ITP Steel: Steel Technology Roadmap -- Chapter Four ... - EERE

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4.3.7 BOF Steelmaking Research and DevelopmentNeeds and OpportunitiesBOF SlagAs discussed in Chapter 3, research is needed to find either alternate uses of BOF slag (with the calcium oxidecontent and hydration effects) or an economical way to remove the calcium oxide. Research is also needed toremove phosphorous from BOF slag because phosphorus content is a limiting factor to increased use of thismaterial. Removing phosphorus from the blast furnace pig iron prior to steelmaking would help increase theamount of this slag that can be recycled to the iron and steelmaking process. Some companies recycle a portionof their BOF slag to the blast furnace in order to supply calcium oxide flux and reclaim the iron oxide contentof the slag.Zinc ContentResearch into the mechanisms of zinc ferrite formation during the steelmaking process to prevent its formationis needed, making it much easier to remove the zinc from fume. BOF fumes contain varying amounts of zinc,lead and other metals. The primary source of these metals is the scrap used in the steelmaking process. If thescrap contains a large amount of zinc, as does much of galvanized steel scrap, the zinc content of the fume canbe high enough to prevent its recycle to the blast furnace. The presence of zinc in the feed materials of a blastfurnace can cause serious damage to blast furnace refractories, which will shorten the life of a blast furnace.Continued research is needed to developeconomical ways to remove zinc from scrapsince zinc is a commercial product. Thiswould help decrease the amount of zinc inBOF fumes and thus promote increasedrecycling of these fumes.Research to determine the distribution of zincthroughout the recycle system could lead to abetter understanding of the chemicalmechanisms at work, which would improveunderstanding of this recycling technique.Some companies recycle BOF fume directly toR & D NeedsBOF Steelmaking< Methods of removing phosphorus from the blastfurnace pig iron prior to steelmaking< Economical ways to remove zinc from scrap< Understanding of zinc ferrite formation mechanism< Determination of zinc distribution throughout therecycle system< Determination of zinc’s effect on the properties ofsteelsteelmaking after mixing and agglomerating it with other iron oxide materials, such as mill scale. Whenrecycling zinc-bearing fumes directly to steelmaking, the zinc content of the fume, slag, or steel will increasesubstantially unless a bleed stream is provided to keep the zinc build-up in the system at manageable levels. Infacilities using this recycling practice, zinc build-up has not occurred.Research will likely be conducted to determine the effect of zinc on the physical, chemical and metallurgicalproperties of steel. When zinc-bearing scrap is used in steelmaking, or when zinc-bearing fumes are recycled tosteelmaking, the zinc concentration in the steel produced also increases. Analysis has shown that some steelsamples from these systems contain several hundred parts per million of zinc.Chapter 4: Environmental Leadership 96 Steel Technology Roadmap
4.4 Steelmaking - Electric Arc FurnaceOver the past 30 years, electric arc furnace fume systems have evolved considerably from simple systems aimedat improving the ambient work environment around the furnace to sophisticated systems aimed at controllingnot only particulate emissions, but also toxic gases. Environmental regulations have stimulated progress inprimary and secondary fume control technology from side draft hoods, furnace roof hoods, and rudimentaryfourth hole extraction systems to today's sophisticated direct evacuation systems and fugitive emission controlsystems. Modern fume systems are now designed to minimize the formation of gaseous pollutants and ensurethat others are destroyed before exiting the system. Figure 4-5 illustrates electric arc furnace steelmaking withits major inputs and outputs.4.4.1 EAF EmissionsSourcesEmissions are generated during each of the five major EAF processes: charging, melting, refining, tapping, andslag handling. During the EAF process, oxide and other metal forms are volatilized in the presence of intenseheat and turbulence inside the furnace. Also, carbon from the addition of coal, iron, and steel scrap and graphiteelectrodes react with injected air or oxygen. Consequently, the primary constituents in EAF emissions areparticulate matter and gases (specifically CO 2 , CO, and NOx). Note that use of EAF for steel productionprovides the single most effective means of reducing CO 2 emissions due to the significantly lower energyrequirements of melting scrap compared to smelting ore.Figure 4-5. Electric Arc Furnace Steelmaking Flow DiagramSteel Technology Roadmap 97 Chapter 4: Environmental Leadership
Page 1 and 2: 4 Environmental LeadershipThrough t
Page 3 and 4: Figure 4-1. Cokemaking Flow Diagram
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Page 8 and 9: particulate matter is subsequently
Page 10 and 11: As a result of the interest in ozon
Page 12 and 13: 4.3.3 BOF By-ProductsBOF steelmakin
Page 16 and 17: Dioxins and furans have become a ma
Page 18 and 19: As noted in the discussion on BOF s
Page 20 and 21: Offgas system research and a more c
Page 22 and 23: 4.5.2 Refining and Casting Effluent
Page 24 and 25: Casting - Air EmissionsEmissions fr
Page 26 and 27: Figure 4-7. Forming and Finishing F
Page 28 and 29: 4.6.4 Hazardous Forming and Finishi
Page 30 and 31: At the post-treatment stage, the em
Page 32 and 33: 4.7.6 New and Emerging Coating Tech
Page 34 and 35: Many issues must be considered for
Page 36 and 37: Standard characterization technique
Page 38: The NOx emissions are often found t

ITP Steel: Steel Technology Roadmap -- Chapter Four ... - EERE

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