PSI - Issue 38

Nitish Shetye et al. / Procedia Structural Integrity 38 (2022) 538–545 Shetye et al. / Structural Integrity Procedia 00 (2021) 000 – 000

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3.2. Steel production phase The steel production phase is the second phase which uses the iron ore pellets made in Phase 1. Different production processes are followed for making Conventional Steel and HYBRIT Steel, these are described in detail in (SSAB, 2017). The energy consumption for the various steps of steel production can be seen in Table 4.

Table 4. Energy required for the steel production processes (Vogl et al., 2018) and (Neelis et al., 2007). Energy [GJ/tonne] Conventional Steel HYBRIT Steel Liquid Steel 12.5 13.2 Continuous Casting 0.1 0.1 Hot Rolling 1.8 1.8 Cold Rolling 0.4 - Finishing 1.1 - Total (E SP tonne ) 15.9 15.1

The energy required for the steel production for the bogie beam is given by Equation 3 and the actual energy consumption for the steel production for making the two designs of bogie beams can be seen in Table 5.

tonne

/1000

(3)

E SP = m beam E SP

Table 5. Steel production energy for the two bogie beams.

Energy [MJ]

A30 Original

A30 Optimized

617.8 587.6

407.8 387.8

Conventional Steel

HYBRIT Steel

3.3. Bogie manufacturing phase The bogie beam manufacturing phase is the third phase which uses the steel produced in Phase 2. This phase includes the following steps: laser Cutting of plates, turning sleeves, bending flanges, manual welding, robot welding, final welding and repairs. Out of these six steps, laser cutting plates, robot welding and manual welding are the more energy intensive steps. The energy required for the rest of the steps was neglected. The energy required for the different processes in bogie beam manufacturing can be seen in Table 6. The energy required in the bogie manufacturing phase is independent of the steel production process as seen in Table 7.

Table 6. Energy required for the bogie manufacturing processes.

Energy [MJ] Laser Cutting Robot Welding Manual Welding Total ( E BM )

A30 Original

A30 Optimized

20.5 11.0 9.8 41.3

13.0 9.9 11.8 34.7

Table 7. Bogie manufacturing energy for the two bogie beams.

Energy [MJ]

A30 Original

A30 Optimized

41.3 41.3

34.7 34.7

Conventional Steel

HYBRIT Steel

3.4. Use phase The bogie beam’s contribution to the use phase energy is obtained by the energy required by to move the bogie