Periodic Reporting for period 1 - GreenHeatEAF (Gradual integration of REnewable non-fossil ENergy sources and modular HEATing technologies in EAF for progressive CO2 decrease)
Período documentado: 2023-01-01 hasta 2024-06-30
GreenHeatEAF aims at demonstrating the integration of non-fossil fuels and renewable C-sources in EAF process to decrease CO2 emissions and dependence from fossil energy and C-sources markets by combining pilot, on field and simulation investigations. The project focuses also on improvement of heat recovery solutions both from off-gases and slag considering the changes of their features with the introduction of H2 and/or biomass and considering different charge materials and modes. Technologies and processes for heat recovery are tested and current control approaches are improved and optimized. Transferability is ensured by different business cases of the industrial partners.
The following specific objectives are pursued:
1) integration of non-fossil gases flows in EAF processes with different charge materials and configurations towards GreenHouse Gases reduction and green transition of steelmaking;
2) development of modular regenerative and alternative heating technologies to increase in-process heat recovery from off-gases and maximize slag latent heat exploitation for their valorization;
3) demonstration of biomass/biochar exploitation for non-fossil energy intake in EAF process;
4) showcase of the potential of coupling of novel measurement techniques and optimized control strategies in managing the exploitation and facilitating the integration of novel non-fossil heat/energy sources and streams;
5) assessment of CO2 emissions and environmental impact of GreenHeatEAF solutions in view of the transition to C-lean steelmaking;
6) development of business case, communication and exploitation strategy for the adoption of GreenHeatEAF results in steelmaking and similar industrial sectors.
The following specific objectives are pursued:
1) integration of non-fossil gases flows in EAF processes with different charge materials and configurations towards GreenHouse Gases reduction and green transition of steelmaking;
2) development of modular regenerative and alternative heating technologies to increase in-process heat recovery from off-gases and maximize slag latent heat exploitation for their valorization;
3) demonstration of biomass/biochar exploitation for non-fossil energy intake in EAF process;
4) showcase of the potential of coupling of novel measurement techniques and optimized control strategies in managing the exploitation and facilitating the integration of novel non-fossil heat/energy sources and streams;
5) assessment of CO2 emissions and environmental impact of GreenHeatEAF solutions in view of the transition to C-lean steelmaking;
6) development of business case, communication and exploitation strategy for the adoption of GreenHeatEAF results in steelmaking and similar industrial sectors.
The scaled burner for demonstration of Hydrogen Enhanced Combustion (HEC) for EAF heating by using standard EAF burner was designed and built.
Demonstration of hydrogen use with CoJet-technology, with different iron carriers, in the pilot EAF at Swerim was completed; evaluations are ongoing.
CFD simulations were performed to study HEC.
Trials to modify EAF slag for the cement industry was carried out on DRI and scrap feeding trials. Additives such as Al, FeSi and SiO2 were used to modify the slag during tapping.
Thorough market research of the available biochar and other renewable materials was carried out and a list was created. The different industrial cases were defined by the industrial partners and their technical requirements were compared to the different properties of the available biochars to select the most adequate materials for the industrial trials.
Using data provided by Sidenor, the EAF dynamic process model of BFI and the EAF and Secondary metallurgy stationary process model of SSSA were updated. In addition, simulation analyses were made to determine the influence of these C-renewable materials on steelmaking process and product. The SSSA model was also preliminary adapted to simulate Hydrogen use in EAF burners in partial/total replacement of Natural Gas, and for feeding DRI/HBI in EAF and preliminary simulations were carried out. First versions of flowsheet models were developed concerning two biomass upgrading processes (i.e. pyrolysis and torrefaction).
Pilot/demo trials were conducted at Swerim using bio-carbon as injection coal, while industrial trials started at Sidenor. So far, different mixtures of plastics and tires were used as substitutes of the foaming coal that is injected in the EAF, and biochar (forest source) was charged through the 5th hole. Other materials are expected to be tested in Sidenor. Further industrial trials will be carried out at Höganäs and CELSA.
A new system to monitor gas heat basing on the specifically adapted Acoustic GAs-Measurement system (“AGAM”) system and other relevant process data was developed as detailed concept, which should be installed by end 2024. To prepare the installation of the AGAM system, the optimal position for the measurement was identified. Höganäs also tested an in-house developed gas analysing system including one thermocouple right after the 4th hole.
An initial impact plan was defined, and possible deployment opportunities were analysed. A preliminary identification of strategic stakeholders and potential adopters was carried out, by also defining the value proposition and compiling a detailed description of the envisaged Key Exploitable Results (KERs). To this aim, a questionnaire was distributed among the partners to develop a gap analysis and the first draft of the project Exploitation Plan. Moreover, some initial transferability guidelines have been elaborated based on a stakeholder consultation.
