ORALS

SESSION: IronTueAM-R2	Assis International Symposium (9th Intl. Symp. on Advanced Sustainable Iron & Steel Making)
Tue. 28 Nov. 2023 / Room: Dreams 2
Session Chairs: Tateo Usui; Marcos De Campos; Session Monitor: TBA

12:25: [IronTueAM03] OS Keynote
HYDROGEN PRODUCTION AND ITS IMPACT FOR SIDERURGY
Marcos De Campos¹ ; Jose Adilson De Castro² ; ¹UFF - Federal Fluminense U., Volta Redonda, Brazil; ²UFF - Federal Fluminense University, Volta Redonda, Brazil;
Paper Id: 20 [Abstract]

One way for energy storage is hydrogen production of the excess of electric energy. However Hydrogen storage is quite complicated because hydrogen is only liquid at 20 Kelvin. Also, as easily explained by the Carnot cycle, there are losses along the several steps of liquid hydrogen production, as for example, hydrolysis efficiency, compression and liquefaction efficiency, and so on. However, excess electric energy can be transformed into hydrogen and immediately used for metal reduction. Here it is discussed the technical and economic feasibility of using hydrogen for iron reduction. Oil importer countries may turn to hydrogen usage in industry, thus avoiding oil price fluctuation, or also coal price fluctuation. Even with higher prices, the use of hydrogen in metallurgical processes gives alternatives to non-renewable commodities. This detail is relevant for strategic planning of governments.

SESSION: IronTuePM2-R2	Assis International Symposium (9th Intl. Symp. on Advanced Sustainable Iron & Steel Making)
Tue. 28 Nov. 2023 / Room: Dreams 2
Session Chairs: Giovanni Felice Salierno; Session Monitor: TBA

16:00: [IronTuePM209] OS
MATHEMATICAL MODELING, SIMULATION AND OPTIMIZATION OF IRON ORE SINTERING PROCESS FOR QUALITY, FUEL EFFICIENCY AND POLLUTION CONTROL
Niloy Kumar Nath¹ ; Paulo Assis² ; Jose Adilson De Castro³ ; ¹JSPM's Rajarshi Shahu College of Engineering, Pune, India, Pune, India; ²UFOP, Ouro Preto, Ouro Preto, Brazil; ³UFF - Federal Fluminense University, Volta Redonda, Brazil;
Paper Id: 338 [Abstract]

Iron ore sintering is a high temperature, high volume process for producing raw material for blast furnace, and the quality requirements for sinter is high strength and Tumbler index, good reducibility and reduction degradation index (RDI). The process involves high temperature gas-solid reaction, drying and condensation, and melting and solidification phenomena. Simulation of the iron ore sintering process reveals considerable variation in thermal and melting profile in the sinter bed [1,2].  Melting is very low in the top critical zone just below the ignition hood, giving rise to low sinter strength and high return fines, where as in the bottom layers melting is much higher, producing glassy phase with low reducibility. Suction pressure applied in the wind boxes for gas velocity in the sinter bed is one of the important process parameter for the sintering process, which is optimized here in three locations, top, middle and lower zones by optimization technique such as Genetic Algorithm (GA), for better melting and sinter quality in the three zones representing the total sinter strand [3].Sinter quality which is combination of high strength and good reducibility, can be attributed to partial melting of about 30%, in the sinter bed. However due to non-uniform combustion zone in the sinter bed, melting is very low in the top critical zone, whereas melting is much higher in the lower regions. Therefore, to overcome this non-uniform melting along the sinter bed height, two-layer sintering process is envisaged with higher coke rate in the top layer, and lower coke rate in the bottom layer. The two-layer sintering process have been optimized by using Multi-Objective Genetic Algorithm, with different coke rates in the top and bottom layers. The thickness of the top and bottom layers are also varied for optimization. The two objectives for optimization are uniform 30% melting throughout the sinter bed, along with minimum overall coke rate, giving rise to two conflicting objectives for Pareto optimization [4]. The lower coke rate in the bottom layer up to the Burn through point (BTP), gives additional benefit of reducing pollution and greenhouse gases [2,5] like CO, CO2, SOx, and toxic gases such as NOx, dioxin and furan.

