Webinar - Technologies for the Electromagnetic Processing of Materials - Energy and Carbon savings

EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

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Electromagnetic Processing of Materials in European Industry

Webinar 23 January, 2013

Technologies for the Electromagnetic Processing of Materials - Energy and Carbon savings

E. Baake, B. Ubbenjans,

Institute of Electrotechnology, Leibniz University of Hanover, Hanover, Germany


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Outline

Introduction, content and aim Primary energy factors & CO2-emission factors Energy consumption of the European industry (EU27) Three different transition scenarios Iron & steel industry Non-ferrous metal industry Chemical industry Glass, pottery & building materials industry Paper & printing industry Summary


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Electromagnetic Processing of Materials (EPM)

- examples -


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Introduction and background

Electromagnetic processing of materials (EPM) provides

significant opportunities for saving primary energy and reducing carbon emissions in industrial processes.

The use of electricity for industrial thermal processes has a final energy share in average of around 10% in Europe (EU-27).

Electricity has the potential to replace up to 100% of other energy carriers used for process heat.

The average primary energy factor gradually decreases from 2.5 currently, to a value between 0 and 1 for a 100% renewable electricity system.


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Content and aim Aim of this work is the demonstration of the scope for energy &

carbon saving in the EU through the use of electromagnetic processing of materials (EPM).

The primary energy factor and CO2-emission factor for electricity has to be estimated year by year till 2050.

From now to the year 2050 transition scenarios should be investigated and compared.

The most energy intensive production processes are switched

from the actual situation to a situation with up to 100% electrically operated industrial processes.


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Primary energy factors (PEF)

PEF for fossil energy can be estimated as constant in the future PEF for electrical energy depends on energy mix PEF is based on a forecast of the European gross electricity generation

Energy Carrier Primary energy factor

Hard coal 1,071811361

Coke 1,114827202

Lignite 1,038421599

Petroleum products 1,095290252

Natural gas 1,072961373

PEF for electrical energy PEF for fossil energy


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CO2-emission factors

Energy carrier CO2 –emission factor

[g/kWh]

Hard coal 406

Coke 473

Lignite 413

Petroleum products 301

Natural gas 227

CO2-emission factor for fossil energy can be estimated as constant in the future CO2-emission factor for electrical energy depends on energy mix CO2-emission factor is based on a forecast of the European gross electricity

generation


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Final energy consumption of the European industry (EU27) in 2009

Reference: Eurostat 2011 (Sum: 3,133,762 GWh)

in GWh


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Branch Industry sector

Calculated final energy demand in

2009 in GWh

Final energy demand of the branch in GWh

Share

Iron & steel Steel 434,923

Grey iron 10,972

Sum 445,904 514,848 87 % NF metals Aluminum 2,774

Sum 2,774 103,681 3 % Chemical Plastic 110,500

Sum 110,500 585,896 19 % Glass, pottery & building materials Glass 55,500

Roof tile 10,493 Brick 28,976

Cement 289,907

Lime 36,400 Sum 421,275 424,832 99 %

Paper & printing Paper 200,299 Sum 200,299 384,116 52 %

Share of the considered final energy demand of the five industrial branches


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Three different scenarios

The reference scenario implies no switching from fossil fuel heated processes to electrical processes

The linear scenario

assumes a linear increase of the share of electrical processes up to 100% in the year 2050

The so-called shock scenario implies an increase from the current situation to 100% electrical processes between 2020 and 2025

100 % electrical processes

Sha

re o

f ele

ctric

al p

roce

sses

Linear scenario

Shock scenario

Reference scenario


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Final energy carrier in the European iron and steel industry in 2009

Reference: Eurostat (Sum: 514,848 GWh)


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Steel production in Europe (EU-27)

Steel production in 2009: 130 Mio tons

Blast furnace: Raw iron

Midrex Process: Direct reduced iron

Oxygen blown converter

Electric arc furnace

There are two principle routes of steel production

Iron ore Iron ore Scrap

78 Mio tons 56 %

61 Mio tons 44 %

1 2


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1st steel production route (classical route) (1) The first step is the production of

raw iron with the blast furnace For the fabrication of 1 ton of

crude iron a typical blast furnace needs:

• 650 kg of iron ore • 907 kg of sinter • 475 kg of coke • 800 MJ of electrical energy • 2.5 kg of scrap

18 % of the blast furnace gas is recovered for the production of coke


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1st steel production route (classical route) (2) The liquid iron is transformed

into steel in an oxygen blown converter

Oxygen is pumped through the melt to reduce the carbon

The oxygen converter needs for 1 ton of steel: • 856 kg of raw iron • 65 m3 of oxygen • 287 kg of scrap • 29 kg carbon • 3 kg coke • 82 kg lime


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2nd steel production route (1) The electric arc furnace can be

charged with scrap or direct reduced ore

The volume is melted down through a powerful electric arc

For the production of 1 ton of steel the arc furnace needs: • 1080 kg of raw material • 1500 MJ of electrical energy • 30 m3 oxygen • 14 kg coke • 38 kg lime


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Today nearly all electric arc furnaces are operating with steel scrap

The amount of available steel scrap will

increase slidely The production of direct reduced ore has

to be enlarged The production of 1 ton of direct reduced

iron needs approx.: • 1500 kg ore, • 376 m3 of natural gas • 486 MJ of electrical power

2nd steel production route (2)


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Save of final energy

1.8 Mio GWh

1.3 Mio GWh

By using the linear switching scenario up to 1.3 million GWh of final energy can be saved. By using the shock scenario 1.8 million GWh of final energy can be saved.

