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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



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 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 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 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.



Biological Material: all plant and animal matters

Short rotation forestry Forest residues Wood waste Crop residues Agricultural crops



Bio Carbon Research Focus in the Steel Sub-sector

Carbon in the charge

BurnersCarbon Injection (Slag foaming)

Photosynthesis

Biomass

Photosynthesis

Biomass

CO2CO2 CO2



Biofuel Composition

Elemental Composition is Critical to Iron and Steelmaking Products



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



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.




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




–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



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



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




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.



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



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



•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?

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