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Article history: As an energy intensive industry, China’s iron and steel industry is faced with the challenges of energy
Received 27 February 2015 saving and carbon emission reduction. The oxygen blast furnace with top gas recycling (TGR-OBF), as a
Received in revised form 18 June 2015 new iron-making process, can significantly reduce CO2 emission. To obtain parameters on the material
Accepted 9 July 2015
and energy flows of this process, a TGR-OBF model was established, which comprises the oxygen blast
Available online xxx
furnace, the top gas removal process and the preheating units. The energy consumption and carbon emis-
sion of the integrated steel mill (ISM) with the TGR-OBF was analyzed based on the material and energy
Keywords:
flows. The analysis concluded that TGR-OBF significantly decreased the generation and consumption of
Oxygen blast furnace
Mathematical model
metallurgy gas. Due to the consumption of large amount of oxygen and the removal of CO2 , the ISMs with
Energy consumption the TGR-OBF purchased 2.8 times more electricity than the conventional ISM, while the energy consump-
Carbon emission tion of the ISM with the TGR-OBF was reduced to 14.4 GJ per ton crude steel, thanks to the reduction of
Integrated steel mill coking coal consumption. Compared with the conventional ISM, the direct CO2 emission from the ISM
with the TGR-OBF was reduced by 26.2%, and it could be reduced by 56.5% when CO2 capture and storage
realized. If the net CO2 emission from the ISM with the TGR-OBF is calculated based on the world average
CO2 emission factors, it would be 1.75 t/t crude steel (without CO2 capture and storage) and 1.17 t/t crude
steel (with CO2 capture and storage).
© 2015 Elsevier B.V. All rights reserved.
1. Introduction During the 20th century, the oxygen blast furnace with top
gas recycling (TGR-OBF) was proposed and developed to raise
The reduction of carbon consumption and carbon dioxide (CO2 ) productivity and reduce coke consumption, such as Lu and Kumar
emission has become a major issue for the mitigation of climate (1984), Fink, (1996), FOBF (Qin et al., 1987) and NKK (Ohno et al.,
change. The energy-intensive iron and steel industry has con- 1992), etc. TGR-OBF can significantly reduce CO2 emission and
tributed to approximately 6.7% of the total CO2 emission across the lower the cost for CO2 capture by top gas recycling after CO2
world according to the International Energy Agency (Steel, in press). removal (Ho et al., 2013). In 2004, 15 European countries initi-
The blast furnace is the main process of the iron and steel industry, ated and implemented the “Ultra-low CO2 Steelmaking” (ULCOS)
which emits over 70% of the CO2 (Xu, 2010). Since 1950s, in-depth plan, focusing on the TGR-OBF process. Researchers built an 8 m3
researches have been conducted around the world to improve experimental oxygen blast furnace (OBF), which reduced fuel con-
the energy efficiency of conventional blast furnaces (BF). After six sumption by 140 kg per ton hot metal and decreased the CO2
decades’ effort, the carbon consumption of conventional BFs has emission by 76% (Danloy et al., 2009).
been reduced by over 50% (Van der Stel et al., 2013). However, little Many researchers investigated the influence of the TGR-OBF on
progress has been made on reducing CO2 emission through modifi- the integrated steel mill (ISM) using the mathematical model. Yin
cation of conventional BF processes. So it is an urgent need for steel et al. (2003) investigated the relation between the blasting parame-
companies to develop new technologies to lower the CO2 emission ters and the output gas quantity based on mass and energy balance.
of the ironmaking process. They demonstrated that the OBF and combined cycle will be an effi-
cient ironmaking and power generation process with higher energy
efficiency and less pollution. Nogami et al. (2006) performed the
energy and material balance analyses of ironmaking systems, and
∗ Corresponding author. Tel.: +86 10 62334971; fax: +86 10 62334971. found that the CO2 emission from the TGR-OBF system becomes
E-mail address: zyjiang@ustb.edu.cn (Z. Jiang). smaller than the standard system after the scrubbed CO2 is stored.
http://dx.doi.org/10.1016/j.resconrec.2015.07.008
0921-3449/© 2015 Elsevier B.V. All rights reserved.