References:
[1] N. K. Nath, A. J. D. Silva and N. Chakraborti: Dynamic Process Modeling of Iron Ore Sintering: Steel Research: (1997); Vol. 68, No. 7, 285-292.
[2] J.A.D. Castro, N.K. Nath, A.B. Franca, V.S. Guilherme and Y. Sasaki. Analysis of iron ore sintering process based on alternative gaseous fuels from steelworks by multiphase multicomponent model; Ironmaking and Steelmaking, (2012), Vol. 39, No. 8, pp 605-613
[3] N. K. Nath and Kishalay Mitra. Optimization of Suction Pressure for Iron Ore Sintering by Genetic Algorithm. Ironmaking and Steelmaking, 2004, Vol. 31, No 3, pp 199-206.
[4] N. K. Nath and K. Mitra. Mathematical modeling and optimization of two-layer sintering process for sinter quality and fuel efficiency by genetic algorithm; Materials and Manufacturing Processes, (2005), Vol. 20, No. 3, pp 335-349.
[5] C.F.C.D. Assis, J.A.S. Tenorio, P.S. Assis and N.K. Nath. Experimental Simulation and Analysis of Agricultural Waste Injection as an Alternative Fuel for Blast Furnace; Energy & Fuels, ACS Pub. 2014, Vol. 28, pp7268-7273.

SESSION: IronWedPM1-R2	Assis International Symposium (9th Intl. Symp. on Advanced Sustainable Iron & Steel Making)
Wed. 29 Nov. 2023 / Room: Dreams 2
Session Chairs: Marcos De Campos; Paulo Assis; Session Monitor: TBA

14:55: [IronWedPM107] OS
RAISE OF RENEWABLE ENERGY - SOLAR AND WIND - AND CONSEQUENCES FOR STEELMAKING
Jose Adilson De Castro¹ ; Marcos De Campos² ; ¹UFF - Federal Fluminense University, Volta Redonda, Brazil; ²UFF - Federal Fluminense U., Volta Redonda, Brazil;
Paper Id: 19 [Abstract]

The big trend nowadays is the replacement of coal plants by wind and solar. This may affect the price of electric energy, enabling processes where the electric energy is relevant, as for example secondary metallurgy where arc furnaces have large applications. Here we will discuss the impact of the new methods of energy generation on the cost of steel production in the next decades. It is forecasted that the price of electric energy will continue high in the next 5-10 years, while the coal energy plants were not completely replaced by wind or solar. Also, energy storage is expensive , and this precludes price energy reduction. The high price of energy storage is a significant bottleneck concerning price reduction of energy. Energy can be exported as a reduced metal, and countries with surplus of electric energy can become exporters of metals for countries with energy deficit. Brazil has one of the best conditions in the world for wind energy production in states near the equator line as Rio Grande do Norte and Ceará. These states are also promising places for production of other reduced metal, as for example aluminum.

SESSION: IronWedPM2-R2	Assis International Symposium (9th Intl. Symp. on Advanced Sustainable Iron & Steel Making)
Wed. 29 Nov. 2023 / Room: Dreams 2
Session Chairs: Paulo Assis; Session Monitor: TBA

16:25: [IronWedPM210] OS
A NUMERICAL STUDY OF SCENARIOS FOR THE SUBSTITUTION OF PULVERIZED COAL INJECTION BY BLAST FURNACE GAS ENRICHED BY HYDROGEN AND OXYGEN
Jose Adilson De Castro¹ ; Giulio Antunes De Medeiros² ; Marcos De Campos³ ; Leonardo Martins Da Silva⁴ ; ¹UFF - Federal Fluminense University, Volta Redonda, Brazil; ²UFF-Programa de Pos Graduação em Engenharia Metalurgica, Volta Redonda, Brazil; ³UFF - Federal Fluminense U., Volta Redonda, Brazil; ⁴Universidade Federal Fluminense, Volta Redonda, Brazil;
Paper Id: 69 [Abstract]

