RecentTrendsinHeatRecoveryCokemaking JohnQuanci

Recent Trends in Heat Recovery Cokemaking Processes
Dr. John F. Quanci SunCoke Energy Vice-President of Technology September 2011
September 2011
SunCoke Energy
Outline
Iron Production: Coke Usage Heat Recovery Cokemaking Technology History Heat Recovery Cokemaking: Current Practice Future Requirements and Direction in Heat Recovery
September 2011
SunCoke Energy
Iron Production: Coke Usage
September 2011
SunCoke Energy
Iron Production: Coke Minimization

Coke is the 2nd highest cost consumable in Steel production
~25% of the total cost Iron highest at ~40% of total cost
Blast furnace competitiveness depends on lowering coke use Steel Industry focused on lowering coke use for the last 50 years by advances in practices and technology
September 2011 SunCoke Energy 4
Reduction Blast Furnace Reducing Agent Consumption

1100
1000 900
consumption of reductants kg/thm
Ore beneficiation Input of overseas rich ores Blast temperature > 1200C O2 enrichment Top pressure Burden distribution Gas flow control Improvement of Fe burden Improvement of coke Small coke in Fe burden
800
700
600 500 400 300 200 100 0
coal oil + others
~30%
104 33
coke
345
482
1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005
year
Impact of Technology over the last 50 years: Reducing Agents lowered by over 50% Coke use lowered by over 65%
September 2011
Source: Sponge Iron Production - Chatterjee
SunCoke Energy 5
Global Demand for Coke and Hot Metal
Source: US Geological Survey
Even though Steel Companies driving down coke/thm through technology and alternate reductants, coke demand still increasing Increasing demand for coking coals expected
Alternate Reductants for Coke Replacement

Increased use of PCI and other reductants to replace coke in Blast Furnaces As high as 30-40% of blast furnace coke has been replaced by alternate reductants like PCI Alternate reductants could potentially make up as much as 50% of the total reductant As alternate reductants like PCI increase, higher quality coke needed:
Supports the burden (about 50% of total reductant) Distributes gases
Will drive demand for larger and stronger coke!

Heat Recovery Technology History
September 2011
SunCoke Energy
SunCoke Energy Process Flow Diagram

Sun Coke Process Flow Diagram
Steam Extracted for Process Use
Turbine
Electricity to Grid
Condenser
Emergency Stack
Feed Water Heaters, Pumps, Deaerators
Coal
1,930 F Flue Gas temperature
Flue Gas Treating for Sulfur Removal
ID Fans
Main Stack
Heat Recovery Steam Generators Co-generation Plant Coal - Blended VM FC Ash Moisture Heat Recovery Coke Ovens 24.50 68.25 7.25 7.00
Run-of-Oven Coke
Furnace coke Breeze
September 2011
SunCoke Energy
SunCoke Energy Horizontal Heat Recovery Oven
September 2011
SunCoke Energy
10
Horizontal Non-Heat Recovery Developmental History

1960s
First SunCoke Horizontal Mitchell Ovens in Jewell
1970s
Jewell Thompson ovens built Precursor to modern HHR design
1980s
Continued R&D Highest quality coke in US
Jewell Plant Vansant, VA (Mid-1970s)
Jewell Plant late 1980s

1990s First Generation Heat Recovery Plant

SunCoke builds first heat recovery plant in world Located in East Chicago, Indiana Started up in March 1998 Coke capacity: 1.3M tpa (268 ovens) Heat Recovery of 1.0 Mlbs/hr of superheated steam Rated for 100 MW of power generation
Indiana Harbor Coke Plant March 1998
September 2011
SunCoke Energy
12
SunCoke Energy History since 2000 New HR Plants

