LARGE-SCALE CHARCOAL PRODUCTION TO REDUCE CO 2 EMISSION AND IMPROVE QUALITY IN THE COAL BASED IRONMAKING INDUSTRY

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1 LARGE-SCALE CHARCOAL PRODUCTION TO REDUCE CO 2 EMISSION AND IMPROVE QUALITY IN THE COAL BASED IRONMAKING INDUSTRY Dr. Ronaldo Santos Sampaio Metallurgical Engineer, M.Sc., Ph.D Director RSConsultants Ltda VP-Renabio The content of this presentation is intellectual property of RSConsultants Ltda and should not be copied, modified, retransmitted or used for any purpose except with RSConsultants s written authorization.

2 TO REDUCE GLOBAL WARMING IT IS NECESSARY TO INCLUDE / CONSIDER FUNDAMENTALS AND NOT ONLY POLITICS! REMOVING CO 2 AND RECOVERING OXYGEN BACK TO THE ATMOSPHERE, PRESERVING NATIVE VEGETATION, TRANSFORMING SOLAR ENERGY INTO MATERIALS, CHEMICALS, ENERGY AND BETTER WHEALTH DISTRIBUTION IS WHAT BIOMASS MEANS TO BRAZIL CO 2 O 2 SUN 6CO 2 + 6H 2 O = C 6 H 12 O O 2 PHOTOSYNTHESIS Year WOOD HARVESTED 1 TON OF STEMWOOD, DRY BASE* PERMANENTE NATIVE VEGETATION PRESERVATION AND PROTECTION IT IS NECESSARY SIX YEARS OF PERMANENT GROWING FOREST TO BE ABLE TO HARVEST IN THE 7TH. YEAR. GROWING BIOMASS 3 TON. OF TIMBER, DB TON. OF ROOTS, DB 0.48 TON. TREE BRANCHES, DB 0.33 TON. OF LEAVES, DB BIOMASS FOR SOIL INCORPORATION AND PART FOR NATURAL DECOMPOSITION 0.41 TON OF LEAVES AND SMALL BRANCHES FOR THE HARVESTED TREE, 7 O. YEAR +? TON. LEAVES AND BRANCHES DROPPED DURING THE 6 YEARS *Source: Mafla/Winrock Foundation/RSConsultants

3 CO 2 INCREASE OR OXYGEN DEPLETION? GLOBAL WARMING CAN BE MORE PROPERLY REFERRED AS OXYGEN DEPLETION IN FAVOR OF CO 2 PRODUCTION DUE TO THE CONSUMPTION OF FIXATED HYDROCARBONS! NATURE SPENT MILLIONS OF YEARS TO REMOVE CO 2 AND OTHER LIGHT HYDROCARBONS FROM ATMOSPHERE, UTILIZING PROCESSES SUCH AS THE PHOTOSYNTHESIS, WHERE OXYGEN REPLACED THOSE HYDRO CARBON GASES AND THE CARBON ON THEM WAS FIXATED BECAME THE COAL, THE NATURAL GAS AND THE OIL OF TODAY. MILLIONS OF YEARS PHOTOSYNTHESIS Primitive atmosphere CO 2 6CO 2 + 6H 2 O = C 6 H 12 O O 2 SUN O 2 Actual atmosphere 6CO 2 + 6H 2 O = C 6 H 12 O O 2 Coal, natural gas and oil FEW YEARS WE ARE RETURNING FAST TO THE PRIMITIVE ATMOSPHERE BY BURNING FOSSIL FUELS!

4 OXYGEN DEPLETION IS HIGHER THAN CO 2 INCREASE DUE TO H 2 & OTHERS -17 ppm The carbon cycle and atmospheric carbon dioxide ppm Example: CH4 + 2O 2 = 2 H 2 O + CO 2 Two volumes of O 2 are removed from atmosphere for each volume of CO 2 formed! -57 ppm Source: Figure rd. IPCC report from Work Group 1. Page ppm 367 ppm +15 ppm

5 OXYGEN DEPLETION MEANS OZONE DEPLETION 3/2O 2 (g) = O 3 (g) P O3 (g) = (3.679E-029) 25oC *(P O2 (g))^3/2 No matter how negligible it can be assumed, ozone (O 3 ) is proportional to the O 2 partial pressure in the atmosphere. If O 2 is being depleted so it is ozone. More than 6 billions tons of coals are burned every year in this Planet. That means that more than 4.3 billion tons of O 2 is removed only in this process. We are not counting natural gas and oil burning. Using CFCs as escape goat to fossil energy utilization was a smart strategy to deal with the Ozone Layer depletion. Utilizing energy efficiency to reduce CO 2 emission is another smart strategy from Kyoto Protocol actual rules to keep the business as it is! Unhappily, at this moment in time, we do not have any economic attractive alternative to the existing fossil fuels. In reality the rate of CO2 emissions is increasing enormously with the growing economies like CHINA. The renewable energies are expensive and will need long time to get their deserved share of the growing total energy being utilized. To produce steel at least 1.4 billions tons of CO 2 are emitted every year. At least here, we can do something to reduce oxygen depletion and CO 2 emissions.

