Furnace Technology Research Articles

Circular Economy Approach on Decarbonization by Repurposing Used Cooking Oil for Nickel Smelter – A Case Study of PT Megah Surya Pertiwi, Obi Island, North Maluku, Indonesia

Abstract This research was instigated by the world’s endeavours to fight dependency on fossil energy sources. While coal prevails as a beneficial energy source, countries worldwide have strived to reduce coal usage in the future under the Net Zero Emission Pledge. Questions linger on how to minimize coal usage, play down its impact on the environment, and maintain economic advantages. This quantitative study focused on the repurposing of used cooking oil for alternative energy sources at PT Megah Surya Pertiwi (PT MSP), the first downstream company of Harita Nickel that processes nickel saprolite ore to Ferronickel using the Rotary Kiln Electric Furnace (RKEF) technology in Obi Island, North Maluku, Indonesia. As the company’s employment grows, wastes, including used cooking oil (UCO), accumulate. The result showed that repurposing UCO in PT MSP has lowered the consumption of coal by 2,206 tons (7.53%), diverted 2,980 tCO2e indirect GHG emission (Scope 1), and saved the total cost up to IDR 1,408,231,332.

Radiative heat recuperation in combustion of layered solid fuel

In this work, we investigate the properties and stability of the combustion waves propagating in a system of layered solid fuel material in which the neighbouring fuel sheets can recuperate heat via thermal electromagnetic radiation. The analysis is undertaken within the flame sheet model, which allows to determine the combustion wave speed and structure and derive the dispersion relation characterising the stability of the reaction front. The proper choice of parameters leads to superadiabatic combustion temperature and significant increase of the combustion wave speed. In addition, the stable steady regimes of combustion can be substantially extended in the space of parameters. Such an enhancement of stability and ability to control the characteristics of the combustion wave propagation can be very attractive for the combustion synthesis of new layered materials, similarly to the chemical furnace technology proposed earlier.

Sun tracking control technology of solar furnace

Sun tracking control technology of solar furnace

Low‐carbon economic schedule of the H2DRI‐EAF steel plant integrated with a power‐to‐hydrogen system driven by blue hydrogen and green hydrogen

AbstractHydrogen direct reduction iron coupled with electronic arc furnace (H2DRI‐EAF) technology, as an important technology for decarbonisation in the iron and steel industry, has the advantages of high electrification and low carbon emissions. However, the large demand for hydrogen in this technology relies significantly on the production of electrolytic hydrogen, leading to a substantial increase in power consumption in the steel production process. Moreover, the use of an unclean power source in electrolytic hydrogen production leads to increases in indirect carbon emissions, reducing the low‐carbon attributes of the technology. This study investigates the integrated flexible operation mode of a steel plant. An illustrating method is utilised for modelling the entire steel production process and power to hydrogen (PtH2) process in detail for the H2DRI‐EAF steel plant, which includes natural gas, photovoltaic, wind power self‐provided power plants, and carbon capture and storage (CCS) systems. A mixed integer linear programming (MILP) model is developed for the comprehensive scheduling of the steel mill. The results of the case studies indicate that by reliably integrating the production of renewable energy and natural gas power plants, the PtH2 system can fully consume the renewable energy output while ensuring the smooth progress of steel production and maximising the reduction of carbon emissions from hydrogen production and the total cost of steel production.

The role of border carbon adjustments and subsidies in incentivising investment: comparing equivalence in the context of steel recycling and decarbonisation

The need to decarbonise has accelerated the quest to find solutions for sectors considered emissions-intensive and trade-exposed. Steel production is one such sector. Policymakers are responding with market-pull and technology-push mechanisms. Risks of carbon leakage have prompted consideration and implementation of border carbon mechanisms. Measures have drawn both positive and negative attention in internationally traded markets. This research quantifies the equivalence of differing measures to promote decarbonisation. It simulates the annual cost-saving equivalent and net present values of different mechanisms in a theoretical conversion to steelmaking with Electric Arc Furnace (EAF) technology from traditional steel production. It demonstrates that, under certain assumptions including removal of free allocation of emissions certificates, incentives per tonne of direct and indirect greenhouse gas emissions for carbon pricing and border carbon adjustments lie in the range EUR 18–76 whereas for cost-of-capital support measures it was EUR 24–41 per tCO2e. Whether firms act upon these incentives will depend on appetite for risk, availability of technology, feedstocks, choice they have in making changes and perceived sustainability of the assumptions made in investment analysis. There are implications for regulators, policy makers and managers as they prepare strategies to be competitive in an increasingly carbon-constrained environment.