Domestic Operations
Indiana Harbor 268 Ovens Capacity: 1,220kt Steam: 1,000klbs/hr Middletown(1) 100 Ovens Capacity: 550kt Power: net 46 MW Haverhill (2005, 2008) 200 Ovens Capacity: 1,100kt Steam: 450klb/hr Power: net 46 MW
International Operations
Brazil
Granite City (2009) 120 Ovens Capacity: 650kt Steam: 450klbs/hr
Jewell Coke 142 Ovens Capacity: 720kt

Existing coke facilities Coke facility under construction
Vitria(2) (2007) 320 Ovens Capacity: 1,700kt Power: 150 MW
(1) Expected start-up in Q4 2011. (2) SunCoke holds a preferred interest of $41 million in Vitria and is the operator.
September 2011
SunCoke Energy
13
SunCoke Heat Recovery Plants

Haverhill, OH Phase II (100 Ovens)
Vitoria, ES Brazil (320 Ovens)
September 2011
SunCoke Energy
14
Most recent project Middletown, OH
September 2011
SunCoke Energy
15
SunCoke Energy Capacity through 2011
Steady increase in SunCoke Energy heat recovery coking capacity over the last 5 10 years All new coke plants in United States since 2000 have been Horizontal Heat Recovery
Heat Recovery Capacity
Last 5-Year Technology Advancements

Improved Oven Design Improved HRSG design Pusher charger machine upgrades Flat push hot car & quench car Further enhanced charging emission control system Advanced FGD Control
EPA Approved Technology
Improved Quench Tower Design
September 2011
SunCoke Energy
17
Heat Recovery Cokemaking: Current Practice
September 2011
SunCoke Energy
18
Typical SunCoke Energy Battery

Coal specifications
Typical volatile matter is 21% to 28%, campaign 19% to 32% Average reflectance range of 1.00 to 1.65
Can generate steam or power

Approximately 9 MW / 100 kmt annual Run of Oven coke production Annual power production of 788 kW-h / mt coke
No wastewater treatment plant required Can be constructed on a new site or existing site (brownfield) 48 hour cycle / 43.2 metric tons (48 short tons) coal 1540C max temperature Plant designed for 30 year run life Approximately 2 4% Yield Loss 2 5 CSR increase over By-product plant using same coals
Improved Strength attributed to slower heating rate, higher temperatures and longer soak time resulting in consistent crystal growth
HHR Coal Flexibility

Not limited by coal expansion
Can use high wall-pressure coals Can use low and high rank coals
SunCoke demonstrated use of PCI coal (25%), Petroleum Coke (10%), noncoking coal (10%), soft or semi-coking coal (25%) and breeze with minimal impact to CSR No oven damage risk associated with blend changes
Minimal need to run pilot/moveable wall oven studies
Less risk of exposure to coal supply shortages / issues

SunCoke Energy facilities can change coal blends weekly Up to 80+ different coal blends used per year
September 2011
SunCoke Energy
20
Heat Recovery Oven Flexibility

Hypothetical blend of 3 coals
HR only
HR & By-Product
HHR Not constrained to this maximum
Heat recovery plants can blend in more high pressure coals Elimination of wall pressure constraints increases blend flexibility
SunCoke Energy 21
September 2011
Environmental Impact Benefits

Low VOC emissions
Ovens operate under negative pressure conditions during coking cycle Complete combustion of VM
SunCoke Energy sets the technology standard in United States

SDA / baghouse is typical Successfully integrated advanced FGD with coking process
No net waste-water discharge

All process water consumed by quenching
September 2011
SunCoke Energy
22
Factors Favoring Heat Recovery Plants

Minimal need for COG in the steel plant High cost of electricity or no electricity supply available Steam required for process needs
HHR is a Cogen plant and can replace existing boilers
Coal blend flexibility (no wall pressure limits) Can utilize wide range of coals (lower cost blends) Plant location at risk for coal supply disruptions Strict environmental regulations No or limited waste water treatment plant Higher quality coke is required Large blast furnaces and/or high PCI rates
September 2011
SunCoke Energy
23
Future Trends in Heat Recovery Cokemaking
SCE Horizontal HR Coke Plant Improvement Summary

