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CCRA Canadian Carbonization Research Association
CCRA Technical Committee
BIO CARBON DEVELOPMENTS in
CANADA
Canadian Carbonization Research Association
Ted Todoschuk, Board Chairman, CCRA
Louis Giroux, Chairman CCRA Technical Committee
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Canadian
Carbonization
Research
Association
Canadian Carbonization ResearchAssociation
(CCRA)
ArcelorMittalDofasco
WalterEnergy
Anglo American
CANMET Energy
Industrial Innovation GroupIndustrial Energy Systems
Energy for High Temperature Processes
Dr. T. MacPhee
2 PhD Scientists 8 Technicians
Equipment
Coal Coke
Personnel
ChemistryPetrographyRheologyPhysicalMovable Wall OvenSole Heated Oven
ChemistrySizeStrengthDensityPorosityCoke Carbon Forms
TeckCoal
2 ResearchEngineers
GrandeCache
SunCokeEnergy
USSCanada
Xstrata
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
CCRA Program Areas of Research
• Energy and CO2 Reduction in the Steel Industry
• Energy and Environment
• Fundamental Aspects of Coal and Coke Utilization
• Database, Standards and Procedures
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
CCRA Program Areas of Research – CO2 Driver
Integrated:
• Blast Furnace Iron: 9 Mt
• Coke consumption: ~4 Mt
• CO2 emission: ~14 Mt
EAF:
• EAF Iron: 6 Mt
• CO2: ~ 1 Mt
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
CCRA Program Areas of Research
1 - Short Term Solutions for Utilizing Bio Carbon in Ironmaking
and Steelmaking.
2 - Long Term Radical Solutions for Utilizing Bio Carbon in
Ironmaking and Steelmaking.
3 – Alternative Primary Processes with CO2 Capture and Storage –
Primary process potential reconfiguration. (will not be discussed)
Mandate is to look at technical solutions, not economics at this
point.
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Biological Material: all plant and animal matters
Short rotation forestry Forest residues Wood waste Crop residues Agricultural crops
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Bio Carbon Research Focus in the Steel Sub-sector
Carbon in the charge
BurnersCarbon Injection (Slag foaming)
Photosynthesis
Biomass
Photosynthesis
Biomass
CO2CO2 CO2
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Biofuel Composition
Elemental Composition is Critical to Iron and Steelmaking Products
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Short Term – Industrial Coal Blend
• Partial replacement of coal in an industrial coal blend
– Cold strength and hot strength of coke to be maintained.
– Found that the charcoal had to be <60mesh (.250mm).
– Washing of the charcoal using diluted acetic acid.
– 5 to 10% addition to start, using small scale coking tests.
– Full scale movable wall oven tests will be completed using an
industrial coal blend (Dofasco).
– Also to be investigated is briquetting of the charcoal allow a
higher percentage of charcoal to be used i.e. up to 50%
– Low in Ca: To maintain hot strength
– Low in Na and K: To avoid alkaline accumulation
– Low in P: To facilitate steelmaking
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Charcoal for PCI Injection
• Partial replacement of coal for PCI injection.
# Coal to make BF coke + coal for injectant at tuyere
#
Use of unprocessed biomass (low C, high O) results in marginal
improvement in CO2 reduction.
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Charcoal for PCI Injection
HM: 9.0 Mt/yr
Charcoal:
1.3 Mt/yr
CO2: 10.5 Mt/yr
Slow Pyrolysis
(Yield 35%)
Raw Biomass:
3.6 Mt/yr
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Charcoal for PCI Injection
–High combustibility: To ensure rapid gasification
– High in C and Low in O: To maximize coke
replacement and maintain furnace heat balance
– Low in Na and K: To avoid alkaline accumulation
– Low in P: To facilitate steelmaking
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Biomass for EAF
Research in biomass in EAF focuses on 38% of CO2 emissions
Carbon in the charge
Burners Carbon Injection (Slag foaming)
Photosynthesis
Biomass
Photosynthesis
Biomass
CO2 CO2 CO2
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Summary - Short Term
• Replacement of PCI with charcoal injection in the blast
furnace, addresses 23.5% of the blast furnace CO2
emission. Further reduction will depend on how much
biomass can replace current blast furnace coke.
• For the EAF, there is a potential to reduce CO2
emissions by 38% with the use of biocarbon. i.e. burners
and slag foaming carbon.
CCRA
Canadian Carbonization Research Association
CCRA Technical Committee
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Long Term – Future Vision
• Current CO2 emissions are ~14 Mt.
• What can be done in the longer term to maximize the
amount of bio based fuels to radically reduce this CO2
emission level.
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Long Term – Future Vision
• Need to take raw biomass and convert to “charcoal”
• Biocarbon production facilities:
– Adding charcoal will be limited in the amount that can
replace traditional coal in a traditional slot oven blend.
– Need to be able to increase the utilization of
briquetting technology.
– Limited in a slot oven due to wall pressure generation
and shrinkage issues.
– Can the amount of charcoal be increased using an
alternative (non-recovery) technology?
Non-recovery=no by-products recovery
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
Raw Bio
Material
Harvest
Bio Treatment
(washing or
chemical
treatment)
Bio Upgrade
and
Beneficiation
Low Temperature
(200-300°C)
Drive off H2O and
VM to minimize
degradation
during coking
Char like material
produced
Tar addition or
suitable binder
(perhaps bio
based)
Have to make
suitable shape
such as
briquettes, pellets,
disks
Size will depend
on process to
receive product
Heat to Carbonize
(adequate time
and temperature)
Temperature
maybe lower than
traditional
cokemaking
Use slot, grate
furnace or non-
recovery
technology
DRI/Smelting
Reduction
EAF
BF
Future
Ironmaking
Process
Product is dry
quenched
Bio Product is
stabilized, crushed
and screened
appropriately
for process to
receive product
(1) Dry Quench Energy Used to dry material
(2) Recycle top gas
(3) Fines are recycled back to bio mixture
(4) Composite mixture of Fe and Bio Carbon
(5) Process off gas to be used directly back in process, bio process or methanation to be used to upgrade gas or
even generate power for processes
(1)
(2)
(3)
(4)
(5)
(5)
(5)
(5)
(5)
Stoves
Corex/Finex(5)
PCI
Char
Long Term Research Proposal
Biomaterials Enrichment
Precarbonization
Carbonization
Treatment
Product
Application
CCRA Canadian Carbonization Research Association
CCRA Technical Committee
•Sustainable raw biomass supply capable to meet the demand by
steel industry?
•Bio-char production capacity?
•Process for removing unwanted minerals in bio-char?
•Chemical composition of “cleaned” bio-char suitability for bio-
cokemaking or direct injection?