Warren
ArcelorMittal Warren converts metallurgical-grade coal into high-grade blast furnace coke. The Ohio facility also contains a by-products operation that processes coke oven off gases into useful, valuable by-products. Its central location between the Great Lakes and Ohio River corridor allow it to take advantage of both low-cost transportation routes. It has access to rail, river and highway transportation along with access to coal fields in the Appalachian region and the steel mills from Pennsylvania to Indiana.
The site of the ArcelorMittal Warren facility has seen steel production since the 1920s. The current coke battery, commissioned in 1979, supplies coke primarily to the Cleveland plant. ArcelorMittal Warren has the capability to make 550,000 tons of coke per year.
Examples of Environmental Excellence
Recycling coke oven gas
One of Warren’s primary initiatives includes more efficient use of coke oven gas. Two projects will deliver both substantial savings in energy cost. They are projected to save a total of $1.5 million annually.
In the first of the projects, two coke-oven-gas-fired boilers feed process steam into the desulphurization plant. These boilers produce 16,000 lbs/hour of steam and can operate on either coke oven gas or natural gas. The boilers are each self-contained with gas train, steam generation and water treatment capabilities and can operate on either coke oven gas or natural gas.
The second project will replace a high-temperature, high-pressure hot water heater used for the pushing emission controls system on a Chemico car at the coke plant. The new heater is designed to operate on either coke or natural gas and features independent natural gas and coke oven gas trains. By using coke oven gas as the primary fuel, the plant will be able to reduce purchases of natural gas by one-third of the plant’s total natural gas usage.
Additional coke oven gas usage projects are being developed in concert with steam production projects to better utilize in house resources and to eliminate exposure to outside disruptions and uncertainties.
Finding new use for by-products
Demonstrating its commitment to sustainability, the facility recycles by-products of the coke-making process for use by other manufacturers. The facility successfully collects gases baked off the coal and then recondenses them for reuse. This includes oil, sulphur and other by-products that can be used by other companies.
Making environmental improvements
Rebuilding of the coke oven battery is one project that will help the facility maintain its excellent environmental performance and continue to minimize the impact of its operations on the community. The rebuild will ensure that the facility exceeds increasingly stringent environmental regulations. The project will take as long as three years to complete and the battery will continue to operate during the process.