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Energy Procedia
Energy Procedia 00
120(2017)
(2017)000–000
20–27
www.elsevier.com/locate/procedia
INFUB - 11th European Conference on Industrial Furnaces and Boilers, INFUB-11
INFUB - 11th European Conference on Industrial Furnaces and Boilers, INFUB-11
Burners in the steel industry: utilization of by-product combustion
Burners in the steel industry: utilization of by-product combustion
gases
The 15thinInternational
reheating furnaces on and annealing
Heating andlines
gases in reheatingSymposium furnaces District
and annealing Cooling
lines
Assessing the feasibility Sébastien
of using Caillat*the heat demand-outdoor
Sébastien Caillat*
temperature function foravenue
Fives Stein, 108-112, a long-term district
de la Liberté, 94700 heatFrance
Maisons-Alfort, demand forecast
Fives Stein, 108-112, avenue de la Liberté, 94700 Maisons-Alfort, France
reheating furnace, where hundreds of tons per hour of steel products (slabs, billets and blooms) are heated up to
1250 °C. The second component is the annealing line, where strips from coils follow different temperature paths,
from ambient temperature up to 950 °C. The by-product fuels characteristics will impose specific constrains to the
furnaces and burners operation and control.
An overview of the steelmaking process in an integrated steelwork is summarized Fig. 1. In short, from iron ore,
limestone and other elements, using energy from coal or natural gas, blast furnace is used to produce iron and
subsequently steel after lowering the carbon excess in the basic oxygen furnace. Then, through the continuous
casting, several items can be generated and transformed, immediately or later: slabs are transformed into either
plates or hot-rolled / cold-rolled strips (coils), billets into hot-rolled bars, rods or tube rounds, and boom into
structural shapes or rails.
Fig. 1. Overview of the steelmaking process (source: World Steel Association [1]).
Different process inputs are needed for the iron and steel production, and subsequent waste materials are
generated all along the route, as represented in Fig. 2. Among the by-products, important quantities of combustible
gases are available: Coke oven gas (COG) from the metallurgical coke production, Blast furnace gas (BFG) from the
blast furnace, and Basic Oxygen Furnace Gas (BOFG) when the liquid iron is refined in a basic oxygen furnace,
where decarburization of the iron leads to steel [3].
These fuels constitute the basis of the energy system in integrated steelworks. The quality (composition, calorific
value and cleanliness) and volume of the different gases may vary significantly, e.g. a typical blast furnace produces
around 1320 to 2210 Nm 3 of BFG per ton of pig iron, and these factors have an impact on where the fuels can be
exploited. When possible, most of the energy demand is satisfied by these gases; the remaining part must be
balanced with purchased energy, such as electrical power and Natural Gas (NG). A high share of steelwork (e.g. in
Brazil, India or China) are not using NG, in certain cases fuel oil is used as backup fuel. In other cases (e.g. in the
USA) coke can be imported on-site, therefore COG will not be locally available. When available, NG will preferably
22 Sébastien Caillat / Energy Procedia 120 (2017) 20–27
Sébastien Caillat / Energy Procedia 00 (2017) 000–000 3
be used on annealing lines (e.g. in Europe) rather than reheating furnaces. The primary task of energy management
in the steel industry is the efficient distribution and use of the process gases and purchased fuels [2].
Fluxes, ore fines, coke fines, flue dust, Flue gases, dust, CO, HCl, SOx, NOx,
waste material sulphides, fluorides, heavy metal, PAH,
PCCD/F, PCB
Mg, CaC, Ca2O, carrier gas, hot metal Flue dust, fume, slag
Fume, slag
Oxygen, hot metal, scrap, lime, fluorspar, Basic Oxygen Furnace Gas
coke Sludge, basic slag, fine dust (high iron
content), CO, Zn, fume
Fig. 2. Overview of the process routes of an integrated steelworks (adapted from [2] and [4]).
