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Negative Emission from Electric Arc Furnace using a Combination of Carbon capture and Bio-coalKapothanillath, Abhijith Namboodiri January 2023 (has links)
Steel is one of the most essential metals in the world, and it plays a vital role in various industries. The growing demand for steel has resulted in increased CO2 emissions, with the steel industry contributing to approximately 7% of global emissions of carbon dioxide. Among the different production methods, the electric arc furnace (EAF) has emerged as a promising option, and its market share is expected to double in the future. While the EAF exhibits high efficiency and a reduced carbon footprint in comparison to alternative production routes, there is still considerable room for improvement. In the EAF, a significant amount of input energy, ranging from 15% to 30%, is wasted through off-gas, along with a substantial amount of CO2. To better understand the current state and ongoing research in off-gas handling, a literature review and a preliminary analysis were conducted which revealed that the waste heat from the off-gas can be effectively recovered using an evaporative cooling system, yielding approximately 105 kg of steam per ton of liquid steel. This emphasizes the importance of waste heat recovery in conjunction with CO2 capture. Calcium looping stands out as a promising carbon capture technology among the available options, primarily because of its lower environmental impacts and energy penalty. Furthermore, with its operation at elevated temperatures and dependence on limestone, calcium looping presents a potential solution to reduce the emissions from steel industry. Therefore, this study focuses on the analysis of a waste heat recovery system integrated with calcium looping technology, aiming to capture CO2 and utilize waste heat from the EAF off-gas. Additionally, the potential of coal substitution with bio-coal in the EAF for achieving negative emissions is also investigated. Through a steady state analysis and by employing semi-empirical mass and energy balance equations, it was determined that capturing 90% of the CO2 emissions from a 145-ton EAF requires 12 MW of heat and 16 kg of fresh limestone per ton of liquid steel. Although the average off-gas temperature is high, it cannot be considered as a reliable heat source. Therefore, the heat demand is met by burning biomass inside the calciner. Despite the increased heat demand, the waste heat recovery system integrated with calcium looping has the potential to generate approximately 11 MW of electricity using a supercritical steam cycle. This significant output can be attributed to the elevated temperature of the off-gas and the exothermic carbonation process. The economic analysis reveals that the levelized cost for capturing and storing CO2 is 1165 SEK per ton of CO2 with a negative Net Present Value (NPV). It was noted that, a higher carbon tax could significantly enhance the economic viability of the system. Moreover, the study found that by introducing bio-coal in the EAF with a fossil coal share below 69%, it has the potential to achieve negative emissions. Furthermore, recent studies have shown an increase in the CO2 content in the off-gas when introducing bio-coal into the EAF which further enhances the efficiency and economic feasibility of carbon capture. / Stål är en av de viktigaske metallerna i världen, och det spelar en avgörande roll i olika branscher. Den ökade efterfrågan på stål har lett till ökade koldikoxidutsläpp, och stålindustrin står för cirka 7% av de globala koldioxidutsläppen. Bland de olika produktionsmetoderna har ljusbågsugnen (EAF) framstått som ett lovande alternativ, och dess marknadsandel förväntas fördubblas i framtiden. Även om EAF uppvisar hög effektivitet och ett minskat koldioxidavtryck jämfört med alternativa produktionsvägar, finns det fortfarande stort utrymme för förbättringar. I EAF går en betydande mängd tillförd energi, mellan 15 och 30%, till spillo genom avgaserna, tillsammans med en betydande mängd CO2. För att bättre förstå det aktuella läget och pågående forskning inom hantering av avgaserna genomfördes en litteraturstudie och en preliminär analys som visade att spillvärmen från avgaserna effektivt kan återvinnas med hjälp av ett evaporativt kylsystem, vilket ger cirka 105kg ånga per ton flytande stål. Dettta understryker vikten av att återvinna spillvärme i samband med CO2-avskiljning. Kalciumlooping framstår som en lovande teknik för koldioxidavskiljning bland de tillgängliga alternativen, främst på grund av dess lägre miljöpåverkan och energiåtgång. Eftersom kalciumlooping används vid förhöjda temperaturer och är beroende av kalksten, utgör den dessutom en potentiell lösning för att minska utsläppen från stålindustrin. Därför fokuserar denna studie på analysen av ett system för återvinning av spillvärme integrerat med kalciumlooping-teknik, i syfte att fånga in CO2 och utnyttja spillvärme från EAF-avgaserna. Dessutom undersöks potentialen för att ersätta kol med biokol i EAF för att uppnå negativa utsläpp. Genom en