RENEWABLE ENERGY SOURCES IN STEEL PLANT PROCESSES - RENEPRO

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1 RENEWABLE ENERGY SOURCES IN STEEL PLANT PROCESSES - RENEPRO Kokkola Material Week Dr. Hannu Suopajärvi Process Metallurgy Research Unit

2 Background 70% 5% 25% Steel production in 2016 was 1630 Mt Steel production and CO 2 Coal is used as reducing agent and fuel Around 7% of the world total is emitted by iron and steel industry Need for CO 2 reduction Several breakthrough technologies under development Biomass as an alternative

3 BF-BOF steelmaking route and CO 2 70% of the world steel production

4 Breakthrough technologies Program Technologies Maturity of the technology ULCOS (Europe) Top-gas recycling blast furnace with CCS Laboratory, pilot trials, industrialization 2020 onwards Bath smelting (HIsarna) Laboratory, pilot trials, industrialization 2030 onwards Direct reduction (ULCORED) Laboratory, industrialization 2030 Electrolysis (ULCOWIN) Laboratory, industrialization 2040 COURSE50 (Japan) H 2 -based reducing agents in BF Laboratory, pilot trials, industrialization 2030 onwards POSCO CO 2 breakthrough framework (Korea) AISI CO 2 Breakthrough Program Australian programme CO 2 sequestration from BF gas Pre-reduction and heat recovery of hot sinter CO 2 absorption using ammonia solution Bio-slag utilization for the restoration of marine environments Hydrogen production using COG and wastes Iron ore reduction using hydrogen-enriched syngas Carbon-lean FINEX process Ironmaking by molten oxide electrolysis Ironmaking by hydrogen flash smelting Use of biomass-derived chars as substitutes for coal and coke Dry slag granulation, waste heat recovery Laboratory, pilot trials, industrialization 2030 onwards Heat recovery system installed Laboratory, pilot trials Commercial Laboratory, pilot Not mentioned Commercial Laboratory Laboratory Laboratory, pilot, also industrial trials Laboratory, pilot

5 Biomass use in BF-BOF steelmaking Up to 57% CO 2 emission reduction! Application Sintering solid fuel Cokemaking blend component BF tuyere injectant BF nut coke replacement BF carbon/ore composites or BOF pre-reduced feed Basis % replacement of fuel 2 10% of coking coal 100% replacement of PCI % replacement 100% of coke dust Net emission reduction % of CO tco 2 /tcs 2 emissions Steelmaking recarburizer 100% Norgate et al. 2012

6 Challenges of using biomass in steelmaking Forest biomass availability Transportation cost Raw material cost Stand-alone or integrated plants Labor cost Economy of scale Centralized or decentralized production By-product biomass availability Competition over raw materials Biomass use in iron and steel production Efficient thermochemical conversion technology Market place for bioreducers Life cycle impacts Raw material and product storage CO 2 emission reduction Bioreducer behavior in metallurgical process

7 Renewable Energy Sources in Steel Plant Processes Biomass-based Reductants, Fuels and Chemicals RENEPRO project is coordinated by the (Process Metallurgy). Project partners: Luleå University of Technology (LTU), Sweden (Department of Engineering Sciences and Mathematics) Swerea Mefos, Sweden (Process Integration) Future Eco North Sweden, Sweden, Finland (Process Metallurgy, Applied Chemistry) Project time and budget Total budget of the project is 1.16 M Financiers of the project Main financier of the RENEPRO project is European Union through Interreg Nord program Co-financiers of the RENEPRO project are Lapin liitto and Länsstyrelsen i Norrbotten

8 RENEPRO-project Objectives of this research project are to: 1) Produce biomass-based reducing agents for blast furnace process and to evaluate their metallurgical properties (LTU, Future Eco, Swerea Mefos, Uni. Oulu) 2) Study the impact of biomass-based reductant introduction to the blast furnace on iron burden reduction and coke gasification (Swerea Mefos, Uni. Oulu) 3) Produce valuable products from biomass and investigate the production of fuels and chemicals (by F-T or methanol syntheses) from steel plant process gases (Uni. Oulu) 4) Evaluate the efficiency of integrating steel, bioreducer and chemical production with system analysis tools (Swerea Mefos, Uni. Oulu) 5) Conduct carbon footprint evaluation for steel production (Uni. Oulu, Swerea Mefos)

9 RENEPRO-project: Some examples Phounglamcheik et al Work package 1: Biomass upgrading Pilot-scale slow pyrolysis reactor has been designed and built Pyrolysis vapors are condensed and impregnated back to the char Increased char yield Laboratory experiments have been conducted to test the idea Mass and energy yields are enhanced

10 RENEPRO-project: Some examples Work package 2: Metallurgical research Addition of Kraft-lignin from pulping process to blast furnace briquettes Replacement of cement as a binder Results Strength of the briquettes decrease with increasing Kraft-lignin Reduction rate increases 25% replacement is applicable Mousa et al. 2017

