Added modular functions to model the production of Green Steel:

hopp/simulation/technologies/steel/eaf_model.py

@@ -0,0 +1,313 @@
+def establish_save_output_dict():
+        """
+        Establishes and returns a 'save_outputs_dict' dict
+        for saving the relevant analysis variables for each site.
+        """
+        save_outputs_dict = dict()
+
+
+        save_outputs_dict['Steel Output Actual (kg)'] = list()
+        save_outputs_dict['Carbon Mass Needed (kg)'] = list()
+        save_outputs_dict['Lime Mass Needed (kg)'] = list()
+        save_outputs_dict['Energy needed for Electric Arc Furnance (kWh)'] = list()
+        save_outputs_dict['Total Indirect Emissions (Ton CO2)'] = list()
+        save_outputs_dict['Total Direct Emissions (Ton CO2)'] = list()
+        save_outputs_dict['Total Emissions (Ton CO2)'] = list()
+        save_outputs_dict['Shaft Total Capital Cost (Mil USD)'] = list()
+        save_outputs_dict['Shaft Operational Cost (Mil USD per year)'] = list()
+        save_outputs_dict['Shaft Maintenance Cost (Mil USD per year)'] = list()
+        save_outputs_dict['Shaft Depreciation Cost (Mil USD per year)'] = list()
+        save_outputs_dict['Total Carbon Cost (Mil USD per year)'] = list()
+        save_outputs_dict['Total Labor Cost (Mil USD per ton)'] = list()
+        save_outputs_dict['Total Emission Cost (Mil USD per year)'] = list()
+        save_outputs_dict['Total Lime Cost (Mil USD per year)'] = list()
+
+
+        return save_outputs_dict
+
+
+class eaf_model():
+    '''
+    Author: Charles Kiefer
+    Date: 8/14/23
+
+    This class holds functions relating to the modeling of a Electronic Arc Furnace
+    in relation to the production of Green Steel.  Pure iron, carbon and slime enter furnace,
+    steel and CO2 leave the system.  The EAF acts a energy transfer method to allow for the energy
+    needed to embed carbon in iron
+
+    Sources will be in each function
+
+    Args:
+    steel_output_desired (kg) or (kg/hr): (float) resulting desired steel output
+    steel_prod_yr (ton/yr): (float) plant capacity steel produced per year. For financial outputs
+
+    returns:
+    save_outputs_dict saves returns
+
+    Steel Output Desired (kg):
+        ['Steel Output Actual (kg)']:
+            -Iron ore that wasn't reduced in the HDRI will reduce and become steel
+
+        ['Carbon Mass Needed (kg)']
+        ['Lime Mass Needed (kg)']:
+            -Lime is a slag former and binds with impurites in the iron to produce more pure steel
+
+        ['Carbon Mass Not Absorbed (kg)']:
+            -Not all the carbon in the EAF will become steel.  Excess Carbon will become CO2
+
+        ['Energy needed for Electric Arc Furnance (kWh)']
+        ['Total Indirect Emissions (Ton CO2)']:
+            -Indirect emissions come from the grid emissions like coal plants and transportation 
+
+        ['Total Direct Emissions (Ton CO2)']
+        ['Total Emissions (Ton CO2)']
+        ['Shaft Total Capital Cost (Mil USD)']
+        ['Shaft Operational Cost (Mil USD per year)']
+        ['Shaft Maintenance Cost (Mil USD per year)']
+        ['Shaft Depreciation Cost (Mil USD per year)']
+        ['Total Carbon Cost (Mil USD per year)']
+        ['Total Labor Cost (Mil USD per ton)']
+        ['Total Emission Cost (Mil USD per year)']
+        ['Total Lime Cost (Mil USD per year)']
+    '''
+    def __init__(self):
+        '''
+        Initializes and stores needed data for functions relating to Electric Arc Furnace
+        for Green Steel
+
+        Sources:
+        [1]: Bhaskar, Abhinav, Rockey Abhishek, Mohsen Assadi, and Homan Nikpey Somehesaraei. 2022. "Decarbonizing primary steel production : Techno-economic assessment of a hydrogen based green steel production plant in Norway." Journal of Cleaner Production 350: 131339. doi: https://doi.org/10.1016/j.jclepro.2022.131339. 
+        [2]: Chase, M.W., Jr. 1998. "NIST-JANAF Themochemical Tables, Fourth Edition." J. Phys. Chem. Ref. Data, Monograph 9 1-1951. doi:https://doi.org/10.18434/T4D303.
