Search Results (10)

Biomass ironmaking is crucial for carbon reduction in the ironmaking industry. To understand this process better, the iron production capacity and energy requirements of biomass were studied. A thermodynamic equilibrium model and energy consumption model for the biomass and iron oxide reduction system at 100–1300 °C was established by the minimum free Gibbs energy method. The effects of factors such as biomass type, temperature, and initial amount of iron oxide on the system were analyzed. The research results indicated that the maximum ironmaking capacity of biomass was determined by the element content of carbon, hydrogen and oxygen in biomass and temperature. The equilibrium H₂/(H₂ + H₂O) and CO/(CO + CO₂) at the maximum iron yield were affected not by the biomass species and element content, but by temperature. The reduction capacity of the ten selected biomass types decreased with a temperature increase from 700 °C to 1300 °C. For the 1 kg of pine sawdust and iron oxide system, the maximum equilibrium state amount of metallic iron was 23.05 mol at 718 °C, and the minimum system energy consumption per ton Fe was 1.16 GJ at 800 °C and 1.18 GJ at 900 °C. These research results will provide a key basis for a deeper understanding of the intrinsic mechanism of biomass ironmaking. Full article

In recent years, the concept of green, low-carbon and clean energy consumption has been deeply rooted in the hearts of the people, and countries have actively advocated the use of new energy. In the face of problems such as resource shortage and environmental pollution, we began to explore the use of new fuels instead of coal for production. Biomass resources have the characteristics of being renewable and carbon neutral and having large output. As an energy utilization, it is helpful to promote the transformation of the energy structure in various countries. Applying it to ironmaking production is not only conducive to energy conservation and emission reduction in the ironmaking process but also can achieve efficient utilization of crop waste. By introducing the source and main preparation methods of biochar, this paper expounds the main links and advantages of biochar in the ironmaking process and puts forward the direction of biochar in ironmaking in the future. Full article

It is critical for the iron and steel industry to achieve green transformation and development by effectively utilizing abundant biomass resources in blast furnace ironmaking. In this paper, four types of typical biomass were carbonized and upgraded using the hydrothermal carbonization (HTC) method, and the metallurgical performance of the prepared hydrochar for blast furnace injection was systematically tested. The results show that HTC treatment could remove volatile matter and dissolved mineral elements in biomass so that the hydrochar had the characteristics of high fixed carbon and low ash and alkali metal content. Moreover, the hydrochar had good grindability and excellent combustion performance, which meet the requirements of blast furnace injection. Finally, the metallurgical performance of blended coal and wood chip hydrochar was examined. It was observed that when the ratio of hydrochar was less than 15%, it would not affect the blast furnace injection, and the potential safety hazard caused by the explosive hydrochar could be resolved by mixing hydrochar with anthracite. The application of hydrochar in blast furnace injection could not only alleviate the current energy shortage situation, but also be of great significance to realize the “carbon peak” of the steel industry. Full article

Iron- and steelmaking processes create slags, valuable by-products. Industrial utilisation of slag as a lower-value secondary mineral source has been established for decades. Slag heat recovery is an ongoing research topic and has the potential to maximise energy efficiency in iron and steel production. Heat recuperation aims to tap the unused thermal recycling potential of molten slags. This short communication expands the concept for the utilisation of recovered heat for producing torrefied biomass and biogas. The torrefaction process is linked with slag heat recovery and via the BASE method with enhanced blast furnace operation. Such a combination reduces CO₂ emissions significantly in ironmaking processes. Assuming a coke consumption of 350 kg coke per tonne of hot metal and replacing it with 5% torrefied biomass injected as PC with an additional 100 m³/t_HM biogas injection, the BF’s CO₂ emission related to the coke can be lowered by 7.9% to 108 kg/t_HM. In such a manner, the recovered slag heat can directly contribute to CO₂-footprint reduction and improve the circular economy and metallurgical sustainability. Full article

Currently, fossil fuels are still the primary fuel source and reducing agent in the steel industries. The utilization of fossil fuels is strongly associated with CO₂ emissions. Therefore, an alternative solution for green steel production is highly recommended, with the use of biomass as a source of fuel and a reducing agent. Biomass’s growth consumes carbon dioxide from the atmosphere, which may be stored for variable amounts of time (carbon dioxide removal, or CDR). The pellets used in this study were prepared from a mixture of low-grade iron ore and palm kernel shells (PKS). The reducing reactivity of the pellets was investigated by combining thermogravimetric analysis (TGA) and laboratory experiments. In the TGA, the heating changes stably from room temperature to 950 °C with 5–15 °C/min heating rate. The laboratory experiments’ temperature and heating rate variations were 600–900 °C and 10–20 °C/min, respectively. Additionally, the reduction mechanism was observed based on the X-ray diffraction analysis of the pellets and the composition of the reduced gas. The study results show that increasing the heating rate will enhance the reduction reactivity comprehensively and shorten the reduction time. The phase change of Fe₂O₃ → Fe₃O₄ → FeO → Fe increases sharply starting at 800 °C. The XRD intensities of Fe compounds at a heating rate of 20 °C/min are higher than at 10 °C/min. Analysis of the reduced gas exhibits that carbon gasification begins to enlarge at a temperature of 800 °C, thereby increasing the rate of iron ore reduction. The combination of several analyses carried out shows that the reduction reaction of the mixture iron ore-PKS pellets runs optimally at a heating rate of 20 °C/min. In this heating rate, the reduced gas contains much higher CO than at the heating rate of 10 °C/min at temperatures above 800 °C, which encourages a more significant reduction rate. In addition, the same reduction degree can be achieved in a shorter time and at a lower temperature for a heating rate of 20 °C/min compared to 10 °C/min. Full article

Iron-based industries are one of the main contributors to greenhouse gas (GHG) emissions. Partial substitution of fossil carbon with renewable biocarbon (biomass) into the blast furnace (BF) process can be a sustainable approach to mitigating GHG emissions from the ironmaking process. However, the main barriers of using biomass for this purpose are the inherent high alkaline and phosphorous contents in ash, resulting in fouling, slagging, and scaling on the BF surface. Furthermore, the carbon content of the biomass is considerably lower than coal. To address these barriers, this research proposed an innovative approach of combining two thermochemical conversion methods, namely hydrothermal carbonization (HTC) and slow pyrolysis, for converting biomass into suitable biocarbon for the ironmaking process. Miscanthus, which is one of the most abundant herbaceous biomass sources, was first treated by HTC to obtain the lowest possible ash content mainly due to reduction in alkali matter and phosphorous contents, and then subjected to slow pyrolysis to increase the carbon content. Design expert 11 was used to plan the number of the required experiments and to find the optimal condition for HTC and pyrolysis steps. It was found that the biocarbon obtained from HTC at 199 °C for 28 min and consecutively pyrolyzed at 400 °C for 30 min showed similar properties to pulverized coal injection (PCI) which is currently used in BFs due to its low ash content (0.19%) and high carbon content (79.67%). Full article

The 2018 IPCC (The Intergovernmental Panel on Climate Change’s) report defined the goal to limit global warming to 1.5 °C by 2050. This will require “rapid and far-reaching transitions in land, energy, industry, buildings, transport, and cities”. The challenge falls on all sectors, especially energy production and industry. In this regard, the recent progress and future challenges of greenhouse gas emissions and energy supply are first briefly introduced. Then, the current situation of the steel industry is presented. Steel production is predicted to grow by 25–30% by 2050. The dominant iron-making route, blast furnace (BF), especially, is an energy-intensive process based on fossil fuel consumption; the steel sector is thus responsible for about 7% of all anthropogenic CO₂ emissions. In order to take up the 2050 challenge, emissions should see significant cuts. Correspondingly, specific emissions (t CO₂/t steel) should be radically decreased. Several large research programs in big steelmaking countries and the EU have been carried out over the last 10–15 years or are ongoing. All plausible measures to decrease CO₂ emissions were explored here based on the published literature. The essential results are discussed and concluded. The specific emissions of “world steel” are currently at 1.8 t CO₂/t steel. Improved energy efficiency by modernizing plants and adopting best available technologies in all process stages could decrease the emissions by 15–20%. Further reductions towards 1.0 t CO₂/t steel level are achievable via novel technologies like top gas recycling in BF, oxygen BF, and maximal replacement of coke by biomass. These processes are, however, waiting for substantive industrialization. Generally, substituting hydrogen for carbon in reductants and fuels like natural gas and coke gas can decrease CO₂ emissions remarkably. The same holds for direct reduction processes (DR), which have spread recently, exceeding 100 Mt annual capacity. More radical cut is possible via CO₂ capture and storage (CCS). The technology is well-known in the oil industry; and potential applications in other sectors, including the steel industry, are being explored. While this might be a real solution in propitious circumstances, it is hardly universally applicable in the long run. More auspicious is the concept that aims at utilizing captured carbon in the production of chemicals, food, or fuels e.g., methanol (CCU, CCUS). The basic idea is smart, but in the early phase of its application, the high energy-consumption and costs are disincentives. The potential of hydrogen as a fuel and reductant is well-known, but it has a supporting role in iron metallurgy. In the current fight against climate warming, H₂ has come into the “limelight” as a reductant, fuel, and energy storage. The hydrogen economy concept contains both production, storage, distribution, and uses. In ironmaking, several research programs have been launched for hydrogen production and reduction of iron oxides. Another global trend is the transfer from fossil fuel to electricity. “Green” electricity generation and hydrogen will be firmly linked together. The electrification of steel production is emphasized upon in this paper as the recycled scrap is estimated to grow from the 30% level to 50% by 2050. Finally, in this review, all means to reduce specific CO₂ emissions have been summarized. By thorough modernization of production facilities and energy systems and by adopting new pioneering methods, “world steel” could reach the level of 0.4–0.5 t CO₂/t steel and thus reduce two-thirds of current annual emissions. Full article