6 BRAZILIAN CHARCOAL CONSUMPTION BY SOURCE (AMS). Very few organizations really follow and collect statistics data about the production and consumption of charcoal in Brazil. Assossiação Mineira de Silvicultura, AMS, is doing a good job but it needs a help to improve and keep this necessary service. Minas Gerais and Carajás (Pará & Maranhão) are where most of charcoal is produced in Brazil. Year Charcoal Integrated Mills Independent Pig Iron Producers Ferro Alloys Producers Others(Barbecue, export, cement industry, ceramics, etc.) TOTAL, millions of cubic meters The very nature of the business makes the largest share of charcoal for barbecue supplied by local sources. This charcoal is almost 100 % from native wood sources. Only companies such as V&M Florestal and Plantar have certified renewable charcoal sources for barbecue.

7 EVOLUTION OF BRAZILIAN OFFICIAL CHARCOAL PRODUCTION After 12 years of decline in the overall share, the non renewable charcoal increased significantly after Some new investments in forest are being done but more is necessary to return to a higher share of renewable charcoal. 90 Million of Metric tons charcoal/year Wt % Native Charcoal % Native Charcoal Million of Charcoal tons/year Non renewable charcoal, like mineral coal is a free source of carbon. The renewable carbon is expensive, takes years (at least seven), environmental (dry seasons, plagues, fires) and political risks (invasion from MST, etc.), huge taxes and regulations, cultural resistance and so on. Source: RSConsultants Ltda adapted from cubic meters of AMS. 2004

8 THE RENEWABLE IRONMAKING PROCESS IS IN EXTINCTION Even with this statistical data the CDM projects being done by the most responsible companies in the sector are not getting approval by the CDM Executive Board. % GLOBAL PIG IRON PROUDCTION USING RENEWABLE CHARCOAL Why? Because they believe (EB revisions) the Brazilian charcoal is almost free and all the Brazilian steel will be naturally based on charcoal. Therefore, not deserving a CDM project approval! Unhappily, the Brazilian steel industry does not know about this and it is growing based o imported coal and coke.

9 KYOTO ZERO EMISSION DEFINITION FOR RENEWABLE ENERGY For renewable energy such as the one from the wood / charcoal, no matter how bad or good is the efficiency in their utilization. In any case the overall emissions are assumed to be zero. Therefore, one can use 1000 t to produce a ton of steel or only 0,5 tons for the same objective, the emissions continues to be considered zero and there is no right to get Emission Reduction Certificates to b more efficient than the Baseline. The same is not true for the fossil energies. If the efficiency of its use goes below the baseline scenario, reducing extra amounts of CO 2 emissions, those extra quantities of CO 2 saved can be converted in Emission Reduction Certificates under CDMs. Based on the above real facts from Kyoto s actual regulations we conclude tha : Kyoto protocol is a Global effort to increase the efficiency and the life span for fossil fuels utilization but not necessarily to reduce Global Warming. Actual photosynthesis processes deserves a privileged role in the Global Warming reduction effort. If this does not became recognized as such, forget about Global Warming reduction!

10 TO PRODUCE RENEWABLE CARBON IS EXPENSIVE AND RISKY THE USE OF A SELF SUSTAINABLE PHOTOSYNTHESIS PROCESS TO REDUCE GLOBAL WARMING IS THE BEST TECHNICAL OPTION. Mother Tree Selection Clone Garden Formation Sprout Collect R & D Clones Propagation Shooting Greenhouse Acclimatization Final Cutting Soil Preparation Planting Planting Irrigation Forest Harvesting Charcoal Production Green Seamless Steel Tubes Green Crude Steel Green Hot Metal Courtesy Plantar & V&M Florestal

11 THE LOW DENSITY RENEWABLE CARBON SOURCES IMPLY IN VERY EXPENSIVE HANDLING AND TRANSPORTATIONS COSTS Mining and Concentrating Renewable Carbon A worker in renewable carbon mine RENEWABLE CARBON MINE The carbon concentration and preparation unit. (SOLAR ENERGY) Mining Coal Worker in a coal mine Wood harvest, João Pinheiro, MG Renewable carbon mine tailings ( = Micronutrients Recycling). 1 st place in the World of work accidents and deaths for silicosis, cancer, explosions, crumbling etc. Mine of Coal, Criciúma, SC

