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The Advanced Exergy Analysis of Green Hydrogen Production System and its Application in Green Steel Production: A Case Study for Butia Iranian Steel Company

Bayat, Delaram | 2024

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 56881 (46)
  4. University: Sharif University of Technology
  5. Department: Energy Engineering
  6. Advisor(s): Khajehpour, Hossein
  7. Abstract:
  8. In recent years, the significant growth of the population has led to an increase in energy demand and subsequent rise in waste production. A substantial share of the energy demand and consumption in the industrial sector, particularly in steel production, requires the utilization of renewable technologies for energy and clean fuel production, such as hydrogen, to address this growing demand and mitigate environmental impact. This study focuses on a waste-to-energy technique as a viable solution to facilitate the transition towards green steel production in the industrial sector of Kerman province, primarily targeting the decarbonization of utility generation in steel production process. Through technical-economic assessments, the process of producing hydrogen-rich synthesis gas using sewage sludge gasification technology was simulated in Aspen Plus, revealing a potential to produce 5-10% of the required synthesis gas crucial for the Direct Reduced Iron (DRI) process at the Iranian Butia Steel Production Plant. Exergy analysis identified process inefficiencies, attributing 48.4%, 36.2%, and 67.6% of total exergy destruction and losses to the central utility system, sludge decomposer, and steam gasifier, respectively. Cost analysis of the gasification process yielded production costs of 0.124, 0.089 and 0.007 ($/kg synthesis gas) for investment, utility demand provision, and process feedstock, respectively. These costs, compared to the current steam methane reforming process, reflect a higher proportion of utility demand provision costs due to the lower calorific value of sewage sludge. Furthermore, environmental analysis revealed respective carbon footprints of 3.28 kg CO2eq/kg and 3.73 kg CO2eq/kg for pipeline and diesel trucks scenarios, compared to 5.37 kg CO2eq/kg and 4.53 kg CO2eq/kg for landfilling and incineration of sludge, respectively, per kilogram of produced synthesis gas. The study also suggests optimizing processes and incorporating gas purification units, considering their economic and environmental implications. The results of this study not only suggest the conversion of sewage sludge waste into an energy carrier as a practical method compared to other sludge management solutions but also promote a circular economy and industrial symbiosis among operational units in the region
  9. Keywords:
  10. Exergy Analysis ; Techno-Economoc Model ; Carbon Footprint Reduction ; Biomass Gasification ; Green Steel Production ; Wastewater Sewage Sludge ; Renewable Energy Resources

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