Demonstration of hydrogen use with CoJet-technology, with different iron carriers, in the pilot EAF at Swerim was completed; evaluations are ongoing.
CFD simulations were performed to study HEC.
Trials to modify EAF slag for the cement industry was carried out on DRI and scrap feeding trials. Additives such as Al, FeSi and SiO2 were used to modify the slag during tapping.
Thorough market research of the available biochar and other renewable materials was carried out and a list was created. The different industrial cases were defined by the industrial partners and their technical requirements were compared to the different properties of the available biochars to select the most adequate materials for the industrial trials.
Using data provided by Sidenor, the EAF dynamic process model of BFI and the EAF and Secondary metallurgy stationary process model of SSSA were updated. In addition, simulation analyses were made to determine the influence of these C-renewable materials on steelmaking process and product. The SSSA model was also preliminary adapted to simulate Hydrogen use in EAF burners in partial/total replacement of Natural Gas, and for feeding DRI/HBI in EAF and preliminary simulations were carried out. First versions of flowsheet models were developed concerning two biomass upgrading processes (i.e. pyrolysis and torrefaction).
Pilot/demo trials were conducted at Swerim using bio-carbon as injection coal, while industrial trials started at Sidenor. So far, different mixtures of plastics and tires were used as substitutes of the foaming coal that is injected in the EAF, and biochar (forest source) was charged through the 5th hole. Other materials are expected to be tested in Sidenor. Further industrial trials will be carried out at Höganäs and CELSA.
A new system to monitor gas heat basing on the specifically adapted Acoustic GAs-Measurement system (“AGAM”) system and other relevant process data was developed as detailed concept, which should be installed by end 2024. To prepare the installation of the AGAM system, the optimal position for the measurement was identified. Höganäs also tested an in-house developed gas analysing system including one thermocouple right after the 4th hole.
An initial impact plan was defined, and possible deployment opportunities were analysed. A preliminary identification of strategic stakeholders and potential adopters was carried out, by also defining the value proposition and compiling a detailed description of the envisaged Key Exploitable Results (KERs). To this aim, a questionnaire was distributed among the partners to develop a gap analysis and the first draft of the project Exploitation Plan. Moreover, some initial transferability guidelines have been elaborated based on a stakeholder consultation.
GreenHeatEAF supports the gradual integration of renewable non-fossil energy sources and modular heating technologies in the electric steelmaking route by providing the following overall results, which go far beyond the state of the art:
• demonstration of the CoJet technology for HEC at the EAF through tests conducted at the pilot EAF at SWERIM in combination with different cases of iron carrier praxis spanning from 100 % scrap bucket charging to 100% DRI/HBI continuous feeding.
• Characterization of different commercial biomass/biochar and development of industrial tests to assess the effects of their usage in partial replacement of fossil C-bearing material at the EAF.
• Extension of existing flowsheet models of the EAF-route to cover usage of non-fossil fuels, renewable C-sources and alternative iron bearing materials at the EAF for scenario analyses guiding and widening the exploration potential of experimental trials.
• Development of novel CFD model covering the influence of suction speed, furnace pressure and false air ingress on the post-combustion reaction efficiency in the freeboard of the EAF to investigate for C-lean production conditions.
• Validation of a heat recovery solution from EAF off-gases by exploiting a novel ceramic recuperator enabling internal and external energy use in an efficient way.
• Field validation of a contactless acoustic system to measure off-gas temperature with a very short response time and placed outside the duct to enhance robustness, reliability and maintainability.
• flexible distributed control solution based on Model Predictive Control to manage the different heat sources and capacities in electric steelmaking.
• Exploitation of latent heat to adjust slag to be suitable for cement production.
• demonstration of the CoJet technology for HEC at the EAF through tests conducted at the pilot EAF at SWERIM in combination with different cases of iron carrier praxis spanning from 100 % scrap bucket charging to 100% DRI/HBI continuous feeding.
• Characterization of different commercial biomass/biochar and development of industrial tests to assess the effects of their usage in partial replacement of fossil C-bearing material at the EAF.
• Extension of existing flowsheet models of the EAF-route to cover usage of non-fossil fuels, renewable C-sources and alternative iron bearing materials at the EAF for scenario analyses guiding and widening the exploration potential of experimental trials.
• Development of novel CFD model covering the influence of suction speed, furnace pressure and false air ingress on the post-combustion reaction efficiency in the freeboard of the EAF to investigate for C-lean production conditions.
• Validation of a heat recovery solution from EAF off-gases by exploiting a novel ceramic recuperator enabling internal and external energy use in an efficient way.
• Field validation of a contactless acoustic system to measure off-gas temperature with a very short response time and placed outside the duct to enhance robustness, reliability and maintainability.
• flexible distributed control solution based on Model Predictive Control to manage the different heat sources and capacities in electric steelmaking.
• Exploitation of latent heat to adjust slag to be suitable for cement production.