Uncovering Fundamental Mechanisms to Enable Sustainable Steel Manufacturing

揭示实现可持续钢铁制造的基本机制

• 批准号: EP/N011368/1
• 负责人: Zushu Li
• 金额: $ 147.82万
• 依托单位: University of Warwick
• 依托单位国家: 英国
• 项目类别: Fellowship
• 财政年份: 2016
• 资助国家: 英国
• 起止时间: 2016 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FN011368%2F1
• 关键词: Uncovering; Fundamental; Mechanisms; Enable; Sustainable

Steel is a backbone material in modern society. Global steel demand is continuously growing and is forecast to double by 2050. Strict environmental regulations, new energy sources, government support for manufacturing, and restructuring of the steel industry in the UK and worldwide are creating the opportunity to revolutionise the industry to produce low carbon, high value added steels. This creates an urgent need for a strong UK research base in process metallurgy that will help transform the UK steel industry into more sustainable operations. This Fellowship aligns well with this urgent need for UK steel industry. Under this EPSRC Manufacturing Fellowship, I will bring best practice in industry to academia. I will establish an internationally recognised multi-disciplinary research team, which will build the research (theoretical, experimental and modelling) capability and create the fundamental knowledge needed to realise transformative changes on extraction, refining and casting of steels, and address the future global mega trends in energy, CO2 regulation and oversupply. A key area of focus will be low carbon, low energy and flexible ironmaking process including HIsarna technology.HIsarna process is a promising breakthrough technology, as an alternative to conventional blast furnace (BF) ironmaking, created under the ULCOS (Ultra-Low CO2 Steelmaking) project (www.ulcos.org). The concept of the HIsarna technology has been successfully validated by four operational campaigns from 2011 to 2014 on the pilot plant with the capacity of 60 kt per year of hot metal constructed at Tata Steel. The confirmed advantages include: very high energy efficiency; flexibility in feed materials (directly using thermal coal, fine iron ore, waste oxides) without coking and ore agglomeration; 20% or above primary energy and CO2 saving; possibly up to 80% CO2 emission reduction with Carbon Capture and Storage (CCS) of the top gas; and flexible operations. Significantly higher CO2 emission reduction by HIsarna (without CCS), 35% or above compared to current BF ironmaking, can be achieved by further combining simultaneous scrap melting, biomass injection (partially replacing coal) and hydrocarbon injection in the process.However, a significant challenging road lies ahead for the HIsarna technology. One of the critical aspects for its up-scaling is that several critical scientific mechanisms have not been discovered due to its innovative nature, but will be uncovered in this Fellowship. These include (1) quantification of the dynamic interfacial phenomena in the reacting slag-metal droplet system due to the element (O, S etc) mass transfer at the slag-metal droplet interface and their important role on the fast reduction of FeO in slag, and (2) reaction mechanisms and rates between hydrocarbons and slag, metal and gases. Under this Fellowship I will also build the modelling capability (CFD model and dynamic process model) for development and optimisation of complex manufacturing processes.The research capability and the critical knowledge created under this Fellowship will be applied to study more fuel-efficient and economical BF ironmaking by shale gas injection, direct reduced iron production by shale gas, phosphorus refining in basic oxygen steelmaking, high residual obsolete scrap recycling, and interfacial phenomena in the casting mould. Furthermore, a capability on extractive metallurgy will help the UK to develop processes for recovering critical materials from wastes and extracting Mg and Ti, and will also be useful to other areas such as gasification and geology where molten oxide phases are encountered.This Fellowship will be held at Warwick Manufacturing Group (WMG), University of Warwick, in collaboration with Tata Steel, the main steel producer in the UK. It will help unlock the potential of the UK steel industry to be more innovative, productive and competitive, whilst using fewer resources and reducing environmental impact.

