In Blast Furnace Ironmaking Analysis, Control, and Optimization (pp. Bataille, C., hman, M., Neuhof, N., Nilsson, L. J., Fischedick, M., Lechtenbhmer, S., Solano-Rodriquez, B., Denis-Ryan, A., Stiebert, S., Waisman, H., Sartor, O., & Rahbar, S. (2020). In a gas-based DRI production process, up to 30% natural gas can be substituted by hydrogen directly without changing the process [(Midrex H2, 2020)]. Special Report on Carbon Dioxide Capture and Storage. First in fossil-free steel. } } color: #494949; Bioreducer use in blast furnace ironmaking in Finland: Techno-economic assessment and CO2 emission reduction potential. From a purely economic point of view, biomass cannot compete with coal today [(Suopajrvi and Fabritius, 2013)]. https://www.epa.gov/sites/production/files/2015-12/documents/ironsteel.pdf, EPA. It also has a better deep decarbonization potential, as the reduction gas is easily replaced with higher H2 mixtures or even full hydrogen [(Midrex H2, 2020)] while BF-BOF faces greater difficulty in higher H2 use due to facility retrofit barriers (see Hydrogen in BF and DRI below).

Lower heating value is used for all fuels and mean value is used if the fuel has a range of heating values (e.g., coal heating value differs greatly due to quality control of the coal). Under the current technical limitations, it is known that the estimated replacement rate of these five raw materials using charcoal can be achieved [(Wiklund et al., 2013)]: Table 6: Biomass input assumptions [(Wiklund et al., 2013)], CO2 emission per unit fossil fuel (kg/kg).

jQuery(this).parent('.views-exposed-widget').addClass('clicked'); Green H2 injection could be regarded as a version of electrification penetration as well, since it adopts zero-carbon electricity to be replace fossil fuel (see Combined technologies set section).

Suopajrvi, H. (2015). The key basis to apply multiple technology sets is to increase the decarbonization potential: As identified, H2, biomass, zero-carbon electricity, and CCS retrofit are all promising options for steelmaking decarbonization. height: 35px; (2017).

Hot iron is then charged to BOF to make steel HM (BOF steel making). #views-exposed-form-resource-library2-page #edit-body-value-wrapper .advanced-filters label:before { } Biomass and CCS are subjected to their geographical limitations (carbon storage and biomass supply), although global transportation newtworks exist for biomass and could exist for CO2 [(ICEF, 2020)].On the other hand, production costs will limit adoption of any decarbonization technology beyond purely technical barriers (figure 14). One can correct the emission of blue hydrogen by using the multiplier in Table A.4. Existing plants retrofit is essential, since most production capacity is in Asia Pacific (e.g., China) and most facilities have more than 25 years average capital life remaining [(IEA industry, 2020)].

https://www.icef-forum.org/roadmap/, IEA. Optimization of a Steel Plant with Multiple Blast Furnaces Under Biomass Injection. In this scenario, secondary EAF-steel in the total steelmaking profile maintains the same share and role, limited to scrap recycling and scrap feedstock. (2017). For these cases, zero-carbon electricity penetration could prove a low-cost, high-effectiveness abatement solution by replacing BF-BOF with any other production pathways. color: #97D8F9; #block-views-podcast-search2-block ul.views-view-grid li:nth-child(2n+1) {

This means hydrogen fuel substituion is a pathway to BF-BOF decarbonization and would require very large volumes of hydrogen production world-wide if deployed in large scale.

padding: 0; Integrated BF-BOF operations (figure 3) include pelleting, sintering, coking, and iron making (in BF) plus steelmaking (in BOF).

In addition, we assess key aspects of current commercial markets and potential policy options to accelerate a transition to low-emissions production of steel.

