Cavaliere Ironmaking and Steelmaking Processes

Greenhouse Emissions, Control, and Reduction
1. Auflage 2016
ISBN: 978-3-319-39529-6
Verlag: Springer Nature Switzerland
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 466 Seiten

Reihe: Chemistry and Material Science (R0)

This book describes improvements in the iron and steel making process in the past few decades. It also presents new and improved solutions to producing high quality products with low greenhouse emissions. In addition, it examines legislative regulations regarding greenhouse emissions all around the world and how to control these dangerous emissions in iron and steel making plants.    

Autoren/Hrsg.

Cavaliere, Pasquale

Inhaltsverzeichnis

1;Preface;6
2;Contents;8
3;Part I: Sintering Plants Operations;11
3.1;Chapter 1: Sinter Plant Operations: Raw Materials;12
3.1.1;1.1 Introduction to the Raw Materials Used in an Integrated Steelworks;12
3.1.1.1;1.1.1 Iron Ores;12
3.1.1.1.1;1.1.1.1 Iron Ore Fines;12
3.1.1.1.2;1.1.1.2 Iron Ore Lump;13
3.1.1.1.3;1.1.1.3 Concentrate;13
3.1.1.1.4;1.1.1.4 Pellet;13
3.1.1.1.5;1.1.1.5 Some Common Iron Ores;13
3.1.1.2;1.1.2 Fuel;15
3.1.1.2.1;1.1.2.1 Coke Breeze;15
3.1.1.2.2;1.1.2.2 Anthracite;16
3.1.1.2.3;1.1.2.3 Biomass (Carbonized Palm Shell);17
3.1.1.3;1.1.3 Fluxes;17
3.1.1.3.1;1.1.3.1 Limestone;17
3.1.1.3.2;1.1.3.2 Dolomite;18
3.1.1.3.3;1.1.3.3 Serpentine or Olivine;18
3.1.1.3.4;1.1.3.4 Silica Sand;19
3.1.1.4;1.1.4 Reverts;19
3.1.1.4.1;1.1.4.1 Dust;20
3.1.1.4.2;1.1.4.2 Scale;20
3.1.1.4.3;1.1.4.3 Sludge and Slurry;21
3.1.1.4.4;1.1.4.4 Slag and Slag Tailing;21
3.1.1.4.5;1.1.4.5 Others;22
3.1.2;1.2 Introduction to Raw Materials Handling;23
3.1.2.1;1.2.1 Unloading and Conveying;23
3.1.2.1.1;1.2.1.1 Unloaders;23
3.1.2.1.1.1;Bucket-Chain CSU;24
3.1.2.1.1.2;Screw Type CSU;25
3.1.2.1.1.3;Grab Type Ship Unloader;25
3.1.2.2;1.2.2 Conveyor;25
3.1.2.2.1;1.2.2.1 Steel Cord Conveyor Belt;26
3.1.2.2.2;1.2.2.2 Canvas Conveyor Belt;26
3.1.2.2.3;1.2.2.3 Aramid Conveyor Belt;27
3.1.2.3;1.2.3 Stock Yard;28
3.1.2.3.1;1.2.3.1 Open Yard;28
3.1.2.3.2;1.2.3.2 Indoor Yards;28
3.1.2.4;1.2.4 Blending Silo and Blending Yard;30
3.1.2.4.1;1.2.4.1 Blending Silos;30
3.1.2.4.2;1.2.4.2 Blending Operations;31
3.1.2.5;1.2.5 Reverts Homogenization Plant;32
3.1.3;References;35
3.2;Chapter 2: Predictions of PCDD/F, SOx, NOx, and Particulates in the Iron Ore Sintering Process of Integrated Steelworks;36
3.2.1;2.1 Introduction;37
3.2.2;2.2 Theory;39
3.2.3;2.3 Results and Discussions;40
3.2.3.1;2.3.1 Model Verification;41
3.2.3.2;2.3.2 New Technologies Based on Fossil Fuels;42
3.2.3.3;2.3.3 New Technologies Based on Biomass and Biogas Operations (Renewable Fuels);42
3.2.4;2.4 Conclusions;46
3.2.5;References;46
3.3;Chapter 3: Dangerous Emissions Control and Reduction in Sinter Plants;48
3.3.1;3.1 Introduction;48
3.3.1.1;3.1.1 Process Description;49