Development and implementation of technological measures to extend the campaign of blast furnace No. 5 of PJSC Severstal

The work presents generalized experience in the development and implementation at PJSC Severstal of technological measures to extend the campaign of blast furnace No. 5. The authors carried out an analysis, identified and described the problem areas, generalized the principles for ensuring the safety of the shaft lining, boshes and metal receiver of the blast furnace. The results of a study of the working space of blast furnace No. 5 in 2006 are also presented. The identified technological factors ensure an increase in duration of the unit campaign. Technolo­gical measures are given for: washing the blast furnace hearth, reducing chemical erosion of the carbon blocks of the hearth and flange, forming a protective skull in the blast furnace shaft, special methods for loading solid coke substitutes, and organizing an effective structure of the charge column in the blast furnace. It is necessary to use digital models integrated into the blast furnace expert system for operational control of blast furnace technology. The results of the current blast furnace campaign were compared with previous ones. It was proven that the systematic use of all elements of the developed technology makes it possible to achieve high economic indicators while exceeding the standard duration of the campaign by 1.75 times. Experience in technology development made it possible to increase the furnace campaign duration to 17.46 years, achieve a reduction in specific coke consumption by 15.9 %, and increase the specific consumption of natural gas for cast iron smelting by 46.4 %; reduce the specific carbon consumption for cast iron smelting by 6.3 %.

Selecting Indonesia’s Iron and Steel Industry Mitigation Pathways Based on AIM/End-use Assessment

The measurement of mitigation pathways is important for Indonesia’s iron and steel industry in terms of reducing GHG emissions. This study conducted a cost-effectiveness analysis to assess the economic impacts with associated emission reduction potential of different mitigation strategies by developing an Abatement Cost Curve (ACC) that selects the mitigation option based on the logic of the AIM/End-use model up to 2050. The model was established through the baseline scenario, and the following appropriate mitigation options: adjusting the production structure (CM1), increasing energy efficiency by promoting low carbon technology and non-blast furnace technology that is un-implemented early in modeling years in Indonesia will be included for future reference (CM2), and switching from fossil fuels to low emission fuels (CM3). Results show that the selected technology roadmap from the abatement cost curve below carbon tax 110 US$/tCO2e in 2050 could lead to the most optimal emission reduction of 19.8 MtCO2e, 50.2 MtCO2e, 54.84 MtCO2e with investment costs 93.55 million US$, 1086 million US$, and 1183 million US$ in the scenarios CM1, CM2, and CM3, respectively. The effectiveness of each mitigation action reveals that energy savings and emission reduction from energy will rely mostly on promoting low-carbon technologies. The most effective strategy to reduce emissions from IPPU is to adjust the production structure.

A comparative study on the effectiveness of pollutants control measures adopted in the steel industry to reduce workplace and environmental exposure: a case study

Our understanding of the environmental and occupational health implications of pollutants emitted in steel production is still lacking, despite the considerable amount of research devoted to this topic. Given the significance of steel recycling and the need to reduce greenhouse gas emissions, many steel factories are adopting electric arc furnace (EAF) technology. The use of a technological system designed for the capture of pollutants emitted through EAF steel production is highly ecological because of its utilization of iron scrap and low investment cost. Despite this, the main issue with the EAF is the environmental impact it poses, specifically the release of pollutants into the air, such as dust and organic substances, chlorinated dioxins and furans, dioxin-like polychlorinated biphenyls and brominated dioxins and furans. As a result, workers in this field have a considerable rate of morbidity. The main challenge for EAFs is to optimize the capture of powders produced during the techno-logical process, both from the EAF and the workplace. A state-of-the art solution for managing pollutants in modern steel manufacturing is highlighted in this paper, featuring a method used in Romania that employs the Best Available Techniques (BAT) reference document for iron and steel production to directly collect pollutants from the EAF. The system included a cylindrical fitting, a heat exchanger to cool the gases and a hood to collect contaminants. In comparison to other ventilation options, this equipment boasts lower investment and lower operational costs because of its effective and minimal air flow. Through the use of cutting-edge technology and progressive strategies, we can move closer toward our objective of a workplace free from injuries in the steel industry.

