Utilising Forest Biomass in Iron and Steel Production

Utilising Forest Biomass in Iron and Steel Production

LICENTIATE T H E SIS Department of Engineering Sciences and Mathematics Division of Energy Science Nwachukwu Chinedu Maureen ISSN 1402-1757 Utilising forest biomass in iron ISBN 978-91-7790-761-9 (print) ISBN 978-91-7790-762-6 (pdf) and steel production Luleå University of Technology 2021 Investigating supply chain and competition aspects Utilising forest biomass in iron and steel production biomass in iron Utilising forest Chinedu Maureen Nwachukwu Energy Engineering 135067 LTU_Nwachukwu.indd Alla sidor 2021-03-12 08:10 Utilising forest biomass in iron and steel production Investigating supply chain and competition aspects Chinedu Maureen Nwachukwu Licentiate Thesis Division of Energy Science Department of Engineering Sciences and Mathematics Lulea University of Technology April 2021 Copyright © 2021 Chinedu Maureen Nwachukwu. Printed by Luleå University of Technology, Graphic Production 2021 ISSN 1402-1757 ISBN 978-91-7790-761-9 (print) ISBN 978-91-7790-762-6 (pdf) Luleå 2021 www.ltu.se ii For my family past, present, and future iii iv Preface The research work presented in this thesis was carried out at the Division of Energy Science, Luleå University of Technology, Sweden, during the period 2017 - 2020. The studies were carried out under the BioMetInd project, partly financed by the Swedish Energy Agency and Bio4Energy, a strategic research environment appointed by the Swedish government. The thesis provides an overview of forest biomass utilisation in the Swedish iron and steel industry from a supply chain perspective. Results also highlight the biomass competition between the iron and steel industry and the forest industry and stationary energy sectors. Findings from the studies are detailed in the three appended papers. v vi Acknowledgements I am grateful to my principal supervisor, Associate Professor Elisabeth Wetterlund, for her support and trust rendered to me since the start of my PhD studies. My gratitude goes to my co-supervisors, Professor Andrea Toffolo and Dr. Chuan Wang, for their patience and assistance. I also thank Professor Carl-Erik Grip for the conversations on steelmaking in Sweden and for providing print and online resources to motivate and guide me at the start of my studies. The discussions and encouragement are appreciated. I would also like to appreciate Elias Olofsson for the opportunity to work together and for all the help rendered while grasping micro-economic concepts related to the Swedish forest sector. I would like to thank my colleagues and all staff at the subject of Energy Engineering for providing a thriving and open work environment. Special thanks to my dear friends, my ‘fellows’, who have proven that laughter is truly the best medicine. My gratitude goes to my family, who have always supported me in all my endeavours. I am grateful for the foundation; this is another win for us. Stephen, your kind support even while juggling several tasks is deeply appreciated. Chikamara, your cheerful disposition, innocent advice, and wonder have been a blessing to me. I still have, and cherish, your drawing illustrating my research work. Thank you! Above all, I am grateful to God for His constant grace and mercies. Chinedu Maureen Nwachukwu Luleå, March 2021 vii viii Abstract The work presented in this thesis explores the internal and external aspects surrounding the use of forest biomass in iron and steel production in Sweden. Bio-products produced via thermo-chemical conversion are considered suitable alternatives to fossil energy and reductants used in existing processes in the iron and steel industry (ISI). However, since the steel production chain is energy intensive, large quantities of raw forest biomass assortments will be required before conversion into the desired bio-products that can substitute fossil products currently used in steel production. A full system analysis of value chains of suitable bio-products is, therefore, a requirement that has been lacking since it sheds insight into the main aspects of fossil substitution in the ISI, such as availability and supply of forest biomass, material and energy-efficient upgrading, and bio-products distribution. External aspects for consideration include broader implications of large biomass utilisation in iron and steel production on other existing biomass users such as the forest industry and stationary energy sectors. The main objective of this thesis is to investigate opportunities to utilise forest biomass in the ISI while simultaneously addressing competing demand for biomass from other sectors. The work consists of three papers that address the main objective via different research questions. Process integration techniques are applied with a biomass supply chain model to evaluate the production and distribution of