3.3.1.2;3.1.2 Emissions Formation;50
3.3.2;3.2 Experimental-Numerical Approach;51
3.3.3;3.3 Results and Discussion;53
3.3.4;3.4 Conclusions;66
3.3.5;References;66
3.4;Chapter 4: Pollutants Emission and Control for Sintering Flue Gas;68
3.4.1;4.1 Overview;68
3.4.2;4.2 De-dust technologies for Sintering Flue Gas Control;69
3.4.2.1;4.2.1 Mechanical Dust Extractors;70
3.4.2.2;4.2.2 Electrostatic Precipitators;70
3.4.2.3;4.2.3  Bag Filters ;71
3.4.2.4;4.2.4 Electric–Bag Composite Dust Collectors;72
3.4.2.5;4.2.5 Wet-Type Electric Dust Collectors;72
3.4.3;4.3 SO2 Control Technologies in Sintering Flue Gas;73
3.4.3.1;4.3.1 Limestone–Gypsum Wet Method of Desulfurization;74
3.4.3.2;4.3.2 Ammonia–Ammonia Sulfate Desulfurization;74
3.4.4;4.4 Control Technologies for Nitrogen Oxide in Sintering Flue Gas;75
3.4.4.1;4.4.1 Flue Gas Circulation;75
3.4.4.2;4.4.2 Selective Catalytic Reduction Method;75
3.4.4.3;4.4.3 Oxidation Absorption Method;77
3.4.5;4.5 Dioxin Control Technology for Sintering Flue Gases;77
3.4.5.1;4.5.1 Emission Characteristics of Dioxin in the Sintering Process;77
3.4.5.2;4.5.2 Control of Dioxin in the Sintering Process;78
3.4.5.2.1;4.5.2.1 Source Reduction;78
3.4.5.2.2;4.5.2.2 Process Control;78
3.4.5.2.3;4.5.2.3 Terminal Management;80
3.4.6;4.6 Multiple Pollutants Control Technologies for Sintering Fuel Gas;80
3.4.6.1;4.6.1 Actived Carbon Multiple Pollutants Control Technology;81
3.4.6.2;4.6.2 Desulfurization with Actived Carbon Injection;81
3.4.6.2.1;4.6.2.1 MEROS Technology;81
3.4.6.2.2;4.6.2.2 IOCFB Multiple Pollutants Control Technology;82
3.4.7;References;83
3.5;Chapter 5: Sinter Plant Operations: Hazardous Emissions;84
3.5.1;5.1 Introduction;84
3.5.1.1;5.1.1 Size Requirements;85
3.5.1.2;5.1.2 Metallurgical Property Requirements;85
3.5.2;5.2 Brief Background on Iron Ore Sintering;86
3.5.2.1;5.2.1 Outline of Sintering Operations;86
3.5.2.2;5.2.2 Fundamental Reactions of the Sintering Process (Pimenta 2012);88
3.5.2.3;5.2.3 Mineral Transformation During Iron Ore Sintering Process;89
3.5.3;5.3 Hazardous Pollutant Emissions from Sinter Plants;90
3.5.3.1;5.3.1 Dust;90
3.5.3.2;5.3.2 NOx (Mou 1998);91
3.5.3.3;5.3.3 De-NOx;91
3.5.3.4;5.3.4 SOx;92
3.5.3.5;5.3.5 Sulfur Journey in Iron Ore Sintering Process;93
3.5.3.6;5.3.6 Conventional De-SOx Technologies;94
3.5.3.7;5.3.7 In-Process De-SOx Technology;94
3.5.3.8;5.3.8 Dioxins-PCDD/PCDF (Kasai 2002);95
3.5.3.9;5.3.9 Formation Mechanism of Dioxins (Kasai 2002);96
3.5.3.10; Dioxin Formation in Sintering Process;96
3.5.3.11;5.3.10 Countermeasures for Dioxin Reduction;101
3.5.3.11.1;5.3.10.1 Dioxin Reduction by SCR Catalyst;101
3.5.3.11.2;5.3.10.2 Dioxin Removal by Lignite Coke Absorption;102
3.5.4;References;106
4;Part II: Blast Furnace Operations;108
4.1;Chapter 6: Recent Trends in Ironmaking Blast Furnace Technology to Mitigate CO2 Emissions: Top Charging Materials;109
