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ENERGIX-Stort program energi

Reduced CO2 emissions in metal production

Alternative title: Reduserte CO2 utslipp fra metall produksjon

Awarded: NOK 20.1 mill.

The Norwegian producers of Silicon, Ferroalloys and Titania slag that are partners in KPN Reduced CO2: Elkem, Wacker, Finnfjord, Eramet, FerroGlobe (participated until 2019) and TiZir all have a strong drive to meet the global climate challenges and reduce their CO2 emissions. In KPN Reduced CO2, the research partners SINTEF and NTNU and the industry partners have worked together to develop the basis required for reducing CO2 emissions by substituting fossil carbon with biocarbon, hydrogen, industrial off-gases or other technologies. The project has contributed with competence to and is included in one of the reports from Process 21. The work has also generated results that has been used in and has lead to new research projects that will contribute with competence needed to reduce CO2 emissions. The project has cooperated closely both directly with industry partners and with other projects as SFI Metal Production. Two PhD candidates have been educated and one Post Doc accomplished through the project. To make substitution of fossil carbon with bio carbon sustainable, change of carbon source must not decrease the efficiency of the alloy production. KPN Reduced CO2 has investigated how physical and electrical properties of the carbon material will affect processes for production of the actual metals. Methods for characterisation of different carbon properties have been evaluated. Methods for measuring electrical conductivity in carbon materials as well as in mixtures of carbon materials and mixtures with other raw materials have been improved. A method to measure evolution of different gases at different temperatures and changes in carbon properties during heating of carbon materials in a metal producing furnace has been developed. Reactions with carbon will affect the energy consumption pr. ton of metal in Si-production. This reaction has been investigated by new methods, and biocarbon seems to have a positive effect. Compared to other carbon material, the same amount in kg of biocarbon will, due to its lower weight, need more room. This effect must be taken into account when biocarbon is substituting other carbon materials. A set and sequence for testing of carbon materials for different uses, has been proposed in a work together with KPN BioCarbUp. Several different biocarbon materials have been characterised in the project. KPN Reduced CO2 has mostly focused on biocarbon properties and reactions with biocarbon materials compared to other carbon sources. Next step towards industrialisation, to find out how these will affect metal production will be done in the spin-off project KPN BioMet. It has been shown experimentally that carbon from biogas is a potential sustainable carbon source that can be used in production of Mn-alloys. Hydrogen gas is formed as a by-product in this process. A PhD study showed through a series of laboratory experiments that hydrogen has a positive effect on pre-reduction of Mn-ores. A model to predict the effect of various parameters have been developed. Laboratory experiments with pre-reduction of ilmenite have given fundamental understanding of this reaction and contributed with background information to industrial development at TiZir. Effect of time and temperature have been described and it is shown that the reduction is possible also when H2O is present. The project has, mainly by PhD study, investigated by laboratory experiments how hydrogen will affect important reactions in silicon production. These are fundamental studies that will pave the way for development of new processes. Several new technologies that potentially can contribute to minimalize fossil CO2 emission in 2050 have been evaluated How to take these further have been discussed in meetings with several participants from all the partners. Based on tis the actual technologies and how these can be further developed are described. This has resulted in several spin-off projects as use of hydrogen plasma in metal production, project studying electrolysis in Mn-production and projects with new concepts for use of hydrogen in Si-production. The results from KPN Reduced CO2 have been shared between partners through meetings, internal workshops and yearly seminars. For a broader dissemination outside partners, 3 open workshops have been arranged, all with large both Norwegian and international participation. Two of these were physical, one in Trondheim and one in Slovakia. Several of the results from the project are published both in academic journals and at international conferences with partners from both academia and industry. INFACON (International Ferroalloy Conference) that was arranged in Trondheim in 2021 by the partners in the project and had more than 300 participants was an important event for the dissemination. The results are also spread through social media as LinkedIn, Facebook and Research gate and as popular science publications.

