SDM: Green leads low-carbon energy
The carbon peak and carbon neutral are the major strategic decisions made by the CPC Central Committee and the State Council to coordinate the international and domestic situations, which have far-reaching impact and significance. The carbon emissions of the iron & steel industry account for about 15% of the total emissions of the country. It is the manufacturing industry with the largest emissions. The steel enterprises are important responsibility subjects to implement the carbon emission reduction goal.
In recent years, Shandong Province Metallurgical Engineering Co., Ltd. (hereinafter referred to as SDM) has vigorously promoted technological innovation and integration, and has been in the forefront of green low-carbon intelligent metallurgy and building a high-quality ecosystem of iron & steel. It has continued to tackle key problems in green and low-carbon technologies, and it is striving to build a new pattern of green low-carbon development of iron & steel in the new era, and to become a demonstrator and leader in promoting green low-carbon transformation and development of the industry.
Focus on green steel, reduce carbon emission in the whole process
It is the unique advantage of SDM to have all the design disciplines of iron and steel metallurgy and advanced engineering technology in the whole process. With dynamic and accurate process design, it will promote the efficient linkage of iron and steel metallurgy processes, reduce energy consumption and form a synergistic carbon reduction effect.
New green intelligent large-sized coke oven equipment technology. The large-sized green intelligent coke oven battery jointly designed and developed by SDM and Paul Wurth of Italy, which adopts world-class processes and technologies, is one of the advanced representatives of the development of large-sized, green and intelligent coke oven batteries, and has reached the domestic and international advanced level in terms of coke oven body, coke oven machinery, process equipment, automation and environmental protection.
The 7.3m large sized green intelligent coke oven battery in Rizhao Iron and Steel Base, designed and general contracted by SDM, consumes wet coal of 2350kJ/kg(7% H2O), which is superior to the level of domestic super coke oven battery. It reduces about 104000 tons of CO2, 157 tons of dust, 473 tons of SO2, and 2128 tons of NOx annually. It also has the advantages of significantly reducing the cost of iron making and pollutant emissions. In order to promote the progress of coking technology, ultra-low emissions, and clean production in China, It has demonstration effect and extensive promotion value to improve the technical equipment level of coking industry and upgradation. Its new green intelligent large sized coke oven equipment technology has won the second prize of the Metallurgical Science and Technology Award of China Iron and Steel Industry Association and China Metallurgical Society. Its characteristic advantages include: low consumption coking technology, asymmetric flue technology of coke oven battery, single coking chamber pressure regulation and control technology, coal humidity control technology, dry quenching and waste heat power generation technology.
The picture shows the 7.3m large sized green intelligent coke oven battery designed and constructed by SDM.
Blast furnace is large-sized, high-efficient and low-carbon emission. Large sized and efficient blast furnace is characterized by stability, low fuel ratio, low process energy consumption and high production efficiency, which is of great significance for low-carbon production, reducing environmental load and realizing ecological development. The 5100m3 super large blast furnace in Rizhao Iron and Steel Base, which is designed and general contracted by SDM, has a utilization coefficient of 2.16t/m3 · d, an average coke ratio of 320kg per ton of iron and a coal ratio of 165kg, reducing fuel consumption by 33kg compared with that of 3000m3 blast furnace. In view of TRT power generation, zero emission of top gas bleeding, etc., the CO2 emission per ton of iron is reduced by 105.5kg, and annually more than 850000 tons of CO2 is reduced.
The picture shows the 5100m3 blast furnace and hot blast stove of Rizhao Iron & Steel Base designed and constructed by SDM
The characteristic and advantageous technologies of the super large sized blast furnace designed by SDM include: comprehensive technology of blast furnace long campaign, comprehensive technology of full dry cleaning of blast furnace gas, modern cast house technology, zero emission process of top gas bleeding and intelligent recovery technology, "clean" rotary drum slag granulation technology, and fully automatic precise coal injection technology.
