In the 21st century, the global steel industry has experienced significant transformations in its development environment. The declining quality of iron-making raw materials, increasing resource and energy costs, and growing pressure to reduce carbon dioxide emissions have imposed stricter requirements on various stages of steel production. As we move further into this new era, steel technology is evolving to adapt to these environmental challenges and address issues related to resources, energy, and pollution. In essence, the comprehensive utilization of secondary energy and waste gas across different production stages has become a crucial strategy for energy conservation, emission reduction, and achieving clean production. As a result, several advanced steel technologies have emerged, such as Blast Furnace TRT (Top Gas Recovery Turbine), dry quenching, dry granulation, coal moisture control, SCOPE21 coking, and environmentally friendly sintering.
Blast Furnace TRT technology is an energy recovery system that uses a turbine expander to convert the pressure and thermal energy of blast furnace gas into mechanical energy, which then drives a generator to produce electricity. This process does not involve combustion, so it maintains the original quality of the blast furnace gas and its normal usage. It recovers a substantial amount of energy—approximately 30% of the energy required by the blast furnace gas blower—and also helps purify the gas, reduce noise, and improve the control of gas pressure at the top of the furnace. Additionally, TRT produces no new pollution and generates electricity at a very low cost, making it a highly efficient and eco-friendly device. With the trend of larger and higher-pressure blast furnaces, along with the use of dry dust removal systems, TRT is now being developed in both dry and wet types, especially in axial flow reaction configurations.
CDQ (Coke Dry Quenching) technology utilizes inert gas circulation to recover the sensible heat from hot coke. This heat is then used to generate high-temperature, high-pressure (or medium-temperature, medium-pressure) steam through a waste heat boiler. This steam can be utilized as a heat source in steel plants for power generation, while also preventing the release of harmful substances like dust and mist into the atmosphere. Moreover, CDQ improves the intrinsic quality of coke, reduces the coke ratio in blast furnaces by 2–2.5%, and increases pig iron output by about 1%. Because of these benefits, it has become a key project supported by many governments worldwide.
Dry granulation is a novel method for treating metallurgical slag, offering a more sustainable approach compared to traditional methods. Unlike dry slag cooling or water flushing, which consume large amounts of water, pollute groundwater, and fail to utilize the slag’s thermal energy, dry granulation allows for the comprehensive use of both the slag and its heat. This technology addresses many of the shortcomings of older methods and represents a major advancement in slag management.
Coal moisture control technology is another energy-efficient innovation that enhances coke oven productivity, improves coke quality, and stabilizes operations. By adjusting the moisture content of coal before it enters the oven, this technique reduces the heat required for coking, increases the density of the coal, and ultimately leads to better-quality coke. It is a valuable tool for optimizing the coking process and reducing energy consumption.
SCOPE21 coking technology was developed over a 14-year period by the Japan Coal Utilization Comprehensive Center and the Japan Iron and Steel Federation, aiming to create a high-yield, low-pollution coking system suitable for the 21st century. This technology effectively utilizes coal resources, boosts productivity, and introduces environmental and energy-saving innovations. The first commercial plant using this technology, Nippon Steel Corporation's Oita Plant No. 5, began operation in May 2008. The process involves rapidly heating the coking coal before charging it into the oven, which enhances coke quality and significantly reduces coking time. This makes it possible to use lower-grade coal more efficiently and achieve greater energy savings.
Environmentally friendly sintering technology, such as the Eposint exhaust gas circulation system and the MEROS dry dust removal system developed by Siemens VAI, plays a vital role in reducing pollution in sintering operations. These systems significantly lower the levels of dust, acid gases, and harmful metals and organic compounds in the exhaust gases compared to traditional treatment methods. They support cleaner production and help steel companies meet stricter environmental standards.
Although the global steel industry has not yet seen groundbreaking technological breakthroughs, including next-generation ironmaking and steelmaking processes, many countries and steel companies are actively developing technologies that align with environmental and user demands. The focus remains on energy efficiency, emission reduction, cost control, and enhancing overall competitiveness. As a result, continuous improvements in steel production methods are expected to shape the future of the industry.
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