Julio Wilder’s Post

Lake Charles Methanol II, LLC announced plans to invest $3.24 B to construct a new manufacturing plant that will produce low-carbon intensity methanol and other chemicals at the Port of Lake Charles. The company plans to use advanced auto thermal gas reforming technology and employ carbon capture and secure geologic storage to produce low-carbon hydrogen for conversion to methanol. If the project moves forward as outlined, the company expects to create 123 direct new jobs in Calcasieu Parish, with an estimated average annual salary of $135,955. LED estimates the project would result in 605 indirect new jobs, for a total of 728 potential new jobs in the Southwest Region. LCM estimates that more than 2,300 construction jobs will be created at the peak of construction. https://lnkd.in/grvEWswz

A bit of good news regarding steel production: Global Energy Monitor reports that "93% of new steelmaking capacity announced thus far in 2024 promises to use lower emission electric arc furnaces (EAFs). It also shows that 49% of the world’s steelmaking capacity under development now uses EAFs, up from just 43% in 2023 and 33% in 2022." https://lnkd.in/eQKSk_j4

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Green iron projects are in the works! There is a long way to go for this technology shift, and many different options are still being explored. It can be a confusing mix of technologies and ore types, so I was glad to provide some basic information to help understand this project under development in Queensland to the ABC recently (note to journalists, remember it's Dr - not Ms...ah well they mostly got it right). If you want to know more about the different options for green iron and green steel (yes, there is a difference!) you would be well placed to look at the work of Tom Honeyands and Arash Tahmasebi with the Centre for Ironmaking Materials Research. I've also got a few projects in the works for new kid on the block, direct electrolytic iron production! Blast furnaces, direct reduced iron and direct electrolytic iron - it's all happening here at the University of Newcastle. #greeniron #greensteel #hydrogen #electrolyticiron #renewables #decarbonisation #electrification #industry

Thank you everybody for the reactions comments and questions! As a result of many questions after the video of the 1st HCFeMn tap on the shaft furnace, I post additional information of the project: Executive Summary- Development of Alternative Smelting Process for HCFeMn Production  A2Z started the development of a combustion energy-based, process order to enable HCFeMn production where electricity is not available approximately 5 years ago. The process generates approximately 50% less CO2 than the conventional electric arc furnace route, assuming electricity is generated by coal fired generation power stations. Additional opportunities to reduce the carbon footprint with hydrogen or renewable carbon sources exist but have not been explored to date. Opex and Capex Opex is estimated to be well below conventional SAF and blast furnace process routes. Capex is estimated to be ± 5% of that required for a SAF (Up to 1500 tpm). Technology Process is based on Cupola shaft furnace technology; energy density is augmented by injection of additional fuel and reductants. Fines are used as raw material; ore, reductant and fluxes and then briquetted. Milestones 1.     Demonstrate the technical feasibility to produce Mn-slag and cast iron, using low quality ore; 25% Mn and 16% Fe. Slag: Mn-content ±40% and Mn:Fe ratio of ± 10. Mn in cast iron ± 3%. 2.    Demonstrate the technical feasibility to produce HCFeMn from ore using silicious Mn-ore. 3.    Identified deficiencies in current pilot plant to be rectified in a new demonstration unit.    Next steps 1.     Attract investor/ shareholder with synergies. 2.    Design and construct a demonstration unit, that address areas for improvement of current pilot plant, to demonstrate commercial feasibility. a.    Planned output ± 400 tpm. b.    Estimated investment required $300,000 to $500,000. c.    Estimated duration from kick-off to commissioning 8 months. 3.    Estimated variable cost ± $650/t based on current market prices of ore and reductants. 4.    After commissioning and optimising, relocate plant to suitable location at a Mn-ore mine or current smelter. 5.    Operate extended trial to optimize and demonstrate full commercial feasibility. 6.    Upscale and rollout according to agreement with partner/investor. Location of current Pilot Plant Ekandustria, Gauteng, Sout Africa Contact Information Hilgard Rademeyer Hilgard@A2Zsmelter.com

The energy requirements for the different steelmaking routes vary widely. Coal-based steel production routes such as the conventional BF-BOF process and the CCS routes have the highest final energy consumption: conventional steelmaking in the BF-BOF process requires approximately 20 gigajoule (GJ) per tonne (GJ/t) of crude steel, mainly coming from the use of coking coal. 15 GJ are needed to produce the coke which acts as a reducing agent in the blast furnace. Pulverised coal injected from the bottom of the blast furnace accounts for another 5 GJ as well as minor shares of natural gas to produce hot air account for another 5 GJ. The off-gases produced by the steel plant are recovered and used for on-site purposes. In addition, any excess off-gases are combusted in a dedicated power plant to generate on-site heat and electricity. Retrofitting the BF-BOF route with post-combustion CCS would increase the specific energy requirement to 22.8 GJ/t of crude steel, due to the additional energy (in the form of electricity) required for CO2 capturing and compression. Assuming that the reference BF-BOF configuration generates exactly the same amount of electricity via the combustion of off-gases in the on-site powerplant as is consumed within the entire plant (see methodology section for more information), this means that additional electricity would have to be purchased when retrofitting with CCS. With an energy demand of 15 GJ/t of crude steel, the HIsarna-BOF with CCS route ranks in the middle of the technologies. Since the agglomeration steps of sintering and coking are eliminated on this route, conversion losses are reduced and less energy is required than on the BF-BOF route. In addition, only a small amount of electricity is needed for CO2 capturing, since the CO2 is already highly concentrated in the exhaust gas of the HIsarna reactor and cryogenic separation can therefore be used instead of the more energy intensive amine-based CO2 absorption.  Source: #Agora Industry Analysis "Low-carbon technologies for the global #steel transformation"