Oxford Institute for Energy Studies. Biomass Carbon Removal and Storage (BiCRS) Roadmap. Table A.2. DRI production requires lower temperatures for its direct reduction reaction and is a solid-state process at temperatures below the melting point of iron (1200 C). flex: 1 1 50%; Byproduct CO2 , ~800,000 tons CO2/y, is transported 42 km by pipeline to the Bab field, where it is injected and stored as part of an enhanced oil recovery project. Wherever CCS is viable, it appears to be most promising option given its substantial potential and relatively low cost (both on a $/ton-HM and $/ton-CO2 basis). -ms-transition: all 0.2s ease-in-out; Goodbye to carbon neutral: Getting biomass footprints right. top: 0; Energy Procedia, 4, Pages 1981-1988. #views-exposed-form-resource-library2-page #edit-combine-wrapper .views-widget } Sweden and SSAB have already made this choice, enabled by low-cost, low carbon, firm electric power from large hydro and nuclear [(SSAB, 2020)].

https://www.iea.org/articles/the-challenge-of-reaching-zero-emissions-in-heavy-industry, IPCC.

margin-bottom: 3em; At high (85%) capacity factors, this would require 60 GW of new zero-carbon power generation. CCS: a necessary technology for decarbonising the steel sector.

Kuramochi, Takeshi, Ramrez, A., Turkenburg, W., & Faaij, A. color: #494949; Journal of Cleaner Production, 203, Pages 736-745. Environments, 5(2), 24. However, the estimated global storage capacity is between 10-20 trillion tons, suggesting ample capacity for CO2 emissions from steel production. display: flex; Given increased urgency to transition the global economy to net-zero CO2 emission, governments and industry have increased focus on decarbonizing hard-to-abate sectors, including steel making, which contributes roughly 6% of global CO2 emission and 8% of energy related emission (including power consumption emission). H2 production consumes 6% of global natural gas and 2% of global coal, emitting 830 million tons of CO2. } Substitution of zero-carbon electricity into current global steel production under different electricity carbon footprint assumptions. Antonini, C., Treyer, K., Streb, A., Spek, M. van der, Bauer, C. B., & Mazzotti, M. (2020). #block-views-exp-event-search2-block .views-submit-button, #block-views-exp-event-search2-block-1 .views-submit-button { background-size: cover; As such, our analyses are representative and inclusive but not comprehensive. max-width: calc(100% - 52px); TFT Research.

Chemical Engineering Journal, 394, 124943. EAF also consumes the products of direct reduction of iron (DRI), also referred as sponge iron. Chemically, H2 is carbon-free and capable of satisfying both heating (direct combustion) and reduction requirements (replacing coke and CO) for steelmaking. Green procurement, including authorization to purchase low-carbon steel made by domestic industry at elevated prices. width: 35px; (2018). Techno-economic study of an integrated steelworks equipped with oxygen blast furnace and CO2 capture. European Steel: The Wind of Change, Brussels Seminar.

For H2 carbon footprint, LCA result is borrowed if its from water electrolysis, include the carbon footprint of electricity.

In contrast, green hydrogen today is extremely costly in most markets, while blue hydrogen should be seriously considered more broadly. background: url(/sites/default/files/podcast-images/Final-Columbia-Energy-Exchange-Cover-Art-01.png) no-repeat center center; Table A.3. Uncertainties of these estimates come from: (1) significant variations in electricity carbon intensity from country to country; and (2) variations in electricity share to total primary energy country to country.

#content-bottom #block-views-podcast-search2-block .views-submit-button { Both limitations prevent EAF from easy penetration deeper into the global steelmaking profile. For this study, blue H2 is selected to be steam methane reforming (SMR) + 89% CCS production. [(Ueki et al., 2014)], German research indicates that when using biomass coke powder to completely replace coal powder, the amount of carbon dioxide input in the blast furnace has been reduced by up to 45%. bizbiz For this study, $60/tCO2 for TGR-BF based CCS retrofit and $58/tCO2 for air-blown BF based CCS retrofit serve as the basis for comparison. Midrex. margin-top: 2em; https://www.iea.org/reports/20-years-of-carbon-capture-and-storage, IEA. Hydrogen production from biomass is highly uncertain for 1) various feedstocks 2) complicated processes, and 3) cost uncertainty. In contrast, the higher penetration of intermittent renewables power generation may lead to increased market share and use.