Critical Areas for Customers Footprint Capital Cost Coke Yield Next Plant Potential 30% Smaller Value Engineered Lower Capital Lower Yield Loss Future Plants >30% Smaller Further Capital Decrease Driven by Footprint Increased Yield Gain
Lower Coal Cost
Flexibility for Stamp Charging Predictive coal blend modeling improvements

Greater than 25% Meet or exceed New EPA Regs New Monitoring Tools Structure Improvements New HRSG Design
New Designs
Turndown Environmental Regs Oven Operation/Life Increased Power
>50% and Turn Off Exceed EPA Regs Continue to set the standard New Materials of Construction and CFD/FEA Further Improvements based on CFD
September 2011
SunCoke Energy
25
Value Engineering Coke Plant: Conceptual Designs

Value engineering can reduce capital investment
Maintain coke rate with less supporting capital equipment Reviewed existing design and reduced number of machines Also looking to use low-cost country sourcing
Design Enhancements
Plot space saving Simplified power production design Meets or exceeds new Environmental requirements
Modular expansion provides more flexibility for brownfield sites

Coke Yield Improvements

Currently studying parameters that effect the Run of Oven coke yield Goal is to minimize burn loss through fundamental design changes of the coke oven Ties in very well with future modeling work (CFD and combustion kinetics)
September 2011
SunCoke Energy
27
Low Cost Coal Utilization

Horizontal Heat Recovery ovens have blend advantage since no wall pressure limit
Larger selection of low quality and low cost coals
Coal Compaction/Stamp charging has high potential to lower overall coke cost
Significantly reduce coal costs and maintain high coke quality Required in India/China where large quantities of low quality coal International coke producers claim 40 to 60% low quality coal usage in coal blends
Coal/Coke Blend Modeling is crucial to take advantage of Coal Flexibility and Stamp Charging
September 2011
SunCoke Energy
28
Coal/Coke Chemistry and Blend Modeling

Advance fundamental knowledge of the coking process Coal blend/coke prediction model for world-wide applications Optimization of coal/coke blends through first principle modeling
Go beyond current empirical correlations Function of Operating Conditions, Coal Properties and Reaction Kinetics CSR, Stability, Yield, Power, etc
Coal/Coke Non-Linear Program Optimization Tool Pilot plant and large-scale testing for coal blend testing, model development and next generation coke oven design
September 2011
SunCoke Energy
29
Model Development: Coal Blends

Coal 1 Coal 2
log(fluidity)
Planned test Space

optimal coking range Coal 3
reflectance Develop coal blends/models with non-linear multidimensional optimization and design of experiment Pilot Plant studies allow for non-production viable blends to be tested for the purpose of statistical leverage on model building and testing
Computational Fluid Dynamics (CFD) Oven Model
Temperature (F)
Advance coke making science, technology and principles through the use and application of Advanced Computational Tools (CFD/FEA/Rxn Kinetics) Link CFD, coke/coal blend/kinetic models and oven structural FEA models to allow fully integrated design and optimization Using CFD to optimize oven design and operation; lower yield loss, faster rates, new designs etc
Coke Oven Turndown Optimization

Allow flexibility for industry turndowns and coal shortages Safe , efficient, and quick turndown of SCE oven without damage to the oven structure or life while maintaining coke yield and quality Improve Max turndown on existing plant
Ovens have been turned down greater than 25% Further tests may show greater turndown possible
Improvements to allow more turndown and potentially turn off existing ovens
September 2011
SunCoke Energy
32
Next Generation Environmental Control

Next North American Plant to meet or exceed EPA regulations
Lower SOx No planned venting Still lowest in HAPs/VOCs since negative pressure
Improved Quench Tower Design

