Arcelor-Mittal, Fos-sur-Mer, France, develops energy efficiency opportunities with ABB

ABB identifies €10 Million annual energy savings at steel mill through an Industrial Energy Efficiency programme.

Develop energy efficiency opportunities

ArcelorMittal’s integrated steel mill in the south of France has the capacity to produce up to 5 Million tonnes of steel per year, with over 4000 employees based at site.

The Fos-sur-Mer site is part of ArcelorMittal’s flat carbon Europe organization, producing black coil, pickled and oiled coil sheet, cut to length sheet and slit coils.

The vast site is a fully integrated steel mill, with quay facilities, sintering plant, coke oven plant, two blast furnaces, two basic oxygen converters, two continuous casters, in ladle vacuum degassing, hot strip mill and multiple finishing lines.

ArcelorMittal had already made significant investment in energy efficient core process technologies and on-site waste gas integration.

To compliment the successfully energy efficiency initiatives, ArcelorMittal challenged ABB to identify and develop energy efficiency opportunities within the site equipment with motors and drives.

Main facts

Industry	Metals
Customer	Arcelor-Mittal steel plant
Country	Fos-sur-Mer, France
Solutions	ABB delivered an Industrial Energy Efficiency (IEE) program tailored to Arcelor-Mittal’s requirements, identifying, confirming, and developing a portfolio of energy saving projects for implementation.
Benefits	53 Individual energy saving opportunities identified Estimated electrical savings €2.5M to €4.3M/year Additional gas savings of up to €6M per year 3 zero capital investment opportunities agreed for immediate implementation with energy savings of €120K/year, payback < 1 year 4 Project specifications developed to implementation with energy savings of €1.9M/year, average payback 1 year

Ian Shaw, Energy Manager, North America

“I was impressed by ABB’s work at Fos‑sur-Mer and will be happy to a have further discussions regarding a broader scope”

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Solution

ABB delivered an Industrial Energy Efficiency (IEE) programme tailored to ArcelorMittal’s requirements, identifying, confirming, and developing a portfolio of energy saving projects for implementation.

The IEE programme consisted of ABB well-established primary and secondary phases:

Opportunity Identification study
Master Plan development
Implementation of quick win projects
Prioritisation of the project portfolio
Development of top tier project specifications

The IEE programme focused on electrical energy savings within key site areas:

BOF steelmaking plant
Blast furnaces
Cowper stoves
Power plant
Sintering plant
Hot rolling mill
De-dusting systems
Compressed air systems

A total of 53 energy saving opportunities were identified across an range of site operations, with a range of solution requirements ranging from low investment quick wins to larger capital investment type projects.

The IEE project portfolio included:

MV variable speed drive opportunities
LV variable speed drive opportunities
Process control changes to optimise energy consumption
Cooling tower optimal operation - for pressure and temperature
Power plant boiler air-to-fuel ratio optimization
Equipment selection for reduced energy consumption
Evaluation of existing process parameters to optimize energy consumption

Jeroen van Lishout, Energy Manager, Europe

“We are very pleased with the results as ABB have defined very clearly where energy can be saved and how to achieve it. The work is really appreciated. It is better than just an audit”