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Description
Norwegian ferroalloy industry produces more than 1 million of tonnes of ferroalloys per year (i.e. FeSi/Si, FeMn/SiMn). Because raw materials of fossil origin (coal and coke) are used as raw materials for ore reduction, the ferroalloy industry is a significant CO2 emitter, and accounts for approximately 9 % of the total industrial CO2 emssions in Norway. Due to the adverse impact of greenhouse gases on the climate, in particular CO2, the policy of the European Union assumes and aims to reduce CO2 emissions by 40% by 2030. The main objective of the project is to develop an innovative and economically viable technology for bio-coke production for the ferroalloys industry (Mn-alloys). A novel material - biocoke will be suitable as a sustainable and cost competitive reductant for ferroalloys production. The implementation of this technology, i.e. the use of bio-coke in the production of ferroalloys in electric arc furnaces, will reduce CO2 emissions from their production. The main idea will be to use biomass as an additive to the coking blend and thus incorporate an environmentally friendly (carbon neutral) component into the coke structure. The project is planned over a period of 36 months and consists of 7 Work Packages whose consecutive implementation will contribute to achieving the project''s objectives. The benefits from the project realization will be for all consortium members. The composition consits of units from the field of business & industry and research & development sector what forms an unique interaction between science and industry with an opportunity of experience and ideas exchanges. The contacts established during the project realization will create opportunities for cooperation in the implementation of research work in the future by tightening contacts between polish and norwegian partners.
Summary of project results
Manganese ferroalloys are an important additives in the production of high-quality steel. Norway produces over 1 MTPA of ferroalloys, including
manganese ferroalloys, where the main reducing agent is classic metallurgical coke, of fossil origin. This is associated with significant CO2
emissions, which can be reduced by using low-emission carbon reductants. The aim of the project was to develop bio-coke as a substitute for
classic coke produced on the basis of a mixture of coal and biogenic substances of biomass origin. Incorporating elemental carbon of biogenic
origin into the structure of bio-coke will significantly reduce CO2 emissions in the process of using this raw material.
Carrying out a number of activities as part of the project, starting from the selection of raw materials, assessment of their quality, laboratory and
pilot scale tests for the production of bio-coke and reduction of manganese ores allowed the development of a technology for the production of
bio-coke and verification of its usefulness in the production of manganese ferroalloys in the carbothermal process of manganese ore reduction.
The developed technology enables the production of bio-coke using technology and production infrastructure operating in existing coking plants
and using raw materials available on the market.
In the long term perspective, taking into account the gradual abandonment of fossil fuels and reductants and the resulting phasing out of
production capacity, the production of bio-coke may become an important element of the process of greening the coke-making industry, making
it more environmentally friendly and prolonging its operation. At the same time, the use of bio-coke in the industrial production of ferroalloys will
significantly reduce CO2 emissions, while also being the first step towards its decarbonization using fully renewable reductants. The expected
implementation of the developed technology and industrial production of bio-coke and its use should potentially contribute to over 20%
reduction of CO2 emissions from the ferroalloy production process.
Summary of bilateral results
The implementation of the BioCoke4FAI project brought the following benefits in connection with cooperation with Norwegian partners: made itpossible to carry out laboratory and pilot research and tests using research infrastructure unavailable in Poland, e.g. bench-scale inductionfurnaces and a pilot furnace for the process of carbothermic reduction of manganese ores. This allowed for a comprehensive assessment of theproduced bio-coke (as a result of the project) in an environment similar to industrial conditions. At the same time, it allowed Polish researchersto better understand the metallurgical processes related to the production of ferroalloys, which largely use carbon reductants produced inPoland. On the other hand, Norwegian researchers also learned in detail about the technologies for producing coke, which is one of the basic rawmaterials (along with manganese ore) for the production of manganese ferroalloys. This allowed for the integration of process knowledge,starting from the raw materials side, through the production processes, to the quality of the final product.Moreover, by promoting the project results at international conferences and seminars, both parties have gained greater recognition in the fieldof industrial technologies that reduce CO2 greenhouse gas emissions, especially those related to the production of low-emission carbonreductants. Thanks to the implementation of the project, ITPE expanded its competences and the scope of services offered to producers offerroalloys and the dynamically developing biochar industry in Europe - related to the assessment of the of conventional and renewable carbonreductants. Thanks to the implementation of the project, a long-term relationship was established between the partners, which resulted in thesubmission of two project applications under the Horizon program - one application received funding (acronym: MECALO). Further cooperationrelated to carbon reductant technologies is planned.