4.1.1;6.1 Introduction;110
4.1.2;6.2 Conventional Top Charging Materials;112
4.1.3;6.3 Shifting the Process Toward Lower CO/CO2;113
4.1.4;6.4 Recently Developed Top Charging Materials;116
4.1.4.1;6.4.1 Active Coke;116
4.1.4.2;6.4.2 In-Plant Fines;118
4.1.5;6.5 Novel Top Charging Materials (Iron Ore-Carbon Composite);120
4.1.5.1;6.5.1 Producing of Iron Ore-Carbon Composites;121
4.1.5.2;6.5.2 Reduction Behavior of Composite Pellets;123
4.1.6;6.6 Alternative Reducing Agents;126
4.1.6.1;6.6.1 Plastic Materials;126
4.1.6.2;6.6.2 Biomass;127
4.1.7;6.7 Summary;128
4.1.8;References;128
4.2;Chapter 7: Dangerous Emissions in Blast Furnace Operations;133
4.2.1;7.1 Introduction;133
4.2.2;7.2 H2S and SO2 Emissions;134
4.2.2.1;7.2.1 Source;134
4.2.2.2;7.2.2 Emission;135
4.2.2.3;7.2.3 Abatement;136
4.2.3;7.3 NOx Emissions;137
4.2.3.1;7.3.1 Source;137
4.2.3.2;7.3.2 Emission;138
4.2.3.3;7.3.3 Abatement;139
4.2.4;7.4 Heavy Metal Emissions;139
4.2.4.1;7.4.1 Source;139
4.2.4.2;7.4.2 Emission;140
4.2.4.3;7.4.3 Abatement;141
4.2.5;7.5 Fluoride Emissions;142
4.2.5.1;7.5.1 Source;142
4.2.5.2;7.5.2 Emission;142
4.2.5.3;7.5.3 Abatement;143
4.2.6;7.6 Conclusions;144
4.2.7;References;144
4.3;Chapter 8: Mathematical Simulation of Blast Furnace Operation;147
4.3.1;8.1 Introduction;147
4.3.2;8.2 Kinetic Model of Reduction;148
4.3.2.1;8.2.1 Simulation of Reduction in the Fixed Bed;148
4.3.2.2;8.2.2 Calculation of Specific Carbon Consumption;150
4.3.3;8.3 Practical Modeling of Results of Reducibility Test;152
4.3.3.1;8.3.1 Example of Calculation of Reduction Run in the Area of Indirect Reduction;152
4.3.3.2;8.3.2 Use of Kinetics Simulation for CDR Diagram Modification;154
4.3.4;8.4 Conclusion;157
4.3.5;References;158
4.4;Chapter 9: CO2 Emission Reduction in Blast Furnaces;159
4.4.1;9.1 Introduction;159
4.4.2;9.2 Blast Furnace Operations;161
4.4.2.1;9.2.1 Blast Furnace Processes;161
4.4.3;9.3 CO2 Emissions;166
4.4.4;9.4 Experimental Procedure;168
4.4.5;9.5 Results and Discussion;170
4.4.6;9.6 Conclusions;176
4.4.7;References;179
4.5;Chapter 10: Recent Trends in Ironmaking Blast Furnace Technology to Mitigate CO2 Emissions: Tuyeres Injection;180
4.5.1;10.1 Introduction;181
4.5.1.1;10.1.1 Iron- and Steelmaking Technologies;182
4.5.1.2;10.1.2 Energy Consumption and CO2 Emissions in Steel Industry;182
4.5.2;10.2 Pulverized Coal Injection into BF;184
4.5.2.1;10.2.1 PCI Technology;185
4.5.2.2;10.2.2 PCI Combustion;187
4.5.2.3;10.2.3 High Rate of PCI;189
4.5.3;10.3 Auxiliary Fuel Injection;190
4.5.3.1;10.3.1 Oil and Natural Gas Injection;190
4.5.3.2;10.3.2 Coke Oven Gas and Converter Gas Injection;192
4.5.3.3;10.3.3 Waste Plastic Injection;195
4.5.3.4;10.3.4 Secondary Material Injection;196
4.5.3.5;10.3.5 Biomass Injection;197
4.5.4;10.4 Summary;199
4.5.5;References;200
