Zulfiadi Zulhan - Innovation and Trends of Green Technology Application in Steel Industry, F

Innovation and Trends of Green
Technology Application in Steel Industry

SEAISI 2023 Traveling Seminar: “Value Creation Through Green Steel
Technology Towards Sustainable Steel Industry”
Zulfiadi Zulhan, Taufiq Hidayat, Setiawan Surakusumah, Bima Satritama,
Widyadhara Ghani Putri, Amalia Jihan Nabilah, Muhammad A’an
Metallurgy Engineering Research Group

Faculty of Mining and Petroleum Engineering
Bandung Institute of Technology
20th March 2023

CO2 gas emission
The iron and steel industry is
responsible for 11% of global
carbon dioxide (CO2) emissions
and needs to change rapidly to
align with the global climate
goals.
https://www.carbonbrief.org/
Balance between the amount of greenhouse gas produced and
the amount removed from the atmosphere
Iron and Steel: 7.2%

Non-ferrous metals: 0.7%
http://berkeleyearth.org/
Zulfiadi Zulhan / Taufiq Hidayat SEASI 2023: Traveling Seminar 20th March 2023 2
The CO2 emission of energy is greater
than the CO2 emission of the process
Metals Production (2021)
100.000.000
Estimated CO2 emissions in Indonesia:
10000
1950.5 - Steel : 10.000 kt * 2.0 = 20.000 kt
World - Aluminum : 300 kt * 1.5 = 450 kt
1000 10.000.000
Indonesia (alumina to aluminum, only process,
134
100 49.5 41 1.000.000 hydropower)
21 13.8
Price (USD/ton)
11.59 8.5 - Nickel : 1.000 kt * 60 = 60.000 kt
million tons
10 100.000
2.7
0.97
1 0.3 10.000 3000 40
0.18 0.14 0.00016
0.085 0.003332 35
Nickel Production (kton)

0.1 1.000 2500
0.027
Share of Indonesia
0.016 30
0.01 100 2000
25
0.001 10 1500 20
15
0.0001 1 1000
10
500
5
0 0
2015 2016 2017 2018 2019 2020 2021
World Indonesia Share of Indonesia
CO2 Emission in the Steel Industry
Blast Furnace – BOF – CCM – HR - Products DR (NG) – EAF – CCM – HR - Products
Coke oven (0.1) 0.10
Direct Reduction (0.95) 0.95
Sintering (0.4) 0.50
Electric Arc Furnace (0.15) 1.10
Blast furnace (1.5) 1.95
Continous Casting Machine (0.05) 1.15
Basic Oxygen Furnace (0.2) 2.15
Hot rolling to products (0.25) 1.40
Continous Casting Machine (0.05) 2.20
0.00 0.50 1.00 1.50 2.00 2.50
BF
Hot rolling to products (0.25) 2.45 CO2 per ton steel (ton)
0.00 0.50 1.00 1.50 2.00 2.50
CO2 per ton steel (ton)
H2: DR – EAF – CCM – HR - Products
Scrap – EAF – CCM – HR - Products Direct Reduction (0.0) 0.00
Electric Arc Furnace (0.15) 0.15 Electric Arc Furnace (0.10) 0.10
Continous Casting Machine (0.05) 0.20 Continous Casting Machine (0.00) 0.10
Hot rolling to products (0.25) 0.45 Hot rolling to products (0.00) 0.10
0.00 0.50 1.00 1.50 2.00 2.50 0.00 0.50 1.00 1.50 2.00 2.50
CO2 per ton steel (ton) CO2 per ton steel (ton)
Iron and Steel Production Routes
Main CO2 Direct
emitter • Iron ore (pellet, lump, fines)
Reduction • Coal / Natural Gas / H
2
Scrap, fluxes (Carbon steel > 3500 grades)