The Influence of Nitrogen on Hydrogen Reduction of Iron Ore Pellets

As the iron and steel industry now strives for a carbon neutral industry, hydrogen‐based direct reduction shaft furnace technology has become an alternative to the heavily fossil‐depending blast furnace route. Research questions related to the future full‐scale production have, therefore, become more interesting. Depending on the operational conditions, the H2 concentration and temperature will vary across the length of the reactor. This work studies the effect of nitrogen in a hydrogen‐reducing gas during the reduction of commercial iron ore pellets using thermogravimetric analysis. The reducing gas consisted of either pure hydrogen or a mixture of 90–70 vol% hydrogen and 10–30 vol% nitrogen at 773, 873, 973, 1073, and 1173 K. It is found that the reduction rate decreased with decreasing temperature and increasing nitrogen content. The effect of nitrogen on the reduction rate is more profound than expected from the decreased hydrogen partial pressure alone. To aid the discussion, partially reduced pellets are studied using optical and scanning electron microscopy. It is found that the microstructure is strongly dependent on the temperature but independent of the nitrogen content.

Impact of Hydrogen Integration and Implementation on Costs in Glass Production

The glass industry stands as a significant contributor to global greenhouse gas emissions, primarily reliant on natural gas during production, posing a considerable environmental challenge. Despite advancements in furnace technologies, achieving substantial reductions in emissions remains a hurdle. Radical redesigns, including advanced heat recovery systems and alternative fuel sources such as hydrogen, emerge as promising avenues. However, current projections indicate modest increases in energy efficiency, insufficient to align with decarbonization objectives. Hydrogen appears promising, offering drastic emissions reductions and operational flexibility. The European glass industry is increasingly considering hydrogen as a sustainable alternative. However, the transition necessitates a comprehensive understanding of the economic implications associated with different delivery and implementation methods. This study developed a simulation model based on empirical data from a case study and analyzed different scenarios with the aim of providing insights into the cost implications of various hydrogen delivery and implementation methods for glass production. The study contributes to providing decision support methodologies and empowering production planners and managers in the glass industry to make informed decisions toward sustainable and economically viable decarbonization strategies.

Assessing the Sustainability Impact of Improving Secondary Steel Production: Lessons Learned from an Italian Plant

Abstract This work presents a sustainability assessment approach to evaluate technological innovations in secondary steel production making use of Electric Arc Furnace (EAF) technology. The assessment covers the environmental, social, and economic dimensions of sustainability by combining different tools (Life Cycle Assessment and Analytic Hierarchy Process), and also provides an integrated assessment of the overall sustainability. The approach, which can also be used to support decision-making, has been applied to a real case study of a steel plant located in Northern Italy. In the case study, environmental sustainability is positively impacted mainly by increased metal yield and reduced furnace energy consumption. The greatest social sustainability benefits are mainly related to improved ergonomic and safety conditions for workers (reduced demand for physical effort, manual handling and repetitiveness, and lower risk of accidents), as a consequence of the introduction of Industry 4.0 technologies. Regarding economic sustainability, a positive impact related to reduced cycle time, increased metal yield and quality yield, reduced maintenance and quality control costs was observed. The integrated assessment of the overall sustainability has proven to be a viable approach to manage trade-offs between the different dimensions of sustainability.

ДОМЕННА РЕВОЛЮЦІЯ, СТОЛІТНЯ ВІЙНА І ПОЧАТОК МАЛОГО ЛЬОДОВИКОВОГО ПЕРІОДУ В ЗАХІДНІЙ ЄВРОПІ XIV–XV СТ.

This article explores the interconnection between the blast furnace revolution, the Hundred Years’ War, and the onset of the Little Ice Age in Western Europe during the 14th and 15th centuries. It analyzes how innovations in blast furnace technology during this period significantly transformed metallurgical production, which in turn had far-reaching economic and social consequences. The first aspect addressed is the blast furnace revolution, which represents a transition from traditional metal production methods to new technologies that dramatically increased productivity and reduced iron manufacturing costs. This had significant implications for military affairs and the economy, as the growth in metal production supported the strengthening of armies. The second aspect examines the impact of the Hundred Years’ War on social and political processes in Western Europe. The war not only stimulated technological development but also altered political boundaries and created new economic and social conditions. The article analyzes how the increase in iron production influenced warfare and military strategies of the time. The third aspect considers the onset of the Little Ice Age and its impact on climate conditions in Europe. The Little Ice Age caused severe changes in the agricultural sector, leading to reduced crop yields, famine, and social upheaval. The article investigates how the colder climate affected economic stability and social life in the context of the existing military and technological changes. Combining historical documents, contemporary research, and archival data, the article provides a comprehensive approach to understanding how these three factors interacted and shaped social, economic, and political processes in Western Europe during the 14th and 15th centuries. It highlights the impact of technological and climatic changes on society, emphasizing how the complex interaction between technological innovations, military conflicts, and climatic conditions defined this historical period.