A numerical simulation procedure is proposed for analyzing the partial replacement of pulverized coal injection by hydrogen, oxygen, and blast furnace gas (BFG) injections mixed with pulverized coal (PCI) within the tuyeres of large blast furnaces. The massive use of hydrogen-rich gas is highly attractive to the steelmaking blast furnace in the context of carbon net-zero hot metal production. Likewise, this new approach allows for increasing productivity and decreasing the specific emissions of carbon dioxide toward a net-zero carbon ironmaking technology. Nevertheless, pulverized coal injection gas mixture is a complex technology, in addition to the impact on chemical reactions and energy exchange, the internal temperature and gas flow pattern can also change drastically. With a view to assessing the state of the furnace in this complex operation, a comprehensive mathematical model using the multiphase theory was developed. The model simultaneously handles bulk solids (sinter, small coke, pellets, granular coke, and iron ore), gas, liquid metal and slag, and coal powder phases. The associated conservation equations are formulated for momentum, mass, chemical species, and energy while being discretized and solved using finite volume techniques. The numerical model was validated against the reference operating conditions using 220 kilograms per ton of pig iron (kg/tHM) of pulverized coal. Therefore, the combined injection of different concentrations of fuel hydrogen, blast furnace gas, and oxygen was simulated for replacing 40, 60 and 80 kg/tHM of coal injection. Theoretical analysis showed that the best scenario with stable operation conditions could be achieved with a productivity increase of 20% corresponding to a CO2 reduction of 15% and 60 kg/tHM of PCI replacement

References:
[1] Castro, J.A.; Takano, C.; Yagi, J. A theoretical study using the multiphase numerical simulation technique for effective use of H2 as blast furnaces fuel. J. Mater Res Technol., 2017, 6, 258-270. [2] Adilson de Castro, J.; Medeiros, G.A.d.; Oliveira, E.M.d.; de Campos, M.F.; Nogami, H. The Mini Blast Furnace Process: An Efficient Reactor for Green Pig Iron Production Using Charcoal and Hydrogen-Rich Gas: A Study of Cases. Metals 2020, 10, 1501. https://doi.org/10.3390/met10111501 [3] Castro, J.A. A Multi-Dimensional Transient Mathematical Model of Blast Furnace Based on Multi-Fluid Model. Doctor Thesis, Ph.D.-Tohoku University, Sendai, Japan, 2001. [4] Castro, J.A.; Araujo G.M.; Mota I.O.; Sasaki Y.; Yagi J. Analysis of the combined injection of pulverized coal and charcoal into large blast furnaces. J Mater Res Technol., 2013, 2, 308-314.

SESSION: IronThuAM-R2	Assis International Symposium (9th Intl. Symp. on Advanced Sustainable Iron & Steel Making)
Thu. 30 Nov. 2023 / Room: Dreams 2
Session Chairs: Wilson Ferreira Santos Jr.; Session Monitor: TBA

12:00: [IronThuAM02] OS
ANALYSIS OF THE HYDROGEN GAS AS FUEL FOR LARGE BLAST FURNACES USING A COMPREHENSIVE MULTIPHASE NUMERICAL SIMULATION APPROACH
Jose Adilson De Castro¹ ; Giulio Antunes De Medeiros² ; Elizabeth Oliveira³ ; ¹UFF - Federal Fluminense University, Volta Redonda, Brazil; ²UFF-Programa de Pos Graduação em Engenharia Metalurgica, Volta Redonda, Brazil; ³Center for Technological Education Celso Suckow da Fonseca, Valenca, Brazil;
Paper Id: 68 [Abstract]

