Influence of direct reduced iron on the energy balance of the electric arc furnace in steel industry

• Published in: Energy (Oxford) 2011-10, Vol.36 (10), p.6146-6155
• Main Authors: Kirschen, Marcus, Badr, Karim, Pfeifer, Herbert
• Format: Article
• Language: English
• Subjects: Applied sciences; case studies; Charging; chemical composition; combustion; cost effectiveness; Direct power generation; Direct reduced iron; EAF; Electric arc furnaces; Energy; Energy balance; Energy conversion efficiency; energy efficiency; Exact sciences and technology; foaming; industry; iron; Iron and steel industry; melting; oxygen; oxygen consumption; Process model; Process parameters; slags; steel; Steel scrap; temperature
• ISSN: 0360-5442
• DOI: 10.1016/j.energy.2011.07.050

A model of the EAF energy efficiency was developed based on a closed mass and energy balance of the EAF melting process. This model was applied to industrial EAFs in steel industry charged with scrap or with mixes of scrap and DRI. Complex mass and energy conversion in the EAF was simplified with the introduction of mass and energy conversion efficiencies for the conversion of oxygen and the energy conversion of electrical energy in the electric arcs, chemical energy from the oxidation reactions in the melt and energy from the combustion of burner gas. It turned out that close agreement with observed process parameters from 16 EAFs is obtained by slight variations of the efficiency values. Especially the sensitivity of the steel temperature from the energy conversion efficiency of the electric arc energy indicates the importance of efficient foaming slag operation in EAF steel making. Characteristics and process parameters of DRI charged EAFs are discussed. Model results for a series of case studies illustrate the correlations between DRI chemical composition, DRI portion, oxygen consumption, etc. with electrical energy demand in order to indentify cost-effective EAF process conditions. ► Energy demand and carbon dioxide emission figures of EAF steelmaking processes based on steel scrap and DRI. ► Complete energy balance of the EAF process using various input materials. ► Application of the model to industrial EAF in steel industry in 4 case studies and discussion of model results. ► Comparison with other models, critical discussion.