12 CARBONIZATION TECHNOLOGIES ARE CONSTRAINED BY THE BIOMASS HANDLING AND PROCESSING COSTS Scale and environmental gains HOT TAIL RECTANGULAR KILN Partial utilization of by-products INNOVATIVE CARBONIZATION PROCESSES P r o c e s s E v o l u t I o n Time JG KILN Partial environmental improvement Quality gain and charcoal/wood yield increase Environmental improvement, scale gain and increasing of charcoal/wood yield. Total byproducts utilization CONTINUOUS CARBONIZATION

13 CHARCOAL IS A COMMODITY. THEREFORE, ITS PRICE IS DEFINED BY THE MARKET (CHEAPEST) AND NOT BY THE RENEWABLE CHARCOAL! To produce a renewable charcoal today its costs will be in the order of 200 US$/t in Minas Gerais (2 R$/US$). Certainly there are many ways to reduce this cost. The values below 200 $/t are not self sustainable under today s exchange ratio Renovável_R$/tCV Nativo_R$/tCV Renovável_US$/tCV Nativo_US$/tCV This band reflects today's real renewable charcoal price! Valor da tonelada de CV, US$ e R$ Jan-02 Mar-02 Mai-02 Jul-02 Set-02 Nov-02 Jan-03 Mar-03 Mai-03 Jul-03 Set-03 Nov-03 Jan-04 Mar-04 Mai-04 Jul-04 Set-04 Nov-04 Jan-05 Mar-05 Mai-05 Jul-05 Set-05 Nov-05 This band reflects today's real renewable charcoal price (US$/t)!

14 THE CHARCOAL PRODUCTION COST STRUCTURE It is much more expensive to bring the wood inside the carbonization furnace than any other costs! % Total Charcoal Cost at Mini Blast Furnace, % typical cost fractions Wood handling will reduce its cost with increasing mechanization and new harvesting tools being developed Charcoal yield is increasing significantly with expert assistance and training plus new charcoal making processes. 0.0 Planted Wood Wood handling Carbonization Charcoal transport ROI for carbonization Dry wood productivity is increasing more than 3 times for the new expert forests Charcoal transportation can be reduced with increasing charcoal bulk density and reducing forest distance from the MBF.

15 USING RENEWABLE CARBON TO REDUCE CO 2 EMISSION IN IRON MAKING EXAMPLE OF CONVENTIONAL WAYS TO REDUCE CO 2 EMISSIONS IN COAL / COKE BASED INTEGRATED STEEL PRODUCTION LARGE SCALE CHARCOAL PRODUCTION IS NECESSARY! From: Paper published in 2003 at IAS International Ironmaking Conference, San Nicolas, Argentina. Authors: Dr. Ronaldo S. Sampaio - RSConsultants Ltda Engo. Mateus Laponez da Silveira - V&M do Brasil S.A.

16 PRIMARY STEEL INDUSTRY Steel production is one of the most intensive in energy utilization. ion. Therefore, the gaseous emissions such as SO x, NO x, CO 2 and CH 4 are very high. Also the oxygen consumption to produce this energy is another intensive in O 2 depletion Typical specific energy consumption to produce one ton of primary steel utilizing the traditional route Blast Furnace Basic Oxygen Furnace. 7400MJ/t 1350 MJ/t Typical specific energy consumption to recycle scrap into steel (secondary steel). Source: J. P.Birat, J. P.,ULCOS project director

17 CO 2, SO X EMISSIONS AND O 2 CONSUMPTION TO PRODUCE 1 t OF PRIMARY IRON (Pig Iron) UTILIZING THE COAL / COKE ROUTE. CO 2 EMISSION COAL MINE (CH4) COKE OVEN SOx 342 SOx 1613 BLAST FURNACE Pig Iron O 2 WITHDRAWN FROM ATMOSPHERE COAL CONCENTRATION Total CO 2 emission Total O 2 depletion Total SO 2 Emis. Cycle: 1955 kg/t pig iron Cycle : 1376 kg/t pig iron Cycle : 9,5 kg/t pig Fonte: Sampaio, R. S., et al. Integrating Cultivated Biomass with Charcoal and Steel Making for CO 2 fixation and O 2 Regeneration. In: Biomass Conference of the Americas, 4., 1999, Oakland, CA, EUA.

