Towards sustainable Iron- and steelmaking with economic optimization

The iron and steelmaking industry is among the major contributors to the anthropogenic emissions of carbon dioxide in the world. The rising levels of CO2 in the atmosphere and the global concern about the greenhouse effect and climate change have brought about considerable investigations on how to reduce the energy intensity and CO2 emissions of this industrial sector. In this thesis the problem is tackled by mathematical modeling and optimization using three different approaches. The possibility to use biomass in the integrated steel plant, particularly as an auxiliary reductant in the blast furnace, is investigated. By pre-processing the biomass its heating value and carbon content can be increased at the same time as the oxygen content is decreased. As the compression strength of the preprocessed biomass is lower than that of coke, it is not suitable for replacing a major part of the coke in the blast furnace burden. Therefore the biomass is assumed to be injected at the tuyere level of the blast furnace. Carbon capture and storage is, nowadays, mostly associated with power plants but it can also be used to reduce the CO2 emissions of an integrated steel plant. In the case of a blast furnace, the effect of CCS can be further increased by recycling the carbon dioxide stripped top gas back into the process. However, this affects the economy of the integrated steel plant, as the amount of top gases available, e.g., for power and heat production is decreased. High quality raw materials are a prerequisite for smooth blast furnace operation. High quality coal is especially needed to produce coke with sufficient properties to ensure proper gas permeability and smooth burden descent. Lower quality coals as well as natural gas, which some countries have in great volumes, can be utilized with various direct and smelting reduction processes. The DRI produced with a direct reduction process can be utilized as a feed material for blast furnace, basic oxygen furnace or electric arc furnace. The liquid hot metal from a smelting reduction process can in turn be used in basic oxygen furnace or electric arc furnace. The unit sizes and investment costs of an alternative ironmaking process are also lower than those of a blast furnace. In this study, the economy of an integrated steel plant is investigated by simulation and optimization. The studied system consists of linearly described unit processes from coke plant to steel making units, with a more detailed thermodynamical model of the blast furnace. The results from the blast furnace operation with biomass injection revealed the importance of proper pre-processing of the raw biomass as the composition of the biomass as well as the heating value and the yield are all affected by the pyrolysis temperature. As for recycling of CO2 stripped blast furnace top gas, substantial reductions in the emission rates are achieved if the stripped CO2 can be stored. However, the optimal recycling degree together with other operation conditions is heavily dependent on the cost structure of CO2 emissions and stripping/storage. The economical feasibility related to the use of DRI in the blast furnace depends on the price ratio between the DRI pellets and the BF pellets. The high amount of energy needed in the rotary hearth furnace to reduce the iron ore leads to increased CO2 emissions.

Evolução de CO2 e atividades enzimáticas em amostras de solo tratado com herbicidas

Os efeitos dos herbicidas bentazon, metolachlor, trifluralin, imazethapyr, imazethapyr+lactofen, haloxyfop-methyl, glyphosate e chlorimuron-ethyl, testados em duas concentrações (duas e dez vezes a dose média recomendada por hectare), sobre a atividade microbiana foram estudados em amostras de solo que nunca haviam recebido tratamento com pesticidas. Como bioindicadores, utilizou-se a respiração microbiana, quantificando a emissão de CO2 aos 2, 4, 8, 12, 16, 20 e 24 dias após incubação, a atividade da enzima desidrogenase e a hidrólise de diacetato de fluoresceína (FDA), aos 8 e 28 dias. Bentazon e a mistura de imazethapyr+lactofen na maior concentração e o haloxyfop-methyl nas duas concentrações apresentaram efeitos inibitórios na respiração edáfica, embora diferentes em época e duração do efeito. Nenhum dos tratamentos herbicidas afetou a hidrólise da FDA. A atividade da desidrogenase foi inibida, o que foi verificado em análise realizada aos oito dias,nas amostras de solo com alta concentração de bentazon e imazethapyr; no entanto, foi estimulada nos tratamentos com baixa concentração de metolachlor e imazethapyr e na maior concentração de glyphosate. A respiração basal e a atividade da desidrogenase mostraram maior sensibilidade na detecção de efeitos dos herbicidas sobre a microbiota do solo que as determinações da hidrólise de FDA. Apenas foi encontrada correlação significativa entre a atividade da desidrogenase e a respiração basal aos oito dias de incubação. Os resultados destacam a importância da consideração de múltiplos indicadores na avaliação dos efeitos de herbicidas na microbiota do solo.

