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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| Format: | Article |
| Language: | English |
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IOP Publishing
2024-01-01
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| Series: | Sustainability Science and Technology |
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| Online Access: | https://doi.org/10.1088/2977-3504/ad72f5 |
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| author | Hao Cheng Guoqiang Cao Zhongren Ba Donghai Hu Yongbin Wang Jonas Baltrusaitis Chunyu Li Jiantao Zhao Yitian Fang |
| author_facet | Hao Cheng Guoqiang Cao Zhongren Ba Donghai Hu Yongbin Wang Jonas Baltrusaitis Chunyu Li Jiantao Zhao Yitian Fang |
| author_sort | Hao Cheng |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-9601da07a2fb4730874d3efcd334b31b |
| institution | Kabale University |
| issn | 2977-3504 |
| language | English |
| publishDate | 2024-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | Sustainability Science and Technology |
| spelling | doaj-art-9601da07a2fb4730874d3efcd334b31b2025-08-20T04:03:25ZengIOP PublishingSustainability Science and Technology2977-35042024-01-011101400410.1088/2977-3504/ad72f5Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis processHao Cheng0https://orcid.org/0009-0001-4150-354XGuoqiang Cao1https://orcid.org/0000-0002-8579-4940Zhongren Ba2Donghai Hu3Yongbin Wang4Jonas Baltrusaitis5https://orcid.org/0000-0001-5634-955XChunyu Li6Jiantao Zhao7Yitian Fang8State Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of China; University of Chinese Academy of Sciences , Beijing 100049, People’s Republic of ChinaState Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of ChinaState Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of ChinaState Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of China; University of Chinese Academy of Sciences , Beijing 100049, People’s Republic of ChinaState Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of China; University of Chinese Academy of Sciences , Beijing 100049, People’s Republic of ChinaDepartment of Chemical and Biomolecular Engineering, Lehigh University , 111 Research Drive, Bethlehem, PA 18015, United States of AmericaState Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of ChinaState Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of ChinaState Key Laboratory of Coal Conversion, Institute of Coal Chemistry, Chinese Academy of Sciences , Taiyuan 030001, People’s Republic of ChinaThe 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.https://doi.org/10.1088/2977-3504/ad72f5coal gasification coupled flash ironmakingmethanol synthesistechno-economic analysiscarbon emission reductionenergy and exergy efficiency |
| spellingShingle | Hao Cheng Guoqiang Cao Zhongren Ba Donghai Hu Yongbin Wang Jonas Baltrusaitis Chunyu Li Jiantao Zhao Yitian Fang Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis process Sustainability Science and Technology coal gasification coupled flash ironmaking methanol synthesis techno-economic analysis carbon emission reduction energy and exergy efficiency |
| title | Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis process |
| title_full | Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis process |
| title_fullStr | Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis process |
| title_full_unstemmed | Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis process |
| title_short | Process design and techno-economic analysis of integrated coal gasification-flash ironmaking-methanol synthesis process |
| title_sort | process design and techno economic analysis of integrated coal gasification flash ironmaking methanol synthesis process |
| topic | coal gasification coupled flash ironmaking methanol synthesis techno-economic analysis carbon emission reduction energy and exergy efficiency |
| url | https://doi.org/10.1088/2977-3504/ad72f5 |
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