Status of the Development of Flash Ironmaking Technology

Sohn, Hong Yong; Mohassab, Yousef; Elzohiery, Mohamed; Fan, De-Qiu; Abdelghany, Amr

doi:10.1007/978-3-319-51091-0_2

Cited by 9 publications

(13 citation statements)

References 11 publications

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“…It receives support from AISI and US' DOE. The project operates a mini-pilot reactor, capable of 1550-1700 °C temperatures with a concentrate feeding rate of 2-5 kg/h and there are plans to scale it up [64].…”

Section: Low-carbon Steelmaking Solutions In the Usmentioning

confidence: 99%

“…It receives support from AISI and US' DOE. The project operates a mini-pilot reactor, capable of 1550-1700 • C temperatures with a concentrate feeding rate of 2-5 kg/h and there are plans to scale it up [64]. The second process originates from the University of Utah (Professor Hong Yong Sohn) and is somewhat similar to the SUSTEEL project already mentioned, except that the reactor concept here is a flash smelter, thus operating at very high temperatures in flight on particulate hematite, cf.…”

Section: Low-carbon Steelmaking Solutions In Japanmentioning

confidence: 99%

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Society, Materials, and the Environment: The Case of Steel

Birat¹

2020

Metals

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This paper reviews the relationship between the production of steel and the environment as it stands today. It deals with raw material issues (availability, scarcity), energy resources, and generation of by-products, i.e., the circular economy, the anthropogenic iron mine, and the energy transition. The paper also deals with emissions to air (dust, Particulate Matter, heavy metals, Persistant Organics Pollutants), water, and soil, i.e., with toxicity, ecotoxicity, epidemiology, and health issues, but also greenhouse gas emissions, i.e., climate change. The loss of biodiversity is also mentioned. All these topics are analyzed with historical hindsight and the present understanding of their physics and chemistry is discussed, stressing areas where knowledge is still lacking. In the face of all these issues, technological solutions were sought to alleviate their effects: many areas are presently satisfactorily handled (the circular economy—a historical’ practice in the case of steel, energy conservation, air/water/soil emissions) and in line with present environmental regulations; on the other hand, there are important hanging issues, such as the generation of mine tailings (and tailings dam failures), the emissions of greenhouse gases (the steel industry plans to become carbon-neutral by 2050, at least in the EU), and the emission of fine PM, which WHO correlates with premature deaths. Moreover, present regulatory levels of emissions will necessarily become much stricter.

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Section: Low-carbon Steelmaking Solutions In the Usmentioning

confidence: 99%

Section: Low-carbon Steelmaking Solutions In Japanmentioning

confidence: 99%

Society, Materials, and the Environment: The Case of Steel

Birat¹

2020

Metals

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“…An industrial flash reactor would be quite different from the laminar-flow reactor used for the rate measurement, including the fact that an oxy-fuel burner would be the main source of heat and the amount of excess reducing gases would be much lower (20-100%). Therefore, a laboratory flash reactor was installed at the University of Utah [29,31,48] to test the Flash Ironmaking Technology (FIT). The experiments performed in this reactor aimed to establish the optimum conditions for the design of the industrial flash reactor.…”

Section: Laboratory Flash Reactormentioning

confidence: 99%

“…are the partial pressures of H 2 and H 2 O at equilibrium with wüstite and Fe. Effect of excess driving force (EDF) on reduction degree (%) when feeding through the two side-ports with the H-O-H configuration [31].…”

Section: Experiments With Hydrogenmentioning

confidence: 99%

“…Given the limited potential for increased efficiency associated with current technologies and considering the other driving forces presented above, a Flash Ironmaking Technology (FIT) has recently been developed at the University of Utah as an innovative alternate ironmaking process [14,[20][21][22][26][27][28][29][30][31]. This technology reduces iron ore concentrate in a flash reactor with a suitable reductant gas such as hydrogen or natural gas, and possibly bio/coal gas or a combination thereof.…”

Section: Introductionmentioning

confidence: 99%

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Energy Consumption and CO2 Emissions in Ironmaking and Development of a Novel Flash Technology

Sohn

2019

Metals

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The issues of energy consumption and CO2 emissions of major ironmaking processes, including several new technologies, are assessed. These two issues are interconnected in that the production and use of fuels to generate energy add to the total amount of CO2 emissions and the efforts to sequester or convert CO2 require energy. The amounts of emissions and energy consumption in alternate ironmaking processes are compared with those for the blast furnace, currently the dominant ironmaking process. Although more than 90% of iron production is currently through the blast furnace, intense efforts are devoted to developing alternative technologies. Recent developments in alternate ironmaking processes, which are largely driven by the needs to decrease CO2 emissions and energy consumption, are discussed in this article. This discussion will include the description of the recently developed novel flash ironmaking technology. This technology bypasses the cokemaking and pelletization/sintering steps, which are pollution prone and energy intensive, by using iron ore concentrate. This transformational technology renders large energy saving and decreased CO2 emissions compared with the blast furnace process. Economic analysis indicated that this new technology, when operated using natural gas, would be economically feasible. As a related topic, we will also discuss different methods for computing process energy and total energy requirements in ironmaking.

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Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

Abdelghany

Fan

Elzohiery

et al. 2019

steel research int.

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A large‐scale bench reactor (LSBR) is operated at the University of Utah to develop a novel flash ironmaking process. The reactor vessel is a refractory‐lined furnace with 0.8 m in diameter and 2.1 m in length, with a capacity of processing 1–7 kg h−1 of magnetite concentrate. Natural gas is partially oxidized with oxygen in a uniquely designed burner, producing a short flame that provides heat (1423–1873 K) and a reducing gas mixture (hydrogen and carbon monoxide). The reducing gas reacts with magnetite (Fe3O4) concentrate particles to produce metallic iron. A computational fluid dynamics (CFD) model is developed to simulate the LSBR runs, in which the kinetics of magnetite concentrate reduction, separately determined in a drop‐tube reactor, is incorporated. The reduction degrees and composition of the off‐gas obtained from the CFD model show reasonable agreements with the experimental results.

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Status of the Development of Flash Ironmaking Technology

Cited by 9 publications

References 11 publications

Society, Materials, and the Environment: The Case of Steel

Society, Materials, and the Environment: The Case of Steel

Energy Consumption and CO2 Emissions in Ironmaking and Development of a Novel Flash Technology

Experimental Investigation and Computational Fluid Dynamics Simulation of a Novel Flash Ironmaking Process Based on Partial Combustion of Natural Gas in a Reactor

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