Technology of super large sized top combustion hot blast stove. SDM is the only engineering company in China with general contracting performance and capability of top combustion hot blast stove with a blast furnace of more than 4000m3. The new generation green intelligent top combustion hot blast stove technology with fully independent intellectual property rights occupies more than 40% of the domestic market share, and has expanded to markets in Asia, Europe, South America and Africa. It has the characteristics of high blast temperature, long life and environmental friendliness; The blast temperature of only blast furnace gas reaches 1250 ℃, and the blast temperature with external combustion furnace system reaches 1300 ℃. The consumption of blast furnace gas is reduced by about 80Nm3 and CO2 is reduced by about 68.56kg per ton of iron. The top combustion hot blast stove designed by SDM has the following distinctive advantages: high efficiency and low nitrogen combustion technology, burner insulation layer technology, hot blast piping arrangement, full-automatic stove burning control system and hot blast stove flue gas denitration technology.
High efficiency and low consumption intelligent bar mill production line integration technology. The new bar production of single line with an annual output of 2 million tons designed by SDM in the No. 1 bar mill shop and No. 2 bar mill shop of Shiheng Special Steel New Area are characterized by advanced technology, intelligence and efficiency, high yield and low consumption, which are of great significance for low energy consumption and low-carbon production. The technical level of production line equipment has reached the leading domestic and international level.
The actual yield of this production line reaches 98.5%, which is 0.5% higher than the domestic advanced bar mill production line; The gas consumption per ton of steel of the production line is lower than 0.4GJ, which is 0.3GJ lower than that of the domestic advanced bar mill production line; The power consumption per ton of steel of the production line is lower than 60kWh, which is 10kWh lower than that of the domestic advanced bar mill production line; Compared with the domestic advanced bar mill production line, for the single line 60000 tons CO2 will be reduced annually.
The advantages of efficient and low consumption intelligent bar mill production line by SDM include: closed-loop controlled rolling and cooling technology, high temperature hot delivery and hot charging technology, double regenerative walking heating furnace technology, cost-effective long billet production technology, intelligent monitoring and control technology of the whole line temperature field, multi line slitting pass development technology, full sizing production technology, cooling bed waste heat recovery technology, intelligent enhanced collection and integration technology, intelligent equipment and intelligent robot technology, automatic rejection and transformation technology of off-size and automatic monitoring technology of key equipment.
Flexible iron steel interface coordination technology. This technology focuses on the automobile transportation of hot metal, scientifically solves many problems of hot metal transportation between large sized blast furnaces and converters, obtains many industry initiatives, and realizes the goal of "five saves" of saving land, investment, staffing, production and operation costs, and energy. The average temperature drop of hot metal with this technology from tapping to converter iron mixing is about 58 ℃, and the CO2 emission reduction per ton of steel is about 35.8kg.
Activated calcium desulfurization technology. It is designed by SDM to remove SO2 from flue gas by injecting active calcium instead of soda desulfurizer. The generated dust is removed by bag filter, so that the flue gas could meet the emission standard and 1.375 tons of CO2 could be reduced for each ton of SO2.
High efficiency utilization technology of waste heat and energy. SDM has mastered dozens of energy conservation and emission reduction featured technologies with independent intellectual property rights, such as efficient power generation by gas in iron and steel enterprises, power generation by dry quenching waste heat, power generation by sinter plant waste heat, converter waste heat and energy recovery and power generation, and power generation by electric furnace flue gas waste heat, as well as HIsmelt smelting gas waste heat recovery technology, gas distributed energy technology, large sized blast furnace blow and gas TRT pressure power generation, and industrial low-quality waste heat heating. There are abundant design and proven EPC achievements covering low pressure saturated steam power generation of 7MW electric furnace to 65MW ultra-high temperature and ultra-high pressure power generation of gas, CCPP gas steam combined power generation, 5000m3 blast furnace blow and gas TRT, million square meters low-temperature waste heat heating project, etc. The performance have reached the domestic and international advanced level. Among them, only 65MW gas power generation with ultra-high temperature and ultra-high pressure can reduce carbon by more than 250000 tons annually.