A numerical simulation procedure is proposed for analyzing hydrogen, oxygen, and blast furnace gas (BFG) injections mixed with pulverized coal within the tuyeres of large blast furnaces. The massive use of hydrogen-rich gas is highly attractive to the steelmaking blast furnace in the context of carbon net-zero hot metal production. Likewise, this new approach allows for increasing productivity and decreasing the specific emissions of carbon dioxide toward a net-zero carbon ironmaking technology. Nevertheless, mixed gas with pulverized coal injections is a complex technology with drastic changes in the inner temperature and gas flow patterns, beyond their effects on the chemical reactions and energy exchanges. Focusing on the evaluation of inner furnace status under such complex operation a comprehensive mathematical model has been developed using the multi-interactions of phases theory. The model treats simultaneously the lump solids (sinter, small coke, pellets, granular coke, and iron ores), gas, liquids metal and slag, and pulverized coal phases. The governing conservation equations are formulated for momentum, mass, chemical species, and energy simultaneously discretized and solved using the finite volume technique. The numerical model is verified against a reference operational condition using pulverized coal of 195 kilograms per ton of hot metal (kg/thm). Thus, combined injections of varying fuel hydrogen, BFG, and oxygen concentrations are simulated for 180 and 220 kg/thm of coal injection. Theoretical analysis showed that stable operations conditions could be achieved with a productivity increase of 53%. Finally, we demonstrated that the net carbon utilization per hot metal ton decreased to 15%.

References:
[1] Castro JA, Takano C, Yagi J. A theoretical study using the multiphase numerical simulation technique for effective use of H2 as blast furnaces fuel. J. Mater Res Technol 2017; 6:258-270. [2] de Castro JA, de Medeiros GA, de Oliveira EM. A Comprehensive Modeling as a Tool for Developing New Mini Blast Furnace Technologies Based on Biomass and Hydrogen Operation. J. Sustain. Metall. 2020; 6:281-293. [3] de Castro JA, de Medeiros GA, de Oliveira EM, de Campos MF, Nogami H. The Mini Blast Furnace Process: An Efficient Reactor for Green Pig Iron Production Using Charcoal and Hydrogen-Rich Gas: A Study of Cases. Metals. 2020; 10(11): 1501-1522.

SESSION: IronThuAM-R2	Assis International Symposium (9th Intl. Symp. on Advanced Sustainable Iron & Steel Making)
Thu. 30 Nov. 2023 / Room: Dreams 2
Session Chairs: Wilson Ferreira Santos Jr.; Session Monitor: TBA

12:50: [IronThuAM04] OS
ANALYSIS OF THE PERFORMANCE OF SHAFT FURNACES WITH PARTIAL REPLACEMENT OF THE BURDEN WITH SELF-REDUCING PELLETS CONTAINING BIOMASS
Jose Adilson De Castro¹ ; Giulio Antunes De Medeiros² ; ¹UFF - Federal Fluminense University, Volta Redonda, Brazil; ²UFF-Programa de Pos Graduação em Engenharia Metalurgica, Volta Redonda, Brazil;
Paper Id: 70 [Abstract]

The shaft furnace known Midrex is used for the production of direct reduced iron with the use of reformed gas. Another process based on shaft reactors is the Tecnored process, which exhibits the great advantage of using self-reducing agglomerates. Therefore, it was proposed a combination of the shaft furnace for direct reduction with self-reducing pellet burden. In addition, with the aim of improving the furnace efficiency and reducing the need for reformed gas, the injection of natural gas and oxygen into the bustle region is proposed. Thus, it is possible to exploit the advantages of direct reduction involving high amounts of hydrogen and faster reactions of the self-reducing process to decrease the CO2 emission, compared to that of blast furnace. The energy profile, productivity, and carbon emission of the traditional shaft furnace were compared with the simulated results after partial replacement of the burden with self-reducing pellets containing fines of elephant grass charcoal. The simulation results for a combination of 15% of self-reducing pellets in the burden with 3.5% oxygen and natural gas injections were the best among the scenarios simulated, with the productivity being 2.9 ton/m3/day and the decrease in the amount of reformed gas being 18%.