钢铁是现代社会的支柱材料。全球钢铁需求持续增长，预计到2050年将翻一番。严格的环境法规、新能源、政府对制造业的支持，以及英国和全球钢铁行业的重组，都为钢铁行业的变革创造了机会，使其能够生产低碳、高附加值的钢铁。这就迫切需要一个强大的英国工艺冶金研究基地，这将有助于英国钢铁行业向更可持续的方向发展。该奖学金与英国钢铁行业的迫切需求非常吻合。在这个EPSRC制造奖学金下，我将把工业界的最佳实践带到学术界。我将建立一个国际公认的多学科研究团队，该团队将建立研究（理论，实验和建模）能力，并创造实现钢铁提取，精炼和铸造变革所需的基础知识，并解决未来全球能源，二氧化碳监管和供应过剩的大趋势。重点关注的领域将是低碳、低能耗和灵活的炼铁工艺，包括HISARNA技术。HISARNA工艺是ULCOS（超低二氧化碳炼钢）项目（www.ulcos.org）下创建的一项有前途的突破性技术，可替代传统高炉（BF）炼铁。HIsarna技术的概念已在2011年至2014年的四次运行活动中得到成功验证，该活动在Tata Steel建造的试验工厂中进行，该工厂的铁水产能为每年60 kt。已确认的优势包括：非常高的能源效率;原料灵活性（直接使用动力煤、粉铁矿、废氧化物），无需结焦和矿石结块;一次能源和CO2节约20%或以上;通过炉顶煤气的碳捕集和封存（CCS），CO2减排可能高达80%;以及灵活的操作。通过进一步将废钢熔化、生物质喷吹（部分替代煤）和碳氢化合物喷吹结合起来，HIsarna（不使用CCS）的CO2减排量可以达到35%以上，但HIsarna技术面临着巨大的挑战。扩大规模的关键方面之一是，由于其创新性质，一些关键的科学机制尚未被发现，但将在本奖学金中被发现。其中包括：（1）定量化反应渣-金属液滴系统中由于元素（O、S等）在渣-金属液滴界面上的传质而引起的动态界面现象及其对渣中FeO快速还原的重要作用;（2）烃类与渣、金属和气体之间的反应机理和反应速率。在这个奖学金下，我还将建立建模能力，（CFD模型和动态过程模型），用于开发和优化复杂的制造工艺。在该奖学金下创建的研究能力和关键知识将应用于研究更节能和更经济的页岩气喷吹高炉炼铁，页岩气直接还原铁生产，碱性氧气炼钢中的磷精炼，高残留废弃废料再循环和铸模中的界面现象。此外，提炼冶金的能力将有助于联合王国开发从废物中回收关键材料和提取镁和钛的工艺，也将有助于其他领域，如遇到熔融氧化物相的气化和地质。该奖学金将在沃里克大学的沃里克制造集团（WMG）与英国主要钢铁生产商塔塔钢铁公司合作举办。这将有助于释放英国钢铁行业的潜力，使其更具创新性，生产力和竞争力，同时使用更少的资源并减少对环境的影响。

项目成果

Effects of residual elements during the casting process of steel production: a critical review

• DOI: 10.1080/03019233.2021.1898869
• 发表时间: 2021-03
• 期刊: Ironmaking & Steelmaking
• 影响因子: 2.1
• 作者: Ishwar Kapoor;C. Davis;Zushu Li

Kinetic Study on Reduction of FeO in a Molten HIsarna Slag by Various Solid Carbon Sources

• DOI: 10.1007/s11663-022-02677-1
• 发表时间: 2022-11
• 期刊: Metallurgical and Materials Transactions B
• 作者: Theint Theint Htet-Theint;Zhiming Yan;Darbaz Khasraw;Johannes L. T. Hage;K. Meijer;Zushu Li

Crystallisation behaviour of liquid CaO-SiO2-FeO-MnO slags in moist gas atmospheres (Keynotes)

液态 CaO-SiO2-FeO-MnO 炉渣在潮湿气体气氛中的结晶行为（主题演讲）

• 发表时间: 2017
• 作者: J. Li

Study on hydrogen smelting reduction behaviour in synthetic molten HIsarna slag

• DOI: 10.1080/03019233.2023.2204267
• 发表时间: 2023-05
• 期刊: Ironmaking & Steelmaking
• 影响因子: 2.1
• 作者: Theint Theint Htet-Theint;Zhiming Yan;Bharath Kumar Sampath Kumar-Bharath-Kumar-Sampath-Kumar-2215925368;Johannes L. T. Hage;K. Meijer;Zushu Li

Splash generation in oxygen steelmaking: What is known?

氧气炼钢中飞溅的产生：已知的是什么？

• 发表时间: 2017
• 作者: Brooks G.