11 RENEPRO-project: Some examples Work package 2: Metallurgical research Bio-coke production by adding charcoal and Kraft-lignin to the coal blend Kraft-lignin derived from pulping process Charcoal produced from pine chips (600 C) Carbonization at lab-scale coking oven (1200 C) Cold strength and reactivity measurements Suopajärvi et al. 2017

12 RENEPRO-project: Some examples Max. stress (MPa) 22,0 20,0 18,0 16,0 14,0 12,0 10,0 8,0 6,0 4,0 2,0 0,0 Charcoal Lignin Ref. 2 2,5 5,0 7,5 10,0 Biomass addition (%) Suopajärvi et al Work package 2: Metallurgical research Thermal behavior differs considerably affects the coking process Cold strength is maintained with charcoal, but not with Kraft-lignin addition Reactivity of the bio-coke increases significantly with charcoal addition, moderately with Kraft-lignin 10.0% charcoal and 2.5% Kraft-lignin addition could be plausible

13 RENEPRO-project: Some examples Kemppainen et al Work package 2: Metallurgical research Iron ore pellet reduction behavior in BF with biomass and top gas injection Mathematical model was used to evaluate the gas atmosphere inside the BF Cases: Pulverized coal injection Charcoal injection Torrefied biomass Top gas recycling Differences in reducibility of the gas

14 RENEPRO-project: Some examples Kemppainen et al Work package 2: Metallurgical research Laboratory investigations were used to evaluate the effects to pellet reduction Torrefied biomass injection showed a minor increase to the reduction rate and final reduction degree Top gas injection indicated highest pellet reduction potential and cracking of the pellets No swelling was detected, shrinking of the pellets occurred Minor effects to the BF process with biomass injection

15 RENEPRO-project: Some examples Lahti et al Work package 3: High value products from biomass Production of biomass-based activated carbons for adsorbents Saw dusts and Kraft-lignin as raw materials Carbonization and steam activation Adsorptive properties (AC from birch) Methylene blue and gentian violet solutions Zinc, nitrate, sulphate and phosphate ion solutions Adsorption capacity of metal cations and dyes was high onto activated carbon prepared from birch. With zinc metal removal was 97 % and with methylene blue dye 86 %. Removal of anions was lower from ~30 to 40 %

16 RENEPRO-project: Some examples Work package 4 and 5: Research under work System integration studies with static mass and energy balance BF model and carbon footprint methodology LCA software Gabi used for steel production life cycle modeling Data from SSAB Raahe MASMOD model (Swerea Mefos) used for biomass injection modeling Also the upgrading of steel plant gases will be studied

17 Conclusions Biomass use could be one solution to decrease the fossil CO 2 emissions in iron and steelmaking industry In RENEPRO project, several important aspects related to biomass introduction to the steel industry processes have been evaluated Pilot plant reactor with tar impregnation has been built (enhanced solid yield) Applicability of the impregnation has been tested in lab-scale New blast furnace burden materials have been developed and tested Kraft-lignin use in blast furnace briquettes Kraft-lignin and charcoal use in coal blend to produce bio-cokes Effect of biomass injection to the iron ore pellet reduction has been evaluated Slight increase in reducibility with torrefied biomass injection High-value products from biomass have been developed Efficient adsorbents, catalyst supports System integration studies under way CO 2 reduction, life cycle impacts

18 Acknowledgements This research is a part of the RENEPRO project ( ) funded by Interreg Nord More information: Steel-Plant-Processes-Biomass-based-Reductants-Fuels-and-Chemicals-2

19 References Kemppainen A, Wang C, Mousa EA, Haapakangas J, Suopajärvi H, Fabritius T. Iron ore pellet reduction behavior in potential low CO 2 blast furnace scenarios. In: Proceedings of 7th European Coke and Ironmaking Congress, Linz, Austria, September 12-14; Lahti R, Bergna D, Romar H, Tuuttila T, Hu T, Lassi U. Physico-Chemical Properties and Use of Waste Biomass- Derived Activated Carbons. Chemical Engineering Transactions 2017; 57: Mousa EA, Ahmed HM, Wang C. Novel Approach Towards Biomass Lignin Utilization in Ironmaking Blast Furnace. ISIJ International 2017; 57: Norgate T, Haque N, Somerville M, Jahanshahi S. Biomass as a source for iron and steelmaking. ISIJ International 2012; 52: Phounglamcheik A, Wretborn T, Umeki K. Biomass pyrolysis with bio-oil recycle to increase energy recovery in biochar. 25th European Biomass Conference and Exhibition (EUBCE), June 12-15, Stockholm Sweden; Suopajärvi H, Dahl E, Kemppainen A, Gornostayev S, Koskela A, Fabritius T. Effect of charcoal and Kraft-lignin addition on coke compression strength and reactivity. Sent for publication in energies.

20 Thank you for your kind attention!