References:
[1] Castro JA, Rocha EP, Oliveira EM, Campos MF, Francisco AS. Mathematical modeling of the shaft furnace process for producing DRI based on the multiphase theory. REM - International Engineering Journal. 2018;71(1):81-87

SESSION: NanomaterialsFriAM2-R3	Echegoyen International Symposium (8th Intl. Symp. on Synthesis & Properties of Nanomaterials for Future Energy Demands)
Fri. 1 Dec. 2023 / Room: Dreams 3
Session Chairs: Yutaka Matsuo; Session Monitor: TBA

10:20: [NanomaterialsFriAM205] OS
REVERSAL OF MAGNETIZATION IN PERMANENT NANOCRYSTALLINE MAGNETS
Marcos De Campos¹ ; Jose Adilson De Castro² ; ¹UFF - Federal Fluminense U., Volta Redonda, Brazil; ²UFF - Federal Fluminense University, Volta Redonda, Brazil;
Paper Id: 293 [Abstract]

Rare-earth permanent magnets have a  broad range of applications, in motors of electric and hybrid cars, in wind turbines, and  in any machine where efficiency is important [1].  Many countries are establishing    rigorous standards for electric motors efficiency, as IE4 and IE5 [1,2].A rotating machine as an  electric motor has two main components: a rotor and a stator.    In essence, by using  a permanent magnet in the rotor, the efficiency of the machine can be increased. This save an energy that would be used to magnetize the rotor. This also makes possible that the motor can be of the brushless type, thus avoiding friction.In the electrical motors, the magnets need to present high resistance against reversal of magnetization. The motor heats during the  motor operation.  As consequence, the magnets embedded in the stator also heats. There is much  research on  increasing motor efficiency [3], especially in the case of electric cars, where automony is an important issue, and where batteries are very expensive.Nanocrystalline magnets display better resistance  against reversal of magnetization. Here this  subject is discussed by considering magnetostatic and  exchange energy terms.    The mechanisms of reversal of magnetization in nanocrystalline permanent magnets are reviewed. Nanocrystalline Rare-earth magnets  can be  used in motors, or also in thin films [4]. Crystallographic texture effects on the coercivity are also discussed [5].

References:
[1] https://commission.europa.eu/news/new-eu-rules-boost-energy-efficiency-electric-motors-2021-06-30_en
[2] https://eandt.theiet.org/content/articles/2023/03/motoring-into-the-ie5-era-for-energy-efficiency/
[3] https://fox5sandiego.com/automotive/internet-brands/how-lucid-leaps-past-tesla-with-smaller-motors/amp/
[4] https://link.springer.com/article/10.1007/s13204-023-02931-1
[5] https://www.sciencedirect.com/science/article/abs/pii/S0304885322010046

SESSION: MineralWedPM1-R7	Torem International Symposium (8th Intl. Symp. on Sustainable Mineral Processing)
Wed. 29 Nov. 2023 / Room: Sunflower
Session Chairs: Fernando Jose Gomes; Session Monitor: TBA

14:05: [MineralWedPM105] OS
RARE-EARTH MARKET AND APPLICATIONS: THE RECENT TRENDS
Marcos De Campos¹ ; Amilton Da Silva Jr² ; Jose Adilson De Castro³ ; ¹UFF - Federal Fluminense U., Volta Redonda, Brazil; ²CEFET - RJ, Valença , Brazil; ³UFF - Federal Fluminense University, Volta Redonda, Brazil;
Paper Id: 292 [Abstract]