Flexibility options in a decarbonising iron and steel industry

The decarbonisation of the iron and steel industry is expected to significantly increase its electricity consumption due to higher levels of electrification and the partial shift to hydrogen as iron reductant. With its batch processes, this industry offers large potential for the application of demand response strategies to achieve electricity cost savings. Previous research has primarily focused on investigating the demand response potential for currently operating manufacturing processes and partly for future low-carbon processes. This study aims to consolidate this knowledge and apply it to a modelling analysis that investigates the demand response potential of two new low-carbon technologies: the hydrogen-based direct reduction of iron with electric arc furnace technology (H2-DRI-EAF) and the blast furnace basic oxygen furnace technology retrofitted with carbon capture (BF-BOF-CCUS). A cost optimisation approach is applied to plant configurations with varying parameters relevant for flexibility, such as electrolyser and storage sizes, and in the context of future electricity prices. Multiple price profiles are selected to encompass uncertainties on the development of the power system. The potential for a H2-DRI-EAF plant is 3–27 times higher than for a BF-BOF-CCUS, with electricity costs savings potentials of 35% and 3%, respectively. The study finds that electricity prices have the most significant impact on the profitability of investing in electrolyser overcapacities, which enable operating costs reduction. Therefore, the profitability of these investments are strongly dependent on future power system configurations.

Toward green steel: Modeling and environmental economic analysis of iron direct reduction with different reducing gases

The objective of the paper is to simulate the whole steelmaking process cycle based on Direct Reduced Iron and Electric Arc Furnace technologies, by modeling for the first time the reduction furnace based on kinetic approach, to be used as a basis for the environmental and techno-economic plant analysis by adopting different reducing gases. In addition, the impact of carbon capture section is discussed. A complete profitability analysis has been conducted for the first time, adopting a Monte Carlo simulation approach.In detail, the use of syngas from methane reforming, syngas and hydrogen from gasification of municipal solid waste, and green hydrogen from water electrolysis are analyzed. The results show that the Direct Reduced Iron process with methane can reduce CO2 emissions by more than half compared to the blast furnace based-cycle, and with the adoption of carbon capture, greenhouse gas emissions can be reduced by an additional 40%. The use of carbon capture by amine scrubbing has a limited economic disadvantage compared to the scenario without it, becoming profitable once carbon tax is included in the analysis. However, it is with the use of green hydrogen from electrolyzer that greenhouse gas emissions can be cut down almost completely. To have an environmental benefit compared with the methane-based Direct Reduced Iron process, the green hydrogen plant must operate for at least 5136 h per year (64.2% of the plant's annual operating hours) on renewable energy.In addition, the use of syngas and separated hydrogen from municipal solid waste gasification is evaluated, demonstrating its possible use with no negative effects on the quality of produced steel. The results show that hydrogen use from waste gasification is more economic with respect to green hydrogen from electrolysis, but from the environmental viewpoint the latter results the best alternative. Comparing the use of hydrogen and syngas from waste gasification, it can be stated that the use of the former reducing gas results preferable, from both the economic and environmental viewpoint.

The Options in Decarbonization Pathways for Malaysia

Abstract Two activities in Malaysia that emit large amounts of CO2 are electricity generation, and iron and steel production. To decarbonize the former, Malaysia should invest in a flexible energy system to overcome the intermittent characteristic of solar energy by influencing the pattern of demand with peak load pricing, increasing energy storage capability, and entering into a regional electricity grid arrangement. Malaysia should respond to the recent large capacity expansion in iron and steel production with blast furnace-basic oxygen furnace (BF-BOF) technology by ending immediately the issuance of new licenses for facilities that use this BF-BOF technology, and speed up the process of adopting advanced green, near-zero emission technologies (e.g., Hydrogen Breakthrough Ironmaking Technology [HYBRIT]), by applying for foreign technical assistance (e.g., the United Nations Climate Technology Center and Networks [UN-CTCN]) and for concessionary climate finance under the Paris Agreement. Finally, to be consistent with the 1.5°C pathway for the world, Malaysia should aim to commit to achieve peak carbon emissions by 2030 and net zero emissions by 2050.