steady state-analys och med hjälp av semi-empiriska mass- och energibalansekvationer fastställdes att det krävs 12 MW värme och 16 kg färsk kalksten per ton flytande stål för att fånga 90% av CO2-utsläppen från en 145-tons EAF. Även om den genomsnittliga avgastemperaturen är hög kan den inte betraktas som en tillförlitlig värmekälla. Därför tillgodoses värmebehovet genom förbränning av biomassa i kalcinatorn. Trots det ökade värmebehovet har systemet för återvinning av spillvärme integrerat med kalciumlooping potential att generera cirka 11 MW el med hjälp av en superkritisk ångcykel. Denna betydande produktion kan hänföras till den förhöjda temperaturen i avgaserna och den exoterna karbonatiseringsprocessen. Den ekonomiska analysen visar att den nivellerade kostnaden för avskiljning och lagring av CO2 är 1165 SEK per ton CO2 med ett negativt nettonuvärde (NPV). Det konstaterades att en högre koldioxidskatt skulle kunna förbättra systemets ekonomiska lönsamhet avsevärt. Dessutom visade studien att genom att introducera biokol i EAF med en andel fossilt kol under 69%, har det potential att uppnå negativa utsläpp. Nya studier har dessutom visat en ökning av koldioxidhalten i avgaserna när biokol införs i EAF, vilket ytterligare förbättrar effektiviteten och den ekonomiska genomförbarheten för koldioxidavskiljning.
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Calcium Oxide based Carbon Capture in District Energy Systems / Kalciumoxidbaserad koldioxidavskiljning i distriktets energisystemVora, Mit Jayesh January 2022 (has links)
Global carbon emissions are higher than ever before and in the last decade of 21st century, focus has shifted on reducing these emissions in various ways possible. Carbon capture, utilization and storage (CCUS) has been identified as one of the important ways to reduce carbon emissions and meet climate targets. For a long time, Sweden has promoted the use of biomass as fuel for heat and power generation which has enabled it to meet its climate targets earlier than projected. Now, major Swedish energy companies are looking into coupling exiting biomass fired heat and power plants with CCUS. This opens up the possibility of attaining negative emissions, also known as Bio Energy Carbon Capture and Storage (BECCS). With the right policy framework in place, BECCS can be a major boon and help Sweden attaining net zero carbon emissions. As a contribution in meeting net zero targets, this thesis is aimed to evaluate the installation of a carbon capture plant to abate flue gas emissions from District heating facility in Jordbro which is a ~70 MW (fuel) CHP plant running on biomass. Among the available carbon capture technologies, Calcium oxide-based carbon capture has been expected to show great promise due to its lower environmental impacts and possibility to extract high quality energy when installed. Hence a concept system for integration calcium looping at Jordbro has been developed through the use of modeling tools like ASPEN. A techno economic assessment was needed to be performed to give conclusive results on the overall viability of the process. Further, key process indicators like energy penalty, plant footprint and cost of capture per tonne of CO2 were identified for making the final evaluation. Finally, through a strategic collaboration with SaltX, major process improvements were introduced and applied to the modeled process. It was concluded that with the current average flowrates at Jordbro it was possible to capture 154,000 tonnes of CO2 annually. The required amount of energy input to the calciner is 48MW (7.29 MW/kg-CO2 captured) which is one of the major findings of this study. Even though a significant amount of heat is recovered, the main boiler is not capable of producing heat over 900 οC and additional biomass needs to be combusted, leading to an additional CO2 emission of about 125 000 tonnes annually. Considering an optimal integration, the energy penalties became 6.25 %. However, the plant footprint increased substantially due to requirement for burning additional biomass in the regeneration reactor and addition of several auxiliary units that come along with calcium-based carbon capture. Further, the total capital investment for this project is 1,219 MSEK with reactor costs being most capital intensive. Assuming a plant life of 25 years, the cost of capture per tonne of CO2 (excluding the costs for carbon transport and storage) was evaluated at 988 SEK, which is 58% higher than the reference Mono-ethanol amine based chemical absorption case. The innovative improvements from SaltX substantially reduced the plant footprint but capture costs did not reduce since material transport costs proved to be the major bottleneck. Upon comparison of this technology with the amine-based technology it was found that Calcium oxide-based carbon capture would need further research and improvements to be more viable than amine-based carbon capture. Integration of thermal energy storage and process intensification can be the possible paths for further improvement.
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