked railway operators to prioritise transporting coal for power use in the winter, stability of supply is more important than price to non-power industries, like steel. So even if the NDRC caps coal prices, non-power coal users will be prepared to pay more to miners or traders to receive their supply. FOB The price cap will have a greater impact after the Chinese New Year holiday.

With the national holiday starting on 15 February, spot coal purchases are currently limited. However, once the holiday period is over, thermal coal demand will rapidly return to normal, especially since the power companies have very low inventories. For example, the six largest coastal power generation companies only have coal stocks to last for around 10 days of consumption.

Last year, restocking demand caused a rise of more than RMB100/t after the Chinese

New Year holiday. We don’t expect the NDRC will tolerate prices rising above RMB800/t this year. We believe it wants to pilot this price cap mechanism before the Chinese New Year so that only a small volume of high-priced coal is impacted. It will then take what it has learned from this pilot to try to stabilise the market if there is a large gap between supply and demand after the holiday.

China’s coal market has increasingly become policy-driven over the past few years. Supply-side reform, stringent environmental restrictions on production, transportation and consumption of coal, and frequent government intervention in price-setting are puzzling market participants and investors alike.

This may be a key reason why the price management scheme introduced last year has not been very successful and supply recovery remains muted. Time will tell how successful raising the scheme’s upper boundary of RMB600/t by 25% will be in controlling volatility and stabilising the market. Meanwhile, seaborne suppliers will continue to benefit from China-driven high prices. � Source: Wood Mackenzie.

* Northeast Asia senior consultant, Wood Mackenzie.

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