Cost and life cycle analysis for deep CO2 emissions reduction of steelmaking: Blast furnace-basic oxygen furnace and electric arc furnace technologies

Iron and steel manufacturing is the largest contributor to CO2 emissions among heavy industries worldwide. This is mostly due to the use of coal in blast furnace-basic oxygen furnace (BF-BOF) process for virgin (primary) steel production. The electricity generation mix used in the electric arc furnace (EAF) process to recycle scrap steel also contributes to the CO2 emission associated with secondary steel production. To decarbonize iron and steel sector, we investigated decarbonization options for BF-BOF and EAF processes, including energy efficiency, carbon capture and storage, and the use of clean energy sources, in various BF-BOF and EAF process configurations. For each decarbonization approach, we evaluated the CO2 reduction potential via life cycle analysis (LCA) and estimated the associated cost through techno-economic analysis (TEA). A typical U.S. BF-BOF for virgin steel production has a cradle-to-gate (CTG) CO2 emissions of 1,990 kg/MT steel with a levelized cost of steel (LCOS) of $439/MT steel, while a typical U.S. EAF process for secondary steel production in the United States has a CTG CO2 emissions of 270 kg/MT steel with a LCOS of $365/MT steel. Combining renewable energy sources and carbon capture, BF-BOF CTG CO2 emissions can be reduced to 16 kg/MT steel, and EAF configurations can achieve similar deep reductions to reach 25 kg/MT steel. The corresponding LCOS with these decarbonization levels is estimated to increase to $542/MT steel and $348/MT steel, respectively. The estimated CO2 avoidance costs vary from -$90/MT CO2 to $646/MT CO2, depending on the various decarbonization technologies and energy prices.

Study of Advancements of Solar Furnace Technology to Find Out Best Suitable Solar Furnace for Indian Conditions

Study of Advancements of Solar Furnace Technology to Find Out Best Suitable Solar Furnace for Indian Conditions

Analysis of process limits for partial hot stamping with controlled pre-cooling by radiation exchange

The increasing demands on part complexity and tailored properties in form of local strength and ductility cannot be achieved with conventionally manufactured hot stamped body components. To meet the requirements of safety-relevant body parts, partial hot stamping is increasingly used in the automotive industry. One approach to achieve tailored properties on hot stamped parts is based on controlled cooling of the blank prior to forming and quenching. The related furnace technology is based on a furnace chamber in which a cooled aluminum mask protects local areas of the blank from thermal radiation while simultaneously absorbing the blank’s own emitted radiation. The sheet thickness and utilized material significantly influence the controlled radiation exchange and present potential process limits. To analyse these lower process limits, blanks made of the materials 22MnB5 AS150 and 8MnB7 AS150 are partially pre-cooled and hot stamped with different sheet thicknesses. In addition, the process is simulated with AutoForm®R10 and validated by the obtained experimental results. The results show that the sheet thickness is a key influencing factor in the process and significantly affects the mechanical properties after partial hot stamping. Especially sheet thicknesses t0 of 2.25 mm can limit the process, as the effectiveness of the radiation exchange for controlled pre-cooling and phase transformation decreases.

Assessing the Global Sustainability Impact of Improving the Secondary Steel Production: Lessons Learned from an Italian Steel Plant

This study presents a comprehensive sustainability assessment of a series of technical interventions aimed at improving a secondary steel production process using the Electric Arc Furnace (EAF) technology in a steel plant located in northern Italy. The assessment covers the environmental, social, and economic dimensions of sustainability by considering three sets of indicators and employing a multi-criteria decision-making approach. The results show that the considered interventions can lead to significant improvements in the sustainability performance of the EAF process. The study also highlights the trade-offs and synergies among the sustainability dimensions and provides recommendations for decision-makers to promote sustainable practices in the steel industry. Overall, this study underscores the importance of addressing the sustainability challenges faced by energy-intensive industries such as steel production.

Cost and Life Cycle Analysis for Deep CO2 Emissions Reduction for Steel Making: Direct Reduced Iron Technologies

Among heavy industrial sectors worldwide, the steel industry ranks first in carbon dioxide (CO2) emissions. Technologies that produce direct reduced iron (DRI) enable the industry to reduce emissions or even approach net‐zero CO2 emissions for steel production. Herein, comprehensive cradle‐to‐gate (CTG) life cycle analysis (LCA) and techno‐economic analysis (TEA) are used to evaluate the CO2 emissions of three DRI technologies. Compared to the baseline of blast furnace and basic oxygen furnace (BF–BOF) technology for steel making, using natural gas (NG) to produce DRI has the potential to reduce CTG CO2 emissions by 33%. When 83% or 100% renewable H2 is used for DRI production, DRI technologies can potentially reduce CO2 emissions by 57% and 67%, respectively, compared to baseline BF–BOF technology. However, the renewable H2 application for DRI increases the levelized cost of steel (LCOS). When renewable natural gas (RNG) and clean electricity are used for steel production, the CTG CO2 emissions of all the DRI technologies can potentially be reduced by more than 90% compared to the baseline BF–BOF technology, although the LCOS depends largely on the cost of RNG and clean electricity.