Xie CSRP08 DryGranulationHeatRecovery (1)
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CSRP’08 conference 18‐19 November 2008 Customs House, Brisbane, Queensland Piloting the Integrated Dry Piloting the Integrated Dry Granulation and Heat Granulation and Heat Recovery Process at CSIRO Recovery Process at CSIRO D Xie , J Donnelley, R Flann, Y Pan, S Sanetsis, B Washington CSIRO Minerals
description
Dry Slag granulaion
Transcript of Xie CSRP08 DryGranulationHeatRecovery (1)
CSRP’08 conference 18‐19 November 2008Customs House, Brisbane, Queensland
Piloting the Integrated Dry Piloting the Integrated Dry Granulation and Heat Granulation and Heat Recovery Process at CSIRORecovery Process at CSIRO
D Xie, J Donnelley, R Flann, Y Pan,S Sanetsis, B WashingtonCSIRO Minerals
Introduction Introduction ‐‐ SlagsSlags
Molten slag ‐ high volume by productsHigh grade waste Heat containedCurrently air cooled or water granulated
No heat recovery
Need for a new sustainable slag process
BlueScope Port Kembla
BUSINESS DRIVERSBUSINESS DRIVERS
Waste Heat
1.83 GJ/t slag is available in cooling from 1500 to 25°C
BlueScope Steel and OneSteel produce >2 Mt‐slag/year
∼4 PJ heat is equivalent to ∼ 0.3 Mt CO2 ↓ if from coal combustion
Granulated BF slag for cement
∼1.5 Mt BF slag available (BSL + OST)
Up to 1.5 Mt CO2e ↓ if limestone is not burnt
Objectives for a New Slag Process (Dry Granulation)
Full value recovery Slag for cement and recover the heat
Minimise environment impact• Reduce air pollution (SO2, H2S)
• Save water: 1.5 GL/year evaporated
Spinning Disc Dry GranulationSpinning Disc Dry Granulation
BACKGROUND
Literature review
Identified as the most prospective dry slag granulation (DSG) process
No commercial process available
Dry granulation at CSIRO (Since 2002)
Method tested, lab to pilot scaleMajor progress recently• Optimised atomisation to produce fine granulates
• Enhanced fast quenching/cooling to improve handling of hot granulates
• More compact unit to reduce cost and for efficient heat recovery
Real Time
Slow Motion
Experimental ResultsExperimental Results
1520 °C 1500 rpm
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Sample 6 19/7
2-Theta Angle (deg)10.00 20.00 30.00 40.00 50.00 60.00 70.00
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XRD scan results 5- 586 CALCITE, SYN
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Poat K Raw
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Green sample(water granulated)
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Sample 4, 19/7
2-Theta Angle (deg)10.00 20.00 30.00 40.00 50.00 60.00 70.00
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1470°C 1000 rpm
1470 °C 1000 rpm
New Integrated DSG & Heat New Integrated DSG & Heat Recovery ProcessRecovery Process
Four‐year project (2006‐2010)CSIRO, BlueScope Steel, OneSteel and CSRPObjective: Optimise DSG and introduce heat recovery
Project planConceptual flowsheet (Year 1, 2006‐2007)
Modelling: optimal disc atomisation and heat recoveryExperimental work
Build a prototype pilot plant (Years 2‐3, 2007‐2009)Prove concept, optimise process designEvaluate of process and products
Scale‐up and plant trials (Years 3‐4, 2009‐2010)Commercialisation (from 2010)
Conceptual: Conceptual: Integrated DSG Integrated DSG and Heat Recovery Processand Heat Recovery Process
Hot air >600°C
Granules <50°C
Hot air >600°C
air 25°C
air 25°C
Dry Granulation(Spinning disc)
Heat exchanger(Packed bed / counter‐current)
Slag 1500°C
DryingPreheatingSteamPowerDesalination
Cement
Solid ∼ 900°C
Recent Progress (2007Recent Progress (2007‐‐2008)2008)
A new pilot plant built to prove conceptOperational and technical challenges resolvedPreparation for scale up and plant trialsIndustry engagement and partnership
Commission of New Pilot PlantCommission of New Pilot Plant
New pilot plant built and commissionedKey operational and technical challenges resolved
Evaluation and OptimisationEvaluation and Optimisation
Evaluation using industrial slags
Effect of slag, temp and operation conditions
Size distribution
Assessment – products suitability for cement
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Preparation for Scale UpPreparation for Scale Up
CFD modelling Disc design for scale up
Integrated process
Plant data / measurement Slag temperature
Sulphur
Industry EngagementIndustry Engagement
Strong interests from industriesAustralia and internationally
Slag producers, ferrous and non‐ferrous
Slag handlers, and cement manufacturer
Engineering companies
Business planDiscussions with potential partners
Commercialisation
Work to FollowWork to Follow
Process optimisation and evaluation
CFD modelling for scale up
Process Scale Up and Plant Trials
Scheduled for 2009‐2010 at BlueScope Steel and OneSteel
Commercialisation
From 2010
Thank youThank you
Dr Dongsheng XieProject Leader – Dry Granulation of SlagsPhone: +61 3 9545 8896Email: [email protected]: www.csiro.au/group