+
+        '''
+        self.eta_el = .6 #(%) electrical efficiency [1]
+
+        self.stream_temp_in = 973 #(k) Temperature of metallic stream input eaf [1]
+        self.eaf_temp = 1923 #(k) Temperature metallic stream out. Temp needed to achieve [1]
+
+        self.mass_carbon_tls = 10 #(kg/tls) [1]
+        self.mass_lime_tls = 50 #(kg/tls) [1]
+
+        self.el_eaf = None #(kwh)
+
+        self.eaf_co2 = 0.050  #ton/tls [1]
+        self.cao_emission = 0.056 #tco2/tls [1]
+        self.co2_eaf_electrode = 0.0070 #tco2/tls [1]
+        self.pellet_production = 0.12 #tco2/tls [1]
+
+        self.steel_out_actual = None #(kg)
+
+        self.hfe_melting = 247 #(kj/kg) Energy needed to melt iron into a liquid [1] 
+
+        self.indirect_emissions_total = None
+        self.direct_emissions_total = None
+        self.total_emissions = None
+
+        self.lang_factor = 3 #(no units) Capital cost multiplier [1]
+        self.plant_life = 40 #(years) [1]
+        self.labor_cost_tls = 20 #(USD/ton/year) [1] $40 is flat rate for hdri and eaf together
+        self.eaf_total_capital_cost = None #(Million USD)
+        self.eaf_cost_per_ton_yr = 140 #(USD/tls/yr)
+        self.eaf_op_cost_tls = 32 #(USD/tls/yr of eaf) [1]
+        self.eaf_operational_cost_yr = None #(Million USD)
+        self.maintenance_cost_percent = .015 #(% of capital cost)[1]
+        self.eaf_maintenance_cost_yr = None #(Million USD)
+        self.depreciation_cost = None #(Million USD)
+        self.total_labor_cost_yr = None #(Million USD)
+        self.emission_cost = 30 #(USD/ton CO2) [1]
+        self.emission_factor = .413 #(ton CO2/kwh) [1]
+        self.carbon_cost_tls = 120 #(USD/ton coal) [1]
+        self.coal_total_cost_yr = None #(Mil USD/year)
+        self.lime_cost = 112 #(USD/ton lime) [1]
+        self.lime_cost_total = None #(USD/year)
+
+
+    def mass_model(self, steel_out_desired):
+        '''
+        Mass model calculates the masses inputted and outputted of 
+        an EAF system for output of tonne liquid steel
+
+        Args:
+        steel_output_desired (kg) or (kg/hr): (float) resulting desired steel output
+
+        Sources:
+        Model derived from: Bhaskar, Abhinav, Rockey Abhishek, Mohsen Assadi, and Homan Nikpey Somehesaraei. 2022. "Decarbonizing primary steel production : Techno-economic assessment of a hydrogen based green steel production plant in Norway." Journal of Cleaner Production 350: 131339. doi: https://doi.org/10.1016/j.jclepro.2022.131339.
+        '''
+        from hopp.simulation.technologies.steel.hdri_model import hdri_model
+
+        model_instance = hdri_model()
+        hdri_mass_model_outputs = model_instance.mass_model(steel_out_desired)
+
+        m3 = steel_out_desired #kg
+
+        m2_feo = hdri_mass_model_outputs[2]
+
+        m6 = self.mass_carbon_tls #kg/tls
+        m7 = self.mass_lime_tls #kg/tls
+
+        self.carbon_total = m6*steel_out_desired/1000 #(kg)
+        self.lime_total = m7*steel_out_desired/1000 #(kg)
+
+        m2_feo_reduced = (m2_feo*.7)  #(kg) assumed 70% feo in EAF gets reduced       
+        m3_actual = m2_feo_reduced + m3 #(kg) Actual steel outputted from excess iron oxidation
+
+        self.steel_out_actual = m3_actual #(kg)
+
+        save_outputs_dict = establish_save_output_dict()
+
+        save_outputs_dict['Steel Output Actual (kg)'].append(self.steel_out_actual)
+        save_outputs_dict['Carbon Mass Needed (kg)'].append(self.carbon_total)
+        save_outputs_dict['Lime Mass Needed (kg)'].append(self.lime_total)
+
+        return (save_outputs_dict, self.steel_out_actual, self.carbon_total, self.lime_total)
+
+    def energy_model(self, steel_out_desired):
+        '''
+        This function calculates the energy balance of the hdri EAF. Negative values designate
+        heat leaving the system. Positive values designate heat needs to enter the system.  
+
+        Energy belance values should be positive.