4.6;Chapter 11: Low CO2 Emission by Improving CO Utilization Ratio in China’s Blast Furnaces;205
4.6.1;11.1 Introduction;205
4.6.2;11.2 The Upper Adjustment;206
4.6.2.1;11.2.1 Batch Weight;206
4.6.2.2;11.2.2 Charging Mode;208
4.6.2.3;11.2.3 Stock Line;211
4.6.3;11.3 The Lower Adjustment;211
4.6.3.1;11.3.1 Gas Volume;211
4.6.3.2;11.3.2 Gas Temperature;212
4.6.3.3;11.3.3 Gas Humility;215
4.6.4;11.4 Conclusions;216
4.6.5;References;217
5;Part III: Electric Arc Steelmaking;219
5.1;Chapter 12: Dioxin Emission Reduction in Electric Arc Furnaces for Steel Production;220
5.1.1;12.1 Introduction;220
5.1.2;12.2 Electric Arc Furnace Operations;222
5.1.3;12.3 Greenhouse Emission Reduction;223
5.1.4;12.4 Conclusions;227
5.1.5;References;227
5.2;Chapter 13: Emission of High Toxicity Airborne Pollutants from Electric Arc Furnaces During Steel Production;228
5.2.1;13.1 Introduction;228
5.2.2;13.2 EAF Plant Description;229
5.2.3;13.3 Emission Measurements;230
5.2.4;13.4 Discussion;232
5.2.5;13.5 Conclusions;239
5.2.6;References;240
5.3;Chapter 14: Use of Sustainable Inorganic Binders in the Treatment of Bag-House Dust;241
5.3.1;14.1 Introduction;242
5.3.2;14.2 Solidification/Stabilisation (S/S) Treatment of Hazardous Wastes;243
5.3.3;14.3 Effect of EAFD Addition on S/S Products Using PC, Lime, LGMgO, Steel Slag and PFA;245
5.3.4;14.4 Conclusions;247
5.3.5;References;248
5.4;Chapter 15: Dangerous Emissions During Steelmaking in Electric Arc Furnaces;250
5.4.1;15.1 Categories of Dangerous Emissions Generated from the Steelmaking in the Electric Arc Furnaces;250
5.4.1.1;15.1.1 What Are Dangerous Emissions?;251
5.4.2;15.2 Potential Sources That Generate the Dangerous Emissions from the Steelmaking in the Electric Arc Furnaces;254
5.4.2.1;15.2.1 Potential Sources That Generate Carbon Oxides;254
5.4.2.2;15.2.2 Potential Sources That Generate Sulphur Oxides;254
5.4.2.3;15.2.3 Potential Sources That Generate Nitrogen Oxides;254
5.4.2.4;15.2.4 Potential Sources That Generate Volatile Organic Compounds;255
5.4.2.5;15.2.5 Potential Sources That Generate Polychlorinated Dibenzo-p-Dioxins and Polychlorinated Dibenzofurans;255
5.4.2.6;15.2.6 Potential Sources That Generate Particulate Matter;255
5.4.3;15.3 The Generation Mechanisms of Dangerous Emissions from the Steelmaking in the Electric Arc Furnaces;256
5.4.3.1;15.3.1 The Generation Mechanisms of Carbon Oxides;256
5.4.3.2;15.3.2 The Generation Mechanisms of Sulphur Oxides;256
5.4.3.3;15.3.3 The Generation Mechanisms of Nitrogen Oxides;257
5.4.3.4;15.3.4 The Generation Mechanisms of Volatile Organic Compounds;259
5.4.3.5;15.3.5 The Generation Mechanisms of Polychlorinated Dibenzo-p-Dioxins and Polychlorinated Dibenzofurans;259
5.4.3.6;15.3.6 The Generation Mechanisms and Compositions of Particulate Matters;261
5.4.4;15.4 Methods of Minimizing the Dangerous Emissions from the Steelmaking in the Electric Arc Furnaces;263
