INJECTION EXPERIENCE OF SHORT CICLE BIOMASS CHARCOAL FINES
IN BLAST FURNACE
Eng. Paulo Afonso GomesEng. Marcelo de Matos
Eng. Ricardo Luchese de Moraes
Rio de Janeiro October 17th, 20121
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THE INJECTION OF FINES IN SMALL BLAST FURNACES IS EXPECTED TO GROWTH
MAIN DRIVERS:
• INCREASE OF BLAST FURNACE PRODUCTIVITY• DEACRESE DEPENDENCE OF PLANTED FORESTS• NEED OF COST REDUCTION ON PIG IRON PRODUCTION
REALITY
• THE CHARCOAL PRODUCTION GENERATES ONLY 10% OF FINES• THE INCREASE OF INJECTION WILL CREATE A DEFICIT OF FINES
SOLUTION
• CHARCOAL FINES FROM SHORT ROTATION CROPS CAN BE THE ANSWER
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WHY USE FINES FROM SHORT ROTATION CROPS?
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MATERIALS AND METHODS• THE CHARCOAL INJECTION EXPERIENCE, USING BIOMASS FROM BAMBOO WAS CARRIED
OUT IN JUN 2010 AT CIA SIDERÚRGICA VALE DO PINDARÉ BLAST FURNACE’S 3 AND 4, OWNED BY QUEIROZ GALVÃO GROUP IN AÇAILÂNDIA – MA, WHICH MAIN CHARACTERISTICS ARE DETAILED BELOW:
BLAST FURNACE
# 3# 3# 3# 3 # 4# 4# 4# 4
NET VOLUME m3
157 178
# TUYERES Unit 10 12
TUYERES
DIAMETERmm. 95 95
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THE BAMBOO USED FOR CHARCOAL FINE PRODUCTION WAS SUPPLIED BY AGRIMEX (COELHO NETO - PI)
SPECIES: ““““BAMBUSA VULGARIS””””
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MATERIALS AND METHODS
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� BAMBOO PLANTATION
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� BAMBOO HARVEST AND CHIP PRODUCTION
BAMBOO PLANTATION AND HARVEST
.
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C. VEGETABLE FINES MOISTURE GCV NCV UHV ASH
EUCALYPTUS % 1,00 6013 5912 5851 12,52
EUCALYPTUS % 1,61 6470 6368 6262 5,78
BAMBOO % 1,50 5882 5781 5691 21,61
BAMBOO % 1,57 5816 5715 5622 18,47
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CARBONIZED BIOMASS ANALYSIS
SOURCE: LQCE- ESALQ – USP -2010
ASH INFLUENCE ON HEATING VALUE
GROSS HEATING VALUE X ASH CONTENT %
ASH CONTENT %
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NAMEWOOD CHARCOAL
(*) BAMBOO
(**)ELEPHANT GRASS
(**)
Density (kg.m-3) 420 a 480 191,70 123,82
Volatile Matter (%) 19,16 15,65 14,22
Ashes (%) 7,32 5,89 13,36
Fixed Carbon (%) 72,47 71,77 67,39
Moisture (%) 1,05 8,03 5,04
Impurities(%) N/A 13,83 15,32
Size (mm.) <0,15 32,18 27,33
CHARCOAL FINES ANALYSES FROM DIFFERENT BIOMASSS
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•After drying in the mill** After carbonization
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NAMEBEFORE MILL PROCESS (%)
PROCESS MILL
REJECT(%)
AFTER MILL PROCESS (%)
Sample 1 Sample 2 Sample 3
Volatile Matter 10,33 1,77 8,76 17,13 11,44
Ashes 18,88 91,44 18,38 14,91 13,11
Fixed Carbon 59,84 6,44 70,95 66,64 76,12
Moisture 10,95 0,35 1,91 1,32 2,43
SiO2 (Ashes) 64,56 53,58
FeO (Ashes) 16,02
VARIATIONS IN BAMBOO FINES CHARACTERISTICS IN GRINDING PROCESS
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DAY
MOISTURE(Mill Process
Entrance)%
MOISTURE(Fines)*
%
SIZE(%< 0,15mm)
DENSITY(kg/m3)
June 22, 2010
8,02 1,74 94 429
June 23, 2010
8,64 1,51 88 442
June 24, 2010
8,11 1,61 92 443
June 25, 2010
8,29 1,84 95 432
INJECTED BAMBOO FINES CHARACTERISTICS AND PROPERTIES
16* After drying
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DAYPRODUCTION(t Pig Iron/Day)
INJECTION RATIO(kg of fines/t pig iron) *
June 22, 2010 332 53
Juse 23, 2010 377 46
June 24, 2010 367 47
June 25, 2010 328 33
LEVELS OF INJECTION OF FINES AT BLAST FURNACE 4
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* The injection rate is limited by the flame temperature;* The QG Group is investing on an oxygen plant, pursuing an increase injection ratio
(aim: until 110 kg/t pig iron)
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BAMBOO EXPERIMENTAL PLANTATION AREA AT PINDARÉ MILL
� AGE – 04 MONTHS � AGE – 09 MONTHS
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ELEPHANT GRASS (MISCANTHUS) EXPERIMENTAL PLANTATION AREA AT PINDARÉ MILL
AGE – 4 MONTHS AGE – 9 MONTHS
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ARUNDO DONAX EXPERIMENTAL AREA AT PINDARÉ PLANT
� AGE – 4 MONTHS � AGE – 9 MONTHS
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CONCLUSIONS
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• THE CHARCOAL FINES PRODUCED FROM BAMBOO MAY BE INJECTED IN BLAST FURNACESIN QUANTITY EQUIVALENT TO THAT OF EUCALYPTUS CHARCOAL FINES.
