Innovative Uses of Hydrogen in Steelmaking

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Innovative uses of Hydrogen in Steelmaking JAYSON RIPKE, PH.D. MIDREX TECHNOLOGIES, INC. FOR PRESENTATION AT: U.S. DEPARTMENT OF ENERGY’S H2@SCALE WORKSHOP MAY 23, 2017 UNIVERSITY OF HOUSTON – HOUSTON, TX Outline I. The 2 Routes to Steelmaking I. Blast Furnace -> Basic Oxygen Furnace (BF/BOF) II. Electric Arc Furnace (EAF) I. Scrap II. Scrap Supplements I. Pig Iron, Direct Reduced Iron (DRI) II. RD&D Needs for H2 Steelmaking I. Emerging Routes II. Existing Routes: BF or EAF Coal Lump Iron Ore Fine Iron Ore Scrap pellets sinter Natural Coke Gas H2? DR Next Slide Coke Oven Coke ● fuel ● H ? ● reductant BF/BOF 2 850 °C EAF ● structure Blast Furnace Hot ‘air’ blast ● O2 Briquette ● Coke breeze Machine ● H2? CDRI HBI 600 °C 1500 °C Solid Pig Iron HDRI Liquid ‘Hot Metal’ Electricity O2 Scrap/HBI BOF Option: 1 2 3 Steel DRI, HBI, & Pig U.S. Shifting from BF/BOF to EAF/DRI Steelmaking BF/ EAF BOF EAF BF/ BOF DRI: Current & Projected Production Energy Efficiency & Emissions EAF/DRI vs. BF/BOF voestalpine’s MIDREX NG® DR plant: Corpus Christie, TX RD&D Needs for H2 Steelmaking Emerging Routes / Low CO2 Steelmaking Hybrit (LKAB and SSAB) Steelanol (PRI, AM) va PEM recycle CO2 into bioethanol FIT (Sohn) - AISI Carbon2chem ULCOS - Ultra-Low CO2 CDA Steelmaking – 45 Europe, 48 Salzgitter groups/15 countries; aim: 50% China Steel CO2. Baowu HIsarna (Coal, sub bio or H2) Course50 ULCORED (DR w/Pox) POSCO (nr 2009) ULCOWIN (electrolysis of FexOy) MEFOS CIRCORED (historical, not emerging) RD&D Needs for H2 in Steelmaking Existing Routes: BF or EAF EAF BF/BOF H2 for iron ore pelletizing? H2 for iron ore pelletizing? S, Q, E, R, CAPEX/OPEX, equipment Any Δ S, Q, E, R in BF/BOF vs. EAF? H2 replace/supplement R-NG(CO+H2) Supplement coke by H2 DRI/HBI product Quality Fuel, reductant, structure Physical: H2 embrittlement, CCS, Steel Quality tumble, fines, sticking/cluster Mass & Energy Balance Metallurgical: reducibility, metallization, carbon Flowsheet Mass & Energy Balance Energy Efficiency Flowsheet Production Rate Energy Efficiency CAPEX/OPEX Production Rate Equipment (embrittlement) CAPEX/OPEX Equipment (embrittlement) S = Safety, Q = Quality, E = Efficiency, R = Rate (throughput) Thank You.

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Schoolcraft Blast Furnace
Pictured Rocks National Lakeshore Schoolcraft National Park Service U.S. Department of the Interior Blast Furnace Schoolcraft furnace With surveyor William Burt’s discovery of iron ore near Teal Lake in Marquette County in 1844, Michigan’s Upper Peninsula suddenly became a hub of activity. The discovery led to construction of a vast mining and manufacturing industry using forges and blast furnaces. When the Civil War ended, many of the South’s furnaces had been destroyed by the war. Westward expansion was occurring across the plains and demand for iron boomed. It was during this era that many of the Upper Peninsula’s furnaces were constructed. There were advantages to smelting iron ore from charcoal fires. Iron produced in this manner was low in carbon content, making it highly fusable, strong, malleable and able to withstand shocks without cracking. The iron made fine wagon rims, horseshoes, and railroad wheels. Before the boom times were over, 29 separate furnaces were located on the Old Munising, ca. 1870 peninsula, though not all operated simultaneously. The business of iron making required more capital than was readily available in the area and financing and management of the operations was often complex. The first group of investors were from Philadelphia. They wished to develop a resort village on Munising Bay’s east shoreline in 1850. Some 87,000 acres of timber were purchased for $.85 an acre. A village was platted on the east shore of Munising Bay, lots were sold, and a dock was built. Henry Mather and Peter White acted as agents for the group of investors who created the Schoolcraft Iron Company in 1866.
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Studying and Improving Blast Furnace Cast Iron Quality
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Copyright © 2014 by International Iron Metallics Association Ltd. This guide published by International Iron Metallics Association Ltd. All rights reserved. This guide may be used or reproduced in any manner whatsoever providing it includes full acknowledgement to the IIMA. 2011 International Iron Metallics Association (IIMA) Printed and bound in the United Kingdom Disclaimer This guide is intended for information purposes only and is not intended as commercial material in any respect. The material is not intended as an offer or solicitation for the purposes of sale of any financial instrument, is not intended to provide an investment recommendation and should not be relied upon for such. The material is derived from published sources, together with personal research. No responsibility or liability is accepted for any such information of opinions or for any errors, omissions, misstatements, negligence, or otherwise for any further communication, written or otherwise. ii ACKNOWLEDGEMENT The International Iron Metallics Association (IIMA) wishes to thank Dr. Oscar Dam, Chief Technical Advisor, and the Pig Iron Sub-Committee, chaired by Rodrigo Valladares, CEO of Viena Siderúrgica S/A, for preparing and editing the information presented in this guide. FOREWORD The International Iron Metallics Association was created to promote the use of ore-based metallics (pig iron, HBI, DRI, and iron nuggets) as value-adding raw materials for the iron and steel and ferrous casting industries. Safe and efficient handling and shipping of merchant ore-based metallics are vital to the commercial trade and use of these materials. Therefore, we are continuing the series of guides begun by IIMA co-founder, HBI Association (HBIA), with this guide which addresses the methods, techniques, and procedures for handling and transferring merchant pig iron at dry bulk terminals.
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