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Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking / JOHN LEWIS

Swansea University Author: JOHN LEWIS

DOI (Published version): 10.23889/SUthesis.63561

Abstract

The manufacturing process of iron, using the blast furnace (BF) generates dust as a by-product, which is recycled, however, the generation of the dust in excess is undesirable. A comprehensive review of the dust has determined that each of the raw materials for blast furnace ironmaking contributes t...

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Published: Swansea, Wales, UK 2023
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Cockings, Hollie.
URI: https://cronfa.swan.ac.uk/Record/cronfa63561
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fullrecord <?xml version="1.0" encoding="utf-8"?><rfc1807 xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" xmlns:xsd="http://www.w3.org/2001/XMLSchema"><bib-version>v2</bib-version><id>63561</id><entry>2023-05-31</entry><title>Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking</title><swanseaauthors><author><sid>a9e9a4eeb211d33b606757fea0740ca5</sid><firstname>JOHN</firstname><surname>LEWIS</surname><name>JOHN LEWIS</name><active>true</active><ethesisStudent>false</ethesisStudent></author></swanseaauthors><date>2023-05-31</date><abstract>The manufacturing process of iron, using the blast furnace (BF) generates dust as a by-product, which is recycled, however, the generation of the dust in excess is undesirable. A comprehensive review of the dust has determined that each of the raw materials for blast furnace ironmaking contributes to its formation, including several forms of carbon thus addressing the hypothesis ‘The raw materials that feed the blast furnace are expelled into the gas stream and all influence the blast furnace dust.’ The current technique for quantifying coal originating carbon type mostly in the form of coal char, referred to as the nominal term Low Order Carbon (LOC) within BF dust consists of thermogravimetric analysis (TGA) however, this technique does not allow for samples of dust to be analysed in a timely manner, in line with the ever-changing conditions of the blast furnace. In this work, the TGA method has been trialled for use with BF dust, with improvements offered to the heating profile, allowing for faster analysis. Moreover, alternative techniques have been trialled, in combination with various characterisation methods such as X-ray diffraction, Scanning Electron Microscopy, total carbon and Optical Emission Spectroscopy. The ‘Winkler Method’ which was originally designed to quantify charcoal in soil sediment has been successfully adapted and optimised to suit LOC quantification in BF dust, showing a good correlation with the original benchmark technique. This answered the hypothesis, ‘Thermal techniques can be used to differentiate carbon sources in dust generated in blast furnaces that use granulated coal injection.’ The techniques for LOC quantification were applied to dust samples spanning a 9 month period. to determine the process parameters that influence the LOC presence within the dust. It was found that the resolution of sampling is key to identify relationships between process parameters and LOC within the dust. A novel technique to continuously monitor the dust output of the furnace found that the dust output and the LOC within the dust are related, where the increasing dust output leads to increasing concentrations of LOC within the carbon profile of the dust itself. Process parameters including blast pressure, blast volume, and production rate were considered to increase the dust output from the furnace based on the work of the dust probe, thus answering the hypothesis ‘Coal combustion in the raceway can be impacted by process parameters and the evidence can be found in the fingerprint of blast furnace dust.’ A node mapping exercise was used to model an ideal set of process conditions for low dust operations. The foundations to make macro advances in carbon and dust output reduction in blast furnace ironmaking are laid out in this thesis.</abstract><type>E-Thesis</type><journal/><volume/><journalNumber/><paginationStart/><paginationEnd/><publisher/><placeOfPublication>Swansea, Wales, UK</placeOfPublication><isbnPrint/><isbnElectronic/><issnPrint/><issnElectronic/><keywords>Blast Furnace, Coal Injection, Ironmaking, Dust, Dust Monitoring, By-Produce Generation</keywords><publishedDay>4</publishedDay><publishedMonth>5</publishedMonth><publishedYear>2023</publishedYear><publishedDate>2023-05-04</publishedDate><doi>10.23889/SUthesis.63561</doi><url/><notes/><college>COLLEGE NANME</college><CollegeCode>COLLEGE CODE</CollegeCode><institution>Swansea University</institution><supervisor>Cockings, Hollie.</supervisor><degreelevel>Doctoral</degreelevel><degreename>EngD</degreename><degreesponsorsfunders>TATA Steel Strip Products UK, UKRI, EPSRC, M2A</degreesponsorsfunders><apcterm/><funders/><projectreference/><lastEdited>2023-09-29T10:19:04.1441490</lastEdited><Created>2023-05-31T14:59:03.1441129</Created><path><level id="1">Faculty of Science and Engineering</level><level id="2">School of Engineering and Applied Sciences - Materials Science and Engineering</level></path><authors><author><firstname>JOHN</firstname><surname>LEWIS</surname><order>1</order></author></authors><documents><document><filename>63561__27660__414bbac47f6646e2ba219496999d1c42.pdf</filename><originalFilename>2023_Lewis_J.final.63561.pdf</originalFilename><uploaded>2023-05-31T15:05:39.8865395</uploaded><type>Output</type><contentLength>14081446</contentLength><contentType>application/pdf</contentType><version>E-Thesis – open access</version><cronfaStatus>true</cronfaStatus><documentNotes>Copyright: The Author, John Lewis, 2023.</documentNotes><copyrightCorrect>true</copyrightCorrect><language>eng</language></document></documents><OutputDurs/></rfc1807>
