Miscanthus to Biocarbon for Canadian Iron and Steel Industries: An Innovative Approach

Iron-based industries are one of the main contributors to greenhouse gas (GHG) emissions. Partial substitution of fossil carbon with renewable biocarbon (biomass) into the blast furnace (BF) process can be a sustainable approach to mitigating GHG emissions from the ironmaking process. However, the main barriers of using biomass for this purpose are the inherent high alkaline and phosphorous contents in ash, resulting in fouling, slagging, and scaling on the BF surface. Furthermore, the carbon content of the biomass is considerably lower than coal. To address these barriers, this research proposed an innovative approach of combining two thermochemical conversion methods, namely hydrothermal carbonization (HTC) and slow pyrolysis, for converting biomass into suitable biocarbon for the ironmaking process. Miscanthus, which is one of the most abundant herbaceous biomass sources, was first treated by HTC to obtain the lowest possible ash content mainly due to reduction in alkali matter and phosphorous contents, and then subjected to slow pyrolysis to increase the carbon content. Design expert 11 was used to plan the number of the required experiments and to find the optimal condition for HTC and pyrolysis steps. It was found that the biocarbon obtained from HTC at 199 °C for 28 min and consecutively pyrolyzed at 400 °C for 30 min showed similar properties to pulverized coal injection (PCI) which is currently used in BFs due to its low ash content (0.19%) and high carbon content (79.67%).

Effect of Coated Cow Dung on Fluidization Reduction of Fine Iron Ore particles

The effects of reduction temperature, gas linear velocity, reduction pressure, reduction time, and reducing gas on the fluidized ironmaking process were studied for the fine iron Newman ore particles (0.154–0.178 mm) and the optimal experimental operating conditions were obtained. Under the optimal conditions, the effects of the coated cow dung on the reduction of fine iron ore particles were studied, and the inhibition mechanism of cow dung on particle adhesion in the fluidized ironmaking process was elucidated. The experimental results show that the optimal operating parameters are linear velocity of 0.6 m/s, reduction pressure of 0.2 MPa, reduction temperature of 1023 K, H2 as the reducing gas, and reduction time of 60 min. Cow dung can react with oxide in the ore powder to form a high melting point substance that can form a certain isolation layer, inhibit the growth of iron whiskers, and improve the fluidization.

Thermodynamic Study of Energy Consumption and Carbon Dioxide Emission in Ironmaking Process of the Reduction of Iron Oxides by Carbon

Carbon included in coke and coal was used as a reduction agent and fuel in blast furnace (BF) ironmaking processes, which released large quantities of carbon dioxide (CO2). Minimizing the carbon consumption and CO2 output has always the goal of ironmaking research. In this paper, the reduction reactions of iron oxides by carbon, the gasification reaction of carbon by CO2, and the coupling reactions were studied by thermodynamic functions, which were derived from isobaric specific heat capacity. The reaction enthalpy at 298 K could not represent the heat value at the other reaction temperature, so the certain temperature should be confirmed by Gibbs frees energy and gas partial pressure. Based on Hess’ law, the energy consumption of the ironmaking process by carbon was calculated in detail. The decrease in the reduction temperature of solid metal iron has been beneficial in reducing the sensible heat required. When the volume ratio of CO to CO2 in the top gas of the furnace was given as 1.1–1.5, the coupling parameters of carbon gasification were 1.06–1.28 for Fe2O3, 0.71–0.85 for Fe3O4, 0.35–0.43 for FeO, respectively. With the increase in the coupling parameters, the volume fraction of CO2 decreased, and energy consumption and CO2 output increased. The minimum energy consumption and CO2 output of liquid iron production were in the reduction reactions with only CO2 generated, which were 9.952 GJ/t and 1265.854 kg/t from Fe2O3, 9.761 GJ/t and 1226.799 kg/t from Fe3O4, 9.007 GJ/t and 1107.368 kg/t from FeO, respectively. Compared with the current energy consumption of 11.65 GJ/t hot metal (HM) and CO2 output of 1650 kg/tHM of BF, the energy consumption and CO2 of ironmaking by carbon could reach lower levels by decreasing the coupled gasification reactions, lowering the temperature needed to generate solid Fe and adjusting the iron oxides to improve the iron content in the raw material. This article provides a simplified calculation method to understand the limit of energy consumption and CO2 output of ironmaking by carbon reduction iron oxides.