1. Sustainable Steel Production: Breakthrough and Enabling Technologies for Reducing Waste and Emissions in Iron & Steel Industry while Improving Business Efficiency Sharif Jahanshahi MINERALS DOWN UNDER NATIONAL RESEARCH FLAGSHIPFe Tech 2013 Conference, 26-27 November 2013, Perth Copyright CSIRO, 2013

2. Outline Drivers How is the world steel industry facing the CO2 reduction challenge? Australian CO2 Breakthrough Research Program What is low-emission Integrated Steelmaking Process (ISP) and its objectives Concluding remarksSustainable Steel Production2 3. Driver 1 - GHG Emission by Metal Production IndustryGlobalAustralia20004015003010002050010te el Sum lu m in i AZi nc0 Le ad0Australian GHG emissions (Mt CO2e / y)50N ic ke lReductive smelting of iron ore and alumina represent ~90% of GHG emission from minerals/metals industry2500C op pe rMetal production industry account for ~7% of global greenhouse gases (GHG) emission annuallyGlobal GHG emissions (Mt CO2e / y)2-3 billion tonnes of CO2-e per year!Source: Norgate et al. Minerals Engineering; 24 (November 2011):1563-1570.Sustainable Steel Production3 4. Driver 2 Reducing Waste, Emission & Water Consumption Over 400 million tonnes of molten slags are produced each year Each tonne of molten slag can liberate 1.6 - 1.8 GJ of thermal energy on cooling Opportunities (globally): Convert of 100s million tonnes/year of waste (slag) into saleable product (Portland cement substitute) Recover ~ 720 PJ of energy (high grade waste heat) Reduce GHG emission by 100s million tonnes of CO2 per year Reduce fresh water usage by 100s GL of per year Avoid sulphur emission & contamination of biosphereSustainable Steel Production4 5. How is the world steel industry facing the CO2 reduction challenge? World:worldsteel CO2 Breakthrough Program - Europe (ULCOS Ultra-Low CO2 Steelmaking) - Japan (Course50) - Korea (POSCO) - USA and Canada - Australia - Taiwan, China, Brazil, etcObjective: Lower CO2 emission by the steel industry by at least 50%Sustainable Steel Production5 6. What is predicted to happen? ULCOS Scenario Modelling: Carbon Constraint Case (F2) Messages: Strong growth in EAF Strong growth in charcoal/renewables Moderate growth in DR with CCS Little new technology penetration till 2025High temp electrolysis Smelt-redn with CCS Alkaline electrolysis Alk Electrol - nuclearAdv DR with CCS DR reference BF with 50% charcoal TGR BF with CCS BF reference Open hearthSource: E Bellevrat and P Menanteau, Revue de Metallurgie, Vol.9, pp.318-324 (2009)Sustainable Steel Production6 7. Australian CO2 Breakthrough Research Program - Project Identification TODAYTRANSITIONFUTUREHigh GGE/t-steelLowering GGE/t-steelLow GGE/t-steelTwo Approaches:Incremental improvements to current technologiesCan charcoal provide a lowcapital path to a low-CO2 future? Can waste heat recovery from molten slag provide a further cut in CO2 emission?or:Can deep cuts into CO2 emissions be made using current process equipment?Progressive adoption of breakthrough technologiesFuture ironmaking technologies are currently unknown (being developed)GGE = Greenhouse Gas Emissions7 8. Low-emission Integrated Steelmaking Process (ISP) ISP has been under development by CSIRO since 2006 in collaboration with the Australian steel industry.ISP has 3 components: a) Energy efficient Slow Autogenous Pyrolysis (SAP) for conversion of biomass to biochar and other valuable by-products (bio-oil, bioenergy) The objectives of ISP are to: Introduce deep cuts (>50%) in net CO2 emissions by the steel industryb) Use of Designer Bio-Char (DBC) as fuel and reductant in iron and steel making processes Recover high grade waste heat from molten slags Reduce fresh water usage in the cooling of molten slagsc) Dry