spelling v2 63561 2023-05-31 Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking a9e9a4eeb211d33b606757fea0740ca5 JOHN LEWIS JOHN LEWIS true false 2023-05-31 The manufacturing process of iron, using the blast furnace (BF) generates dust as a by-product, which is recycled, however, the generation of the dust in excess is undesirable. A comprehensive review of the dust has determined that each of the raw materials for blast furnace ironmaking contributes to its formation, including several forms of carbon thus addressing the hypothesis ‘The raw materials that feed the blast furnace are expelled into the gas stream and all influence the blast furnace dust.’ The current technique for quantifying coal originating carbon type mostly in the form of coal char, referred to as the nominal term Low Order Carbon (LOC) within BF dust consists of thermogravimetric analysis (TGA) however, this technique does not allow for samples of dust to be analysed in a timely manner, in line with the ever-changing conditions of the blast furnace. In this work, the TGA method has been trialled for use with BF dust, with improvements offered to the heating profile, allowing for faster analysis. Moreover, alternative techniques have been trialled, in combination with various characterisation methods such as X-ray diffraction, Scanning Electron Microscopy, total carbon and Optical Emission Spectroscopy. The ‘Winkler Method’ which was originally designed to quantify charcoal in soil sediment has been successfully adapted and optimised to suit LOC quantification in BF dust, showing a good correlation with the original benchmark technique. This answered the hypothesis, ‘Thermal techniques can be used to differentiate carbon sources in dust generated in blast furnaces that use granulated coal injection.’ The techniques for LOC quantification were applied to dust samples spanning a 9 month period. to determine the process parameters that influence the LOC presence within the dust. It was found that the resolution of sampling is key to identify relationships between process parameters and LOC within the dust. A novel technique to continuously monitor the dust output of the furnace found that the dust output and the LOC within the dust are related, where the increasing dust output leads to increasing concentrations of LOC within the carbon profile of the dust itself. Process parameters including blast pressure, blast volume, and production rate were considered to increase the dust output from the furnace based on the work of the dust probe, thus answering the hypothesis ‘Coal combustion in the raceway can be impacted by process parameters and the evidence can be found in the fingerprint of blast furnace dust.’ A node mapping exercise was used to model an ideal set of process conditions for low dust operations. The foundations to make macro advances in carbon and dust output reduction in blast furnace ironmaking are laid out in this thesis. E-Thesis Swansea, Wales, UK Blast Furnace, Coal Injection, Ironmaking, Dust, Dust Monitoring, By-Produce Generation 4 5 2023 2023-05-04 10.23889/SUthesis.63561 COLLEGE NANME COLLEGE CODE Swansea University Cockings, Hollie. Doctoral EngD TATA Steel Strip Products UK, UKRI, EPSRC, M2A 2023-09-29T10:19:04.1441490 2023-05-31T14:59:03.1441129 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering JOHN LEWIS 1 63561__27660__414bbac47f6646e2ba219496999d1c42.pdf 2023_Lewis_J.final.63561.pdf 2023-05-31T15:05:39.8865395 Output 14081446 application/pdf E-Thesis – open access true Copyright: The Author, John Lewis, 2023. true eng
title Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking
spellingShingle Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking
JOHN LEWIS
title_short Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking
title_full Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking
title_fullStr Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking
title_full_unstemmed Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking
title_sort Optimising Carbon Type Differentiation Techniques to Reduce Dust Emissions in Blast Furnace Ironmaking
author_id_str_mv a9e9a4eeb211d33b606757fea0740ca5
author_id_fullname_str_mv a9e9a4eeb211d33b606757fea0740ca5_***_JOHN LEWIS
author JOHN LEWIS
author2 JOHN LEWIS
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publishDate 2023
institution Swansea University
doi_str_mv 10.23889/SUthesis.63561
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
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description The manufacturing process of iron, using the blast furnace (BF) generates dust as a by-product, which is recycled, however, the generation of the dust in excess is undesirable. A comprehensive review of the dust has determined that each of the raw materials for blast furnace ironmaking contributes to its formation, including several forms of carbon thus addressing the hypothesis ‘The raw materials that feed the blast furnace are expelled into the gas stream and all influence the blast furnace dust.’ The current technique for quantifying coal originating carbon type mostly in the form of coal char, referred to as the nominal term Low Order Carbon (LOC) within BF dust consists of thermogravimetric analysis (TGA) however, this technique does not allow for samples of dust to be analysed in a timely manner, in line with the ever-changing conditions of the blast furnace. In this work, the TGA method has been trialled for use with BF dust, with improvements offered to the heating profile, allowing for faster analysis. Moreover, alternative techniques have been trialled, in combination with various characterisation methods such as X-ray diffraction, Scanning Electron Microscopy, total carbon and Optical Emission Spectroscopy. The ‘Winkler Method’ which was originally designed to quantify charcoal in soil sediment has been successfully adapted and optimised to suit LOC quantification in BF dust, showing a good correlation with the original benchmark technique. This answered the hypothesis, ‘Thermal techniques can be used to differentiate carbon sources in dust generated in blast furnaces that use granulated coal injection.’ The techniques for LOC quantification were applied to dust samples spanning a 9 month period. to determine the process parameters that influence the LOC presence within the dust. It was found that the resolution of sampling is key to identify relationships between process parameters and LOC within the dust. A novel technique to continuously monitor the dust output of the furnace found that the dust output and the LOC within the dust are related, where the increasing dust output leads to increasing concentrations of LOC within the carbon profile of the dust itself. Process parameters including blast pressure, blast volume, and production rate were considered to increase the dust output from the furnace based on the work of the dust probe, thus answering the hypothesis ‘Coal combustion in the raceway can be impacted by process parameters and the evidence can be found in the fingerprint of blast furnace dust.’ A node mapping exercise was used to model an ideal set of process conditions for low dust operations. The foundations to make macro advances in carbon and dust output reduction in blast furnace ironmaking are laid out in this thesis.
published_date 2023-05-04T10:19:05Z
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score 11.036116

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