The main impact of KPN Reduced CO2 is its contribution to reduce the climate effects from the production of Si, FeSi, Mn-alloy and TiO2 slag to obtain 30% lower CO2 emission in 2030 and zero CO2 emission in 2050. Competence needed to substitute fossil carbon with bio-carbon, hydrogen, or process off gases in production of these materials have been developed and new technologies with a high potential to produce Si, FeSi and Mn-alloys with zero CO2 emissions in 2050 have been identified. Globally production of each of these alloys generated around 5-25 million tons CO2 pr year and all contributions to reduce this will have an impact on our society. A main outcome is the projects contribution to partners and other stakeholders of knowledge needed to realise a reduction in CO2 emissions. New methods for characterisation and evaluation of biocarbon has been developed with a focus on electrical conductivities, physical properties. and reactions with SiO-gas. Methods for characterisation and evaluation of bio-carbon materials have been systemised into a test matrix describing the sequence of properties to be tested for each alloy. Dissemination of the knowledge outside consortium have given partners increased network and biocarbon suppliers and potential users outside consortium better understanding of requirements. A spin-off project, KPN BioMet will focus on how to industrialise the results Generated data about prereduction of Mn-ores are used as basis for design and development of prereduction technologies both by industrial partners and in cooperating projects as EU H2020 PreMa. Generated competence about reactions with hydrogen in Si production have contributed to realisation of new projects as IPN H2Si and Researcher project SiH2. These will contribute with important competence for involved partners from industry and academia. Developed methods for studying reactions with hydrogen will be used in future work at the research partners. Through dissemination of results and by arranging the large hydrogen workshop, the project partners have established a broader network that also includes hydrogen producers and distributors. Identification and evaluation of new technologies with high potential for reducing CO2 emissions have increased the partners interest in completely new approaches and new technologies. It has increased focus on developments from a low TRL level both at partners and outside consortium. Spin-off projects within electrolysis and plasma has generated competence in new areas, development of new methods and equipment and new networks. KPN Reduced CO2 has led to five realised spin-off projects, contributed to realisation of two other, and led to a spin-off project application. KPN Reduced CO2 has contribute to education and further recruitment of highly qualified personnel within sustainable metal production The two PhD candidates graduated in the project have been recruited to SINTEF and the PostDoc to an industrial partner.

CO2 emission from the metal industry is around 4.83 mill CO2 equivalents pr year, around 10 % of the Norwegian emissions. Emissions from the Norwegian process industry has decreased with 40 % since 1990 and with an increased value creation. The industry wants to continue to be in the forefront. The overall aim of KPN Reduced CO2 emissions is to develop the basis for reduced climate effects from the production of Si, FeSi, Mn-alloy and TiO2 slag to obtain 30% lower CO2 emission in 2030 and zero CO2 emission in 2050. The industrial partners in the project are all the Norwegian Si, FeSi and Mn-alloy producers; Eramet, Glencore, Elkem, Wacker and Finnfjord, and TiZir that produces TiO2 slag. CO2 emissions from this industry is mainly caused by solid carbon used in the process. KPN Reduced CO2 will develop methods to substitute fossil carbon with bio-carbon, hydrogen and other gases. Some of the new technologies will reduce specific energy consumption. In addition, 4 new technologies will be identified and prepared for further development. To ensure that the most sustainable technologies are chosen, methods to quantify climate effects will be developed and used in the project. The industrial partners will be strongly involved, and project activities planned in 3 industrial seminars. KPN Reduced CO2 brings together 2 research partners: Sintef and NTNU and CICERO and establishes a multidisciplinary collaboration that contributes to future development towards reduced CO2 emissions. The project includes 3 PhD candidates and 1 MSc studies, important for the recruitment in the industry. Extensive dissemination of scientific results are planned. Communication of project findings to the society is a priority several outreach articles will be published in national media and public events arranged in addition to publication on project web site. Results will be spread to the project partners through newsletters and project meetings.

Publications from Cristin

Funding scheme:

ENERGIX-Stort program energi