Application of chemical vapor infiltration(CVI) for

new ironmaking process

Rochim B. Cahyono (D2)

July 10, 2013

Pig iron production,

103 Mt

Ironmaking industry

Adapted from World Steel Association, 2011.

Years

Raw materials : Coal (HG) = 690 kg/ton-pig iron

Iron ore (HG) = 1390 kg/ton-pig iron
Consumes around 5% of the total world energy
Energy recovery : 25.3 % input energy
CO2 emission: 1519 kg-CO2/ton-pig iron
World Steel Association, 2011. Steel statistical yearbook 2011, world steel Committee on Economic Studies-BRUSSELS,
2011. World Steel Association, p. 101; The Japan Iron and Steel federation

Ironmaking problems
Resources
Iron ore & coal
Expensive & depletion

Environment

Energy

Large emission of
CO2

Consume >10 % of Japan

primary energy

Our solutions
Low grade ore
and coal

Biomass

Carbon cycling
CH4

Waste heat
utilization

CO2
BF

Heat CO, H
2
Cheap and stable supply

Carbon netrual

Less CO2 emission

High energy saving

Experimental method
Experiment conditions:
-

Pisolate ore : 3 gram

Coal feed
: 0.1 g/min
Total N2 flow : 250 mL/min
Reaction time : 40 min
Temperature : 600-800oC
Ore and fuels particles size : 0.952
mm and 250500 m

Solid fuels

Iron ore

Energy Fuels 2009, 23, 11281131; Energy Fuels 2012,

26, 31963200

Porous Iron ore

2FeO(OH) Fe2O3 H 2O

(a)

(b)

Layer by layer structure of iron ore was found after

dehydration process due to breaking of hydrogen bond OH.
Micro-pore was created dominantly during dehydration
process
Tar component infiltrated within pore structure and
decompose into carbon and gas product

5
Fuel 89 (2010) 17841795; ISIJ International, Vol. 51 (2011), No. 8, pp. 12341239

Carbon deposition
Tar product distribution
Gas

Deposited carbon tar

Unreacted tar

Carbon yield [%mass-C]

100
80

60
40
20

Unreacted tar decreased

H ore, Pyrolysis temp : 800 oC

0
400

500
600
700
Tar decomposition temp [oC]

800

Carbon content within steelmaking slag increased after tar

carbonization process
Experiments at high temperature resulted small carbon
deposition because tar easier to decompose into gas phase
and decreased carbon content.
At higher temperatures, gasification of the deposited carbon
took place and enhanced carbon conversion to gas
products.
Energy Fuels 26 (2012), 31963200

Reactivity of Carbonized ore

Fe3O4

FeO

Fe

As-carbnoized

Intensity, a.u.

400C

670C

770C

820C

1000C
20

30

40

50

60

70

80

2, degree (CuK

Fe3O 4 4C 3Fe 4CO(g)

Fe3O 4 2C 3Fe 2CO 2 (g)
Fe3O 4 C 3FeO CO(g)
CO 2 (g) C 2CO(g)

The nanoscale contact between iron ore and

carbon improved contacting area and resulted in
the increasing reaction rate and decreasing
reaction temperature

XRD patterns confirmed that the reduction

reaction was initiated at range 750 800 oC.
7

Energy Fuels, 2012, 26, 72747279

R&D: Steelmaking slag

Application to sinter plant:
Coke breeze usage [kg/ton sinter]

38

Conventional
36

Proposed system
Reduce : 6.32 %

34

28 kg slag/ton sinter [17]

32
0

Tar H2 CO CO2 CH 4 other H.C C

20
40
60
Steelmaking slag charging [kg/ton sinter]

80

Carbon content within steelmaking slag increased after tar carbonization process
Experiments at high temperature resulted small carbon deposition because tar
easier to decompose into gas phase and decreased carbon content.
The process reduced the usage of coke breeze of 6.32% in the sinter plant with
slag recycling system
Energy Fuels 26 (2012), 31963200; Fuel 109 (2013), 439-444