18 CO 2, SO X EMISSIONS AND O 2 CONSUMPTION TO PRODUCE 1 t OF PRIMARY IRON (Pig Iron) UTILIZING RENEWABLE CARBON. CO2 REMOVED FROM ATMOSPHERE ,695 WOOD CARBONIZATION KILN MAF Gusa HARVESTIN G7 TH YEAR O2 PRODUCED CO 2 Fixated Cycle: 160 kg/t pig In the growing forest : kg/t gusa O 2 Released Cycle: -59 kg/t pig In the growing forest : kg/ t gusa SO 2 Emis. Cycle: 0 kg/t pig Fonte: Sampaio, R. S., et al. Integrating Cultivated Biomass with Charcoal and Steel Making for CO 2 fixation and O 2 Regeneration. In: Biomass Conference of the Americas, 4., 1999, Oakland, CA, EUA.

19 THERMOCHEMICAL SIMULATION TO MEASURE EMISSIONS COMPARATIVELY The following combination of fuels and reductants were used to calculate c CO 2 and SO 2 emissions plus metallurgical results of each pig iron 100 % Coke Reference or Coke + CV or CV Pulverized coal injection (fossil +) Natural gas injection (fossil -) Pulverized renewable charcoal or or

20 THERMAL REDUCTANTS CHARACTERISTICS IMMEDIATE CHEMISTRY FOR EACH THERMAL REDUCTANT 89% 69% 75% 75% 25% 24,5% 24,5% 10% 6% 1% 1% 0,6% 1% 0,6% 1,5% 5% 0,0% 1,5% 1% 0,0% Coke Coal Ren. Charcoal Charcoal Fines Fix Carbon Volatile Material Ash H2O Sulphur RENEWABLE CHARCOAL FINES COMPARED TO COAL FINES -Much higher reactivity -Very low sulphur levels (0.01 % vs 0.6 %) -Very low ash content (2 % vs 10 %) -Ash chemistry rich is CaO, reducing slag volume and flush consumption -Bosh gas with lower density due to more H2 (better gas flow in th porous media)

21 ASH CHEMISTRY FOR A RENEWABLE CHARCOAL AND A COAL 60,0% 50,0% kg / tg 40,0% 30,0% 20,0% Coal ash chemistry Renewable charcoal ash 10,0% 0,0% %Fe %SiO2 %Al2O3 %CaO %MgO %P %Na2O+K2O - Renewable wood ash (Eucalyptus) is basic in nature (CaO+MgO > SiO2+Al2O3). This is a significant advantage in iron ore reduction due to the need of lower limestone consumption and less slag generation. Reducing fuel rate and increasing productivity in the Blast Furnace process.

22 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets SCENERY 1 REFERENCE = 100% COKE ALL COKE OPERATION CO 2 Emissions: 2006 kg/t pi Coke top charged: 499 kg/t pi ~444 kg Fix Carbon/t pi O 2 Consumption: 1048 kg/t pi Pi = pig iron or hot metal or primary iron kg / t gusa

23 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets Scenery 2 COKE + PCI of 160 kg/t pi coal fines Top charged coke: 339 kg/tpi ~ 299 kgcf/t pi CO 2 Emission: 1810 kg/t pi O 2 Consumption: 871 kg/t pi PULVERIZED COAL INJECTED: 160 kg/t pi ~110 kg FC/t pi Assumptions: Fines / coke replacement ratio = 1: 1 kg fines = 1 kg coke kg / t gusa

24 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets Scenery 3 COKE Nm 3 / t PI NATURAL GAS CO 2 Emission: 1665 kg/t pi Top charged coke: 370 kg/t pi ~326kg CF/t pi O 2 Consumption: 858 kg/t pi NATURAL GAS :100 Nm 3 /t pi Assumptions Coke / natural gas replacement ratio: 1,28 kg of coke / 1Nm 3 GN kg / t gusa

25 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets Scenery 4 COKE + 10 % TOP FIX CARBON FROM RENEWABLE CARBON TOP CHARGED COKE: 449 kg/tpi = 395 kg FC/tpi CO 2 Emission: 1797 kg/t pi O 2 Consumption: 965 kg/t pi TOP CHARCOAL: 62 kg/t pi = 45 kg FC/t pi Assumptions: 1 % FC from coke = 1% FC from charcoal (conservative) kg / t gusa

26 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets Scenery 5 COKE kg RENEWABLE CHARCOAL FINES CO 2 Emissions: 1330 kg/t pi Top Charged Coke: 339 kg/tg ~302 kg FC/tpi O 2 Consumption: 727 kg/t pi Renewable charcoal fines: 160 kg/t pi ~120 kg FC/t pi Assumptions: PCI replacement ratio: 1 kg of charcoal fines = 1 kg coke kg / t gusa