The interest of the steel industry in utilizing bio-coal (pre-treated biomass) as CO₂-neutral carbon in iron-making is increasing due to the need to reduce fossil CO₂ emission. In order to select a suitable bio-coal to be contained in agglomerates with iron oxide, the current study aims at investigating the thermal devolatilization of different bio-coals. A thermogravimetric analyzer (TGA) equipped with a quadrupole mass spectrometer (QMS) was used to monitor the weight loss and off-gases during non-isothermal tests with bio-coals having different contents of volatile matter. The samples were heated in an inert atmosphere to 1200 °C at three different heating rates: 5, 10, and 15 °C/min. H₂, CO, and hydrocarbons that may contribute to the reduction of iron oxide if contained in the self-reducing composite were detected by QMS. To explore the devolatilization behavior for different materials, the thermogravimetric data were evaluated by using the Kissinger– Akahira–Sonuse (KAS) iso-conversional model. The activation energy was determined as a function of the conversion degree. Bio-coals with both low and high volatile content could produce reducing gases that can contribute to the reduction of iron oxide in bio-agglomerates and hot metal quality in the sustained blast furnace process. However, bio-coals containing significant amounts of CaO and K₂O enhanced the devolatilization and released the volatiles at lower temperature. Full article

The iron and steel industry is still dependent on fossil coking coal. About 70% of the total steel production relies directly on fossil coal and coke inputs. Therefore, steel production contributes by ~7% of the global CO₂ emission. The reduction of CO₂ emission has been given highest priority by the iron- and steel-making sector due to the commitment of governments to mitigate CO₂ emission according to Kyoto protocol. Utilization of auxiliary carbonaceous materials in the blast furnace and other iron-making technologies is one of the most efficient options to reduce the coke consumption and, consequently, the CO₂ emission. The present review gives an insight of the trends in the applications of auxiliary carbon-bearing material in iron-making processes. Partial substitution of top charged coke by nut coke, lump charcoal, or carbon composite agglomerates were found to not only decrease the dependency on virgin fossil carbon, but also improve the blast furnace performance and increase the productivity. Partial or complete substitution of pulverized coal by waste plastics or renewable carbon-bearing materials like waste plastics or biomass help in mitigating the CO₂ emission due to its high H₂ content compared to fossil carbon. Injecting such reactive materials results in improved combustion and reduced coke consumption. Moreover, utilization of integrated steel plant fines and gases becomes necessary to achieve profitability to steel mill operation from both economic and environmental aspects. Recycling of such results in recovering the valuable components and thereby decrease the energy consumption and the need of landfills at the steel plants as well as reduce the consumption of virgin materials and reduce CO₂ emission. On the other hand, developed technologies for iron-making rather than blast furnace opens a window and provide a good opportunity to utilize auxiliary carbon-bearing materials that are difficult to utilize in conventional blast furnace iron-making. Full article

Replacement of fossil carbon by renewable biomass-based carbon is an effective measure to mitigate CO₂ emission intensity in the blast furnace ironmaking process. Depending on the substitution rate of fossil fuels, the required amount of biomass can be substantial. This raises questions about the availability of biomass for multiple uses. At the same time, the economic competitiveness of biomass-based fuels in ironmaking applications should also be a key consideration. In this assessment, availability of energy wood, i.e., logging residues, small-diameter wood and stumps, in Finland is discussed. Since biomass must be submitted to a thermochemical process before use in a blast furnace, the paper describes the production chain, from biomass to charcoal, and economics related to each processing step. The economics of biomass-based reducing agents is compared to fossil-based ones by taking into account the effect of European Union Emissions Trading System (EU ETS). The assessment reveals that there would be sufficient amounts of energy wood available for current users as well as for ironmaking. At present, the economics of biomass-based reducing agents in ironmaking applications is unfavorable. High CO₂ emission allowance prices would be required to make such a scheme competitive against fossil-based reducing agents at current fuel prices. Full article