from sustainable cooperation to sustainable technologies

From sustainable cooperation to sustainable technologies

Joint Ukrainian-Swedish project:National Metallurgical Academy of Ukraine

Prof V.ShatokhaRoyal Institute of Technology

Prof S.Seetharaman

Science and Technology Center in Ukraine: PROMOTIONAL ACTIONS IN SWEDEN – 2009

Thematic Roundtable on Materials Science15/10/2009

Background: History of Collaboration KTH-NMetAU

2002-2003: grant from Swedish Institute under VISBY programme; a project “Knowledge basis for the sustainable development|” to start up of joint collaboration (8 visits NMetAU→KTH; 6 visits KTH→NMetAU)2004-2007: 16 NMetAU students attended International Summer School at KTH2005-2008: Joint European Project “Curricular reform of MSc and PhD Metallurgy Programmes” under TEMPUS programme


2007: – International conference “Advances in the Metallurgical Processes and Materials” in Dnipropetrovskled by KTH and NMetAU organisers (over 120 attendees from 22 countries)


Sept 2008 – Ukrainian-Swedish seminar “Materials and energy – key factors of the sustainable development” in Dnipropetrovsk (19 visitors from Sweden representing 3 universities, 2 research institutes, 2 industrial companies, Jernkontoret)


Nov 2008 – continuation of the seminar by visit of Ukrainian delegation to Sweden (8 visitors, representing 2 universities, 3 industrial companies and 1 investment company)

Mobility

Visits professors

Sweden → Ukraine – 36Ukraine → Sweden – 27

studentsSweden → Ukraine – 4 (2 PhD, 2 Master)Ukraine → Sweden – 28( 3 PhD, 9Master, 16 summer school)

Joint ResearchEven though we never had any financial support for joint research activities, due to active involvement of students we’ve been managed to fulfill some research projects:• Process development towards improvement of nodulization of graphite in cast iron• Efficient utilising of steelmaking slag based on innovative iron recovery solutions

Joint publications:1. Shatokha V., Seetharaman S., Semykina A.: Investigation of redox

reactions in a view to recover iron-bearing compounds from steelmaking slags/ Metallurgija (Journal of Croatian Metallurgical Society). - 2008 (47). – N3. - P.258.

2. Semykina A., Shatokha V., Seetharaman S.: Studies of the melting point of the industrial slags from BOF converter/Nowe Technologie i Osiagnecia w Metalurgii i Inzenierii Materialowej. Wydawnictwo Politechniki Czestochowskej, 2008. – P.409-411

3. A.Semykina, V.Shatokha, S.Seetharaman: Development of Innovative Solutions for Recovery of Iron From Steelmaking Slags/MOLTEN-2009. Proceedings of the VIII International Conference On Molten Slags, Fluxes and Salts, Santiago, Chile. - 18-21 January 2009. - P.61

4. Семикіна

А., Шатоха

В., Ситараман

С.: Исследование

закономерностей окисления

железосодержащих

оксидов

сталеплавильных

шлаков/Теория

и практика

металлургии. – 2009. - №1-2. – с. 18-215. Спосіб

переробки

металургійних

шлаків: Деклараційний

патент

України

(МПК 7С21С5/06)/ Семикіна

А., Шатоха

В., Сітараман

С.6. Семикіна

А., Шатоха

В., Сітараман

С.: /Металлургическая

и

горнорудная промышленность

(в

печати

–

in press)

New project: sustainable sponge iron production technology

Concept:

to apply cutting-edge knowledge in the fields of gas-solid reactions, fluidised bed mechanics and innovative heating methods in order to bring the new technology for production of the metallised product with the improved properties from iron ore, ferrous wastes and low grade coal


Objectives:1. To develop the technological regime for metallisation

of composite micro-pellets, containing iron-bearing material and low cost coal, based on the in-depth study of the gas-solid interactions, reduction mechanism, partition of sulphur, separation of primary slag compounds and mechanics of fluidised bed

2. To ensure utilising in the developed technology of solid ferrous wastes (sludge, scale, dust), recovery of heat and capturing of CO2 from the waste gases

3. To bring lab-scale demonstration for further industrial application of the developed technology


Main features of the new technology:- low energy consumption,- low emission,- capability to utilise solid and gaseous wastes,- simple layout and applicability to different industrial

environments

Swedish-Ukrainian collaboratorshave passed initial phase

focused on the preparation of composite pellets,fluidising techniques, reduction kinetics