CO2:n adsorptio Loviisan voimalaitoksen päästöilmasta 14C-päästöjen määrittämiseksi

Tämän kandidaatintyön tavoitteena oli selvittää mahdollisuuksia 14C:n kemiallisten muotojen eriyttämiseen käyttäen Loviisan voimalaitoksella olemassa olevaa näytteenkeräyslaitteistoa. Lisäksi tarkoituksena oli selvittää parhaiten tähän käyttötarkoitukseen soveltuva zeoliittityyppiä tyypeistä 4A, 5A ja 13X. Työn kirjallisessa osassa käsitellään ydinvoimalaitoksen C14-päästöjä keskittyen pääosin Loviisan VVER-laitokseen. Adsorption osalta esitellään kaupallisesti käytettyjä adsorptiomateriaaleja ja paneudutaan adsorptioon fysikaalisena ja kemiallisena ilmiönä. Lisäksi esitellään kahden desorptiomenetelmän perusperiaatteet. Kirjallisen osan lopussa kootaan tutkimukseen vaikuttavia tekijöitä ja esitellään aiemmin käytössä ollut näytteenkeräyslaitteisto. Kokeellisessa osassa esitellään työssä käytetyt laitteistot. Lisäksi on kuvattu mittausten suoritus nestetuikelaskurilla. Tämän jälkeen työssä esitellään mittaustuloksien käsittely ja näin saadut tulokset.

Utilization of steelmaking waste materials for production of calcium carbonate (CaCO3)