• Iron ore
(sinter, EAF
pellet, lump)
• Coke, Coal
• Fluxes
LF
(limestone,
dolomite) Blast furnace
Cooling Scrap, fluxes BOF
DRI,
107.6, 8%
Direct
Reduction
Technology
2019 Blast
1388 Juta tonton
mio. Furnace
Iron
Pig Iron
(Hot
metal),
1280.7,
92%
Thyssenkrupp Steel Europe
J. Reichel, ASK 35, 2021
Ironmaking Capacity under Development
https://globalenergymonitor.org/wp-content/uploads/2022/06/GEM_SteelPlants2022.pdf
BF-BOF capacity under development
https://globalenergymonitor.org/wp-content/uploads/2022/06/GEM_SteelPlants2022.pdf
Alternative Technologies For “Green” Iron &
Steelmaking
1. Shaft Furnace (DR) – EAF
High quality HYBRIT (Hydrogen
High quality pellet Breakthrough Ironmaking
pellet Technology)
• C addition in EAF
• Graphite electrode
• Nitrogen pick-up • C addition in EAF
• Graphite electrode
• Nitrogen pick-up
da Costa et al., 2013 https://www.hybritdevelopment.com/
Steelmaking
2. Shaft Furnace – SAF – BOF
• C addition in SAF
High quality • Graphite electrode
pellet
Slag
FeNi/NPI
ELECTRIC FURNACE
SAF BOF LF CCM
SF
DRI, EAF OH, 5.6,
107.6, 8% EAF, 0%
517.4,
Direct 28%
Reduction
Technology
2019 Blast 2019
1388 Juta
mio.tonton Furnace mio.ton
ton
1867 Juta
Iron Steel
Pig Iron BOF
(Hot
metal), BOF,
1280.7, 1343.0,
92% 72%
Steelmaking
3. Molten Oxide Electrolysis (MOE), Boston Metal
https://www.bostonmetal.com/transforming-metal-production/
Steelmaking Reductant
4. Fluidized Bed – EAF / Rotary Kiln – SAF – BOF (No pelletizing!)

Fuel H2
ID Fan
ESP Multiclone
Rotary Kiln
ROTARY
KILN
https://www.youtube.com/watch?v=9u3I2lfuDnc&t=214s
Slag
FeNi/NPI
ELECTRIC FURNACE
Electric Furnace BOF
New Zealand Steel
Biomass for Biogas / H2 for
reductant reductant and fuel
https://www.nzsteel.co.nz/
Evraz Highveld Steel & Vanadium
RKEF 7 Unit: 45
Biogas / H2 for
reductant and fuel & 65 MVA
Biomass for
13 Unit
reductant
Rotary Kiln – Electric Furnace (RKEF) Mini Blast Furnace
(MBF)
6%
Nippon Yakin Oheyama
Process (Krupp-Renn)
1%
Nickel
Bijih nikelore
basah
CO2
Pyrometallurgy
Fuel halus
Batubara ID Fan
ESP
Udara primer
Reductant
H2 for fuel Udara

sekunder
Rotary Kiln - Electric
Furnace (RKEF)
93%
ROTARY DRYER Fuel
CO2
ID Fan
ESP Multiclone
H2 for reductant
ROTARY
and fuel
CO2 KILN
ID Fan
CO2
from Power plants:
Coal, Oil, Gas
Bag house
Renewable energy for
electricity (Smelting
Slag ~ 1600 C and H2 production)
FeNi/NPI
ELECTRIC FURNACE
Granulation
Lab Scale Experiment: Hydrogen gas as reductant
Nickel ore
Calcine B. Satritama, T. Hidayat, Z. Zulhan, 2022
Calcination and reduction by H2 gas in a Smelting in a vertical tube furnace to

horizontal tube furnace to simulate the RK simulate the Electric Furnace
Reductant
Fuel
ID Fan
ESP Multiclone
Slag
ROTARY FeNi/NPI
KILN ELECTRIC FURNACE
H2 gas as reductant for Ferronickel Production:
Calcine Smelting, 1550 C, 2h
B. Satritama, T. Hidayat, Z. Zulhan, 2022

CH4 gas as reductant for FeNi Production:
900 C, 15 min → Smelting: 1550 C, 2h
OXIDE
METAL METAL OXIDE
Code Phase Fe Ni Si Cr Mg Al Ca P
Spc_003 Metal 56.00 10.05 21.39 10.81 0.16 0.22 0.08 Nd Nd
Spc_001 Metal 27.47 39.52 29.77 1.49 0.24 0.12 0.12 Nd Nd
FeO NiO SiO2 Cr2O3 MgO Al2O3 CaO CoO
Spc_001 Slag 0.41 0.08 46.21 0.10 17.03 26.70 9.46 Nd
Spc_002 Forsterite 0.41 0.38 44.12 0.09 54.00 0.60 0.40 0.01
A.J. Nabilah, B. Satritama, T. Hidayat, Z. Zulhan, 2022
H2 gas as reductant for Iron Production
900 C, 1550 C,