5.4.5;15.5 Conclusions;265
5.4.6;References;265
5.5;Chapter 16: Electric Arc Furnace;269
5.5.1;16.1 Electric Steelmaking;269
5.5.1.1;16.1.1 Equipment;272
5.5.1.2;16.1.2 Melting Practice;273
5.5.2;16.2 EAF CO2 Emissions;274
5.5.3;16.3 Technologies to Decrease EAF CO2 Emissions;277
5.5.4;16.4 CO2 Emissions and the Future of the Electric Arc Furnace;282
5.5.5;16.5 Conclusions;282
5.5.6;References;283
6;Part IV: Greenhouse Emissions;284
6.1;Chapter 17: Technological Methods to Protect the Environment in the Ukrainian BOF Shops;285
6.1.1;17.1 Introduction;285
6.1.2;17.2 Affection of Harmful Factors of Steelmaking Production on the Biosphere;286
6.1.3;17.3 Technical Solutions for the Atmosphere Protection on the Metallurgical Plants;288
6.1.3.1;17.3.1 Cleaning and Cooling of the BOF Waste Gases;288
6.1.3.2;17.3.2 BOF Pipeline;289
6.1.3.3;17.3.3 Units with Full Post-Combustion of Carbon Monoxide;290
6.1.3.4;17.3.4 Units with Partial Post-Combustion of Carbon Monoxide;292
6.1.3.5;17.3.5 Units Without Carbon Monoxide Post-Combustion;293
6.1.4;17.4 Decrease of Unorganized Emission of Harmful Substances into the Atmosphere on Metallurgical Plants;296
6.1.5;17.5 Conclusions and Recommendations;298
6.2;Chapter 18: State of the Art in Air Pollution Control for Sinter Plants;300
6.2.1;18.1 Introduction;300
6.2.2;18.2 Emissions from the Sintering Process and Primary Methods of Emission Reduction;302
6.2.2.1;18.2.1 The Sintering Process;302
6.2.2.2;18.2.2 Emissions from the Sintering Process;303
6.2.2.3;18.2.3 Primary Measures for Emission Reduction;305
6.2.2.3.1;18.2.3.1 Control of Recycling Material;305
6.2.2.3.2;18.2.3.2 Off-Gas Recirculation;306
6.2.2.3.3;18.2.3.3 Suppression of PCDD/F Formation;307
6.2.3;18.3 Emission Reduction Processes;308
6.2.3.1;18.3.1 Advanced Dry De-dusting of Sintering Off-Gas;308
6.2.3.2;18.3.2 Reduction of SOx Emissions;309
6.2.3.3;18.3.3 Reduction of PCDD/F Emissions;309
6.2.3.4;18.3.4 Reduction of NOx Emissions;310
6.2.3.5;18.3.5 Simultaneous Reduction of SOx and NOx Emissions;311
6.2.3.6;18.3.6 Advanced Wet Emission Reduction Processes;311
6.2.4;18.4 Residues from Dry Off-Gas Cleaning at Sinter Plants;312
6.2.4.1;18.4.1 Residue from De-dusting of Sintering Off-Gas;312
6.2.4.2;18.4.2 Residues from Desulphurization of Sintering Off-Gas;312
6.2.5;18.5 Future Developments;313
6.2.5.1;18.5.1 Reduction of NOx Emissions in Sinter Plants with Catalytic Bags Filters;313
6.2.5.2;18.5.2 Single-Stage Gas Cleaning with a Bag Filter;313
6.2.5.3;18.5.3 Metal Mesh Dust Filter;314
6.2.6;18.6 Conclusions;314
6.2.7;References;314
6.3;Chapter 19: Risk Assessment and Control of Emissions from Ironmaking;319
6.3.1;19.1 Introduction;319
6.3.2;19.2 Pollutant Types and Their Effects;321
6.3.3;19.3 Material Inputs and Outputs of Iron Industrial Processes;322
6.3.3.1;19.3.1 Sintering Process;322