The steel industry produces, besides steel, also solid mineral by-products or slags, while it emits large quantities of carbon dioxide (CO2). Slags consist of various silicates and oxides which are formed in chemical reactions between the iron ore and the fluxing agents during the high temperature processing at the steel plant. Currently, these materials are recycled in the ironmaking processes, used as aggregates in construction, or landfilled as waste. The utilization rate of the steel slags can be increased by selectively extracting components from the mineral matrix. As an example, aqueous solutions of ammonium salts such as ammonium acetate, chloride and nitrate extract calcium quite selectively already at ambient temperature and pressure conditions. After the residual solids have been separated from the solution, calcium carbonate can be precipitated by feeding a CO2 flow through the solution. Precipitated calcium carbonate (PCC) is used in different applications as a filler material. Its largest consumer is the papermaking industry, which utilizes PCC because it enhances the optical properties of paper at a relatively low cost. Traditionally, PCC is manufactured from limestone, which is first calcined to calcium oxide, then slaked with water to calcium hydroxide and finally carbonated to PCC. This process emits large amounts of CO2, mainly because of the energy-intensive calcination step. This thesis presents research work on the scale-up of the above-mentioned ammonium salt based calcium extraction and carbonation method, named Slag2PCC. Extending the scope of the earlier studies, it is now shown that the parameters which mainly affect the calcium utilization efficiency are the solid-to-liquid ratio of steel slag and the ammonium salt solvent solution during extraction, the mean diameter of the slag particles, and the slag composition, especially the fractions of total calcium, silicon, vanadium and iron as well as the fraction of free calcium oxide. Regarding extraction kinetics, slag particle size, solid-to-liquid ratio and molar concentration of the solvent solution have the largest effect on the reaction rate. Solvent solution concentrations above 1 mol/L NH4Cl cause leaching of other elements besides calcium. Some of these such as iron and manganese result in solution coloring, which can be disadvantageous for the quality of the PCC product. Based on chemical composition analysis of the produced PCC samples, however, the product quality is mainly similar as in commercial products. Increasing the novelty of the work, other important parameters related to assessment of the PCC quality, such as particle size distribution and crystal morphology are studied as well. As in traditional PCC precipitation process, the ratio of calcium and carbonate ions controls the particle shape; a higher value for [Ca2+]/[CO32-] prefers precipitation of calcite polymorph, while vaterite forms when carbon species are present in excess. The third main polymorph, aragonite, is only formed at elevated temperatures, above 40-50 °C. In general, longer precipitation times cause transformation of vaterite to calcite or aragonite, but also result in particle agglomeration. The chemical equilibrium of ammonium and calcium ions and dissolved ammonia controlling the solution pH affects the particle sizes, too. Initial pH of 12-13 during the carbonation favors nonagglomerated particles with a diameter of 1 μm and smaller, while pH values of 9-10 generate more agglomerates of 10-20 μm. As a part of the research work, these findings are implemented in demonstrationscale experimental process setups. For the first time, the Slag2PCC technology is tested in scale of ~70 liters instead of laboratory scale only. Additionally, design of a setup of several hundreds of liters is discussed. For these purposes various process units such as inclined settlers and filters for solids separation, pumps and stirrers for material transfer and mixing as well as gas feeding equipment are dimensioned and developed. Overall emissions reduction of the current industrial processes and good product quality as the main targets, based on the performed partial life cycle assessment (LCA), it is most beneficial to utilize low concentration ammonium salt solutions for the Slag2PCC process. In this manner the post-treatment of the products does not require extensive use of washing and drying equipment, otherwise increasing the CO2 emissions of the process. The low solvent concentration Slag2PCC process causes negative CO2 emissions; thus, it can be seen as a carbon capture and utilization (CCU) method, which actually reduces the anthropogenic CO2 emissions compared to the alternative of not using the technology. Even if the amount of steel slag is too small for any substantial mitigation of global warming, the process can have both financial and environmental significance for individual steel manufacturers as a means to reduce the amounts of emitted CO2 and landfilled steel slag. Alternatively, it is possible to introduce the carbon dioxide directly into the mixture of steel slag and ammonium salt solution. The process would generate a 60-75% pure calcium carbonate mixture, the remaining 25-40% consisting of the residual steel slag. This calcium-rich material could be re-used in ironmaking as a fluxing agent instead of natural limestone. Even though this process option would require less process equipment compared to the Slag2PCC process, it still needs further studies regarding the practical usefulness of the products. Nevertheless, compared to several other CO2 emission reduction methods studied around the world, the within this thesis developed and studied processes have the advantage of existing markets for the produced materials, thus giving also a financial incentive for applying the technology in practice.

Energiantuotannossa talteenotetun hiilidioksidin hyötykäyttö

Hiilidioksidilla on merkittävä vaikutus ilmastoon ja suurin osa ihmisten käyttämästä energiasta perustuu hiilipohjaisiin polttoaineisiin. Energiantuotannossa talteenotetun hiilidioksidin hyötykäyttö tarjoaa erinomaisen mahdollisuuden ilmastonmuutoksen vai-kutusten vähentämiseen vaikuttamatta kuitenkaan merkittävästi käytettyihin energialäh-teisiin. CO2:n talteenottotekniikat voidaan jakaa neljään periaatteeltaan erilaiseen tyyppiin: pol-ton jälkeiseen talteenottoon, ennen polttoa tapahtuvaan talteenottoon, happipolttoon ja kemialliseen kiertoon perustuvaan palamiseen. Polton jälkeinen ja ennen polttoa tapah-tuva talteenotto edustavat eniten tutkittua ja käytettyä tekniikkaa. Hyötykäyttökohteita CO2:lla on useita, joista nykyiset merkittävimmät ovat öljyn tuo-tannon tehostus ja elintarviketeollisuus. Tulevaisuudessa merkittäviä käyttökohteita tulee todennäköisesti olemaan uusiutuvan energian varastointi synteettiseen metaa-niin/metanoliin, kemian-, paperi- ja selluteollisuuden prosessit ja vedenkäsittely.

