Ironmaking process using carbon deposition by

Chemical Vapor Infiltration (CVI) method

((CVI))
Rochim Bakti Cahyono
Supervisor: Prof. Tomohiro Akiyama
Laboratory of Energy Media
Center for Advanced Research of Energy and Materials
Hokkaido University
2014.12.10
1

Research background
Steel consumption and income per capita

World crude steel production

20

Crude steel production

[102 million ton]

EAF

BF OHF

BF BOF

Total

15

10

0
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Year [-]

Steel consumption is one of indicators in prosperity and industrialization.

The steel demand would increase significantly to fulfill to economic growth
in the potential countries such as China, Brazil, Indonesia and India
Ref: [1] M. Walsh. Steel Logistics conference 2007, Hatch Beddows. [2] World steel association, Steel statistical yearbook 2013. [3] The Japan Iron and
Steel federation.

Research background
Iron and steel production

Raw materials:
High grade coal = 690 kg/ton-pig iron
High grade iron ore = 1390 kg/ton-pig iron
Limestone = 120 kg/ton-pig iron

Non-renewable resources
Limited amounts
Expensive

[3] The Japan Iron and Steel federation. [4] http://www.profisol.gr/en/production/steelmaking.aspx

Research background
Coal: reserves vs production

Iron ore production and price

3500
100

Price [US dollar/ton]

80

2500
2000

60

1500
40
1000
20

500

Ore price [US dollar/ton]

Ore production [million ton]

Production [million ton]

3000

Ratio of reserves to production [-]

700

600

Bituminous and antracite [HGC]

Sub-bituminous [LGC]
Lignite [LGC]

500

400
300
200

100
0

1993
0

0
2003 2004 2005 2006 2007 2008 2009 2010 2011

Year [-]

Consumes around 5% of the total world

energy[=24 EJ]
Energy recovery: 25.3% of input energy
CO2 emission: 1519 kg-CO2/ton-pig iron

1996

1999
2002
Year [-]

2005

2008

Industrial worldwide
CO2 emission

Ref: [5] USGS, iron ore mineral commodity summaries (2003-2011). [6] K. Morita, IEEJ 13 (2013),
November issue. [7] IEA, worldwide trends in energy use and efficiency (2008).

Summary : Ironmaking Problems

Resources

Environment

Iron ore & coal

Expensive & depletion

Large emission of
CO2

Energy
Consume >10 % of Japan
primary energy [=2018 PJ]

Our solutions
Low grade ore and
coal

Biomass

Carbon cycling
HC

Waste heat
utilization

CO2
BF

Heat
Wooden

Cheap and stable supply

CO, H2

Palm fiber

Carbon neutral

Less CO2 emission

High energy saving

Advanced ironmaking process is strongly needed to solve the

problems simultaneously.
Ref: [8] http://www.eiron.de/products.htm; [9] http://www.livemint.com/Industry/ruTZoaEQPUtprleESD665J/Power-projects-face-highgrade-coal-hurdle.html;
[10] http://everindex.co.za/evrazhighveld.co.za

Chemical Vapor Infiltration (CVI) process

CVI=Chemical Vapor Infiltration

(3) Adsorption onto the

pore surface

(4) Occurrence
of chemical
reactions

(7) Return to the

bulk gas

(6 Diffusion outwards
of by-products

(5) Desorption
of by-products

CVI can be applied to the production

of carbon-carbon composites
and ceramic matrix composites.
Close arrangement of carbon and iron
ore gives fast iron reduction reaction.

Ref: [11] Y.Xu and X-T.Yan, Chemical Vapor Deposition, Springer-Verlang, 2010.
[12] Prof. Shimizu (private communication);

Sec

New agglomeration

High

Reaction rate

Formation of
coating on
surface

Ionic exchange

Vicinity arrangement
of ore and carbon

Ferro-coke
Carbon composite

Min

Blast furnace
Layer thickness control

Mixing
layer

Ore

Low

(1) Gas penetration

into boundary layer

(2) Diffusion
into pore

Unique process which matrix

material is infiltrated into porous
material by the use of reactive
gases to form fiber-reinforced
composites.

Ore Coke

Coke

Hr
large

cm

mm

Distance between ore and carbon

small

Existing BF: slow

reduction rate and high
temperature (1900oC)

Key Technology : CVI Ironmaking

Chapter 1 General introduction
Chapter 2 Carbon deposition through CVI process over low grade ore
Tar decomposition and carbon deposition from various solid fuels
Effect of temperature on low grade coal-tar decomposition for enhancing
reactivity of iron ore
Optimum temperature for maximizing carbon deposition within ore

Pyrolysis
Fuel

Char

High grade coal

Low grade coal
Biomass
H2, CO, CH4,
Tar(CnHm)

Low grade ore

(FeO-OH)

Chapter 6 General
conclusions
H2, CO

Chapter 4 Structure of
deposited carbon within ore

Porous ore
(Fe2O3)

CVI ore
(Fe3O4+C)

Heat

CVI process:

Reduction/

treatment

Tar decomposition

oxidation

Dehydration process
FeOOH
Fe2O3 + H2O

Fe2O3 + CnHm
(Fe3O4 + C )+ CO + H2

Reduced/
oxidized ore

Fe3O4 + C
(Fe + FeO) + CO
2Fe3O4 + C
3Fe2O3+ CO2

Chapter 3 Kinetic analysis

of tar decomposition
Chapter 5 Exergy analysis and
its application of CVI ironmaking
7

Academic achievements
International Journal (first author):
1.

2.

3.

4.
5.

6.