6.3.3.2;19.3.2 Iron Ore Pelletising;324
6.3.3.2.1;19.3.2.1 Iron Ore Pelletising Process;324
6.3.3.2.2;19.3.2.2 Comparison of Sintering and Pelletising;326
6.3.3.3;19.3.3 Cokemaking;327
6.3.3.4;19.3.4 Ironmaking in Blast Furnaces;329
6.3.4;19.4 Emission Abatement Measures;331
6.3.5;19.5 Conclusions;331
6.3.6;References;336
6.4;Chapter 20: CO2 Emission in China’s Iron and Steel Industry;338
6.4.1;20.1 Introduction;338
6.4.2;20.2 Factors Affecting Carbon Emissions in Iron and Steel Industry;339
6.4.2.1;20.2.1 The Production Process;339
6.4.2.2;20.2.2 Energy Structure;340
6.4.2.3;20.2.3 Energy Efficiency;340
6.4.2.4;20.2.4 Production Equipment;340
6.4.2.5;20.2.5 Quality of Raw Material;340
6.4.2.6;20.2.6 Low Carbon Production Technology;341
6.4.3;20.3 Carbon Emissions in Iron and Steel Industry;341
6.4.3.1;20.3.1 Coke Oven Process;342
6.4.3.2;20.3.2 Sintering Process;344
6.4.3.3;20.3.3 Pelletizing Process;344
6.4.3.4;20.3.4 The Blast Furnace Iron-Making Process;345
6.4.3.5;20.3.5 The Converter Steelmaking Process;346
6.4.3.6;20.3.6 The Electric Steelmaking Process;347
6.4.3.7;20.3.7 The Refining Process;348
6.4.3.8;20.3.8 Casting and Rolling Process;349
6.4.4;20.4 CO2 Emissions Reduction Technology;350
6.4.5;References;351
6.5;Chapter 21: Particulate Matter Emission in Iron and Steelmaking Plants;352
6.5.1;21.1 Introduction of Steel Production Process and Particle Emission;352
6.5.2;21.2 Distribution of Particle Emission Sources in Steelworks;354
6.5.2.1;21.2.1 The Sintering Procedure;354
6.5.2.2;21.2.2 The Coking Procedure;355
6.5.2.3;21.2.3 The Iron-Making Procedure;356
6.5.2.4;21.2.4 The Steelmaking Procedure;356
6.5.3;21.3 Intensity of Smoke and Dust Emission in Steelworks;357
6.5.4;21.4 Control Measures to Reduce Particle Emission in Steelworks;360
6.5.4.1;21.4.1 Mechanical Precipitator;363
6.5.4.2;21.4.2 Wet Dust Precipitator;364
6.5.4.3;21.4.3 Electrostatic Precipitator;364
6.5.4.4;21.4.4 Filtration Collector;365
6.5.5;21.5 Development Directions of Particle Emission Control in Steelworks;365
6.5.5.1;21.5.1 Efficient Dust Removal Techniques;366
6.5.5.2;21.5.2 Fine Particle Coagulation Techniques;367
6.5.6;21.6 Suggestions on Smoke Dust Pollution Control in Steelworks;368
6.5.7;References;369
6.6;Chapter 22: Recent Progress and Future Trends of CO2 Breakthrough Iron and Steelmaking Technologies for CO2 Mitigation;370
6.6.1;22.1 Introduction;370
6.6.2;22.2 Key Challenges for CCS Implement in Iron and Steel Industry;371
6.6.3;22.3 CO2 Emission Sources in the Iron and Steel Industry;372
6.6.4;22.4 CO2 Breakthrough Programs;374
6.6.4.1;22.4.1 Ultra-Low Carbon Dioxide Steelmaking (ULCOS) Program;375
6.6.4.2;22.4.2 ULCOS CO2 Breakthrough Technologies;375
6.6.4.2.1;22.4.2.1 ULCOS Blast Furnace Process (SP1 & SP2);377
6.6.4.2.2;22.4.2.2 HIsarna Smelter;378