Participation of nitric oxide in the nucleus isthmi in CO2-drive to breathing in toads

The nucleus isthmi (NI) is a mesencephalic structure of the amphibian brain. It has been reported that NI plays an important role in integration of CO2 chemoreceptor information and glutamate is probably involved in this function. However, very little is known about the mechanisms involved. Recently, it has been shown that nitric oxide synthase (NOS) is expressed in the brain of the frog. Thus the gas nitric oxide (NO) may be involved in different functions in the brain of amphibians and may act as a neurotransmitter or neuromodulator. We tested the hypothesis that NO plays a role in CO2-drive to breathing, specifically in the NI comparing pulmonary ventilation, breathing frequency and tidal volume, after microinjecting 100 nmol/0.5 µl of L-NAME (a nonselective NO synthase inhibitor) into the NI of toads (Bufo paracnemis) exposed to normocapnia and hypercapnia. Control animals received microinjections of vehicle of the same volume. Under normocapnia no significant changes were observed between control and L-NAME-treated toads. Hypercapnia caused a significant (P<0.01) increase in ventilation only after intracerebral microinjection of L-NAME. Exposure to hypercapnia caused a significant increase in breathing frequency both in control and L-NAME-treated toads (P<0.01 for the control group and P<0.001 for the L-NAME group). The tidal volume of the L-NAME group tended to be higher than in the control group under hypercapnia, but the increase was not statistically significant. The data indicate that NO in the NI has an inhibitory effect only when the respiratory drive is high (hypercapnia), probably acting on tidal volume. The observations reported in the present investigation, together with other studies on the presence of NOS in amphibians, indicate a considerable degree of phylogenetic conservation of the NO pathway amongst vertebrates.

Effect of acute and repeated restraint stress on glucose oxidation to CO2 in hippocampal and cerebral cortex slices

It has been suggested that glucocorticoids released during stress might impair neuronal function by decreasing glucose uptake by hippocampal neurons. Previous work has demonstrated that glucose uptake is reduced in hippocampal and cerebral cortex slices 24 h after exposure to acute stress, while no effect was observed after repeated stress. Here, we report the effect of acute and repeated restraint stress on glucose oxidation to CO2 in hippocampal and cerebral cortex slices and on plasma glucose and corticosterone levels. Male adult Wistar rats were exposed to restraint 1 h/day for 50 days in the chronic model. In the acute model there was a single exposure. Immediately or 24 h after stress, the animals were sacrificed and the hippocampus and cerebral cortex were dissected, sliced, and incubated with Krebs buffer, pH 7.4, containing 5 mM glucose and 0.2 µCi D-[U-14C] glucose. CO2 production from glucose was estimated. Trunk blood was also collected, and both corticosterone and glucose were measured. The results showed that corticosterone levels after exposure to acute restraint were increased, but the increase was smaller when the animals were submitted to repeated stress. Blood glucose levels increased after both acute and repeated stress. However, glucose utilization, measured as CO2 production in hippocampal and cerebral cortex slices, was the same in stressed and control groups under conditions of both acute and chronic stress. We conclude that, although stress may induce a decrease in glucose uptake, this effect is not sufficient to affect the energy metabolism of these cells.

Inhibition of in vitro CO2 production and lipid synthesis by 2-hydroxybutyric acid in rat brain

2-Hydroxybutyric acid appears at high concentrations in situations related to deficient energy metabolism (e.g., birth asphyxia) and also in inherited metabolic diseases affecting the central nervous system during neonatal development, such as "cerebral" lactic acidosis, glutaric aciduria type II, dihydrolipoyl dehydrogenase (E3) deficiency, and propionic acidemia. The present study was carried out to determine the effect of 2-hydroxybutyric acid at various concentrations (1-10 mM) on CO2 production and lipid synthesis from labeled substrates in cerebral cortex of 30-day-old Wistar rats in vitro. CO2 production was significantly inhibited (30-70%) by 2-hydroxybutyric acid in cerebral cortex prisms, in total homogenates and in the mitochondrial fraction. We also demonstrated a significant inhibition of lipid synthesis (20-45%) in cerebral cortex prisms and total homogenates in the presence of 2-hydroxybutyric acid. However, no inhibition of lipid synthesis occurred in homogenates free of nuclei and mitochondria. The results indicate an impairment of mitochondrial energy metabolism caused by 2-hydroxybutyric acid, a fact that may secondarily lead to reduction of lipid synthesis. It is possible that these findings may be associated with the neuropathophysiology of the situations where 2-hydroxybutyric acid is accumulated.

