Fcto h2atscale Flash iron making technology with h2 sohn
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This document describes a novel Flash Ironmaking Technology (FIT) that uses hydrogen or natural gas to directly reduce iron ore into iron without the need for coke production, pelletization, or sintering. FIT is based on proven flash smelting technology and can reduce iron ore concentrates into iron in 2-7 seconds at high temperatures. FIT offers significantly lower carbon dioxide emissions and energy usage compared to traditional blast furnace ironmaking. Economic modeling indicates FIT can be cost competitive and even profitable with carbon credits or at large commercial scales. FIT could enable huge reductions in global carbon emissions from steel production and create vast new demand for hydrogen.
Fcto h2atscale Flash iron making technology with h2 sohn
- 1. Clean - Smart - Secure 1 Hong Yong Sohn Distinguished Professor and TMS Fellow University of Utah Novel Flash Ironmaking Technology (FIT)
- 2. Flash Ironmaking Technology (FIT) (FIT for H2@Scale) Fe3O4 + (H2, CO) → Fe + (H2O, CO2) Gas-Solid Suspension Reduction Hydrogen or Natural Gas Fine iron ore WITHOUT Coke/Pelletization/Sintering Significant Reduction in CO2 & Energy Consumption Replace BF Direct steelmaking process based on Flash Ironmaking Oxygen Hydrogen
- 3. Flash Ironmaking Technology (FIT) – cont’d Process based on proven flash technology, e.g. copper smelting furnaces Applicable to iron ore concentrates; magnetite from taconite, hematite-bearing jaspers, etc. Reducing/fuel gases include H2 and CH4 Magnetite taconite is the principal iron ore in the U.S. In 2008, the gross ore production in the U.S. was 54 MM tonnes. Minnesota (Mesabi Range) and Michigan (Marquette Range) mines account for almost all U.S. iron ore production. 3 Taconite ore: 70% concentrate, <100 µm
- 4. What Now and Next Project Objectives Kinetic Feasibility Technology Road Map (2005-2007) Proof of Concept at Lab Scale AISI CO2 Breakthrough (2008-2011) Process Validation/ Scale-up Innovative Manufacturing Initiative (2012-2017) Industrial Pilot TBD (2017+) ExperimentalApparatuses Approaches 1. Large scale 75-100k tpy 2. Modest-scale: 10-25k tpy 3. Expand U of Utah work: Similar to bench reactor but larger Funding Federal, $350k Industry, $150k Total, $500k Federal, $ 0 Industry, $ 4.8M Total, $4.8M Federal, $ 8.0 Industry, $ 2.6M Total, $10.6M $10 - 75M Funding TBD
- 5. 5 Flash Ironmaking Process Pilot-scale furnace testing & demonstration • Reduction with partial oxidation of natural gas, 1,200-1500°C • Dimensional and residence time relative to commercial plant • $10.6 Million cost-share project • Current Partners AISI / DOE ArcelorMittal USA Berry Metal Co. Timken Steel U. S. Steel University of Utah
- 6. H2-reduced iron at 1073 K (800 ℃) FIT produces non-pyrophoric iron Flash reduced iron at 1623 K (1350 ℃)
- 7. 7 Commercial-Scale Plant Modeling • One-step and Two-step commercial-scale reformerless ironmaking process • 1 million tons annual output, 300 day/yr operation • 1,500 °C operation • Excess driving force = 0.5 • METSIM process model
- 8. CO2 Emissions (tons per ton iron) 1.6 0.04 1.02 1.08 Avg. Blast Furnace Flash Ironmaking (Hydrogen) Flash Ironmaking (Natural Gas w/o Reformer) Flash Ironmaking (Natural Gas w/ Reformer) CO2(tons/tonmolteniron) Carbon dioxide emission from ore/coke preparation is not included. % of BF = 2.5 % (H2); 64 % (Natural Gas w/o Reformer) H. K. Pinegar, M. S. Moats, H. Y. Sohn, Iron and Steelmaking 2012
- 9. Energy Requirement (GJ per metric ton molten iron) 12.7 5.7 8.9 12.9 Avg. Blast Furnace Flash Ironmaking (Hydrogen) Flash Ironmaking (Natural Gas, w/o Reformer) Flash Ironmaking (Natural Gas, w/ Reformer) EnergyRequirement(GJ/tonmolteniron) Pelletizing = 3; Sintering = 0.7; Cokemaking = 2 % of BF = 45 % (H2); 70 % (Natural Gas w/o Reformer)
- 10. Economic Feasibility – Hydrogen 10 • Hot metal price: $512/ton • Hydrogen cost: $2.5/kg-H2 (2010) • 500,000 tons/yr hot metal • 15 year capital project • 10% discount rate H. K. Pinegar, M. S. Moats, H. Y. Sohn “Process Simulation and Economic Feasibility Analysis for a Hydrogen-Based Novel Suspension Ironmaking Technology” Steel Research Int. 82, 2011, No. 8. NPV = (minus $546 million), no CO2 credit NPV = $48 million, with $50/ton CO2 credit
- 11. Financial Feasibility – Natural Gas 11 • Hot metal price: $512/ton • 1 million ton hot metal/year • Natural gas feed: $5/million Btu • 15 year capital project • 10% discount rate H. K. Pinegar, M. S. Moats, H. Y. Sohn “Flowsheet development, process simulation and economic feasibility analysis for novel suspension ironmaking technology based on natural gas: Part 3 – Economic feasibility analysis” Iron and Steelmaking 2013 vol.40 No.1 NPV = $401 for Reformerless one-step process NPV = $214 for SMR Hydrogen Process
- 12. Potential Implications H2 Requirement = 0.1 ton / ton iron Rate of Iron Production (2015): U.S.+ Canada = 32.5 million tons/year World = 1.2 billion tons/year H2 Equivalent: U.S.+ Canada = 3.3 million tons/y = 3.7x1010 m3/y World = 120 million tons/y = 130x1010 m3/y Reduction in CO2 Emissions: U.S.+ Canada = 54 million tons/y World = 2 billion tons/y
- 13. Summary Low CO2 emissions: 2.5% of BF ironmaking (w/ H2) Energy saving: 3.0 GJ/ton Fe (55%) cf. BF (w/ H2) Eliminate cokemaking and pelletization/sintering & associated pollution. 90-99% reduction in 2-7 seconds at 1200-1500oC Enormous hydrogen utilization potential