Theoretical Minimum Energies to Produce Steel for Selected Conditions

Fruehan, R. J.; Fortini, Otavio; Paxton, H. W.; Brindle, R E

doi:10.2172/769470

Cited by 59 publications

(31 citation statements)

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“…The evolution of electric furnaces is reflected mainly in the progressive reduction of specific consumption of energy, tap-to-tap times and improvement of the metallic yield [2]. A deep study, comparing energy consumed currently in the production of steel with theoretically needed energy, was made by the Carnegie Mellon University (Pittsburg, USA) for the US Department of Energy [3][4][5][6][7][8]. The principal analytical tools used for second phase were the operations research techniques of project management and heuristic scheduling [6].…”

Section: Discussionmentioning

confidence: 99%

“…In case of machine tools, product quality in terms of surface finish or dimensional tolerances is often an indication of problems. As all these techniques have value and merit, the application of any particular technique depends on the suitability and ease of implementation [1][2][3][4].…”

Section: Methodsmentioning

confidence: 99%

“…With this realization that maintenance management can cost 35 -40 percent of revenues and, in most cases up to 15 percent of unit production cost, steel companies are increasingly opting for new maintenance technologies which can be effectively and relatively easily implemented for reduced costs and increased profitability. According to industry estimates, a 10 percent reduction in maintenance costs translates to a 30 percent increase in profitability [1][2][3].…”

Section: Introductionmentioning

confidence: 99%

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Case Study and Analysis of the Production Processes in a Steel Factory in Jordan

Asfar¹,

Salim²

2011

Linköping Electronic Conference Proceedings

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This work represents a true case study and analysis of the technical and energy managerial aspects of recommended designs of the production lines of a steel factory in Jordan. A modern structure of a control system based on SCADA (Supervisory Control And Data Acquisition) technology is proposed. Furthermore, the mechanical and electrical maintenance sections in the factory were reviewed due to their major effects on the production cost and energy consumption of the factory. This study was performed in two main phases: The first phase contains the collected data and process assessment that were undertaken by traditional direct observation and activity categorization, while the second phase gave details on the proposed control methodology in terms of design and architecture. Moreover, a proposal on maintenance planning and procedure program was also included in this study in order to reduce the time and accordingly the cost of maintenance. The steel factory studied produces various steel products such as: Concrete Reinforcement Steel Bars (Rebars), Flat & Square Bars Section which includes standard flat bars, standard square bars, and plane round bars, in addition to Wire mesh in different sizes and steel billets. In steel production industries, two automation levels can, in general, be identified. The first level involves the electromechanical actuation of the devices in the production plant; this level of automation is currently available in every plant. The second level involves the supervision of the production process; this level of automation is less frequent and is generally only partial. In fact, steel production involves a variety of complex physical phenomena, described by sophisticated mathematical models which are rarely usable to derive real-time advice for process supervision and control. Most operators' support systems for steel production are represented by simple technologies such as microprocessor-based systems. Based on the outcomes of this study, the factory purchased a new melting furnace of (60) tons capacity instead of the (30) tons capacity melting furnace used in the factory before the study. The factory is considering also the purchase of a scrap press in its new budget in order to improve scrap quality before melting it; in order to reduce the rate of consuming the furnace electrodes. Also, the maintenance section will be restructured by merging electrical and mechanical maintenance sections into one section headed by the deputy of the factory manager.

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Section: Discussionmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Case Study and Analysis of the Production Processes in a Steel Factory in Jordan

Asfar¹,

Salim²

2011

Linköping Electronic Conference Proceedings

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“…The total of these two steps is 8.6 MJ/kg [12]. In the same analysis, Fruehan and collaborators also estimated that the "practical" minimum to produce a hot rolled steel product is 9.1 MJ/kg.…”

Section: Upper Bound On Steel Output: 20% Average Annual Growth Untilmentioning

confidence: 94%

“…First note that bounds do exist for elements of equation (1), in particular e(t). The energy requirements of smelting steel from iron ore will never improve beyond the enthalpy of the basic chemical reaction (2Fe 2 O 3 + 3 C 4 Fe + 3CO 2 ) plus the heat capacity of the melt, around 8.6 MJ per kg [12]. Assuming recycling involves melting and recasting, the energy to make steel from recycled scrap will never be less than the heat needed to melt scrap steel, about 1.3 MJ per kg (Ibid).…”

Section: Methods -Bounding Analysismentioning

confidence: 99%

Bounding scenario analysis: A case study of future energy demand of China's steel sector

Williams

Kahhat

Kaneko

2012

2012 IEEE International Symposium on Sustainable Systems and Technology (ISSST)

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The scenario approach is a key tool in futures analysis. The likelihood of scenarios is evaluated by subjective judgment of analysts. In order to assert futures with higher certainty this article explores the notion of bounding scenarios. Making an analogy to the notion of mathematical bounds, bounding scenarios aim to exclude what will not occur rather than guess what will. The hope is that bounds established with a high degree of confidence can constrain the future in a useful way. We develop bounding scenarios through a case study of the potential for plant-level efficiency improvements to reduce net energy demand in the Chinese steel sector from 2008-2027. A lower bound is developed which reflects slow growth in industry output and rapid adoption of an idealized technology. The result is 0.9% annual average increases in energy use to 2027. The upper bound reflects dramatic growth in industry output and static technology, resulting in 9.5% average growth in net energy demand. Even rapid deployment of an idealized technology does not result in net reductions in energy demand. This suggests that managing climate and other energy issues should encompass strategies beyond plant level efficiency, such as efficiency of steel use.

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Determination of Energy Requirements for Ironmaking Processes: It's not that Straightforward

Sohn

Olivas-Martinez²

2014

Energy Technology 2014

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Theoretical Minimum Energies to Produce Steel for Selected Conditions

Cited by 59 publications

References 0 publications

Case Study and Analysis of the Production Processes in a Steel Factory in Jordan

Case Study and Analysis of the Production Processes in a Steel Factory in Jordan

Bounding scenario analysis: A case study of future energy demand of China's steel sector

Determination of Energy Requirements for Ironmaking Processes: It's not that Straightforward

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