Please cite this article in press as: Jin, P., et al., The energy consumption and carbon emission of the integrated steel mill with oxygen
blast furnace. Resour Conserv Recy (2015), http://dx.doi.org/10.1016/j.resconrec.2015.07.008
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steelmaking and rolling processes. Metallurgy gases comprise of = hgs a Tg − Ts + (−Ri Hi ) (3)
∂z
coke oven gas (COG), blast furnace gas (BFG) and Linze–Donawitz i=1
Please cite this article in press as: Jin, P., et al., The energy consumption and carbon emission of the integrated steel mill with oxygen
blast furnace. Resour Conserv Recy (2015), http://dx.doi.org/10.1016/j.resconrec.2015.07.008
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Please cite this article in press as: Jin, P., et al., The energy consumption and carbon emission of the integrated steel mill with oxygen
blast furnace. Resour Conserv Recy (2015), http://dx.doi.org/10.1016/j.resconrec.2015.07.008
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Fig. 3. The flow rate (a), temperature (b), gas composition (c) and fractional reduction (d) as functions of the dimensionless distance from the tuyere level.
etc. The comprehensive energy consumption is calculated on the When the volume of the oxygen blast is 239 N m3 (xO2 = 90%,
basis of energy balance: xN2 = 10%) and the recycle gas through two rows of tuyeres is
300 N m3 , to produce one ton of hot metal, 190 kg coke and 170 kg
m
n
E= eiin × pi − eiout × pi (8) injection coal are needed, and 74 N m3 BFG can be outputted to
the other users. The calorific value of the BFG from the TGR-OBF is
i=1 i=1
6034 kJ/N m3 , which is approximately two times that of the con-
2.3.2. The CO2 emission ventional BF.
The net CO2 emission comprises the direct and the indirect Fig. 3 presents the flow rate (a), the temperature (b), the gas
CO2 emission as well as the CO2 credit according to the GHG composition (c) and the fractional reduction (d) as functions of the
(greenhouse gas) protocol (World Resources Institute and World dimensionless distance from the main tuyere level. At the lower
Business Council for Sustainable Development, 2013). The direct tuyere level, the gas flow of the TGR-OBF is much less than that
CO2 emission of the ISM is from fossil fuel combustion, metallurgy of the conventional BF. Although the recycled gas injected through
gas combustion and decomposing of carbonate, and can be calcu- the stack tuyeres effectively supplements the ascending gas, the
lated on the basis of carbon balance. The indirect CO2 emission gas flow rate at the upper zone of the OBF is only 67% of that of the
is from the electricity and steam consumed in the ISM. The CO2 conventional BF. The lowered gas flow rate results in lower temper-
credit is calculated based on the outputs of electricity and steam ature in the OBF, which helps reduce gasification of the coke. Due
from the ISM. The net and direct CO2 emissions are calculated as to the oxygen blast and the gas recycling, the CO concentration in
follows: the OBF is higher than that of the conventional BF, which facili-
tates the indirect reduction of iron oxide. The fractional reduction
CE = CEd + CEi − CEc (9) of iron ore (fs ) is the ratio of the oxygen actually removed from the
iron oxide against all the removable oxygen in it. Zero fs means the
Cin − Cp − Cbyp
CEd = (10) iron is fully oxidized as hematite and unity fs means the iron is fully
12 × 44 reduced. The dimensionless height for full reduction in the OBF is
higher than that of the conventional BF. It means that the reduction
3. Results and discussion
rate of iron oxide in the OBF is faster than that in the conventional
3.1. The study on the TGR-OBF process BF. The low temperature and high reductive environment in the
OBF is favorable to lower the coke gasification and raise the reac-
The process parameters of TGR-OBF calculated by the mathe- tion rate of iron oxide, and facilitate the process of iron ore heating,
matical model were presented in Fig. S1 (Supporting information). reduction and melting.
Please cite this article in press as: Jin, P., et al., The energy consumption and carbon emission of the integrated steel mill with oxygen
blast furnace. Resour Conserv Recy (2015), http://dx.doi.org/10.1016/j.resconrec.2015.07.008
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Fig. 4. The material flows of conventional ISM and ISM with TGR-OBF.
3.2. Analysis of the material and energy flows and ironmaking processes, which greatly influences the balance of
metallurgy gases. Fig. 6(a) presents the metallurgy gas balances
The material and energy flows of the ISM were developed on of the conventional ISM and the ISM with the TGR-OBF. The TGR-
the basis of the operation parameters. The effects of the TGR-OBF OBF reduces the generation of metallurgy gas by 53.4% and cuts
on the material and energy flows were studied based on the data the consumption of metallurgy gas by 26.2% for the ISM. In the
from the mathematical model. Fig. 4 presents the comparison first half of 2014, the emission rates of BFG and COG of China’s key
between the material flows of the conventional ISM and that of the steel enterprises are 2.32% and 0.72% respectively (Wang, 2014).