The market of rare-earths is reviewed.  The rare-earth market is driven by three main applications: permanent magnets, luminescent phosphors and  catalysis. The market is currently driven by  iron based rare-earth magnets.  Luminescent phsophors are a relevant application, but in this case the rare-earth acts as a dopant and  the  demand volume is not so high as  in rare-earth magnets.  Cheaper rare-earths as cerium and lanthanum are  used in catalysis. Lanthanum is used for oil cracking, for stabilizing zeolites . Other applications are also reviewed. Yttrium demand increased recently, probably due  to  increased production of yttria stabilized zirconia.Electrical cars use typically 1-2 kg of permanent magnets of the NdFeB type, based on the NBd2Fe14B, with partial replacement of Nd by Pr, and by Dy and Tb to increase the operation temperature.  In many applications, there is the possibility of replacement of NdFeB magnets by hard ferrites as Sr2Fe12O19 or BaFe12O19. However, for electric cars, NdFeB-type magnets are preferrable  because they increase the machine efficiency. Many rare-earth extraction projects were recently announced in Brazil. One of the main drawbacks is the lack of technology for rare-earth concentration, and also for rare-earth oxide separation. Here, it is discussed the roadmaps to be followed to overcome such problems.  China developed better technology for rare-earth  oxide separation [1], and  this possibly is the reason for the  Chinese leadership in the rare-earth market.Ores  containing  rare-earth are very abundant along the globe. The main problem is  cheap technology for rare-earth concentration and also for rare-earth oxide separation. Brazil has  potential for becoming a significant producer of rare-earths, by using the tailings of niobium and tin mines. However, proper technology has to be developed for using these tailings.  

References:
[1] https://newsen.pku.edu.cn/news_events/news/people/9479.html

SESSION: MineralWedPM1-R7	Torem International Symposium (8th Intl. Symp. on Sustainable Mineral Processing)
Wed. 29 Nov. 2023 / Room: Sunflower
Session Chairs: Fernando Jose Gomes; Session Monitor: TBA

14:55: [MineralWedPM107] OS
ANALYSIS OF SUSTAINABLE IRON ORE SINTERING PROCESS USING MODELING APPROACH
Jose Adilson De Castro¹ ; Marcos De Campos² ; Elizabeth Oliveira³ ; Giulio Antunes De Medeiros⁴ ; Leonardo Martins Da Silva⁵ ; ¹UFF - Federal Fluminense University, Volta Redonda, Brazil; ²UFF - Federal Fluminense U., Volta Redonda, Brazil; ³Center for Technological Education Celso Suckow da Fonseca, Valenca, Brazil; ⁴UFF-Programa de Pos Graduação em Engenharia Metalurgica, Volta Redonda, Brazil; ⁵Universidade Federal Fluminense, Volta Redonda, Brazil;
Paper Id: 71 [Abstract]

The decreasing of CO2 emissions on the ironmaking industries is a challenging issue. The massive use of granulated biomass and biogas in the iron ore sintering process are promising technological solutions to mitigate the environmental impacts on the steel plant. We focused on the development of a computational tool to analyze and suggest new practices for the sintering process using an integrated modeling approach by applying the multiphase and multicomponent theory. New phases, chemical species and rate equations are included. The model predictions were confronted with industrial data showing good adherence. New scenarios for utilizing the combined technologies of granulated biomass and biogas injection are investigated. The model predictions indicated that the high performance of the process with suitable sinter quality could be achieved. The sintering process fully operating with renewable energy sources is demonstrated.

References:
[1] J. A. Castro, E. M. Oliveira, M. F. Campos, C. Takano and J. Yagi: Journal of Cleaner Production 198(2018), 654. https://doi.org/10.1016/j.jclepro.2018.07.082 [2] J. A. Castro, N. Nath, A. B. França, V. S. Guilherme and Y. Sasaki: Ironmaking & Steelmaking 39(2012), 605. [3] J. A. Castro, C. J. L. Pereira, V. S. Guilherme, E. P. Rocha and A. B. França: J. Mater Res Technol, 2 (2013), 323. http://dx.doi.org/10.1016/j.jmrt.2013.06.002.