RB. Cahyono, N. Yasuda, T. Nomura, T. Akiyama. Utilization of low grade iron ore (FeOOH) and
biomass through integrated pyrolysis-tar decomposition (CVI process) in ironmaking industry: Exergy
analysis and its application. ISIJ International 55, No. 2 (2014) In press
RB. Cahyono, G. Saito, N. Yasuda, T. Nomura, and Tomohiro Akiyama. Porous ore structure and
deposited carbon type during integrated pyrolysis-tar decomposition. Energy Fuels 28 (2014): 2129
2134
RB. Cahyono, N. Yasuda, T. Nomura, T. Akiyama. Optimum temperatures for carbon deposition during
integrated coal pyrolysistar decomposition over low-grade iron ore for ironmaking applications. Fuel
Processing Technology 119 (2014): 272-277
RB. Cahyono, AN. Rozhan, N. Yasuda, T. Nomura, H. Purwanto, T. Akiyama Carbon deposition using
various solid fuels for ironmaking applications. Energy Fuels 27 (2013): 26872692.
RB. Cahyono, AN. Rozhan, N. Yasuda, T. Nomura, S. Hosokai, Y. Kashiwaya, T. Akiyama. Integrated
coal-pyrolysis tar reforming using steelmaking slag for carbon composite and hydrogen production.
Fuel 109 (2013): 439-444.
RB. Cahyono, AN. Rozhan, N. Yasuda, T. Nomura, S. Hosokai, Y. Kashiwaya, T. Akiyama. Catalytic
coal-tar decomposition to enhance reactivity of low-grade iron ore. Fuel Processing Technology 113
(2013): 84-89.

International Journal (co-author):

1.

2.

AN. Rozhan, RB. Cahyono, N. Yasuda, T. Nomura, S. Hosokai, H. Purwanto, T. Akiyama. Carbon
deposition from biotar by fast pyrolysis using CVI within porous, low-grade iron ore for ironmaking.
Energy and Fuels 26 (2012): 7340-7346.
AN. Rozhan, RB. Cahyono, N. Yasuda, T. Nomura, S. Hosokai, T. Akiyama. Carbon Deposition of
Biotar from Pine Sawdust by Chemical Vapor Infiltration on Steelmaking Slag as a Supplementary
Fuel in Steelworks. Energy Fuels 26(2012): 3196-3200.
8

Academic achievements
International Conference:
1.

2.

3.

4.

RB. Cahyono, N. Yasuda, T. Nomura, T. Akiyama. Optimum temperatures for carbon deposition
during integrated coal pyrolysistar decomposition (CVI ironmaking). Symposium on Green
Energy and Technology 2013. Kualalumpur Malaysia, Dec 12-14, 2013
RB. Cahyono, N. Yasuda, T. Nomura, T. Akiyama. Innovative utilization of steelmaking slag waste
for improving the energy efficiency of pyrolysis process.
The 6th Regional Conference on Chemical Engineering (RCChE). Manila Philippines, Dec 2-3,
2013
RB. Cahyono, N. Yasuda, T. Nomura, T. Akiyama. Reduction Improvement of Low-grade Iron Ore
by Carbon Deposition through Chemical Vapor Infiltration (CVI) of Pyrolysis Tar.
International Conference on Smart Carbon Saving and Recycling for Ironmaking (ICSRI).
Hayama, Kanagawa, Japan, Oct 2-4., 2013
RB. Cahyono, Naoto Yasuda, Takahiro Nomura, Tomohiro Akiyama. Application of chemical
vapor infiltration for new iron-making process. The 5th Regional Conference on Chemical
Engineering (RCChE). Pattaya, Thailand, Feb 7-8, 2013.

Domestic Conference:
1.

2.

Rochim B. Cahyono, Naoto Yasuda, Takahiro Nomura, Tomohiro Akiyama. Ironmaking process
by Chemical Vapor Infiltration (CVI) using low grade iron ore and tar material. The 168th Iron and
Steel Institute of Japan (ISIJ). Nagoya University. 2014.09.26-27
Rochim B. Cahyono, Naoto Yasuda, Takahiro Nomura, Tomohiro Akiyama. Effect of temperature
on carbon deposition during integrated coal pyrolysistar decomposition over low grade iron ore.
The 167th Iron and Steel Institute of Japan (ISIJ). Oral presentation. Tokyo Institute of
Technology 2014.03.21-23
9

Academic achievements
Domestic Conference:
3.
4.

5.

6.

7.
8.

9.

, Rochim B. Cahyono, , .
. 166 (2013) . 2013.9.17
Rochim B. Cahyono, Naoto Yasuda, Takahiro Nomura, Tomohiro Akiyama. Iron-making
process through carbon deposition from various solid fuels. The 165th Iron and Steel Institute of
Japan (ISIJ). Oral presentation. Tokyo Denki University campus 2013.03.27-29
Rochim B. Cahyono.
. 78
2013.3.17
Rochim B. Cahyono, Alya Naili Rozhan, Sou Hosokai, Tomohiro Akiyama. Integrated coal
pyrolysis-reforming using hot steelmaking slag for carbon composite and syngas production. The
163th Iron and Steel Institute of Japan (ISIJ). Oral presentation. Yokohama National University,
Japan. 2012.03.28-30
, , Rochim B. Cahyono, Hadi Purwanto, , .
CVI. 164
Rochim B. Cahyono, Alya Naili Rozhan, Naoto Yasuda, Takahiro Nomura, Sou Hosokai,
Tomohiro Akiyama. Increasing the degree of reduction and reactivity of low-grade iron ore. The
164th Fall Meeting of the Iron and Steel Institute of Japan. Oral presentation. Ehime University,
Matsuyama. 2012.9.17
, , Rochim B. Cahyono, Alya Naili Rozhan, , .
. 164 .
2012.9.19

10