Advances in Pyrometallurgy: Developing Low Carbon Pathways: Keynote
Sponsored by: TMS Extraction and Processing Division, TMS: Pyrometallurgy Committee
Program Organizers: Camille Fleuriault, Eramet Norway; Joalet Steenkamp, XPS Glencore; Dean Gregurek, RHI Magnesita; Jesse White, Kanthal AB; Quinn Reynolds, Mintek; Phillip Mackey, P.J. Mackey Technology, Inc.; Susanna Hockaday, Curtin University, WASM
Monday 2:00 PM
March 20, 2023
Room: 29B
Location: SDCC
Session Chair: Phillip Mackey, P.J. Mackey Technologies Inc.; Joalet Steenkamp, XPS Glencore
2:00 PM Introductory Comments
2:10 PM Keynote
The HYBRIT Demonstration of a Fossil-free Iron- and Steelmaking Value Chain: Amanda Ohman1; 1Hybrit Development AB
The HYBRIT (HYdrogen BReakthrough Ironmaking Technology) Demonstration project aims to revolutionize and decarbonize the European iron and steel industry, by replacing traditional blast furnace technology with direct reduction based on fossil-free hydrogen. Currently, hot metal production in coal-fired blast furnaces, followed by steelmaking using oxygen converters, represents 95% of the global steel production from iron ore. However even a state-of-the-art blast furnace process results in generation of about 1.6 tons of CO2 per ton of crude steel (global average approximately 2.2 tons of CO2 per ton crude steel). The HYBRIT Demonstration project plans to realise the breakthrough of fossil-free steel production by developing a new value chain based on fossil-free hydrogen, resulting in an annual production of 1.2 Mt crude steel in Sweden. This entails a significant degree of innovation at both technological and logistical levels: with regards to plant design, operating approach, construction, quality, reliability, availability, and maintenance.
2:35 PM Keynote
Decarbonisation of High-temperature Processes in the Australian Context: Graham Nathan1; 1University of Adelaide
The pathways being developed by the Heavy Industry Low-carbon Cooperative Research Centre to de-risk the transition to net-zero CO2 emissions for the iron/steel, cement/lime and alumina/aluminium industries, will be presented. Specific technology platforms are being evaluated and developed to support the introduction of selected low-carbon products for new markets for each of these industries, both as new primary products and as new associated products via the circular economy and CO2 capture and re-use through regional hubs. The presentation will give an overview of the new opportunities emerging from the synergy between these industries, together with selected examples of specific technology developments in these industries.
3:00 PM Keynote
The Pathway to CO2-Reduction in the Refractory Industry: Thomas Drnek1; 1RHI Magnesita GmbH
The whole society is forced to reduce the CO2-Emissions to tackle the climate-change. The industry is one of the largest emitters of CO2, therefore also the refractory industry hast to act. The article gives an overview about the CO2-Emissions of the sector and the company RHI Magnesita in detail. The journey starts, with exact CO2-data collection and calculation and ends with the development and implementation of measurements to reduce the footprint of the sector.The CO2-data collection is done with an SAP-Tool and will be introduced in detail. The different measures are recycling, green-electricity, energy-efficiency and fuel switch will be analyzed as well. That is the starting point of the CO2-journey towards net-zero or zero-emissions. On the upcoming measures an outlook is enclosed.
3:25 PM Break
3:45 PM Keynote
Electrification to Decrease the Carbon Footprint of Iron and Steelmaking: Petrus Pistorius1; 1Carnegie Mellon University
Large-scale electrification is seen as a pathway to carbon neutrality; in one estimate, the goal to “electrify everything” would imply tripling the electricity consumption of the United States (currently approximately 4,000 TWh per year). In the case of ironmaking – whether by using green hydrogen or oxide electrolysis – the electricity requirement would be approximately 4 MWh per tonne of iron. Recycling scrap steel requires approximately one order of magnitude less electricity, around 400 kWh per tonne of steel. In this presentation, the fundamental basis of these figures will be presented, to support future choices for steel producers.
4:10 PM Keynote
Roadmap for Reduction of Fossil CO2 Emissions in Eramet Mn Alloys: Benjamin Ravary1; Pierre Gueudet2; 1Eramet Norway AS; 2Eramet SA
Eramet produces materials useful for a low emission society, in a resource effective way and for Mn alloys, with a lower climate footprint than the industry average. Such high standards give increased competitivity through being greener and eventually improving the profitability. Eramet has set goals for reduction of emission of greenhouse gases from their production in the framework of the Science Based Target. In this paper we present the roadmap to reach the target in Eramet Mn alloys activity. The roadmap is made a reality through actions and investments. The reduction initiatives can be divided into four main areas, roughly reflecting time phases, from short term (2025) to long term (2050 and beyond): improvement of existing processes in resource and energy efficiency, increase or introduction of biomass-based reductants to replace fossil carbonaceous materials, carbon capture and usage (CCU) or storage (CCS), and development of innovative technologies.
4:35 PM Keynote
Towards Net Zero PyroMetallurgical Processing with the ISASMELT™ and ISACYCLE™: Stuart Nicol1; Stanko Nikolic1; Ben Hogg1; 1Glencore Technology
With the growing global focus on reducing environmental and social impacts, smelters and recyclers are moving rapidly to decarbonise their processes. Both existing and new solutions are required for all three scopes of emission. Scope 1 emissions can be addressed directly via aspects of the smelting process. Scope 2 emissions can be decreased by minimising feed pre-treatment, furnace maintenance and consumables. For scope 3 emissions, lower metal prices improve the feasibility of renewable energy. Ways in which the ISASMELT™ technology can be installed or modified for a low or zero carbon smelting solution will be explored. Options for the ISASMELT™ plant will be identified, including efficient and simple feed preparation, fluxing optimisation, oxygen enrichment, advanced refractory designs, alternative fuels (municipal wastes or hydrogen), autogenous smelting, and molten material handling. In addition, the impacts of high reliability equipment, steady furnace control, and long campaigns in a compact furnace will be explored.
5:00 PM Panel Discussion