The picture shows the panorama of dry desulfurization project designed and constructed by SDM.
The picture shows the panorama of HIsmart project.
Assisting the low carbon production of iron and steel plants with intelligent technology
Under the national strategic background of achieving carbon peak and carbon neutralization, intelligent manufacture has come to a new mode of green, low-carbon and smart. "Intelligent sensing, intelligent analysis and intelligent control" are the core contents of intelligent manufacturing. Therefore, on the basis of stable and reliable measurement, detection, transmission and control, through the development of a series of advanced and practical intelligent optimization control systems and intelligent management systems, SDM improves the control level and intelligent decision-making ability in production, quality, safety, management, etc.; improves the comprehensive labor productivity and resource utilization; reduces the defective rate of products, operation and maintenance costs; and reduces carbon emissions and pollutant emissions.
Energy intelligent control center integration technology. SDM has established energy integrated intelligent control, including a data center, which integrates energy centralized monitoring, energy unified measurement, energy flow balance, energy control, energy big data mining, energy performance and other functions to achieve global energy monitoring, energy scheduling, energy forecasting, to improve the operation and coordination efficiency of the energy management and control system of iron and steel enterprises, and to reduce the comprehensive energy consumption per ton of steel to more than 2%.
Intelligent combustion system for hot blast stove of blast furnace. The hot blast stove intelligent combustion system designed and developed by SDM is an integrated solution that fits the hot blast stove combustion control. It provides the hot blast stove system with all-round intelligent services such as automatic stove change, intelligent combustion, scheduling of stove resources, estimation of stove heat storage, data summary and display. With this system, the unit gas consumption per ton of iron is reduced by about 30m3, and the CO2 emission per ton of iron is reduced by about 25.4kg.
Smart coke oven battery technology. Based on stable and reliable measurement, detection and control, the smart coke oven battery technology designed by SDM realizes the optimal control of the production process through the artificial intelligence software model, and achieves the goal of environmental protection meeting the standard, energy efficiency fully optimized, production fully controlled, ultra-low pollutant emission, great reduction of energy consumption, and high economic benefits.
The picture shows the new and medium-sized special steel production line of Shandong Iron & Steel Group Laiwu branch (designed and constructed by SDM).
Development and integration of low carbon and zero carbon metallurgical technology
In order to implement the national "double carbon" strategy and the CO2 emission reduction target of the steel industry, SDM will actively develop integrated low-carbon steel smelting technology. In addition to further improving the forward stability of the blast furnace, optimizing the operation technology and reducing the fuel consumption of the blast furnace, the high oxygen enrichment natural gas injection or coke oven gas injection technology designed and developed by SDM in the 14th Five Year Plan and before 2030 will reduce carbon emissions by more than 50% compared with the traditional blast furnace.
HIsmelt ironmaking process is one of the smelting reduction ironmaking technologies that have achieved industrial production. After more than 30 years of research, development and production practice, the process technology has gradually proven with obvious environmental advantages. It is the most green, environmentally friendly and low emission metallurgical technology in the world at present, and has a high concern in the international metallurgical field. HIsmart technology can reduce environmental impact. Through revolutionary process innovation, coking, sinter plant and pellet plant have been eliminated. Compared with traditional metallurgical processes, it can reduce CO2 emissions by more than 15%, SO2 emissions by 90% and NOx emissions by 50%, and basically the generation of dioxins, tar, phenol and other pollutants is contained.
SDM develops a hydrogen based direct reduction electric furnace short process production line in the long term to significantly reduce the CO2 emissions per ton of steel in the whole process and achieve the goal of carbon neutralization; Sponge iron is produced by hydrogen based direct reduction technology, and it is provided to electric furnace or converter for steel making; Through the production of sponge iron, the reduction of hot metal output of blast furnace in the future should be met, and the shortage of scrap steel and the need of smelting high-quality steel should be met.