The project addresses major needs of the Ukrainian as well as Swedish industries:

- Ferrous wastes need to be utilised in a more efficient way

- Alternative ironmaking technologies are on the agenda- Technological application for the low grade coals should

be developed- Efficient capturing of the CO2 from the waste gases in

order to reduce industrial footprint of the environment should be found

Needs analysis


Conventional steelmaking: 4.5% of C as average is obtained in the semi-product (pig iron) produced at the blast furnaces; most of this carbon is then burnt out in steelmaking. At the actual world production volumes it corresponds to around 40 mln t of carbon (or about 60 mlnt of middle grade coal), followed with the emission of about 150 mln t of CO2 contributing to greenhouse effect. DRI (direct reduced iron) technologies are mainly based on application of the natural gas which makes this technology not feasible for the countries where this fossil fuel is not available at low cost. Indirect use of coal through gasification has certain perspective however the whole plant becomes rather complicated and more expensive.Ore-coal composite pellets are considered nowadays as a prospective burden material for new generation of ironmaking processes (FASTMELT, ITmk3, HiQip etc). However the product - molten iron -contains 1.1 – 3.6 mass % of carbon and saturation of the product with sulphur and other detrimental elements is usually uncontrolled.

State-of-the-art


The sustainable technology where sponge iron is produced from composite micro-pellets, containing iron-bearing material and low cost coal will be developed.Composition of the pellets will allow “self-reduction”, so the process might be conducted in low-reduction, neutral and even low-oxidising atmospheres (e.g. smokes of the industrial or combustion power plant origin – thus delivering improvement of the carbon life-cycle in the industry).

Progress beyond the state-of-the-art


reduction regime allows control of carburisation process and obtaining of pure product which will be followed with the decrease of the CO2 emission for 20%;application of composite pellets ensures decrease of the production cost for at least 30% to compare with SynGasbased DRI;due to heat recovery from the waste gases, energy consumption will be reduced at least for 15 % to compare with existing analogues;simultaneous control of carburisation and sulphurisationprocesses ensures production of the cleaner sponge iron which can be used not only for steelmaking but even for the value added applications (absorbers, catalysers, filters etc)

Advantages of the concept


The project will comprise following phases Estimation of the specific reduction and heating regimes, optimal for given burden material and type of the coal – 1-6th

monthsInvestigation of fluidising regimes – 3-9th monthsLab scale trials 9-15th monthsFeasibility study 11-14th monthsCompletion of the documentation for further industrial implementation 15-18th months

Workplan


From the Swedish side the project will be led by Prof.Seshadri Seetharaman (KTH).Laboratory equipment (fluidising bed reactor, various heating furnaces, termogravimetry equipment) will be involved.

Staffing and laboratory base of the project


From the Ukrainian side the project will be led by Prof.VolodymyrShatokha. He currently supervises 3 PhD students who will be involved to perform certain parts of the research:

Anna Semykina (joint PhD with Prof. S.Seetharaman) – application of the technology for treatment of ferrous slag wastes;Iurii Korobeynikov – reduction regimes, production and properties of composite pellets;Andriy Petrenko – fluidising techniques and regimes, technology layout

Equipment of the Chair of Ironmaking and Chair of the Physical Chemistry and Theory of Metallurgical Processes (pelletising drums, grinding facilities, furnaces) will be involved

Staffing and laboratory base of the project


Authors are aware of other activities in the research domain:FP 7: Ultra-low carbon dioxide steelmaking (ULCOS) http://ec.europa.eu/research/industrial_technologies/case_studies/case-studies-006_en.htmlRFCS programme : COMTES700 http://www.comtes700.org

As soon as the IPR issues will arise consortium will undertake necessary measures for patenting of the technology

Management of the Intellec tual Property

http://www.comtes700.org/


Areas of ApplicationExisting steelmaking companies of each size and product profile – plants for processing of wastes.Small and medium-size companies – production of value added materials based on sponge iron.

Dissemination strategyBasic dissemination (project web-site, flyer, logo)Scientific dissemination (peer-reviewed journals, conferences)Dissemination towards industry

Exploitation and dissemination

Thank you very muchfor your kind attention !

from sustainable cooperation to sustainable technologies

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