3h, 75% DRI 2h, 100%Ar Smelting
Iron Ore
H2:25%Ar Al
Fe: 99.08%
Mn: 0.15%
Si: 0.06%
P: nd
S: nd
Cr: 0.01%
O Fe Mg Si
W.G. Putri, B. Satritama, T. Hidayat, Z. Zulhan, 2022
Thermochemical calculations:
Partial hydrogen combustion
Fe2O3 Partial H2
H2O combustion O2
H2 Fe
Basis: 1000 kg Fe Basis: 1000 kg Fe
2000 2500 2000 2500
1800 Fe2O3 Temp 1800 Fe2O3 H2O
1600 Fe3O4 2000 1600 Fe3O4 2000
1400 1400 FeO
Temperature (C)
Temperature (C)
1200 H2O 1500 1200 1500
Mass (Kg)
Mass (Kg)
Temp
1000 FeO 1000
800 Fe 1000 800 Fe 1000
600 600
400 500 400 H2 500
H2
200 200
0 0 0 0
0 100 200 300 400 500 0 100 200 300 400 500
H2 (Kg) H2 (Kg)
H2 combustion with O2 : 0.4  Stoichiometric H2 combustion with O2 : 0.3  Stoichiometric

Fe2O3 Partial H2
H2O combustion O2
H2 Fe
2000 2500 2000 2500
1800 Fe2O3 1800 Fe2O3
1600 Fe3O4 2000 1600 Fe3O4 2000
H2O
1400 1400
Temperature (C)
Temperature (C)
FeO Fe
1200 1500 1200 FeO Fe 1500
Mass (Kg)
Mass (Kg)
1000 1000
800 1000 800 1000
Temp Temp H2O
600 600
H2
400 500 400 500
200 200 H2
0 0 0 0
0 100 200 300 400 500 0 100 200 300 400 500
H2 (Kg) H2 (Kg)

Fe2O3 Partial H2
H2O combustion O2
H2 Fe
2000 2500 2000 2500
1800 Fe2O3 1800 Fe2O3
1600 Fe3O4 2000 1600 Fe3O4 H2O 2000
1400 H2O 1400
Temperature (C)
Temperature (C)
FeO Fe Temp
1200 1500 1200 1500
Mass (Kg)
Mass (Kg)
1000 1000
800 1000 800 Fe 1000
600 Temp 600
400 500 400 H2 500
200 200 FeO
H2
0 0 0 0
0 100 200 300 400 500 0 100 200 300 400 500
H2 (Kg) H2 (Kg)

Reaction of H2 with Fe2O3
Fe2O3 H2
H2O
Fe
H2

2000 2000
Fe2O3 1400 Fe2O3 1400
1800
600 C 1800 800 C
1600 1200 1600 1200
Fe3O4 Fe3O4
1400 1400
Temperature (C)
Temperature (C)
1000 FeO 1000
1200 FeO Fe 1200 Temp
Mass (Kg)
Mass (Kg)
800 800
1000 1000
800 600 800 Fe 600
600 H2O Temp 600
400 400
400 400
200
H2O 200
200
H2
200 H2
0 0 0 0
0 100 200 300 400 500 0 100 200 300 400 500
H2 (Kg) H2 (Kg)
Reaction of H2 with Fe2O3
Fe2O3 H2
H2O
Fe
H2

2000 2000
Fe2O3 1400 Fe2O3 1400
1800
900 C 1800 1000 C
1600 1200 1600 Fe3O4 Temp 1200
Fe3O4
1400 Temp 1400
Temperature (C)
Temperature (C)
1000 1000
1200 1200
Mass (Kg)
Mass (Kg)
FeO
800 800
1000 1000
800 Fe 600 800 Fe H2O 600
FeO
600 600
400 400
400 400
H2O 200 200
200
H2 200 H2
0 0 0 0
0 100 200 300 400 500 0 100 200 300 400 500
H2 (Kg) H2 (Kg)
Reductant
EAF vs SAF ID Fan