Slag Granulation (DSG) to recover high grade waste heat and convert slag into Portland cement substitute. Convert 100s million tonnes/year of waste (iron making slag) into a high value product (green cement). Concept Development2006 Sustainable Steel ProductionTechno-economic and LCAProof of Concept Large Scale Piloting20092012Demonstration via Full Scale Plant Trials2016 9. Australian Project 1Use of Biomass in Iron and Steel MakingSustainable Steel Production9 10. Some questions regarding biomass/charcoal ...Can charcoal be considered to be a sustainable fuel with zero net CO2 emissions?Yes, even ive. (CSIRO LCA study)Are there sufficient forest resources already in eastern Australia?Yes, forest residue. (CSIRO study)Can charcoal be produced at a cost comparable with coal/coke now?Yes, in Brazil.Sustainable Steel Production(CSIRO study positive)10 11. Technical challenges and issues Roadmap for sustainable supply of biomass eg. various biomass sources spread over a very large areasProduction of large tonnages of charcoal eg. lack of versatile facilities for pyrolysis of tonnage quantities of biomass at competitive costCharcoal product quality (Designer char concept) eg. volatile matter, ash, density, reactivity Utilisation of charcoal in the steelmaking process chain eg. demonstration of charcoal injection into a large ironmaking blast furnace11 12. Techno-economics of Biomass to Charcoal $/t charcoal 050100150200250300350400450500Raw biomass cost Transport Labour & utility Interest on capital & maintenance, insurance etc Gross total operating cost = $446/tBio-oil revenue Value-in-use Carbon credit for charcoalCarbon credit for bio-oilGross total revenue other than charcoal = $304/t Charcoal price (min) = $142/tFeasible/attractive option when the value of the coproducts and value-in-use of charcoal are realised with a carbon price of $23/t . Potential to further improve by reducing capital and operating costs through a continuous energy efficient pyrolysis process that gives higher charcoal yield. Biomass cost includes biomass plantations and harvesting Transport cost covers a distance of 70 km to a biomass processing facility Capital cost is for fast pyrolysis with low charcoal yieldSustainable Steel Production12 13. Production of Large Tonnages of Charcoal Aim: To develop a new large-scale pyrolysis process Low emissions, continuous, high productivity Full value-recovery of by-products with a high charcoal yield Energy efficient, thermally autogenous, flexible products Innovative design highly energy efficient (autogenous) 200 -300 kg/h pilot plant designed, constructed and commissioned at CSIRO Proof of concept mid 2013, Optimization and modeling 2013/14 Scale up and demonstration to follow.13 14. Potential Charcoal usage in BF-BOF Integrated Steel Plant 2. Sintering solid fuel 4. Carbon/ore compositesIron ore & pelletsSINTER PLANT1. Coal blend component Coal3. Nut coke replacementSinterCOKE OVENSBLAST FURNACE5. Tuyere injectantCoke Molten pig iron / hot metal SlagAustralian Integrated ~ 3.8 Mt-steel/yr ~ 2.2 t-CO2/t crude steelSTEELMAKING CONVERTER (BOF) Crude liquid steel6. Liquid steel recarburiserGraded Liquid SteelSTEEL REFINING STATION CONTINUOUS CASTER REHEAT FURNACEROLLING MILLHot Rolled ProductsSustainable Steel Production14 15. Forest-to-Steel LCA Results: Integrated Route - Cradle-to-Gate LCA for BF-BOF Steelmaking25% Min33% Max 42% MinNote: Percentages are based on 2.2 t-CO2/t-crude steel.75% MaxSource: Mathieson et al, 6th IICSTI, October 2012, 602-1613.15 16. Biomass Project Scope and Status... Project 1: Use of Biomass in the Iron and Steel Industry Commenced:October 2006ProjectStatus1a: Low-VM Charcoal as a recarburiser for Liquid Steel (CSIRO, OST, BSL)Complete1b: Blast Furnace charcoal injection (BlueScope Steel, CSIRO)Complete,1c: Biomass supply, economics, etc (CSIRO, EcoWaste)Complete1d: Charcoal densification, e.g. DBF, briquetting, compression (CSIRO)Complete1e: Iron ore sintering using charcoal as solid fuel (CSIRO)Complete,1f: Development of self-reducing composite pellets/briquettes (CSIRO)awaiting trialawaiting trialActive FY20131g: Development of strong bio-coke (CSIRO)Active1h: Novel autogenous pyrolysis technology (CSIRO)Active16 17. Australian Project 2Heat Recovery from Molten Slags through Dry GranulationSustainable Steel Production17 18. Vision - New Sustainable Dry Slag Granulation Process Slag 1500C Drivers Hot air >600C Reduction in energy, GHG, water and sulphur emission Lower capital and operating costs ChallengesMotor Disc and reactor designDischarge 600C Handling of hot granules Compact reactor for efficient heat recovery and lower capital costAirAir 100CConcept Development 2006/7Proof of Concept 2007/9Semi-industrial Scale PilotingIndustrial Scale Piloting2009/132013/15 18 19. Semi-industrial Scale Dry Slag Granulation Pilot PlantInstrumented with various sensors and cameras for on-line measurement and observationTapping of molten blast furnace slag at ~ 1500 CCirculation and cooling of droplets and granules in the cyclonic sectionHigh speed video of spinning disc during dry granulation of blast furnace slag at 4.5 t/h19 20. Properties of Granulated Blast Furnace Slag Dry granulated slags > 90% of granules were smaller than 1.5 mm Appear darker in colour due to their higher density, but change in colour on grindingDry granulated XRD and optical microscopy of BF slag showed glass content of > 99% Tests showed good cementitious properties and suitable for cement production.Ground dry granulatedWater granulated20 21. Project Scope and Status... Project 2: Heat Recovery from Molten Slags through Dry Granulation Commenced:August 2006ActivityStatus2a: Proof-of-concept through 1.2 m diameter (0.6 t/h) pilot plantComplete2b: Survey of BF slag temperature and flowComplete2c: CFD modelling process modelling, optimisation for scale upComplete, several studies completed2d: Fundamental studies e.g. droplet collision, dynamic wetting etcComplete2e: Scale up to a 3 m diameter (6t/h) semi-industrial granulatorComplete optimising underway2f: Second stage heat recoveryActive2g: Preparation for full scale plant trials (60t/h) e.g. modelling heat transfer/losses slag pot etc.Active21 22. Concluding Remarks 1. The ISP represents an integrated, innovative and potentially very effective program to reduce waste and net CO2 emissions from the steel industry. 2. It is based on 7 years of productive collaboration 3. The World Steel Association has recognised these innovative technologies, which do not depend on carbon capture and storage, as the best options for short and medium term CO2 reduction within the steel industry and, when proven, they will be widely applicable throughout the world.Sustainable Steel Production22 23. Acknowledgement Contribution by many colleagues and particularly the ISP Project team: CSIRO:Michael Somerville, Alex Deev, Dongsheng Xie, Liming Lu, Terry Norgate, Nawshad Haque, Yuhua Pan, Benny Kuan, Peter Witt, Jason Donnelly, Dylan Marley, Steve Sanetsis, Bob Flann, David Langberg and Bernie WashingtonBlueScope Steel: John Mathieson, Paul Zulli, Harold Rogers and Mark Biasutti OneSteel/Arrium: Phil Ridgeway, Mike Davies and Francois Verdoorn. ASMSSustainable Steel ProductionMarc Smith23 24. Thank you!Sharif Jahanshahi Theme Leader Sustainable Metal Production Minerals Down Under Flagship E: Sharif.jahanshahi@csiro.au T: +613 9545 8621 http://www.csiro.au/org/MineralsDownUnderFlagship.html