Cost Effective Pollution Control in a Direct Reduction Plant with a CO2 Desorption Model
In 2005 GCES began their first project in steel production providing a cost effective pollution control solutions for a direct reduction plant with a CO2 desorption model. We were contacted to provide treatment for volatile air pollutants (VOCs) and green-house gases (GHGs). Since that time our thermal oxidizer systems have been implemented to provide a pollution control solution in dozens of steel production facilities across the globe and continue to operate with efficiency and effectiveness.
Direct reduction (DR) technologies to improve steelmaking efficiencies have been continually advancing since the 1960s. In producing direct reduced iron (DRI), carbon dioxide (CO2) is released as an off-gas to the process. Many steel plants worldwide have been upgrading their DR process to include a CO2 desorption module. CO2 desorption models are used to recapture the CO2 which is then used in oilfields or bottling operations developing additional profit lines for the steel production facilities. Through the CO2 capturing operation, pollutants and green-house gases (GHGs) must be treated before being released into the atmosphere.
Direct-reduced iron often referred to as sponge iron is produced from the direct reduction of iron ore by reducing gas. The term reduced iron comes from the chemical change that iron ore goes through when it is heated in a furnace at high temperatures in the occurrence of hydrogen-rich gasses. Direct-reduction is the processes which reduce iron oxides into metallic iron to below the melting point. The product of this process is direct reduced iron. The reducing gas is a mixture of gasses, primarily hydrogen (H2) and carbon monoxide (CO).
Gulf Coast Environmental Systems (GCES) was initially chosen in 2005 to provide a Thermal Oxidizer system (TO) for treatment of the pollutants and GHG emissions. After much research and discussion with the CO2 desorption technology provider, the selection was made to use a Regenerative Thermal Oxidizer (RTO) to improve fuel efficiencies and NOX production from a standard direct-fired TO.
Because this was the 1st worldwide application of an RTO in a Direct Reduction Plant, many parameters were considered carefully to properly design the RTO system. Potential high pressure conditions resulted in the use of a cylindrical rather than rectangular design. The correct heat recovery efficiency had to be calculated to maintain outlet temperatures above the condensation levels of post-combustion by-products. Stainless steel was selected for resistance to the potential formation of sulfuric acid.
The first RTO system was successfully installed and commissioned in 2006. As the complete CO2 process became more defined, GCES worked with the original technology provider to improve and supply another system for a plant expansion. Directly after the original purchase of our GCES 3 canister RTO in 2005 two additional RTO systems were provided for another Steel Maker in the Middle East. With these three systems operating with efficiency and effectiveness our solution was proven. This has opened the door for many additional applications across the globe.
If you would like more information about how these systems works, information about our RTO or contact information for our technology partners for these projects please contact firstname.lastname@example.org.