ESP Multiclone
Fuel
ROTARY
KILN Slag
RK FeNi/NPI
ELECTRIC FURNACE
SAF BOF LF CCM
Slag
FeNi/NPI
LF
ELECTRIC FURNACE
SAF BOF LF CCM
EAF CCM SF
SF/FB – EAF SF – SAF – BOF RK – SAF – BOF

Shaft furnace / fluidized
Pre-reduction / reduction Shaft furnace Rotary kiln
bed
2 (reduction – 3 (reduction – smelting – 3 (reduction – smelting –
Main equipment
melting/refining) refining) refining)
Batch / continuous Continuous - Batch Continuous – Continuous Continuous – Continuous
Iron ore form Pellet / fine iron ore Pellet Flexible
Iron ore quality (Fe
High High Low to high
content)
Reductant Gas (H2, Biogas) Gas (H2, Biogas) Biomass, Biogas, H2 (?)
Electrical heating / Gas Electrical heating / Gas
Burner (energy) Gas (Biogas, H2)
(Biogas, H2) (Biogas, H2)
Hot charging to melting /
Possible Possible Possible
smelting unit
Reductant
Fuel
EAF vs SAF ID Fan

ESP Multiclone
ROTARY
KILN Slag
RK FeNi/NPI
ELECTRIC FURNACE
SAF BOF LF CCM
Slag
FeNi/NPI
LF CCM
ELECTRIC FURNACE
SAF BOF LF CCM
EAF SF
Smelting SF/FB – EAF SF – SAF – BOF RK – SAF – BOF

Batch / continuous Batch Continuous Continuous
Electrode Prebaked Soderberg/paste Soderberg/paste
Furnace power High (up to 350 MW) Low (< 120 MW) Low (< 120 MW)
Power fluctuation High Low Low
Energy efficiency Less than SAF Better than EAF Better than EAF
Slag foaming Required Not required Not required
N pick-up High Less Less
Fe – scrap Required, 10 – 20% for Not required Not required
each heat.
Environment Oxidation by oxygen Reduction (biomass to Reduction (biomass to
blowing adjust C and Liq. Temp.), adjust C and Liq. Temp.),
requires BOF for refining requires BOF for refining
Refractory lifetime Short High with cooling system High with cooling system
Municipal Solid Waste as reductant (Ferronickel):
Dry fermentation of MSW
using an aerobic bio-drying
(peuyeumisasi)
MSW
Nickel ore
Element Wt.%
Fe 78,09
Ni 15,07 1450 C
Si 0,98
P 3,18
Metal
S 2,67
Oxides Wt.%
SiO2 51,66
MgO 15,74
Al2O3 20,44
FeO 5,57
Slag SDS Djaja, Z Zulhan, T Hidayat, M A’an, RMN Salmanhakim, 2022
CaO 3,64
Tin Ore
Municipal Solid Waste as reductant (tin):
Flux
Element Wt.%
Sn 100,0
Fe 0,00
Oxides Wt.% Metal

SiO2 29,22
1300 C, 1 h
SnO2 26,03
Al2O3 14,93
FeO 5,94
CaO 8,75
TiO2 0,93
WO3 10,00
Slag
SDS Djaja, Z Zulhan, BT Situmorang, T Hidayat, M A’an, 2022
Waste to Resource: Leaching Nickel Residue as
Source of Sulphur and Iron
Hydrometallurgy
CaCO3
CaO
Leaching
MHP
NiSO4.7H2O
S
CoSO4.7H2O
16.23% Fe
48.63% Fe 12.18% S
1.13% S Sulphuric Acid Plant
Biocarbon
? Leaching Residue Natrojarosite

Reduction Roasting
18
Metal
17
21
20
Metal
Iron & Steel Plant Metallic Iron 19
22
Oxide
Z. Zulhan, Z. Adzana, M. Munawaroh, A.H. Yusro, J.D. Christian, A.D. Saputri, T. Hidayat, 2022
Waste to Resource: Bauxite Residue (Red Mud) as
Source Iron and Other Metals
Element Typical *) Indonesia
Fe (%) 4.52 – 50.60 31.28
Al (%) 4.42 – 16.06 10.16
Si (%) 2.16 – 14.86 6.24 C-Material
Na (%) 0.98 – 7.79 3.09
Ca (%) 0.39 – 16.72 3.19 Red Mud
Ti (%) 0.98 – 5.34 1.82
Ga (ppm) 60 – 80 39.75
Sc (ppm) 50 - 120 120
Extraction of
V (ppm) 730 998 other metals
Zr (ppm) 1230 290
Y (ppm) 68 5.72
*)
Iron recovery > 70%
Liu, et al., 2014
Fe content >95% Muffle Furnace
1300 °C 1350 °C 1400 °C 1500 °C
1450 °C Zamzammi, A.I., Zulhan, Z., 2018
Hydrogen Plasma
I. R. Souza Filho, et al., 2021 https://www.youtube.com/watch?v=FRyJcKBrEvc&t=1098s

