scholarly journals Decarbonization of the Iron and Steel Industry with Direct Reduction of Iron Ore with Green Hydrogen

Energies ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 758 ◽  
Author(s):  
Abhinav Bhaskar ◽  
Mohsen Assadi ◽  
Homam Nikpey Somehsaraei
Keyword(s):  
Energy Consumption ◽  
Iron Ore ◽  
Direct Reduction ◽  
Ghg Emissions ◽  
Steel Production ◽  
Water Electrolysis ◽  
Basic Oxygen Furnace ◽  
Iron And Steel ◽  
Reduction Of Iron ◽  
Direct Reduction Of Iron

Production of iron and steel releases seven percent of the global greenhouse gas (GHG) emissions. Incremental changes in present primary steel production technologies would not be sufficient to meet the emission reduction targets. Replacing coke, used in the blast furnaces as a reducing agent, with hydrogen produced from water electrolysis has the potential to reduce emissions from iron and steel production substantially. Mass and energy flow model based on an open-source software (Python) has been developed in this work to explore the feasibility of using hydrogen direct reduction of iron ore (HDRI) coupled with electric arc furnace (EAF) for carbon-free steel production. Modeling results show that HDRI-EAF technology could reduce specific emissions from steel production in the EU by more than 35 % , at present grid emission levels (295 kgCO2/MWh). The energy consumption for 1 ton of liquid steel (tls) production through the HDRI-EAF route was found to be 3.72 MWh, which is slightly more than the 3.48 MWh required for steel production through the blast furnace (BF) basic oxygen furnace route (BOF). Pellet making and steel finishing processes have not been considered. Sensitivity analysis revealed that electrolyzer efficiency is the most important factor affecting the system energy consumption, while the grid emission factor is strongly correlated with the overall system emissions.

scholarly journals Lowering the Carbon Footprint of Steel Production Using Hydrogen Direct Reduction of Iron Ore and Molten Metal Methane Pyrolysis

2019 ◽  
Author(s):  
Abhinav Bhaskar ◽  
Mohsen Assadi ◽  
Homam Nikpey Somehsaraei
Keyword(s):  
Natural Gas ◽  
Carbon Footprint ◽  
Iron Ore ◽  
Bubble Column ◽  
Direct Reduction ◽  
Steel Production ◽  
Bubble Column Reactor ◽  
Column Reactor ◽  
Reduction Of Iron ◽  
Direct Reduction Of Iron

Reducing emissions from the iron and steel industry is essential to achieve the Paris climate goals. A new system to reduce the carbon footprint of steel production is proposed in this article by coupling hydrogen direct reduction of iron ore (H-DRI) and natural gas pyrolysis on liquid metal surface inside a bubble column reactor. If grid electricity from EU is used, the emissions would be 435 kg CO2/tls without considering methane leakage from the extraction, storage and transport of natural gas. Solid carbon, produced as a by-product of natural gas decomposition, finds applications in many industrial sectors, including as a replacement for coal in coke ovens. Specific energy consumption (SEC) of the proposed system is approximately 6.3 MWh per ton of liquid steel(tls). It is higher than other competing technologies, 3.48 MWh/tls for water electrolysis based DRI, and, 4.3-4.5 MWh/tls for natural gas based DRI and blast furnace-basic oxygen furnace (BF-BOF) respectively. Utilization of large quantities of natural gas, where the carbon remains unused, is the major reason for high SEC. Preliminary analysis of the system revealed that it has the potential to compete with existing technologies to produce CO2 free steel, if renewable electricity is used. Further studies on the kinetics of the bubble column reactor, H-DRI shaft furnace, design and sizing of components, along with building of industrial prototypes are required to improve the understanding of the system performance.