ISM with the TGR-OBF. Compared with the conventional ISM, the Therefore, while meeting the need of gas balance, the TGR-OBF can
coal input of the ISM with the TGR-OBF is reduced by 26.1% due to realize zero emission of metallurgy gas.
the decrease of coke consumption. The oxygen consumption of the
ISM with the TGR-OBF is 2.7 times higher than that of the conven-
3.3.2. Electricity
tional ISM. In the ISM with the TGR-OBF, most of the blast furnace
Fig. 6(b) presents the electricity balance of the conventional ISM
gas (BFG) is recycled as reductant, and only a small amount of the
and the ISM with the TGR-OBF. The CO2 removal at the VPSA unit
BFG is output as by-product. Approximately 295.6 m3 pure CO2 is
will raise the electricity demand in the ironmaking process by 89%.
captured for every ton of crude steel from the TGR-OBF, which can
The electricity consumption of the oxygen plant increases by 1.7
be used to produce methanol or be stored underground.
times with increasing demand for oxygen from the TGR-OBF. In
Fig. 5 presents the comparison between the energy flows of the
general, the electricity demand of the ISM with the TGR-OBF is
conventional ISM and that of the ISM with the TGR-OBF. As the met-
50.9% higher than that of the conventional operation. The electric-
allurgy gas generated from the coking and iron-making processes
ity output of the energy system decreases from 265.6 kW h/t steel
is reduced in the ISM with the TGR-OBF, the outputs of electricity
to 2.5 kW h/t steel with less metallurgy gas output into the power
and steam of the energy system are reduced by 88.2% and 10.7%
plant. Compared with the conventional ISM, the electricity pur-
respectively. Compared with the conventional ISM, the electricity
chased for the ISM with the TGR-OBF increases from 185.7 kW h/t
purchased for the ISM with the TGR-OBF is significantly increased
steel to 698.5 kW h/t steel.
due to the increase of electricity consumption of the ironmaking
process and the oxygen plant.
3.3.3. Energy consumption
Fig. 6(c) presents the energy balances of the conventional ISM
3.3. The energy consumption and carbon emission and the ISM with the TGR-OBF. Although the purchased electricity
of the ISM with the TGR-OBF increases from 0.66 GJ to 2.52 GJ for
3.3.1. Metallurgy gas one ton of crude steel, the energy input decreases from 17.89 GJ/t
The oxygen blast and top gas recycling can significantly reduce to 14.67 GJ/t due to the sharp decrease of coking coal consump-
the generation and consumption of metallurgy gas in the coking tion. Compared with the conventional ISM, the comprehensive
Please cite this article in press as: Jin, P., et al., The energy consumption and carbon emission of the integrated steel mill with oxygen
blast furnace. Resour Conserv Recy (2015), http://dx.doi.org/10.1016/j.resconrec.2015.07.008
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Fig. 5. The energy flows of conventional ISM and ISM with TGR-OBF.
energy consumption of the ISM with the TGR-OBF is reduced from which realized a reduction of 37.5% in direct CO2 emissions by
17.49 GJ/t to 14.40 GJ/t, saving energy by 17.7%. TGR-OBF (Helle et al., 2010a). The indirect CO2 emission and credit
are affected by the CO2 emission factors of the steam and the
3.3.4. CO2 emission electricity. As for the CO2 emission factors of the electricity, the
The CO2 emissions of the conventional ISM and the ISM with the factors of North China Grid ( = 1.0302) and the world average
TGR-OBF are listed in Table 1, in which Case 0 represents the con- ( = 0.504) are referred to respectively (Worldsteel Association,
ventional ISM, Case 1-1 represents the ISM with the TGR-OBF, Case 2013). The indirect emission of the ISM with the TGR-OBF is 3.8
1–2 represents the ISM with the TGR-OBF considering CO2 capture times that of the conventional ISM, due to its large amount of elec-
and storage. Compared with the conventional ISM, the direct CO2 tricity consumption. The net CO2 emission rate of the ISM with the
emission of the ISM with the TGR-OBF is reduced by 26.2%, and it TGR-OBF is 2.12 t/t steel ( = 1.0302) and 1.54 t/t steel ( = 0.504).
could be further reduced by 56.5% were storage of the captured CO2 When the captured CO2 is stored, the net CO2 emission rate of
realized. The result has the same trend with the previous research the ISM with the TGR-OBF would be 1.75 t/t steel ( = 1.0302)
Please cite this article in press as: Jin, P., et al., The energy consumption and carbon emission of the integrated steel mill with oxygen
blast furnace. Resour Conserv Recy (2015), http://dx.doi.org/10.1016/j.resconrec.2015.07.008
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Table 1
The CO2 emissions for conventional ISM and ISM with TGR-OBF.
4. Conclusion
Acknowledgements
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Please cite this article in press as: Jin, P., et al., The energy consumption and carbon emission of the integrated steel mill with oxygen
blast furnace. Resour Conserv Recy (2015), http://dx.doi.org/10.1016/j.resconrec.2015.07.008