https://www.dierk-raabe.com/green-steel-reduction-of-iron-ore-by-hydrogen-plasma/
Hydrogen Plasma
https://www.youtube.com/watch?v=FRyJcKBrEvc&t=1098s
https://www.dierk-raabe.com/green-steel-reduction-of-iron-ore-by-hydrogen-plasma/
HPSR
M. Shahabuddin, et al., 2023
Summary
• Steel industry is responsible for around 11% of global CO2 emissions that must be
changed rapidly.
• The period 2023 – 2035 will be crucial in improving existing technologies and
creating new technologies for the decarbonization of steel industries.
• To achieve a green industry, the Indonesian iron and steel industry shall start to
reduce energy consumption. An energy audit shall be carried out to map the
potential for reducing energy consumption.
• Most steelmakers tend to use hydrogen as a reducing agent in the steel industry.
• Biogas and municipal waste can be used as an alternative reductant for
ironmaking.
Summary
• Most of the steel makers tend to adopt “shaft furnace – electric furnace (EAF /
SAF)” technology for green steel production.
• Alternatively, a rotary kiln–electric furnace (EAF/SAF) shall be developed for green
steel production.
• The residue of the metallurgical industries (tailing, slag, etc.) shall be treated as
raw materials for other applications or extraction of other metals.
• Metallurgy Research Group, Bandung Institute of Technology, conducts research
to provide alternative processes for CO2 emissions reduction in the metal
industries.
Thank You!

Zulfiadi Zulhan - Innovation and Trends of Green Technology Application in Steel Industry, F

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Zulfiadi Zulhan - Innovation and Trends of Green Technology Application in Steel Industry, F

Uploaded by

Copyright:

Available Formats

Innovation and Trends of Green

Technology Application in Steel Industry

Metallurgy Engineering Research Group

20th March 2023

Iron and Steel: 7.2%

Nickel Production (kton)

World Indonesia Share of Indonesia

Scrap, fluxes (Carbon steel > 3500 grades)

J. Reichel, ASK 35, 2021

da Costa et al., 2013 https://www.hybritdevelopment.com/

4. Fluidized Bed – EAF / Rotary Kiln – SAF – BOF (No pelletizing!)

H2 for fuel Udara

ROTARY DRYER Fuel

Calcine B. Satritama, T. Hidayat, Z. Zulhan, 2022

Calcination and reduction by H2 gas in a Smelting in a vertical tube furnace to

B. Satritama, T. Hidayat, Z. Zulhan, 2022

METAL METAL OXIDE

900 C, 1550 C,

W.G. Putri, B. Satritama, T. Hidayat, Z. Zulhan, 2022

H2 combustion with O2 : 0.4  Stoichiometric H2 combustion with O2 : 0.3  Stoichiometric

H2 combustion with O2 : 0.2  Stoichiometric H2 combustion with O2 : 0.1  Stoichiometric

H2 combustion with O2 : 0.15  Stoichiometric H2 combustion with O2 : 0.25  Stoichiometric

Basis: 1000 kg Fe Basis: 1000 kg Fe

Basis: 1000 kg Fe Basis: 1000 kg Fe

EAF vs SAF ID Fan

SF/FB – EAF SF – SAF – BOF RK – SAF – BOF

EAF vs SAF ID Fan

Smelting SF/FB – EAF SF – SAF – BOF RK – SAF – BOF

Oxides Wt.% Metal

? Leaching Residue Natrojarosite

1450 °C Zamzammi, A.I., Zulhan, Z., 2018

I. R. Souza Filho, et al., 2021 https://www.youtube.com/watch?v=FRyJcKBrEvc&t=1098s

M. Shahabuddin, et al., 2023

You might also like