At the moment, Tata Steel emits 12.6 Mt CO2 per year while producing 7.2 Mt steel per year. To reduce these emissions, Tata Steel has decided to replace the blast furnaces with direct reduced iron (DRI) plants in combination with reducing electrical furnaces. The DRI plants will first operate with a 100% natural gas feed. Whenever green hydrogen becomes available on the market, the natural gas will gradually be substituted with green hydrogen, reducing direct CO2 emissions. Producing steel using 100% green hydrogen as the reducing gas, called green steel, comes along with an awkward problem regarding the carbon content of the DRI. Green steel has a carbon content of 0%, while carbon is essential for multiple aspects of the production process. Furthermore, the metallization of the DRI is a critical parameter in the production process. Thus, the following research question is established: ”What is the influence of the ratio of hydrogen to natural gas inserted in the direct reduced iron plant on the performance of the reactor?”
To answer this research question, an extensive literature review is performed to gain knowledge of the reduction process, reduction technologies, and the existing mathematical models of the DRI plant. Furthermore, a multiscale mathematical model is made of the shaft furnace of the MIDREX plant. This model uses a grain-based pellet model, which incorporates the morphological structure of the pellets during the reduction process. The shaft furnace is modelled as a 1D model with multiple zones, in which the local energy, mass, and momentum equations are solved. However, due to the time restrictions of the thesis period, only the two reduction zones of the shaft furnace are incorporated. Hence, the shaft furnace model lacks the transition and cooling zones.
The shaft furnace model is compared to a real operating MIDREX plant named ”Gilmore”. The simulation results are validated against the simulation results from literature and the real plant data. The average relative error of the simulation results compared to the Gilmore plant is 14.4%. The most significant error can be attributed to the carbon weight fraction in the solid. This is the result of the missing transition and cooling zones, as most of the carburization occurs inside the transition zone. Neglecting the carbon weight fraction, the average relative error is 9.2%.
Increasing the ratio H2 / CH4 in the feed of the MIDREX plant results in an increasing H2 / CO ratio of the reducing gas entering the shaft furnace. Five cases with different H2 / CO ratios are simulated to answer the research question. The metallization of the DRI is affected by two different phenomena. First, increasing the H2 / CO ratio results in a larger gas input mole flow for the same input pressure, which is the effect of a smaller pressure drop over the shaft furnace. Subsequently, a larger gas input mole flow results in better metallization, which is the effect of more heat input and a lower gas oxidation degree in the shaft furnace. Second, as the hydrogen content increases, the temperature decreases as a result of more endothermic reduction. The thermodynamics and kinetics of reduction by hydrogen are favourable at higher temperatures, which results in a slow-down of the reduction. At lower temperatures, the thermodynamics of reduction by carbon monoxide is more favourable, realizing more reduction and increasing the temperature. This second phenomenon is predominant for equal input mole flow, resulting in worse metallization when increasing the H2 / CO ratio, as confirmed by literature. Consequently, to achieve equal metallization for a higher H2 / CO ratio, the process gas compressors of the MIDREX plant will consume more electrical energy. To conclude, substituting natural gas with hydrogen does have its disadvantages, but it is highly necessary to become CO2 neutral in the future.
For further research, the addition of transition and cooling zones to the shaft furnace model is recommended, allowing investigation of the carburization of the DRI. Furthermore, the shaft furnace model is extremely useful for implementation in a complete MIDREX plant model. Such a model could be used to investigate the total CO2, energy, and material balance of the plant for different H2 / CH4 ratios of the feed of the plant.