Environmental Sustainability

D2.3:Enterprise-wide Energy Optimization for Steel Making

Plant-wide minimisation of energy consumption and emissions in the steelmaking industry will provide economic, social and environmental benefits. To address this problem for an integrated steel plant, complex flow sheets are normally developed, providing the capability to assess the best or optimal options, for various operational scenarios.

This research addresses the modelling of energy sources, flows and sinks that occur in an integrated steel plant. The model will provide insights into system behaviour that will lead to optimum energy generation and use. The outcomes will consider the individual operating units, and look at the planning and scheduling issues that affect optimal energy generation and use.

Team: Simon Smart, Ian Cameron, Greg Siemen, Habib Zughbi, Alan Bennett

D2.5 Application of Process Integration Models to Optimise and Monitor Energy Usage and Emissions

This research activity aims to extend previous plant wide-based studies involving elemental balances of trace elements across an integrated steel plant. Using a Process Integration methodology, the project will provide a basis for estimating the emissions from the entire plant, as well as enabling the evaluation of various scenarios, including recycling of plant by-products. A modelling platform for these calculations is the Integrated Steelworks Energy and Emissions Model (ISEEM) which calculates energy consumption and CO2 emissions across the Port Kembla Steelworks. The scope includes estimating the partitioning of these trace elements across the various processing streams.

Team: Simon Smart, Ian Cameron, Chris McMahon, Habib Zughbi, Alan Bennett

D2.7 Zinc Removal via the Iron Ore Sintering Process

This is an applied research investigation to assess the feasibility of processing Zn-bearing by-product streams through a conventional iron ore sintering plant. The objective is to generate a zinc-lean product sinter, with zinc concentrating to the captured waste dust. A targeted experimental program employing a recently commissioned Sinter Millipot facility will be used to develop the case for a plant-based trial. Successful sinter plant implementation could result in economic displacement of iron ore and flux if at least 50% of the Zn in the by-product streams can be removed.

Team: Guangqing Zhang, David Pinson, Brian Monaghan, Sheng Chew, John Heslin, Ray Longbottom

D2.8 Zinc removal via the Acid Leaching Process

The project investigates the feasibility of processing zinc-bearing by-product streams from iron and steelmaking through acid leaching, so that the leached solid residues can be processed by a conventional iron ore sinter plant. The project will develop better understanding of the presenting states of zinc in the by-product materials and their leachability by different acids, as well as establishing optimal conditions for the leaching removal of zinc without significant loss of iron. The investigation will contribute to the utilisation of the by-product materials in iron and steelmaking and the sustainable development of the steel industry.

Team: Guangqing Zhang, David Pinson, Brian Monaghan, Sheng Chew, John Heslin, Paul Zulli, Andrew Lang