Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis process
The conventional blast furnace (BF) ironmaking and coal-to-methanol (CTM) process both suffer from high energy consumption and significant carbon emissions. In this work, a novel coal gasification, flash ironmaking, and methanol synthesis coupled process (CG-FI-MS) was proposed and designed to simul...
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| Main Authors: | , , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
IOP Publishing
2024-01-01
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| Series: | Sustainability Science and Technology |
| Subjects: | |
| Online Access: | https://doi.org/10.1088/2977-3504/ad72f5 |
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| Summary: | The conventional blast furnace (BF) ironmaking and coal-to-methanol (CTM) process both suffer from high energy consumption and significant carbon emissions. In this work, a novel coal gasification, flash ironmaking, and methanol synthesis coupled process (CG-FI-MS) was proposed and designed to simultaneously obtain high-quality iron metal and methanol. The new process contains eight units: air separation, CG-FI, smelting reduction, water gas shift, acid gas removal, CO _2 compression, Claus unit, MS and purification unit. The impact of critical operating parameters on the CG-FI unit was investigated including iron ore/coal, oxygen/coal, and steam/coal ratios. The thermodynamic properties and techno-economic analysis of the proposed process were examined. The analysis demonstrated that the optimum operating conditions for a flash ironmaking furnace were using iron ore/coal = 1.43, oxygen/coal = 0.79, and steam/coal = 0.01. 1 million tonnes of iron and 0.7 million tonnes of methanol as a basis for techno-economic analysis, the CO _2 emissions of the CG-FI-MS process decreased considerably by 74%, compared to conventional CTM and BF processes with the same methanol and iron yields. The energy and exergy efficiencies were 74.69% and 70.60%, respectively. The total capital investment and total production cost of the CG-FI-MS process are 1058 million and 494 million, respectively. The internal rate of return, payback period, net present value, and return on investment are estimated as 26%, 1018 million, 22.65%, and 3.20 years based on current prices, respectively. Meanwhile, the influences of coal and iron ore prices and iron and methanol prices on economic performance are explored. |
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| ISSN: | 2977-3504 |