Promote upstream and downstream industries to coordinate carbon reduction
At present, the iron and steel industry and its upstream and downstream industries cooperate to reduce carbon and achieve joint production of iron and steel and chemical industry. In recent years, SDM has explored CO2 capture, storage and utilization technologies.
The steel waste heat coupled with CCUS ethanolamine method by SDM is used for CO2 capture, and the captured CO2 is used as the protection gas for coal injection of blast furnace. By the sinter plant waste heat coupled with CO2 capture technology, the cost of CO2 capture per ton can be reduced by more than half. They cooperated with chemical, petroleum, geological and other industries and companies to carry out demonstration applications of CO2 liquefaction, oilfield displacement and underground storage.
In the near future, SDM will focus on CO2 removal of converter gas, tail gas of blast furnace hot blast stove, tail gas of coke oven flue, tail gas of steel rolling heating furnace, etc., and they will be used through oil field displacement; Before and after 2030, develop and apply CO2 hydrogenation to produce chemical primary products (methanol, fuel ethanol, etc.); research and develop the technology of reforming converter gas and coke oven gas to produce gas for blast furnace injection or gas based shaft furnace direct reduction.
For the iron and steel production, a large number of by-product gas will be produced, mainly including coke oven gas, blast furnace gas and converter gas. The by-product gas accounts for about 30%~40% of the total energy consumption of the enterprise. Its efficient resource utilization is not only conducive to reducing the energy consumption and pollutant emissions of the unit products of the steel plant, but also can form an industrial ecological chain with the petrochemical industry, generating new economic and social benefits, which is of great significance.
For this reason, SDM takes coke oven gas, blast furnace gas or converter gas of iron and steel enterprises as raw materials to produce ethylene glycol, ethanol and other chemical products, so as to realize the application of metallurgical gas with high added value and low carbon; The production of ethanol from metallurgical gas mainly includes biological fermentation, synthesis gas methanol acetic acid ethanol or synthesis gas methanol acetic acid ethyl acetate ethanol, and synthesis gas methanol dimethyl ether methyl acetate ethanol. These technologies can make rational application of metallurgical gas, avoid environmental pollution caused by direct application as fuel, and reduce CO2 emissions.
Compared with directly using coke oven gas as fuel to produce hydrogen, LNG or other chemical products, the added value of coke oven gas can be nearly doubled or higher, and the steel enterprises can reduce CO2 emissions by more than 1%.
In recent years, SDM uses the roofs of steel rolling shop and steel making shop, with a total photovoltaic power generation capacity of 8MW for every 100000 square meters, which can realize continuous power generation for 25 years; In the whole life cycle, it can provide about 190 million kilowatt hours of green power, save about 73000 tons of standard coal, reduce about 50200 tons of carbon dust, about 188800 tons of CO2 emissions, about 5600 tons of SO2 emissions and about 2600 tons of NOx emissions.
In addition, the new connection joint of H-shaped steel truss without gusset plate designed and developed by SDM, which is similar to the steel pipe truss connection, is directly welded to eliminate the gusset plate, which is simple in structure and convenient in processing, thus reducing the steel consumption and processing difficulty of H-shaped steel truss joint, and applying it to the lattice column of industrial shops and civil steel structure truss, promoting the wide application of H-shaped steel truss in industrial and civil buildings. Compared with the conventional design, this technology can reduce the steel consumption by more than 3%.
Facing future, SDM will implement Xi Jinping Thought on Ecological Civilization under the guidance of Xi Jinping Thought on Socialism with Chinese Characteristics for a New Era; adhere to the concept of "lucid waters and lush mountains are invaluable asset"; with innovation driven as the engine, we adhere to the principle of "all for the customers, all life cycle service"; and contribute the wisdom and strength of SDM staff to the green and low-carbon development of the steel industry.
The picture shows the panorama of Rizhao Iron and Steel Base of Shandong Iron and Steel Group Co., Ltd., which was designed and contracted by Shandong Metallurgical Group Co., Ltd.