The inherent difficulty of steel decarbonization will require innovation in policy and market design that embrace multiple options and possibly all options. https://biochar-us.org/presentation/lca-biochar-how-feedstocks-and-production-systems-stack.

float: right; https://doi.org/10.2355/isijinternational.54.2454, UNEP. Blue (brown/gray) hydrogen carbon footprint is underestimated comparing with green hydrogen since it has much smaller boundary. Given the limits detailed above, more and better options are urgently needed to decarbonize steelmaking.

margin-top: calc( 6.9em ); Sources: [(Friedmann et al., 2019)][ (Vogl et al., 2018)]. Techno-economic assessment and comparison of CO2 capture technologies for industrial processes: Preliminary results for the iron and steel sector. Deliberate early retirement and replacement of current steel-producing facilities with low-emission options, as well as a shift to increased scrap steel recycling using zero-carbon electric power. Wilcox, J. https://www.ipcc.ch/sr15/. padding: 0; height: 100%; Economic models developed by Boston Metal show that MOE could be cost competitive with electricity prices at $15/MWh a very difficult threshold without subsidies, especially for firm power.

The challenge of reaching zero emissions in heavy industry. representing the maximum amount CO2 abatement and lowest abatement cost biomass (later referred as ideal biomass).

https://materialeconomics.com/publications/the-circular-economy-a-powerful-force-for-climate-mitigation-1, Mathieson, J. G., Rogers, H., Somerville, M. A., Jahanshahi, S., & Ridgeway, P. (2011). EAF contributes ~24% of global steel production, over 430 million tons (Mt) in 2018 [(Worldsteel Association, 2019)].

(2020). In contrast, studies of.

Low CO2 emission technologies for iron and steelmaking as well as titania slag production. While the ability to change existing plants is limited (e.g., most gas-based DRI plants are in Iran), some systems worldwide may prove amenable to retrofit and modification, and ultimately replacement. Direct Reduction: Transition from Natural Gas to Hydrogen? display: inline-block; width: 100%; Nature, 479, 353356. U.S. Department of Energy Office of Industrial Technologies. As the most widely commercialized woody biomass process technology, bio-charcoal has carbon content the highest, up to 85%-98% [(Mayhead et al., n.d.)], most chemically suitable for iron making, chemical reduction and replacement of coke.

padding-top: 0.5em; Waste and Biomass Valorization, 5, 4355. width: 35px; [(Vogl et al., 2018)] shows how renewable power is used to produce hydrogen and the preheat step to reduce DRI-related CO2 emission, theoretically reducing emissions to only 2.8% of BF. Second, batch operation yields intermittent and discontinuous duty cycles causing power quality problems for transmission and generation [(Seker et al., 2017)]. https://usea.org/sites/default/files/012012_CO2%20abatement%20in%20the%20iron%20and%20steel%20industry_ccc193.pdf, Chevrier, V. (2018). In these facilities, the main function of feed-coal is to act as a reducing agent and react with the ore; some energy required for the kiln reactions also comes from the coal. As shown in table 2, DRI-EAF plants are much less carbon intensive than traditional BF-BOF route, and deep electrification via DRI-EAF replacement in table 11 could significantly reduce carbon emission from steelmaking in two ways: DRI-EAF is technically available and could play an essential role for decarbonizing steelmaking industry. https://www.energy.gov/sites/prod/files/2018/08/f54/fcto-h2-scale-kickoff-2018-8-chevrier.pdf, Compare your country. Both EAF steelmaking pathways flow diagram are shown jointly in figure 4. z-index: 1; } } CO2 capture in industries and distributed energy systems: Possibilities and limitations. Bio-charcoal replacing coal in BF-BOF under different cost/carbon footprint. If zero-C electricity was added, carbon abatement potential would further increase. Hooeya, L., Tobiesen, A., Johns, J., & Santos, S. (2013). margin-left: 0; Cost of hot metal and carbon abatement using zero-carbon electricity, Full electrification of steel HM production with advanced technology. https://www.engineeringtoolbox.com/fuels-higher-calorific-values-d_169.html, EPA. margin-bottom: 5em; https://ec.europa.eu/research/index.cfm?eventcode=80BB405C-DA08-56D3-800BC46FC9A6F350&pg=events.

