INJECTION EXPERIENCE OF SHORT CICLE BIOMASS CHARCOAL FINES

IN BLAST FURNACE

Eng. Paulo Afonso GomesEng. Marcelo de Matos

Eng. Ricardo Luchese de Moraes

Rio de Janeiro October 17th, 20121

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THE INJECTION OF FINES IN SMALL BLAST FURNACES IS EXPECTED TO GROWTH

MAIN DRIVERS:

• INCREASE OF BLAST FURNACE PRODUCTIVITY• DEACRESE DEPENDENCE OF PLANTED FORESTS• NEED OF COST REDUCTION ON PIG IRON PRODUCTION

REALITY

• THE CHARCOAL PRODUCTION GENERATES ONLY 10% OF FINES• THE INCREASE OF INJECTION WILL CREATE A DEFICIT OF FINES

SOLUTION

• CHARCOAL FINES FROM SHORT ROTATION CROPS CAN BE THE ANSWER

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WHY USE FINES FROM SHORT ROTATION CROPS?

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MATERIALS AND METHODS• THE CHARCOAL INJECTION EXPERIENCE, USING BIOMASS FROM BAMBOO WAS CARRIED

OUT IN JUN 2010 AT CIA SIDERÚRGICA VALE DO PINDARÉ BLAST FURNACE’S 3 AND 4, OWNED BY QUEIROZ GALVÃO GROUP IN AÇAILÂNDIA – MA, WHICH MAIN CHARACTERISTICS ARE DETAILED BELOW:

BLAST FURNACE

# 3# 3# 3# 3 # 4# 4# 4# 4

NET VOLUME m3

157 178

# TUYERES Unit 10 12

TUYERES

DIAMETERmm. 95 95

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THE BAMBOO USED FOR CHARCOAL FINE PRODUCTION WAS SUPPLIED BY AGRIMEX (COELHO NETO - PI)

SPECIES: ““““BAMBUSA VULGARIS””””

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MATERIALS AND METHODS

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� BAMBOO PLANTATION

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� BAMBOO HARVEST AND CHIP PRODUCTION

BAMBOO PLANTATION AND HARVEST

.

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CHIPPED BAMBOO STORAGE AT PINDARÉ PLANT

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CYLINDRICAL FURNACE USED TO CARBONIZE THE BAMBOO AT PINDARÉ MILL

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BAMBOO CHARCOAL AT THE END OF CARBONIZATION

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BAMBOO CHARCOAL FINES READY TO BE SENT TO INJECTION SYSTEM

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FINE INJECTION SYSTEM ON PINDARÉ’’’’S BLAST FURNACE

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3% MOISTURE

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FINES INJECTION PLANT AT PINDARE PLANT

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PENDULUM GRINDER FINES INJECTION CONTROL

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C. VEGETABLE FINES MOISTURE GCV NCV UHV ASH

EUCALYPTUS % 1,00 6013 5912 5851 12,52

EUCALYPTUS % 1,61 6470 6368 6262 5,78

BAMBOO % 1,50 5882 5781 5691 21,61

BAMBOO % 1,57 5816 5715 5622 18,47

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CARBONIZED BIOMASS ANALYSIS

SOURCE: LQCE- ESALQ – USP -2010

ASH INFLUENCE ON HEATING VALUE

GROSS HEATING VALUE X ASH CONTENT %

ASH CONTENT %

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NAMEWOOD CHARCOAL

(*) BAMBOO

(**)ELEPHANT GRASS

(**)

Density (kg.m-3) 420 a 480 191,70 123,82

Volatile Matter (%) 19,16 15,65 14,22

Ashes (%) 7,32 5,89 13,36

Fixed Carbon (%) 72,47 71,77 67,39

Moisture (%) 1,05 8,03 5,04

Impurities(%) N/A 13,83 15,32

Size (mm.) <0,15 32,18 27,33

CHARCOAL FINES ANALYSES FROM DIFFERENT BIOMASSS

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•After drying in the mill** After carbonization

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NAMEBEFORE MILL PROCESS (%)

PROCESS MILL

REJECT(%)

AFTER MILL PROCESS (%)

Sample 1 Sample 2 Sample 3

Volatile Matter 10,33 1,77 8,76 17,13 11,44

Ashes 18,88 91,44 18,38 14,91 13,11

Fixed Carbon 59,84 6,44 70,95 66,64 76,12

Moisture 10,95 0,35 1,91 1,32 2,43

SiO2 (Ashes) 64,56 53,58

FeO (Ashes) 16,02

VARIATIONS IN BAMBOO FINES CHARACTERISTICS IN GRINDING PROCESS

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DAY

MOISTURE(Mill Process

Entrance)%

MOISTURE(Fines)*

%

SIZE(%< 0,15mm)

DENSITY(kg/m3)

June 22, 2010

8,02 1,74 94 429

June 23, 2010

8,64 1,51 88 442

June 24, 2010

8,11 1,61 92 443

June 25, 2010

8,29 1,84 95 432

INJECTED BAMBOO FINES CHARACTERISTICS AND PROPERTIES

16* After drying

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DAYPRODUCTION(t Pig Iron/Day)

INJECTION RATIO(kg of fines/t pig iron) *

June 22, 2010 332 53

Juse 23, 2010 377 46

June 24, 2010 367 47

June 25, 2010 328 33

LEVELS OF INJECTION OF FINES AT BLAST FURNACE 4

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* The injection rate is limited by the flame temperature;* The QG Group is investing on an oxygen plant, pursuing an increase injection ratio

(aim: until 110 kg/t pig iron)

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BAMBOO EXPERIMENTAL PLANTATION AREA AT PINDARÉ MILL

� AGE – 04 MONTHS � AGE – 09 MONTHS

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ELEPHANT GRASS (MISCANTHUS) EXPERIMENTAL PLANTATION AREA AT PINDARÉ MILL

AGE – 4 MONTHS AGE – 9 MONTHS

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ARUNDO DONAX EXPERIMENTAL AREA AT PINDARÉ PLANT

� AGE – 4 MONTHS � AGE – 9 MONTHS

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CONCLUSIONS

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• THE CHARCOAL FINES PRODUCED FROM BAMBOO MAY BE INJECTED IN BLAST FURNACESIN QUANTITY EQUIVALENT TO THAT OF EUCALYPTUS CHARCOAL FINES.

