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Pressurized Chemical Looping for Direct Reduced Iron Production: Economics of Carbon Neutral Process Configurations

Author

Listed:
  • Nicole K. Bond

    (Natural Resources Canada, CanmetENERGY-Ottawa, Ottawa, ON K1A 1M1, Canada)

  • Robert T. Symonds

    (Natural Resources Canada, CanmetENERGY-Ottawa, Ottawa, ON K1A 1M1, Canada)

  • Robin W. Hughes

    (Natural Resources Canada, CanmetENERGY-Ottawa, Ottawa, ON K1A 1M1, Canada)

Abstract

The replacement of the blast furnace—basic oxygen furnace (BF-BOF) steelmaking route with the direct reduced iron—electric arc furnace (DRI-EAF) route reduces the direct CO 2 emissions from steelmaking by up to 68%; however, the DRI shaft furnace is one of the largest remaining point source emitters in steelmaking. The capital and operating expenses of two potential nearly carbon-neutral DRI process configurations were investigated as a modification to a standard Midrex DRI facility. First, amine-based post-combustion capture with a 95% capture rate was considered as the benchmark, as it is currently commercially available. A second, novel configuration integrated the Midrex process with pressurized chemical looping—direct reduced iron (PCL-DRI) production. The capital expenditures were 71% and 28% higher than the standard Midrex process for a Midrex + amine capture plant, and a PCL-DRI plant, respectively. There was an incremental variable operating cost of USD 103 and USD 44 per tonne of CO 2 for DRI production using amine capture and PCL-DRI, respectively. The amine capture configuration is most sensitive to the cost of steam generation, while PCL-DRI is more sensitive to the cost of electricity and the makeup oxygen carrier. An iron-based natural ore is recommended for PCL-DRI due to the low cost and availability. Based on the lower costs compared to amine-based post-combustion capture, PCL-DRI is an attractive means of eliminating CO 2 emissions from DRI production.

Suggested Citation

  • Nicole K. Bond & Robert T. Symonds & Robin W. Hughes, 2024. "Pressurized Chemical Looping for Direct Reduced Iron Production: Economics of Carbon Neutral Process Configurations," Energies, MDPI, vol. 17(3), pages 1-20, January.
    • Handle: RePEc:gam:jeners:v:17:y:2024:i:3:p:545-:d:1324464
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    References listed on IDEAS

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    1. Patrick Moldenhauer & Carl Linderholm & Magnus Rydén & Anders Lyngfelt, 2020. "Avoiding CO2 capture effort and cost for negative CO2 emissions using industrial waste in chemical-looping combustion/gasification of biomass," Mitigation and Adaptation Strategies for Global Change, Springer, vol. 25(1), pages 1-24, January.
    2. Calin-Cristian Cormos, 2018. "Techno-Economic Evaluations of Copper-Based Chemical Looping Air Separation System for Oxy-Combustion and Gasification Power Plants with Carbon Capture," Energies, MDPI, vol. 11(11), pages 1-17, November.
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