3. Combustible by-products
Typical compositions of recoverable by-product gases from the iron and steel production are given in Table 1. It
must be noted that the characteristics will constantly fluctuate, depending on the generation step and on the raw
material properties (e.g. coal composition). In consequence, when using such gases, very accurate settings of
burners, for example very low excess air, may need extra equipment, such as gas composition analyzers and gas
mixing stations, rather than just calibrated orifice plate and pressure control system. One of the biggest challenges
for optimum utilization of the by-product combustible gases is to cope with the constant variations of compositions
and physical characteristics. Each burner can be adjusted individually, but the more convenient is to adjust the
combustible characteristics for the entire furnace, using for example gas-mixing stations (with up to four gases mix).
Several strategies exist on the parameters to control: either to keep the heating value constant, the Wobbe index
(heating value divided by square route of specific gravity) or the combustion air requirement index (air
demand/divided by square route of specific gravity) to keep a constant air excess.
Available pressure for these gases can be under 100 mbar, so great care must be taken concerning pressure losses
in the different apparatuses.
Sébastien Caillat / Energy Procedia 120 (2017) 20–27 23
4 Sébastien Caillat / Energy Procedia 00 (2017) 000–000
Coke Oven Gas is generated during the iron ore and coal coking (carburization); it contains high concentrations
of hydrogen and methane. The Net Calorific Value of COG is around half lower than that of natural gas. This is due
to the high concentration of hydrogen in COG, which results in a relatively low density and a high net Wobbe index.
One of the biggest consumers is the coke plant itself, where up to 50 % is used as the coke plant fuel [5]. COG is
generally cleaned before being used as fuel. The cleaning includes the removal of dust, tar, naphthalene, light oil,
sulfurous compounds and the cracking of ammonia to hydrogen. Since it has a relatively high calorific value, it can
be used alone or mixed with other gases in blast furnace stoves, coke ovens, reheating furnaces of the hot strip mills
but also in annealing lines or power plants.
Blast Furnace Gas contains usually around 19 - 27 % of carbon monoxide and 1 - 8 % hydrogen, and high
quantity of nitrogen and carbon dioxide. It can be relatively clean. The low heating value is typically between 2.6
and 4.0 MJ/Nm3, i.e. around a tenth of the natural gas, and the adiabatic flame temperature is too low to heat product
above 1200 °C. Therefore, it is either used in low-temperature processes such as hot blast stoves or under firing coke
oven, or often enriched with COG or natural gas before being used as a fuel, called mixed gas (MG) [6], [7]. It is
also generally used with preheated air.
Basic Oxygen Furnace Gas is generated by the partial oxidation of the carbon in the liquid iron to carbon
monoxide. Basic oxygen the furnace is operated as a batch, the CO concentration released is not constant during this
process. At the start and at the end of the process, the CO concentration is very low, in these periods the gas is flared.
In the period where the carbon monoxide concentration in the gas is sufficiently high (i.e. > 30 %), the gas is
collected in a gasholder and can be valorized [8]. BOFG lower heating value is around ¼ of the natural gas, is is
usually saturated with water vapor.
Table 1. Typical gas composition and characteristics in steel mills [2], [5], [6], [8].
Element/Parameter Unit COG BFG BOFG
H2 % vol. 36.1 - 61.7 1-8 2 - 10
CO % vol. 3.4 - 5.8 19 - 27 55 - 80
CH4 % vol. 15.7 - 27 - -
CxHy % vol. 1.4 - 2.4 - -
CO2 % vol. 1 - 5.4 16 - 26 10 - 18
N2 + Ar % vol. 1.5 - 6 44 - 58 8 - 26
Low Heating Value MJ/Nm3 9 - 19 2.6 - 4.0 7.1 - 10.1
Density kg/Nm3 0.45 - 0.65 ~1.3 1.32 - 1.38
Specific air demand Nm3/Nm3 4.2 - 4.9 0.5 - 0.8 1.34 - 1.90
Adiabatic flame temperature °C ~2000 ~1400 ~2000
The collected by-product gases are generally water saturated and contain impurities, with variable concentrations
depending on the productions sites. Examples of values are given in Table 2; dust, tar and naphthalene may fool the
piping and the equipment and should be removed first. Depending on the burner control, i.e. on/off or proportional
mode, too dirty gases may cause malfunction on valves sealing, thus degrade the furnace performances. Sulphur
compounds and ammonia may cause corrosion and SOx emissions, detailed examples of cleaning system can be
found in reference [2].
