Outokumpu – Leading Natural Gas and Nitrogen Oxides Reductions

Partners for Environmental Progress recently awarded Outokumpu a 2024 Environmental Stewardship Award. Outokumpu Stainless, recognized globally for their leadership in sustainability and environmental stewardship, continuously strives to enhance environmental performance across their operations, including here in Alabama. PEP is spotlighting two groundbreaking projects that exemplify Outokumpu’s commitment to a greener future.

Annealing Furnace Energy Efficiency and Natural Gas Reduction

The Challenge

Annealing furnaces are essential in processing stainless steel, but they are also significant consumers of natural gas. Outokumpu saw an opportunity to improve the operating efficiency of these furnaces and reduce natural gas consumption—vital for both cost savings and environmental impact. 

The Solution

In November 2022, Outokumpu began a technical assessment of their annealing furnaces. They discovered that applying a high emissivity coating to the inner walls and roof of the furnace could significantly reduce heat loss. This innovative technology, certified by the Space Foundation, enhances radiant heat transfer, thereby lowering the required furnace temperature and reducing natural gas usage.

The Impact

The results were nothing short of impressive:

• CO2 Reduction: More than 1,100 tons in 2023
• Energy Savings: Over 6,100 megawatt-hours (MWh) of energy saved in 2023 alone

Richard Chinery, Combustion Systems Manager for Outokumpu business area Americas, remarked, “The Emisshield coating technology is a game changer for Outokumpu. It allows for more efficient heat transfer, lower required furnace temperature, leading to less fuel used and less CO2 released.”

Nitrogen Oxides Reduction Project

The Challenge

Nitrogen oxides (NOx) are harmful pollutants that contribute to air quality issues. At their Calvert mill, Outokumpu set out to reduce NOx emissions in their Hot Annealing and Pickling Line, which utilizes nitric and hydrofluoric acid in its processes.

The Solution

Outokumpu collaborated with suppliers to trial a process involving the injection of hydrogen peroxide into the acid baths. This innovation allows nitric acid to stay in solution longer, reducing the need for fresh nitric acid and minimizing NOx generation. This also leads to reduced ammonia usage for NOx reduction.

The Impact

The environmental benefits were substantial:

• Raw Nitric Acid Reduction: Over 3,000 gallons per month
• CO2 Reduction: More than 1,400 tons
• Ammonia Consumption Reduction: 25%

Wayne Denton, Director of Environmental, Health, & Safety for Outokumpu business area Americas, stated, “Alabama requires us to meet a minimum standard for air quality control. However, here at Outokumpu, we are striving to exceed the minimum standard. Our team is dedicated to reducing air emissions; and with this project of reducing nitrogen oxides (NOx), so far, we have exceeded our own expectations.”

A Commitment to Sustainability

These projects are just two examples of Outokumpu’s unwavering dedication to sustainability and innovation. Their efforts not only enhance operational efficiency but also set a powerful example for the industry.