6.6.4.2.3;22.4.2.3 Direct-Reduced Iron with Natural Gas (ULCORED) (SP3);379
6.6.4.2.4;22.4.2.4 Direct Electrolysis of Iron Ore (ULCOwin & ULCOlysis) (SP5);380
6.6.4.2.5;22.4.2.5 Hydrogen-Based Steelmaking (SP4);381
6.6.4.2.6;22.4.2.6 Biomass-Based Steel Production (SP7);382
6.6.4.2.7;22.4.2.7 ULCOS CCS Project (SP6);383
6.6.5;22.5 Conclusions;384
6.6.6;References;385
6.7;Chapter 23: Manganese Emissions From Steelmaking;386
6.7.1;23.1 Introduction;387
6.7.2;23.2 Theoretical Considerations;389
6.7.2.1;23.2.1 Mechanisms of Dust Formation During Steelmaking;389
6.7.2.2;23.2.2 Size Distribution and Chemistry;394
6.7.2.3;23.2.3 Factors Affecting End Blow Mn Content;397
6.7.3;23.3 Results and Discussion;399
6.7.3.1;23.3.1 Mn Emissions From BOFs;399
6.7.3.2;23.3.2 Manganese Emission From High Mn Steels and Other Pyrometallurgical Processes;402
6.7.3.3;23.3.3 Manganese Consumption;404
6.7.4;23.4 Conclusions;404
6.7.5;References;405
6.8;Chapter 24: Potential of Best Available and Radically New Technologies for Cutting Carbon Dioxide Emissions in Ironmaking;407
6.8.1;24.1 Introduction;408
6.8.2;24.2 Methodology;409
6.8.3;24.3 Technologies and Scenarios;410
6.8.3.1;24.3.1 Best Available Energy-Saving Technologies;410
6.8.3.2;24.3.2 The Breakthrough Technologies;412
6.8.3.3;24.3.3 Scenarios;415
6.8.4;24.4 Results and Discussion;416
6.8.5;24.5 Conclusions;420
6.8.6;References;420
6.9;Chapter 25: Greenhouse Gas Emissions and Energy Consumption of Ironmaking Processes;423
6.9.1;25.1 Introduction;423
6.9.2;25.2 Blast Furnace and Needs for Alternate Ironmaking Processes;424
6.9.3;25.3 Major Alternate Ironmaking Processes;426
6.9.3.1;25.3.1 Direct Reduction;426
6.9.3.2;25.3.2 Smelting Reduction;427
6.9.4;25.4 Major Novel Technologies Under Development;429
6.9.4.1;25.4.1 Flash Ironmaking Technology;429
6.9.4.1.1;25.4.1.1 Process Description;429
6.9.4.1.2;25.4.1.2 Reduction Kinetics;431
6.9.4.1.3;25.4.1.3 Slag Chemistry;435
6.9.4.1.4;25.4.1.4 Economic and Environmental Aspects;436
6.9.4.2;25.4.2 Electrolytic Ironmaking;436
6.9.5;25.5 Methods for Calculating Energy Requirements: Need for Standardization;438
6.9.5.1;25.5.1 Introduction;438
6.9.5.2;25.5.2 Energy Requirement in Ironmaking Processes;439
6.9.5.2.1;25.5.2.1 General Energy Balance and Total Energy Requirement;439
6.9.5.2.2;25.5.2.2 Definitions of Chemical Energy Terms;441
6.9.5.2.2.1;Basis of the Simplified Demonstration;441
6.9.5.2.3;25.5.2.3 Chemical Reactions;441
6.9.5.2.3.1;Approach 1: Energy Requirement for Reduction Reaction Based on Oxide Decomposition;442
6.9.5.2.3.2;Approach 2: Energy Requirement Based on Oxide Reaction with Reductant;442
6.9.5.3;25.5.3 Results;443
6.9.5.3.1;25.5.3.1 Material and Energy Flows: System Boundary;443
6.9.5.3.2;25.5.3.2 Energy Balances for Ironmaking Processes;443
6.9.5.4;25.5.4 Discussion;447
6.9.6;25.6 Conclusions;448
6.9.7;References;449
7;Index;452