biomass-based fuels and reductants and quantify the possible extent for CO2 emissions reduction in the ISI. Competition effects on regional biomass markets are analysed by linking a partial equilibrium forest model to the biomass supply chain model. Economic implications for forest biomass use in the ISI are quantified for both the ISI and forest sector industries. Results from the studies conclude that the maximum possible use of alternative fuels and reductants from forest biomass can achieve a 43% reduction in CO2 emissions, although at an increased energy cost of 27% for the ISI compared to the fossil use. Effective policies such as the combined use of substitution mandates and carbon emission fees are suggested, bearing in mind the relatively high costs for alternative energy use in the ISI. Effects on forest industries, such as increased feedstock costs from increased feedstock competition, may prompt individual forest industries to experience negative economic impacts that come at a disadvantage to society at large. ix x List of Appended Papers I. Nwachukwu C.M, Toffolo A., Wetterlund E. Biomass-based gas use in Swedish iron and steel industry - Supply chain and process integration considerations. Renewable Energy, Volume 146, 2020, Pages 2797-2811, ISSN 0960- 1481 Nwachukwu planned the investigation, developed the methodology with support from Wetterlund, gathered process data, conducted the analysis in collaboration with Toffolo, and wrote most of the paper under the supervision of the co-authors. II. Nwachukwu C.M., Wang C., Wetterlund E. Exploring the role of forest biomass in abating fossil CO2 emissions in the iron and steel industry – the case of Sweden. Applied Energy, 2021. https://doi.org/10.1016/j.apenergy.2021.116558 Nwachukwu contributed to modifying an existing model developed by Wetterlund, participated in data collection and validation with Wang, carried out model runs, result analysis, wrote the paper and incorporated suggested revisions from the co-authors. III. Nwachukwu C.M., Olofsson, E., Lundmark, R., Wetterlund E. Evaluating fuel switching options in the ISI under increased competition for forest biomass. Manuscript to be submitted Nwachukwu planned an external collaboration for a model linking study, developed the methodology with Olofsson using two existing models, carried out result analysis and interpretation, and wrote most of the paper with input from Olofsson. xi xii Full papers presented in Conferences (not included in thesis) 1. Nwachukwu C.M., Toffolo A., Wang C., Grip C-E., Wetterlund E. (2018). Systems analysis of sawmill by-products gasification towards a bio-based steel production. Paper presented at the ECOS 2018 - Proceedings of the 31st International Conference on Efficiency, Cost, Optimisation, Simulation and Environmental Impact of Energy Systems, ECOS 2018; Guimaraes; Portugal; 17 June 2018 - 21 June 2018. (peer-reviewed) 2. Wang C., Suopajärvi H., Ng K., Nwachukwu C.M., Wetterlund E. Research development on utilising biomass in the blast furnace for CO2 emission reduction: Experiences from Nordic countries and Canada. Paper presented at the 8th International Congress on Science and Technology of Ironmaking (ICSTI 2018) at Vienna, Austria; September 2018. (peer-reviewed) 3. Nwachukwu C.M., Wang C., Toffolo A., Wetterlund E. (2020). Use of biomass in steelmaking and its effects for forest industries. Paper in Proceedings of the 33rd International Conference on Efficiency, Cost, Optimisation, Simulation and Environmental Impact of Energy Systems, ECOS 2020, Pages 1883 – 1894, Osaka – Japan, 29 June – 3 July 2020. (peer-reviewed) Other conference contributions 4. Optimising biomass utilisation in iron and steel production. Nwachukwu C.M., Wang C., Toffolo A., Wetterlund E. Oral presentation at EUBCE 2020 e-event (peer-reviewed) 5. Impact of carbon prices on fuel switching in the iron and steel industry. Nwachukwu C.M., Wang C., Toffolo A., Wetterlund E. Oral presentation and extended abstract at eceee digital event Industrial Efficiency 2020, Gothenburg. (peer-reviewed) 6. Perspectives of using biomass to reduce fossil CO2 emission in the Swedish steel industry. Wang C., Nwachukwu C.M., Sandberg E., Lundgren J., Wetterlund E. Accepted for Oral presentation at the ESTAD 2021 conference (peer-reviewed) xiii xiv Table of Contents 1 Introduction ....................................................................................................................... 1 1.1 Aims and objectives .................................................................................................... 3 2 Forest biomass utilisation in the Iron and Steel Industry ...................................................... 5 2.1 Biomass applications ..................................................................................................

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