Lower Emissions Better Reliability Faster and more efficient quenching
Environmental Controls can be optimized to meet local requirements and needs
September 2011
SunCoke Energy
33
Next Generation Coking Process

Future Goals
Lower Capital Cost and Lower Cost of Conversion High Turndown (turn off) Improved HRSG/FGD reliability and integration Low yield loss (<1%) Increased Yield Improved VM range/capability Higher power production (>9 MW/100k mtpa Coke) Smaller Footprint Coke Plant Improved Coke Quality Maximize low quality coal Increased throughput over current designs Meet or exceed Environmental requirements
September 2011
SunCoke Energy
34
Summary
SunCoke Energy has advanced horizontal heat recovery technology over the last 50 years
Oven design perfected from 1960s to 2010s Currently looking to optimize heat recovery and push the limits of technology
Will continue to improve the Heat Recovery process

Better coal blend predictions Lowest possible turndown capabilities Advanced process modeling for optimal operation Smaller footprint with lower CapEx and OpEx costs Improved Environmental Controls
Aspiring to bring science to the art of cokemaking


RecentTrendsinHeatRecoveryCokemaking JohnQuanci

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Recent Trends in Heat Recovery Cokemaking Processes

Dr. John F. Quanci SunCoke Energy Vice-President of Technology September 2011

Iron Production: Coke Usage

Iron Production: Coke Minimization

Reduction Blast Furnace Reducing Agent Consumption

coal oil + others

Source: Sponge Iron Production - Chatterjee

Global Demand for Coke and Hot Metal

Source: US Geological Survey

Alternate Reductants for Coke Replacement

Will drive demand for larger and stronger coke!

Heat Recovery Technology History

SunCoke Energy Process Flow Diagram

Feed Water Heaters, Pumps, Deaerators

1,930 F Flue Gas temperature

Flue Gas Treating for Sulfur Removal

Furnace coke Breeze

SunCoke Energy Horizontal Heat Recovery Oven

Horizontal Non-Heat Recovery Developmental History

Jewell Plant Vansant, VA (Mid-1970s)

Jewell Plant late 1980s

1990s First Generation Heat Recovery Plant

Indiana Harbor Coke Plant March 1998

SunCoke Energy History since 2000 New HR Plants

Granite City (2009) 120 Ovens Capacity: 650kt Steam: 450klbs/hr

Jewell Coke 142 Ovens Capacity: 720kt

Vitria(2) (2007) 320 Ovens Capacity: 1,700kt Power: 150 MW

SunCoke Heat Recovery Plants

Vitoria, ES Brazil (320 Ovens)

Most recent project Middletown, OH

SunCoke Energy Capacity through 2011

Heat Recovery Capacity

Last 5-Year Technology Advancements

Improved Quench Tower Design

Heat Recovery Cokemaking: Current Practice

Typical SunCoke Energy Battery

Can generate steam or power

HHR Coal Flexibility

Less risk of exposure to coal supply shortages / issues

Heat Recovery Oven Flexibility

HHR Not constrained to this maximum

Environmental Impact Benefits

SunCoke Energy sets the technology standard in United States

No net waste-water discharge

Factors Favoring Heat Recovery Plants

Future Trends in Heat Recovery Cokemaking

SCE Horizontal HR Coke Plant Improvement Summary

Lower Coal Cost

Flexibility for Stamp Charging Predictive coal blend modeling improvements

Turndown Environmental Regs Oven Operation/Life Increased Power

Value Engineering Coke Plant: Conceptual Designs

Modular expansion provides more flexibility for brownfield sites

Coke Yield Improvements

Low Cost Coal Utilization

Coal/Coke Chemistry and Blend Modeling

Model Development: Coal Blends

Planned test Space

Computational Fluid Dynamics (CFD) Oven Model

Coke Oven Turndown Optimization

Next Generation Environmental Control

Improved Quench Tower Design

Environmental Controls can be optimized to meet local requirements and needs