Hiilidioksidin käsittely P2G prosessia varten

Power-to-Gas (P2G) tarkoittaa sähköenergian muuttamista kaasuksi. Kyse on konseptista, jossa uusiutuvaa energiaa varastoidaan kaasuun kemialliseksi energiaksi. Siinä tuotettava kaasu on joko vetyä tai metaania. Metanoinnissa muodostetaan hiilidioksidista ja vedystä kemiallisella prosessilla metaania, joka voidaan syöttää maakaasuverkkoon. Hiilidioksidin laadulle tässä prosessissa ei ole selkeitä ohjeita. Tässä työssä on tavoitteena selvittää miten hiilidioksidin laatu vaikuttaa metanointiprosessiin ja miten sitä tulee käsitellä tätä prosessia varten. Selvitetään myös mahdollisia hiilidioksidinkäsittelymenetelmiä, sekä lyhyesti talteenotto- ja kuljetustapojen vaikutuksia niihin. Esitetään kirjallisuudesta löytyviä arvioita hiilidioksidin käsittelyn kustannuksille.

Climatic changes: what if the global increase of CO2 emissions cannot be kept under control?

Climatic changes threaten the planet. Most articles related to the subject present estimates of the disasters expected to occur, but few have proposed ways to deal with the impending menaces. One such threat is the global warming caused by the continuous increase in CO2 emissions leading to rising ocean levels due to the increasing temperatures of the polar regions. This threat is assumed to eventually cause the death of hundreds of millions of people. We propose to desalinize ocean water as a means to reduce the rise of ocean levels and to use this water for populations that need good quality potable water, precisely in the poorest regions of the planet. Technology is available in many countries to provide desalinated water at a justifiable cost considering the lives threatened both in coastal and desertified areas.

PURIFICAÇÃO DE ÓLEOS VEGETAIS POR EXTRAÇÃO COM CO2 SUPERCRÍTICO

Este estudo constatou a possibilidade de extrairem-se ácidos graxos livres de óleos vegetais com CO2 supercrítico. Utilizou-se neste trabalho óleos de soja e de castanha do Pará. A pesquisa desenvolveu-se em duas etapas, inicialmente investigou-se a possibilidade de se extrairem os ácidos graxos destes óleos em condições de extração que variaram de 50-140 bar e de 40-80oC durante 40-160 minutos. Concluiu-se que é possível realizar a desacidificação de óleos vegetais. A eficiência da extração foi de aproximadamente 30% a 140 bar e 80oC para ambos os óleos. Após esta primeira etapa, o próximo passo foi a tentativa de obter-se um aumento na eficiência do processo promovendo a pré-degomagem nos óleos brutos como uma etapa anterior ao processo de desacidificação com CO2 supercrítico. A degomagem foi realizada através de dois métodos diferentes, um para extrair as gomas hidratáveis e outro para extrair tanto as hidratáveis como as não-hidratáveis. Os resultados experimentais foram obtidos a 140 bar e 80oC durante 40-160 minutos, mostrando que a pré-degomagem é realmente necessária, pois a eficiência da extração aumentou para 57% para o óleo de soja e 42% para o de castanha do Pará totalmente degomados, sendo que o método escolhido deve extrair tanto as gomas hidratáveis como as não-hidratáveis. Finalmente, utilizou-se cossolvente (etanol a 1-5% do peso do óleo) para auxiliar a extração, observando-se um aumento na eficiência para aproximadamente 65% para o óleo de soja e 56% para o de castanha do Pará totalmente degomados a 140 bar e 80oC por 40-160 minutos.