27 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets Scenary 6 COKE kg RENEWABLE CHARCOAL FINES CO 2 Emissions: 1208 kg/t pi COQUE TOPO: 310 kg/tg ~273 kgcf/tg O 2 Consumption: 678 kg/t pi Ren. Charcoal fines: 210 kg/t pi ~158 kgcf/t pi Assumptions: PCI replacement ratio: 1 kg charcoal = 1 kg coke kg / t gusa

28 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets Scenery 7 RENEWABLE CHARCOAL Nm 3 NATURAL GAS CO 2 Emission: 137 kg/t pi REN. CHARCOAL: 483 kg/t pi ~ 344 kg FC/t pi O 2 Consumption: 298 kg/t pi NATURAL GAS: 100 Nm 3 /tg Assumptions: PCI replacement ratio: 1,28 kg of charcoal = 1Nm 3 NG kg / t gusa

29 SIMULATION SCENERY DESCRIPTIONS Metallic charge considered for all sceneries 50% lump iron ore 50% pellets Scenery % RENEWABLE CHARCOAL CO 2 Emission: -125 kg/t pi REN. CHARCOAL: 617 kg/t pi ~440 kg FC/t pi O 2 Consumption: 117 kg/t pi kg / t gusa

30 % S in pi g ir o n METALLURGICAL BENEFITS Slag volume produced by each scenery simulated The use of eucalyptus charcoal fines reduce the slag volume and the sulphur content of the produced liquid iron % 0.025% 0.020% 0.015% 0.010% %S hot metal 0.005% 0.000% BF 100% coke BF coke + PCI 160 kg de CM BF coke + NG BF coke + 5%CV BF coke + 10%CV BF coke + PCI 160 kg de CV BF coke + PCI 210 kg de CV BF CV + NG BF 100% CV BF 100% coke BF coke + PCI 160 kg de CM BF coke + NG BF coke + 5% CV BF coke + 10% CV BF coke + PCI 160 kg de CV BF coke + PCI 210 kg de CV BF CV + NG BF 100% CV kg / tg

31 CO 2 EMISSIONS AND O 2 CONSUMPTION FOR THE SCENERIES SIMULATED Renewable carbon from planted biomass is able to reduce CO 2 emissions in the steel industry by more than 40% % Emissão de CO2 Consumo de O % More than 40% reduction AF 100% coque AF coque + PCI 160 kg de CM AF coque + GN AF coque + 5% CV AF coque + 10% CV AF coque + PCI 160 kg de CV AF coque + PCI 210 kg de CV AF CV + GN AF 100% CV kg / t gusa 100 % renewable carbon has negative emission! If the seven years carbon present in the growing forest is also considered, there is at least another renewable carbon for each renewable carbon utilized in the iron production cycle, e.g., more negative emission. The content of this presentation is intellectual property of RSConsultants Ltda and should not be copied, modified, retransmitted or used for any purpose except with RSConsultants s written authorization.

32 CONCLUSIONS By not considering the actual photosynthesis base processes as absolute additionalities, the Kyoto Protocol did no addressed properly the fundamentals behind the CO 2 emission reduction. Oxygen depletion covers more precisely the Global Warming and the Ozone layer reduction causes. Energy sources that does not remove oxygen from atmosphere needs extra CO 2 credits besides the carbon converted to CO 2. The no rights of CO2 credits by increasing efficiency in the use of renewable carbon is a unfair rule of Kyoto protocol against renewable carbon. The use of renewable carbon as energy source is the cleanest and more socially responsible way to produce goods is this Planet. Places and processes that can use this possibility need all the support and incentives to do so!. The various ironmaking sceneries simulated demonstrated the huge benefit to the environment as well as for the metallurgical process with the use renewable carbon from cultivated biomass. It shows that a traditional coke based reactor can gain quality and reduce up to 40 % its CO 2 emission by simply replacing the pulverized coal injection by a renewable charcoal fines injection. The use of 100 % renewable carbon generates negative CO 2 emissions and almost no oxygen is removed from the atmosphere. Considering the need to have a permanent growing forest in a seven years cycle, at least another 2 tons of CO 2 are kept fixated while this virtuous production cycle goes on.

33 THANK YOU VERY MUCH FOR YOUR ATTENTION Dr. Ronaldo Santos Sampaio Rua Ribeiro Junqueira, 161 a Belo Horizonte, MG Brazil Phone & Fax: Mobile: