Simulation techniques for an Efficient Use of Resources: An overview for the steelmaking field

Resource efficiency has always been a hot topic for the steel industry, due to the large amounts of primary raw materials, by products and water, which are handled in the steelmaking cycle as well as the considerable energy consumptions. The ever more stringent environmental regulations also contribute to pressurize the iron and steel industry to strengthen further its research activities fostering an optimal management and exploitation of resources. Thus important research efforts are spent in order to find the best way to recover wastes and wastewater also involving the implementation of retrofit actions and major plant modifications allowing also the reduction of primary raw material consumption and of waste disposal. In order to achieve such ambitious objective, which implies both environmental benefits and cost savings, process integration is a powerful tool. The assessment of the viability of process integration solution necessarily include a final experimental stage to be performed at plant level, which can be expensive or unsafe. To this aim process simulation can be a useful alternative to accomplish preliminary feasibility studies allowing a deep analysis of all the aspect of a particular technology or retrofit actions, which also allows testing conditions that are very difficult to replicate within practical experiments. Different levels of detail can be achieved and a comprehensive analysis can be carried out. The present paper provides an overview of the simulation techniques exploited during the project entitled "Efficient Use of Resources in Steel Plants through Process Integration" to the aim of optimizing the use of resources in an Italian integrated steelmaking plant. In particular, different case studies are proposed and the obtained meaningful and practical results are presented and discussed.