Low-emission Integrated Steelmaking Process (ISP)

MINERALS DOWN UNDER NATIONAL RESEARCH FLAGSHIP

Sharif JahanshahiTheme Leader – Sustainable Metal Production

Overview of SMP Theme |

Presentation by Sharif Jahanshahi, PhD

Dr. Sharif Jahanshahi has over 30 years experience in R&D across; high temperature processing of ferrous and base metals, thermodynamics and kinetics of high temperature systems, melt chemistry, process modelling, simulation and development

Currently consulting for leading global players in the metallurgical industry through Meta-Logical Solutions Pty Ltd.

Website: http://www.metalogical.solutionsEmail: sharif@metalogical.solutions

Driver 1: GHG Reduction

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500

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Glo

bal G

HG e

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t CO

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y)

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Aust

ralia

n G

HG e

mis

sion

s (M

t CO

2e /

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Global Australia

~ 2.2 billion tonnes of CO2-e

per annum!

Driver 2: Salinity

Problem2M ha of farmland degraded by salinity

(6M ha by 2040)SolutionPartial revegetation with Mallee treesElectricity and charcoal from the

biomassChallengeFull rehabilitation results in 25Mt/a

biomass – charcoal market?

• Special planting of trees in the Western Australian wheat belt could restore soil and land quality

• Plantation of over 12,000 ha in WA has taken place recent years

Metallurgical application of the charcoal in smelting (eg ironmaking) could be a GHG neutral alternative to coal

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ObjectivesThe low-emission Integrated Steelmaking Process (ISP) aims to:

– Substantially (>50%) reduce CO2 emissions by the steel industry

– Address salinity affected regions– Recover high grade waste heat from molten slags– Reduce to zero the use of fresh water in the cooling of molten slags – Enable waste (iron making slag) to be converted into a useful product (cement).

The concept is based on industrial ecology and if fully implemented will also address other environmental issues e.g. restoring soil and land quality in salinity affected regions and production of bio-based products from renewable sources.

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What is ISP

• ISP has been under development by CSIRO since 2006

• ISP has 3 key components:

a) Slow Autogenous Pyrolysis (SAP) for conversion of biomass to biochar and other valuable by-products (bio-oil, bio-energy)

b) Use of Bio-Char (UBC) as fuel and reductant in iron and steel making processes

c) Dry Slag Granulation (DSG) to recover high grade waste heat and convert slag into Portland cement substitute.

• ISP development has been supported since 2006 by BlueScope and OneSteel

Our Vision for Future of Australian Industries

Biomass Energy Iron & steel Energy CementSalinity control

Dry granulation

Cement makingAgriculture

Bio-fuel processing Smelting

TREE PLANTING BIOCHAR HOT SLAG SLAGBIOMASS

Look at the CSIRO, which has been working with BlueScope and OneSteel on a low-carbon breakthrough program for five years. CSIRO's integrated steel-making process is one of the few known technologies which can deliver a substantial cut in carbon emissions at minimal cost to smelters. The estimated value of that knowledge over the next twenty years is $42 billion, assuming just 10 per cent global market penetration. That is the potential we can unlock in this country.

Senator Kim Carr, Former Minister for Innovation, Industry Science & Research

BIO-OIL

Appendix

Overview of SMP Theme |

Fuel Reductant

Energy

Converter

CO2

+

H2O

Plants, Algae farm

Solar Energy

CO H2

CO2CO2 H2O

Power plant

Metal & Building Products

Biomass

(Charcoal)

Ore, fluxes

Concept - Closing the Carbon Loop

By-products

electricity Bio-oil

• ISP has been under development by CSIRO since 2006 in collaboration with the Australian steel industry.

• The objectives of ISP are to:− Introduce deep cuts (>50%) in net CO2

emissions by the steel industry− Recover high grade waste heat from molten

slags− Reduce fresh water usage in the cooling of

molten slags − Convert 100s million tonnes/year of waste

(iron making slag) into a high value product (“green cement”).

Low-emission Integrated Steelmaking Process (ISP)

ISP has 3 components: a) Slow Autogenous Pyrolysis (SAP)

for conversion of biomass to biochar and other valuable by-products (bio-oil, bio-energy)

b) Use of Designer Bio-Char (DBC) as fuel and reductant in iron and steel making processes

c) Dry Slag Granulation (DSG) to recover high grade waste heat and convert slag into Portland cement substitute.

Concept Developmen

t

Techno-economic and LCA

Proof of Concept - Large Scale Piloting

Demonstration via Full Scale Plant Trials

2006

2012

2016

2009