Effects of reductant type on coal-based direct reduction of iron ore tailings

2018 ◽  
Vol 42 (3) ◽  
pp. 453-466
Author(s):  
Wei WANG ◽  
Pengfei YE ◽  
Xiaoli ZHOU ◽  
C WANG ◽  
Zekun HUO ◽  
...  
Keyword(s):  
Iron Ore ◽  
Direct Reduction ◽  
Iron Ore Tailings ◽  
Reduction Of Iron ◽  
Direct Reduction Of Iron

A simplified approach to the simulation of direct reduction of iron ore

2010 ◽  
Vol 107 (5) ◽  
pp. 195-204 ◽  
Author(s):  
M. Vannucci ◽  
V. Colla ◽  
G. Corbo ◽  
S. Fera
Keyword(s):  
Iron Ore ◽  
Direct Reduction ◽  
Simplified Approach ◽  
Reduction Of Iron ◽  
Direct Reduction Of Iron

scholarly journals Reduction Kinetics of Hematite Powder in Hydrogen Atmosphere at Moderate Temperatures

Metals ◽  
2018 ◽  
Vol 8 (10) ◽  
pp. 751 ◽  
Author(s):  
Zhiyuan Chen ◽  
Jie Dang ◽  
Xiaojun Hu ◽  
Hongyan Yan
Keyword(s):  
Activation Energy ◽  
Direct Reduction ◽  
Reduction Process ◽  
Kinetic Mechanism ◽  
Hydrogen Atmosphere ◽  
Morphological Transformation ◽  
Iron And Steel ◽  
Multi Stage ◽  
Reduction Of Iron ◽  
Direct Reduction Of Iron

Hydrogen has received much attention in the development of direct reduction of iron ores because hydrogen metallurgy is one of the effective methods to reduce CO2 emission in the iron and steel industry. In this study, the kinetic mechanism of reduction of hematite particles was studied in a hydrogen atmosphere. The phases and morphological transformation of hematite during the reduction were characterized using X-ray diffraction and scanning electron microscopy with energy dispersive spectroscopy. It was found that porous magnetite was formed, and the particles were degraded during the reduction. Finally, sintering of the reduced iron and wüstite retarded the reductive progress. The average activation energy was extracted to be 86.1 kJ/mol and 79.1 kJ/mol according to Flynn-Wall-Ozawa (FWO) and Starink methods, respectively. The reaction fraction dependent values of activation energy were suggested to be the result of multi-stage reactions during the reduction process. Furthermore, the variation of activation energy value was smoothed after heat treatment of hematite particles.

scholarly journals Hydrogen Ironmaking: How It Works

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 922 ◽  
Author(s):  
Fabrice Patisson ◽  
Olivier Mirgaux
Keyword(s):  
Iron Ore ◽  
Shaft Furnace ◽  
Direct Reduction ◽  
Water Electrolysis ◽  
Current Standard ◽  
Ore Pellets ◽  
Production Of Hydrogen ◽  
Produce Steel ◽  
And Performance ◽  
Direct Reduction Of Iron

A new route for making steel from iron ore based on the use of hydrogen to reduce iron oxides is presented, detailed and analyzed. The main advantage of this steelmaking route is the dramatic reduction (90% off) in CO2 emissions compared to those of the current standard blast-furnace route. The first process of the route is the production of hydrogen by water electrolysis using CO2-lean electricity. The challenge is to achieve massive production of H2 in acceptable economic conditions. The second process is the direct reduction of iron ore in a shaft furnace operated with hydrogen only. The third process is the melting of the carbon-free direct reduced iron in an electric arc furnace to produce steel. From mathematical modeling of the direct reduction furnace, we show that complete metallization can be achieved in a reactor smaller than the current shaft furnaces that use syngas made from natural gas. The reduction processes at the scale of the ore pellets are described and modeled using a specific structural kinetic pellet model. Finally, the differences between the reduction by hydrogen and by carbon monoxide are discussed, from the grain scale to the reactor scale. Regarding the kinetics, reduction with hydrogen is definitely faster. Several research and development and innovation projects have very recently been launched that should confirm the viability and performance of this breakthrough and environmentally friendly ironmaking process.

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