EXTRACTION OF OIL FROM PRESSED PALM OIL (Elaes guineensis) FIBERS USING SUPERCRITICAL CO2

Residual fibers from palm oil production are a good source of carotene, since they contain more than 5% of the original oil, with about 5000 ppm of carotenoids. As carotenoids are thermosensitive molecules, supercritical CO2 can be used for oil recovery, because this technique employs low temperatures. In this work results of oil extraction experiments from pressed palm oil fibers are shown. Fibers were from AGROPALMA, an industry which is located in Tailândia (Pará, Brazil). Extractions were carried out at 200, 250 and 300 bar and at temperatures of 45 and 55oC. Oil was analyzed by UV/vis spectrophotometry for total carotene determination. Results showed a large increase in extraction rate from 200 to 250 bar and a small variation from 250 to 300 bar. The total amount of carotenes did not increase in the course of extraction at 300 bar, but it showed a large increase at 200 and at 250 bar. Free fatty acids are present in amounts larger than those found in commercial oils.

THE EFFECTIVE DIFFUSIVITY OF CLOVE(Eugenia caryophyllus) ESSENTIAL OIL IN PRESSURIZED CO2

The effective diffusivity of clove essential oil in subcritical liquid CO2 was estimated. The experimental apparatus employed was a fixed-bed extractor. The fixed bed was formed with grounded (mesh -32 + 65) and compacted clove buds which were considered a solid element. The effective diffusion coefficient was evaluated by fitting the experimental concentration profile to the unsteady state mass balance equation for unidirectional diffusion in a finite solid medium. The diffusion coefficient was related to the concentration of oil in the solid by an exponential function. The estimated values of the effective diffusion coefficient varied from 3.64 to 5.22x10-10 m2/s. The average relative errors were lower than 3.1%.

EXTRAÇÃO DE OLEORESINA DE CÚRCUMA (Curcuma longa L) COM CO2 SUPERCRÍTICO

Dentre as fontes de corantes naturais mais utilizadas na indústria de alimentos, encontra-se a cúrcuma (Curcuma longa L), um rizoma do qual podem ser obtidas substâncias como a curcumina, demetoxicurcumina e bis-demetoxicurcumina. Estes pigmentos possuem coloração amarela e capacidade de substituir corantes artificiais. Com a finalidade de verificar a influência do pré-tratamento de secagem na extração, foram realizados experimentos de extração de oleoresina de cúrcuma com CO2 supercrítico, na unidade de extração do Laboratório de Engenharia Química da Universidade Federal do Pará, submetendo-se a matéria-prima a uma secagem nas temperaturas de 70 e 105oC. As extrações foram feitas a pressões de 200, 250 e 300 bar, e na temperatura de 45oC. Os resultados estão apresentados em tabelas e gráficos, em termos de rendimentos totais e teor de curcumina presente na oleoresina. A secagem a 70oC favoreceu a extração de oleoresina em termos de tempo de extração, e contribuiu para a manutenção de curcumina na matéria-prima.

EXTRAÇÃO DE LIPÍDEOS DA AMÊNDOA DE CASTANHA DE CAJU COM CO2 SUPERCRÍTICO

Nos últimos anos, vem crescendo o interesse em alimentos com baixo índice de calorias. Nos métodos tradicionais de extração de lipídeos com solventes orgânicos, devido as condições de extração, a integridade dos compostos extraídos e da matriz pode ser afetada pela decomposição térmica ou por contaminação pelo solvente. A extração com fluido supercrítico (EFSC) pode proporcionar um método alternativo para remover lipídeos, sem que haja redução significativa nas propriedades organolépticas do produto. O objetivo deste trabalho é extrair parcialmente o óleo contido na amêndoa da castanha de caju (Anacardium occidentale) com dióxido de carbono (CO2) supercrítico em condições de pressão de 100-170 bar e temperatura de 40-80 (C, para obter um produto de valor calórico reduzido que poderá ser usado como substituto para o amendoim e outras amêndoas na indústria de confeitos. Os experimentos foram realizados em um extrator de 300 ml, dispondo de sistemas de agitação magnética e variação de temperatura. Os resultados experimentais mostraram que o aumento da pressão acarretou um aumento na eficiência de extração. O efeito da temperatura foi o mesmo porém menos significativo.