• THE SUBSTITUTION RATIO IS THE SAME AS THE CHARCOAL FINES FROM EUCALYPTUS ASLONG AS IMPURITIES ARE NOT INCORPORATED ON THE CARBONIZATION PROCESS;

• THE QUEIROZ GALVÃO GROUP, AFTER THIS SUCCESSFUL INJECTION EXPERIENCE, HASSTARTED EXPERIMENTAL PLANTATIONS OF BAMBOO, ELEPHANT GRASS AND ARUNDODONAX, AIMING BIOMASS PRODUCTION FOR CARBONIZATION AND AS WEL, AIMING TOINCREASE THE INJECTION RATES ON BLAST FURNACES AND, IN THE FUTURE, TO USE THEMIN THE IRON ORE SINTERING PROCESS;

• THE SHORT ROTATION BIOMASS PRODUCTION COST IS CURRENTLY SIMILAR TOEUCALYPTUS, BUT IT CAN BE REDUCED;

• THE START OF ““““PROJETO DE FOMENTO”””” AT THE PINDARÉ MILL’S INFLUENCE ZONE COULDDECREASE THE CURRENT BIOMASS PRODUCTION COST AND FURTHER INCENTIVE IN THEUSE OF SHORT ROTATION BIOMASS FINES.

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THANK YOU

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BIOMASS COST (R$/t Dry Basis)

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BIOMASS CULTIVATION HARVEST FREIGHTTOTAL (CASH)

FINANCIAL COST

TOTAL (CASH +

FIN.)

LANDCOST

CASH + LAND +

FIN.

CONVENTIONAL EUCALYPTUS 39.34 34.19 7.00 80.53 11.00 91.53 20.40 114.07

SHORT ROTATIONEUCALYPTUS

62.86 44.56 7.00 114.42 15.48 129.90 18.60 148.51

ELEPHANT GRASS 36.57 46.05 8.56 91.17 0.00 91.17 15.14 106.31

BAMBOO 33.75 53.66 4.53 91.94 2.08 94.01 23.44 117.46

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CULTIVATION COST

CONVENTIONAL EUCALYPTUS

S. ROTATION EUCALYPTUS

ELEPHANT GRASS

BAMBOO

Formation (R$ / ha) 4.679 5.540 3.083 3.973Maintenance (R$ / ha) 559 821 1.074 73Conducting (R$ / ha) 2.221 2.431 0 946

Cycle (years) 14 9 14 14Cycle Formation 1 1 1 1

Maintenance per Cicle 12 6 13 8Regowth per Cicle 1 2 0 6

Yield (t dried / ha / Year) 24,70 27,09 33,30 21,.50Production (t dried/ ha / Cicle) 345,80 243,84 466,20 301,00Cultivation Cost (R$/ha/Cicle) 13.604 15.328 17.047 10.232Cultivation Cost (R$/ha/Year) 972 1.703 1.218 731Cultivation Cost (R$/t dried) 39,34 62,86 36,57 33,75

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BIOMASS COST (R$/t Dry Basis)

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HARVEST COST + FREIGHT

CONVENTIONAL EUCALYPTUS

S. ROTATION EUCALYPTUS

ELEPHANTGRASS

BAMBOO

Harvest + Chipping (R$ /ha) 5.911,00 3.621,69 1.533,47 2.307,25

Average Harvested Volume (BDMT / ha) 172,90 81,28 33,30 43,00

Harvest / BDMT* 34,19 44,56 46,05 53,66

Freight (10 km) per GMT* 3,85 3,85 3,85 3,85

Moisture 45% 45% 55% 15%

Freight per BDMT* 7,00 7,00 8,56 4,53

BIOMASS COST (R$/t Dry Basis)

* BONE DRY METRIC TON** GREEN METRIC TON

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FINANCIAL + LAND COST

CONVENTIONAL EUCALYPTUS

S. ROTATION EUCALYPTUS

ELEPHANTGRASS BAMBOO

Cycle Financial Cost (R$/ha) 4.542 3.775 0.00 625

Cycle (yers) 14 9 14 14

Yield (BDMT* /ha / Year) 24,70 27,09 33,30 21,50

Financial Cost (R$ / BDMT*) 13,13 15,48 0,00 2,08

Land Price (R$/ha) 4.200 4.200 4.200 4.200

Land usage % 50% 50% 50% 50%

Land Price + Legal Reserves + PPAs** 8.400 8.400 8.400 8.400

Land Cost (% - Real) 6% 6% 6% 6%

Annual Land Cost (R$/ha) 504,00 504,00 504,00 504,00

Yield (BDMT* / ha / Year) 24,70 27,09 33,30 21,50

Land Cost (R$/BDMT) 20,40 18,60 15,14 23,44

BIOMASS COST (R$/t Dry Basis)

* BONE DRY METRIC TON** PERMANENT PRESERVATION AREAS

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