“Merus Power joins the #transformation of #steelindustry by delivering #compensators for #greensteel production” 8.7.2024 “Merus Power has received a significant compensator order from one of the leading systems providers of construction and design services for #steelplants in the #metalindustry .” “The compensators are designed to improve the #energyefficiency of a #greensteelplant and will be delivered to a European customer during 2025. Typically, Merus® STATCOM systems in this power class and scope of supply cost between 4.5-6.5 million euros depending on final scope of supply and possible extension to be contracted.” “Green steel is #steel produced using #hydrogen produced from #renewableenergysources , which significantly reduces #CO2emissions compared to traditional manufacturing methods.” “Merus Power is actively involved in this transformation of the steel industry, providing solutions that improve energy efficiency and support #carbonneutrality targets.” https://lnkd.in/e3kfHhTa Source- original post Read all my posts #MariusPreston

🌟 The Future of Steel Making! 🌟 As we march towards a sustainable future, it's inspiring to witness the innovative strides being made in the steel industry. The combination of renewable energy, Direct Reduced Iron (DRI), and arc smelting is poised to revolutionize steel making as we know it. 🔋 Renewable Energy: Embracing renewable energy sources such as solar, wind, and hydro power, we're not only reducing carbon emissions but also utilizing them to power the production of green hydrogen. This green hydrogen serves as a critical component in the Direct Reduced Iron (DRI) process, enabling us to move away from carbon-intensive methods. 🔥 Direct Reduced Iron (DRI): Through the use of green hydrogen, we're able to reduce iron ore in a process that emits significantly fewer greenhouse gases compared to traditional methods reliant on coal or natural gas. This sustainable approach to DRI results in high-purity iron, setting the stage for environmentally conscious steel production. ⚡ Arc Smelting: The high-purity iron produced through the DRI process is perfectly suited for arc smelting, an electricity-powered method that offers superior control over temperature and composition. By seamlessly integrating renewable energy sources into the arc smelting process, we're further reducing our carbon footprint while delivering high-quality steel products. The synergy created by combining renewable energy, DRI, and arc smelting holds immense promise for the future of steel making. Not only does it enable us to meet growing global demand for steel sustainably, but it also drives innovation, fosters economic growth, and helps combat climate change. We want to be at the forefront of this transformation, leveraging cutting-edge technologies to drive sustainability and excellence in steel manufacturing. We are actively seeking interested partners who share our vision and want to accelerate the promotion of this sector. Join us in shaping a brighter, greener future for the steel industry! #RenewableEnergy #SteelMaking #Sustainability #Innovation #GreenTechnology #DRI #ArcSmelting #CleanEnergy #FutureOfWork #ClimateAction #Partnerships

Coal is the Prime source of Energy & Chemical Reagent in Iron & Steel Plant Every technology / innovation aims at achieving lower specific energy consumption and conservation of natural resources. Steel, one of the prime infrastructure industries has followed the same road map starting from utilization and washing & blending of coal, alternative to scarce coking coal resources ,optimization captive fuel gas energy network . Coal plays an important role in conversion of iron ores to useful iron & steel in different form. It is the prime source of energy for iron & steel making process . Coal not only function as direct thermal energy source and reducing agent in iron making but also produce captive secondary fluid energy in different process routes of Iron and Steel Making Process such as Coke Oven Gas, Blast Furnace Gas, Corex Gas, BOF Gas. Optimization and energy balance in Steel Plant is dynamic and it’s smart control through energy monitoring and control system can limit specific energy consumption. Also recovery of fluid energy is maximized from intermediate process and thereby allowing minimum energy waste to the sink. Similarly conservation of natural resources program ensure reduction, recovery, recycling and reuse of ores, fossil fuels specially coking coal, water and solid wastes to reduce carbon foot print .

Lake Charles Methanol II LLC plans to invest $3.24 billion in a manufacturing plant at the Port of Lake Charles, producing low-carbon intensity methanol and other chemicals. The facility aims to use advanced auto thermal gas reforming technology, employing carbon capture and secure geologic storage for low-carbon hydrogen production. If realized, the project is expected to create 123 direct jobs, with an average annual salary of $135,955. The proposed facility would reform natural and renewable gas into hydrogen, capturing carbon dioxide to produce around 3.6 million tons of methanol annually. The project is undergoing a FEED study, with a final investment decision anticipated in mid-2024.