Table 2. Example of impurities concentrations found in COG (source Fives Stein and [2]).
Element Unit COG
Ammonia (NH3) mg/Nm³ 50 - 100
Cyanide (HCN) g/Nm³ 0,3- 1,5
BTX (benzene, toluene, & xylene isomer) g/Nm³ 1 - 10
Naphthalene (C10H8) mg/Nm³ 200 - 500
Hydrogen sulphide (H2S) mg/Nm³ 20 - 700
Organic sulphur mg/Nm³ Up to 150
Sulphur total mg/Nm³ 100 - 800
Tar mg/Nm³ 20 - 31
Sébastien Caillat / Energy Procedia 00 (2017) 000–000 5
4. Examples of utilities
In integrated steelworks, the by-product gases can be used in different parts such as coking plant, blast furnace,
power station, hot strip mill, reheating furnace or annealing lines. The last two examples are illustrated and discussed
below.
After the continuous casting (see Fig. 1), the metal is split into slabs, billets or booms, which must be reheated in
reheating furnaces up to 1250 °C before milling. An example of recent furnace, with digital control and lateral
burners is shown in Fig. 3.
Several types of reheating furnace geometry and burner arrangement have been used during the past decades; a
quick summary is given Table 3. Comprising several dozens of burners, the total power output can be around 50
MW. In recent furnaces, the trend is to lengthen the preheating zone for better thermal efficiency. In this zone
without burners, the hot combustion gases are used to preheat the products, and then the residual waste gases energy
is used to preheat the combustion air.
Inside reheating furnaces, the atmosphere is in air excess, to reach complete combustion but also to avoid sticky
scale on the heated products. In some cases, such as high carbon content steel, the atmosphere can be set with a very
low air excess in certain zones, in order to compensate for unwanted air inlets. This will reduce steel decarburizing
and control scale formation in zones above 900 °C. The cooler sections have a slightly higher air excess.
Preheating of the combustion air, typically around 450 °C and up to 600 °C, is commonly used. Regenerative
burners, (self)recuperative burners, or oxygen enrichment can be pertinent, in particular for low heating value
combustible gases. The reader may refer to J. Newby presentation at previous Infub-10 conference for detailed
explanations on regenerative burners [9].
Depending on the burner location and on the required temperature profile of the product, the flame produced by
the burner will have different shapes: frontal burners will produce long and narrow flames, roof burner will create
short wide flames (e.g. Fig. 4), lateral burners will create short, long or modulated flames (e.g. Fig. 5). The power
output of each burner is usually around a few MW. Latest technologies allow to obtain NOx emissions as low as
120 mg/Nm³ @ 3 % O 2 for natural gas [10], and 200 mg/Nm³ @ 3 % O 2 for COG.
Sébastien Caillat / Energy Procedia 120 (2017) 20–27 25
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Table 3. Overview of different types of reheating furnaces on the market during the last decades, product enters left hand side.
Pusher furnace,
1970s ~35 m
frontal burners
Fig. 4. Examples of roof burner principle for reheating furnaces (left), view inside the furnace (right).
Fig. 5. Examples of lateral burners for reheating furnaces in short mode (left), long mode (middle), view inside a furnace (right).
Annealing lines are used to heat and cool down metal strips from coils, following a specific temperature pattern,
up to 950 °C, under controlled atmosphere (typically 5 to 30 % H 2 in N2). An example of vertical annealing line is
presented in Fig. 6. Part of the heating is made on the pre-heating furnace (4) where the strip is also cleaned, usually
in reducing atmosphere; therefore, natural gas is generally preferred in this section for a better fine control. Another
part of the heating is needed in the radiant tube furnace (5, RTF). Electric heating can be used but usually the costs
are lower with fossil fuels or by-products. To avoid the combustion gases contact with the load, an indirect method
of heating is used: burners in radiant tubes.