The analysis result of steelmaking and fossil fuels carbon footprint represents the actual onsite carbon emission. A policyto grow recycling could help improve the fraction of secondary steel production share, especially in developing countries; however, it would be unlikely to reduce primary steel production. Energy-Related Carbon Dioxide Emissions, 2018. https://www.eia.gov/environment/emissions/carbon/archive/2018/, engineeringtoolbox. In current applications, the proportion of H2 and CO after reformer is approximately 55% and 36%. Biomass conversion (biocoke reduction or combustion) emits CO2 onsite, which can be captured, leading to additional carbon footprint reductions. Oxygen Blast Furnace (OBF), is less carbon intensive for its inherent ability to capture and disposal of the CO2 of the BF top gas, which implies additional cost as $56/to-CO2 [(Wilcox, 2020)]. IEA. border-right: 3px solid #FFFFFF;

Industry CCS Workshop.

From a non-technical perspective, challenges include the globally traded nature of the commodity, national dependencies for both security and economic well-being, the small margins of most producers, and labor politics [(ICEF,2019]]. (2020). Assessment of hydrogen direct reduction for fossil-free steelmaking. It is widely understood that man-made climate change is chiefly caused by greenhouse gas emissions, especially CO2, and that the consequences of global warming will be profound, widespread and destructive [(IPCC,2018]]. .view-distinguished-visiting-fellows .view-content .views-row img { From the perspective of hot-metal production costs, CCS and zero-carbon electricity appear better options but with modest total decarbonization potential. Energy Procedia, 37, Pages 7117-7124. https://dspace.library.uu.nl/bitstream/handle/1874/205115/kuramochi.pdf?sequence=1. width: calc(100%); border: none; Preheating and other pretreatment of injected hydrogen might be needed depending on hydrogen quality and quantity [(Vogl et al., 2018)]. }

(n.d.). Biomass feedstocks for hydrogen production can result in very different hydrogen LCA. } are not the same for bio-charcoal as coal or coke, and manufacturing performance standards may not be guaranteed. Gernaat, D. E. H. J., Bogaart, P. W., Vuuren, V., Biemans, H., & Niessink, R. (2017). Friedmann, J. (2019).

padding: .5em 1em 0 0; Effect of hydrogen addition on reduction behavior of iron oxides in gas-injection blast furnace. (2011).

This study covers the integrated route carbon emission and energy consumption, where assumptions are listed in table 1. The future of hydrogen. http://www.compareyourcountry.org/climate-policies?cr=oecd&lg=en&page=2, CSLForum. Uitgeverij BOXPress, Oisterwijk. width: calc(100% - 52px); Global Efficiency Intelligence. Reducing gases are produced from natural gas (gas-based DRI) or coal (coal-based DRI) called syngas, a mixture of H2 and CO. In their system, about 4 MWh are needed to produce 1 ton steel HM. margin-right: 60px; HIsarna is a direct bath-smelting reduction technology that combines coal preheating and partial pyrolysis with the smelting reduction vessel working as its core reaction container [(Stel et al., 2013)]. Table 9 assumes an ideal biomass scenario for coal substitution, i.e., it does not include carbon footprint estimates from production LCA or land use change. min-height: unset; 2007]], * The U.S. average electricity carbon intensity case: CO2 460 kg/MWh. Puettmann, M. (2016).

The results show that using biomass-based reducing agents produced from torrefaction have the best operational properties. 2016 Billion ton report: Advancing Domestic Resources for a Thriving Bioeconomy. Mitsubishi Heavy to build biggest zero-carbon steel plant. opacity: 1; In most facilities, elextricity is almost entirely provided by fossil fuels, which provide the necessary high capacity factors (one noteworthy exception is Sweden, where steel plants have access to grid power with high fractions of both hydropower and nuclear).

#block-views-exp-event-search2-block #edit-body-value-wrapper, #block-views-exp-event-search2-block-1 #edit-body-value-wrapper { It can allow non-coking coal and low-cost iron ores (outside BF quality range) to produce iron with 20% less carbon footprint [(Quader et al., 2016)]. Similar preheating requirement does not show up in the BF injection due to inherent hot air blast design. For the baseline scenario (table 7), the model assumes carbon-neutral biomass, i.e. box-sizing: border-box; Renewable and Sustainable Energy Reviews, 25, Pages 511-528.