Iron & steel industry / steel industry


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Save of primary energy

7,850 PJ

5,680 PJ

By using the linear switching scenario up to 5,680 PJ of primary energy can be saved. By using the shock scenario 7,850 PJ of primary energy can be saved.



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Save of CO2-emission By using the linear switching scenario up to 1,470 million tons of CO2-emission can be saved. By using the shock scenario up to 2,040 million tons of CO2-emission can be saved. 2,040 Mio tons

1,470 Mio tons



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Cast iron industry Iron & steel industry / cast iron industry

Production in 2007: 13 million tons Melting processes:

Medium frequency induction crucible furnace (50 %) 520 kWh/to electrical energy 48 kWh/to oxidation losses 74 kWh/to carburization

Hot blast cupola furnace (50 %) 900 kWh/to coke 20 kWh/to gas 30 kWh/to electrical energy 143 kWh/to oxidation losses


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By using the linear switching scenario up to 53,833 GWh of final energy can be saved. By using the shock scenario 74,841 GWh of final energy can be saved.

Iron & steel industry / cast iron industry

74,841 GWh

53,833 GWh


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By using the linear switching scenario up to 135.6 PJ of primary energy can be saved. By using the shock scenario 184.5 PJ of primary energy can be saved.


184.5 PJ 135.6 PJ


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Save of CO2-emission By using the linear switching scenario up to 48.1 million tons of CO2-emission can be saved. By using the shock scenario up to 66.6 million tons of CO2-emission can be saved.


66.6 Mio tons

48.1 Mio tons


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Production of casted aluminum in 2009: 1.96 million tons

Melting processes:

Induction channel furnace (8 %)

415 kWh/to electrical energy 200 kWh/to combustion losses

Gas fired furnaces (92 %)

712 kWh/to natural gas 775 kWh/to combustion losses

Aluminum industry Non-ferrous metal industry / aluminum


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By using the linear switching scenario up to 32,137GWh of final energy can be saved. By using the shock scenario 44,678 GWh of final energy can be saved.

Non-ferrous metal industry / aluminum

44,678 GWh

32,137 GWh


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By using the linear switching scenario up to 105 PJ of primary energy can be saved. By using the shock scenario 155 PJ of primary energy can be saved.


145 PJ

105 PJ


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Save of CO2-emission By using the linear switching scenario up to 13 million tons of CO2-emission can be saved. By using the shock scenario up to 18 million tons of CO2-emission can be saved.


18 Mio tons

13 Mio tons


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Production of plastics in 2007: 65 million tons

Specific use of energy: 1.7 MWh/to

Energy carrier:

61 % electrical energy 30 % gas 9 % oil

Plastic industry Chemical industry / plastic industry


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By using the linear switching scenario up to 0 GWh of final energy can be saved. By using the shock scenario 0 GWh of final energy can be saved.

Chemical industry / plastic industry


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-1,250 PJ

-1,790 PJ

By using the linear switching scenario up to 1,250 PJ of primary energy have to be spend additionally. By using the shock scenario 1,790 PJ of primary energy have to be spend additionally.



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Save of CO2-emission By using the linear switching scenario up to 103 million tons of CO2-emission can be saved. By using the shock scenario up to 139 million tons of CO2-emission can be saved. 139 Mio tons

103 Mio tons



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Production of glass in 2007: 37 million tons


Energy carrier:

20 % electrical energy 34 % gas 46 % oil

Glass industry Glass, pottery & building materials / glass industry


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Glass, pottery & building materials / glass industry


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-1,258 PJ

-1,806 PJ



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175 Mio tons 129 Mio tons


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Production in 2008: 255.4 million tons

Specific use of energy: 867 kWh/to

Energy carrier:

11.4 % electrical energy 0.9 % gas 2.7 % oil 41.2 % petcoke 23.6 % coal 4.3 % lignite 15.9 % waste

Cement industry Glass, pottery & building materials / cement ind.


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Glass, pottery & building materials / cement ind.


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- 7,182 PJ

- 10,312 PJ


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Save of CO2-emission By using the linear switching scenario up to 1,604 million tons of CO2-emission can be saved. By using the shock scenario up to 2,205 million tons of CO2-emission can be saved.


1,604 Mio tons 2,205 Mio tons


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Production in 2009: 87.1 million tons


Energy carrier:

30 % electrical energy 42 % gas 2 % oil 12 % hard coal 14 % others

Paper industry Paper & printing industry / paper industry


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Paper & printing industry / paper industry


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- 3,815 PJ

- 5,470 PJ


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374 Mio tons 508 Mio tons


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A switching from fuel operated processes to a production applying mainly electrical operated processes offers big potentials for saving CO2-emission. But for saving of energy it is necessary to improve or change the process not only the energy carrier. By using the linear switching scenario in all the presented case studies

• 1.38 million GWh of final energy, • - 9690 PJ of primary energy and • 3.97 billion tons of CO2-emission can be saved in sum. By using the shock scenario it is possible to save

• 1.92 million GWh of final energy, • -14210 PJ of primary energy and • 5.46 billion tons of CO2-emission.

Summary I


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The primary energy factor and CO2-emission factor for

electricity are analyzed and estimated year by year till 2050. From now to the year 2050 transition scenarios are developed, where three transition scenarios are compared in detail.

Part of the most energy intensive production processes are

switched from the actual situation to a situation with 100% electrically operated industrial processes.

A switching from fuel operated industrial thermal processes to a production applying mainly EPM technologies offers big potentials for saving of energy and CO2-emission.

For saving of energy it is necessary to increase the efficiency of the production process not only to change the energy carrier.

Summary II


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Thank you for your attention!

Technology

Webinar - Technologies for the Electromagnetic Processing of Materials - Energy and Carbon savings