Sébastien Caillat / Energy Procedia 00 (2017) 000–000 7
26 Sébastien Caillat / Energy Procedia 120 (2017) 20–27
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Fig. 6. Schematic view of a hot dip galvanizing line, metal strip goes from the left to the right side ( 1: Pay-off reels, 2: Degreasing, 3: Entry looper,
4: Pre-heating furnace, 5: Radiant tube heating furnace, 6: Slow cooling, 7: Flash Cooling ®, 8: Overaging, 9: Induction reheating, 10: Zinc bath, 11: After-pot cooling,
12: Looper, 13: Skin-Pass mill, 14: Tension leveler, 15: Post-treatment, 16: Exit looper, 17: Inspection, 18: Tension reel ).
A RTF contains several hundreds of radiant tubes in different materials (NiCr cast, welded Inconel...), shapes (I,
U, W, P, double P, e.g. Fig. 7) and diameters (between 6” and 10”, but 7” or 8” are preferred). The tubes and burners
characteristics will be chosen according to the temperatures needed for the strip (typically around 900 – 1000 °C), to
the atmosphere to be used, and to the strip width (usually less than 2 m) but also according to owners or
manufacturers preferences. A typical metallic radiant tube will have an heating rate around 25 kW/m², composite
material such as silicon carbide can withstand up to 68 kW/m² [11].
Each radiant tube is equipped with a burner using NG, COG or MG, with a power output less than 200 kW.
Maximum transfer between the generated hot gases, the radiant tube and the strip is an important quality criterion.
The lower the exit flue gas temperature, the higher the efficiency. To do so, different internal or external air heating
technologies exist, like plugin recuperator, (self)recuperative and (auto)regenerative burners, more details can be
found in ref. [9], [11] and [12]. In new lines, recirculating radiant tubes (with internal or external flue gas
recirculation) are preferred to non-recirculating ones.
Good temperature uniformity is an important criterion for radiant tube lifetime. The maximum temperature
withstand by the tube material, under the imposed mechanical load, thermal stress and creep stress must also be
taken into account [13]. The lifetime will depend on the tube geometry, type of burner, fuel and operating
conditions. Hot gases recirculation allows to lower the temperature gradients, along with different types of burners:
non-premixed, partially premixed, with staged air or staged gas, or diluted combustion. The dilution allows to obtain
a longer flame, and therefore to diminish the hot points on the radiant tubes. The flame dilution, or mild combustion
[14], contribute to lower NOx emissions. Recent technologies allow obtaining NOx emissions under 100 mg/Nm³
@ 3 % O2 for natural gas or COG. Regenerative system will allow better tube temperature homogeneity, but higher
NOx emissions.
The burner choice will depend on system design factors. For example, in order to protect the controlled
atmosphere in the furnace, pull or push-pull systems will be preferred, to maintain an inferior pressure in the radiant
tube than in the furnace. In case of tube crack, atmosphere will be aspired in the tube; the combustion gas will not
contaminate the furnace. Forced-draft systems, i.e. burner supplied with pressure air and fuel allows a better fine-
tuning of the burners, but implies more piping for each radiant tube than natural draft, or suction systems.
Exhaust
Air
Gas
Fig. 7. Examples of W-shape radiant tubes (left), single ended (middle, Fives North American), and double-P shape (right) [15].
Sébastien Caillat / Energy Procedia 120 (2017) 20–27 27
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5. Conclusions
In integrated steel mills, by-product combustible gases from different parts of the process (coke oven, blast
furnace and basic oxygen blast furnace) are exploited, pure or mixed with others fuels, saving energy and reducing
environmental footprint. Examples of application in reheating furnace and annealing lines with radiant tube burners,
were shown. Some by-product combustible gases contain several types of impurities that must be cleaned to avoid
damaging and clogging of pipes, burners and other equipment. This valorization is less straightforward than
commercial fuels utilization, due to the constant variations of gases compositions and characteristics. Special
strategies are needed to allow good performances, but no major obstacles prohibit the usage of by-product
combustibles of steelworks.
References