Fossil fuels carbon footprint is the most underestimated but used for it is the convention to calculate steelmaking carbon footprint, i.e., in steelmaking carbon footprint analysis, only direct combustion emission rate is considered instead of LCA of fuels. Abatement cost is calculated by dividing added fuel cost (in $, bio-charcoal more expensive than fossil coal) and its carbon abatement value (ton-CO2).

.page-our-work-resource-library2 .sidebars .block { background-color: transparent; If the cost is represented by a range of values, it represents the lowest/highest range of costs. Yilmaz, C., Wenderstorf, J., & Turek, T. (2017). The CO2 emission intensity of green and blue H2 equals its life-cycle assessment (LCA) results (sources and assumptions see appendix): The calculation results in table 5 show that the use of H2 instead of natural gas for DRI production will significantly reduce CO2 emissions but at substantially higher costs. (2020). } To increase beyond this small fraction, deeper levels of electrification are required. Direct Reduced Iron (DRI): This iron production process directly reduces iron ore in solid-state with the reaction temperature below the melting point of iron.

Today, almost all H2 supply is produced from fossil fuel, with global demand exceeding 73.9 million tons in 2018 [(IEA H2, 2019)]. Substitution of DRI-EAF with zero-C electricity supply for BF-BOF production, (Medium DRI penetration profile, hypothetical future), (High DRI penetration profile, hypothetical future). Alvarez, R. A., Zavala-Araiza, D., Lyon, D. R., & Barkley, Z. R. (2018).

https://www.globalccsinstitute.com/news-media/insights/ccs-a-necessary-technology-for-decarbonising-the-steel-sector/. font-weight: normal; display: flex; https://www.cslforum.org/cslf/sites/default/files/documents/AbuDhabi2017/AbuDhabi17-TW-Sakaria-Session2.pdf, Santos, S. (2014). Life cycle assessment of hydrogen production via electrolysis a review. Applied Energy, 230, 330343.

CCUS (2020). Where CCS is viable, retrofits could include both blue hydrogen and top-gas capture with some economic benefits in shared infrastructure.

(2019). The potential of using biomass-based reducing agents in the blast furnace: A review of thermochemical conversion technologies and assessments related to sustainability.

IEA. } box-sizing: border-box; In this report, if the cost is represented by a single value, its the mean value of the range of the cost. Avoidance cost per ton CO2 is estimated to be $48~$71/tCO2. This would require enormous new supplies of zero-carbon power generation. } Additional cost due to transportation would occur addition cost. However, straw is also the hardest to commercialized since its carbon content is the lowest at only 20% (compared to ~80% for bamboo char and biomass charcoal). * self reference takes its own production method emission as reference (e.g., DRI using Zero-C electricity comparing with DRI baseline). #views-exposed-form-resource-library2-page #edit-combine-wrapper { (2013). The high-DRI substitution case would require 1010 TWh additional generation roughly the same as all of Japan. #block-views-event-search2-block .view-footer, #block-views-exp-event-search2-block-1 .view-footer { It is used in construction, military and defense, and manufacturing (e.g., automobiles). Table 13. Table 1. } The zero-carbon electricity assumption is for simplicity to avoid discussion of various renewable LCA results and demonstrate its maximum decarbonization potential. { position: absolute; In: Global Warming of 1.5C. Our analysis focuses on applications of bio-charcoal and bio-coal (often mixed with coal for coke making) as replacements for solid fossil fuels in BF-BOF steelmaking. Yilmaz et al.

min-height: unset; U.S. min-height: unset; Of the options assessed, blue hydrogen, carbon neutral biomass, and CCS appear to have the lowest cost and highest technical maturity.

.view-distinguished-visiting-fellows .view-content .views-row

University of Wollongong. 20 years of carbon capture and storage.

z-index: 1; line-height: 35px; https://www.nrcan.gc.ca/energy/efficiency/industry/processes/energy-systems/metallurgical-fuels/5619?wbdisable=true.

border-right: 3px solid #fff; Figures 13 and 14 demonstrate the dilemma of steelmaking decarbonization and why the sector is hard-to-abate: cost effective ways approaches are limited in potential and adoption of high decarbonization options would lead to high cost burdens for producers.



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