• THE SUBSTITUTION RATIO IS THE SAME AS THE CHARCOAL FINES FROM EUCALYPTUS ASLONG AS IMPURITIES ARE NOT INCORPORATED ON THE CARBONIZATION PROCESS;
• THE QUEIROZ GALVÃO GROUP, AFTER THIS SUCCESSFUL INJECTION EXPERIENCE, HASSTARTED EXPERIMENTAL PLANTATIONS OF BAMBOO, ELEPHANT GRASS AND ARUNDODONAX, AIMING BIOMASS PRODUCTION FOR CARBONIZATION AND AS WEL, AIMING TOINCREASE THE INJECTION RATES ON BLAST FURNACES AND, IN THE FUTURE, TO USE THEMIN THE IRON ORE SINTERING PROCESS;
• THE SHORT ROTATION BIOMASS PRODUCTION COST IS CURRENTLY SIMILAR TOEUCALYPTUS, BUT IT CAN BE REDUCED;
• THE START OF ““““PROJETO DE FOMENTO”””” AT THE PINDARÉ MILL’S INFLUENCE ZONE COULDDECREASE THE CURRENT BIOMASS PRODUCTION COST AND FURTHER INCENTIVE IN THEUSE OF SHORT ROTATION BIOMASS FINES.
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BIOMASS COST (R$/t Dry Basis)
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BIOMASS CULTIVATION HARVEST FREIGHTTOTAL (CASH)
FINANCIAL COST
TOTAL (CASH +
FIN.)
LANDCOST
CASH + LAND +
FIN.
CONVENTIONAL EUCALYPTUS 39.34 34.19 7.00 80.53 11.00 91.53 20.40 114.07
SHORT ROTATIONEUCALYPTUS
62.86 44.56 7.00 114.42 15.48 129.90 18.60 148.51
ELEPHANT GRASS 36.57 46.05 8.56 91.17 0.00 91.17 15.14 106.31
BAMBOO 33.75 53.66 4.53 91.94 2.08 94.01 23.44 117.46
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CULTIVATION COST
CONVENTIONAL EUCALYPTUS
S. ROTATION EUCALYPTUS
ELEPHANT GRASS
BAMBOO
Formation (R$ / ha) 4.679 5.540 3.083 3.973Maintenance (R$ / ha) 559 821 1.074 73Conducting (R$ / ha) 2.221 2.431 0 946
Cycle (years) 14 9 14 14Cycle Formation 1 1 1 1
Maintenance per Cicle 12 6 13 8Regowth per Cicle 1 2 0 6
Yield (t dried / ha / Year) 24,70 27,09 33,30 21,.50Production (t dried/ ha / Cicle) 345,80 243,84 466,20 301,00Cultivation Cost (R$/ha/Cicle) 13.604 15.328 17.047 10.232Cultivation Cost (R$/ha/Year) 972 1.703 1.218 731Cultivation Cost (R$/t dried) 39,34 62,86 36,57 33,75
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BIOMASS COST (R$/t Dry Basis)
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HARVEST COST + FREIGHT
CONVENTIONAL EUCALYPTUS
S. ROTATION EUCALYPTUS
ELEPHANTGRASS
BAMBOO
Harvest + Chipping (R$ /ha) 5.911,00 3.621,69 1.533,47 2.307,25
Average Harvested Volume (BDMT / ha) 172,90 81,28 33,30 43,00
Harvest / BDMT* 34,19 44,56 46,05 53,66
Freight (10 km) per GMT* 3,85 3,85 3,85 3,85
Moisture 45% 45% 55% 15%
Freight per BDMT* 7,00 7,00 8,56 4,53
BIOMASS COST (R$/t Dry Basis)
* BONE DRY METRIC TON** GREEN METRIC TON
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FINANCIAL + LAND COST
CONVENTIONAL EUCALYPTUS
S. ROTATION EUCALYPTUS
ELEPHANTGRASS BAMBOO
Cycle Financial Cost (R$/ha) 4.542 3.775 0.00 625
Cycle (yers) 14 9 14 14
Yield (BDMT* /ha / Year) 24,70 27,09 33,30 21,50
Financial Cost (R$ / BDMT*) 13,13 15,48 0,00 2,08
Land Price (R$/ha) 4.200 4.200 4.200 4.200
Land usage % 50% 50% 50% 50%
Land Price + Legal Reserves + PPAs** 8.400 8.400 8.400 8.400
Land Cost (% - Real) 6% 6% 6% 6%
Annual Land Cost (R$/ha) 504,00 504,00 504,00 504,00
Yield (BDMT* / ha / Year) 24,70 27,09 33,30 21,50
Land Cost (R$/BDMT) 20,40 18,60 15,14 23,44
BIOMASS COST (R$/t Dry Basis)
* BONE DRY METRIC TON** PERMANENT PRESERVATION AREAS
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