+
+        Args:
+        steel_output_desired (kg) or (kg/hr): (float) resulting desired steel output
+
+        Sources:
+        Model derived from: Bhaskar, Abhinav, Rockey Abhishek, Mohsen Assadi, and Homan Nikpey Somehesaraei. 2022. "Decarbonizing primary steel production : Techno-economic assessment of a hydrogen based green steel production plant in Norway." Journal of Cleaner Production 350: 131339. doi: https://doi.org/10.1016/j.jclepro.2022.131339.
+
+        '''
+        from hopp.simulation.technologies.steel.hdri_model import hdri_model
+        from hopp.simulation.technologies.steel.enthalpy_functions import fe_enthalpy, fe_enthalpy
+
+        model_instance = hdri_model()
+
+        hdri_mass_model_outputs = model_instance.mass_model(steel_out_desired)
+
+        m2_fe = hdri_mass_model_outputs[1]
+
+
+        hfe_T2 = fe_enthalpy(self.stream_temp_in)    #Enthalpy of DRI entering Eaf (kj/g)
+        hfe_T3 = fe_enthalpy(self.eaf_temp)    #Enthalpy steel exiting EAF (kj/g)
+        h3 = ((hfe_T3 - hfe_T2)*m2_fe*1000) + (m2_fe*self.hfe_melting)  #Total Enthalpy at output Kj
+
+        h3_kwh = h3 / 3600 #(kwh)
+
+        self.el_eaf = h3_kwh/self.eta_el #kwh
+
+
+        save_outputs_dict = establish_save_output_dict()
+
+        save_outputs_dict['Energy needed for Electric Arc Furnance (kWh)'].append(self.el_eaf)
+
+        return (save_outputs_dict,self.el_eaf)
+
+
+
+    def emission_model(self, steel_out_desired):
+        '''
+        This function models the emissions from the EAF.  This incorporates direct and indirect emissions
+
+        Args:
+        steel_output_desired (kg) or (kg/hr): (float) resulting desired steel output
+
+        Sources:
+        Model derived from: Bhaskar, Abhinav, Rockey Abhishek, Mohsen Assadi, and Homan Nikpey Somehesaraei. 2022. "Decarbonizing primary steel production : Techno-economic assessment of a hydrogen based green steel production plant in Norway." Journal of Cleaner Production 350: 131339. doi: https://doi.org/10.1016/j.jclepro.2022.131339.
+
+        '''
+        from hopp.simulation.technologies.steel.hdri_model import hdri_model
+
+        eaf_model.energy_model(self,steel_out_desired)
+        model_instance = hdri_model()
+
+        el_heater = model_instance.heater_mass_energy_model(steel_out_desired)[1]
+
+        indirect_emissions = ((self.el_eaf + el_heater)*self.emission_factor) #tco2 or tco2/hr
+
+        direct_emissions = (self.eaf_co2 + self.cao_emission + self.co2_eaf_electrode 
+                            + self.pellet_production) #tco2/tls or tco2/hr/tls
+
+        indirect_emissions_total = indirect_emissions #tco2 or tco2/hr
+        direct_emissions_total = direct_emissions*steel_out_desired/1000 #tco2 tco2/hr
+
+
+        self.indirect_emissions_total = indirect_emissions_total
+        self.direct_emissions_total = direct_emissions_total
+        self.total_emissions = self.indirect_emissions_total + self.direct_emissions_total
+
+        save_outputs_dict = establish_save_output_dict()
+
+        save_outputs_dict['Total Indirect Emissions (Ton CO2)'].append(self.indirect_emissions_total)
+        save_outputs_dict['Total Direct Emissions (Ton CO2)'].append(self.direct_emissions_total)
+        save_outputs_dict['Total Emissions (Ton CO2)'].append(self.total_emissions)
+
+        return (save_outputs_dict,self.indirect_emissions_total, self.direct_emissions_total, self.total_emissions)
+
+
+
+
+    def financial_model(self, steel_prod_yr):
+        '''
+        This function returns the financials for a rated capacity plant for EAF
+
+        Args:
+        steel_prod_yr (ton/yr): (float) plant capacity steel produced per year. For financial outputs
+
+        Sources:
+        Model derived from: Bhaskar, Abhinav, Rockey Abhishek, Mohsen Assadi, and Homan Nikpey Somehesaraei. 2022. "Decarbonizing primary steel production : Techno-economic assessment of a hydrogen based green steel production plant in Norway." Journal of Cleaner Production 350: 131339. doi: https://doi.org/10.1016/j.jclepro.2022.131339.
+
+        '''
+
+        self.eaf_total_capital_cost = ((self.eaf_cost_per_ton_yr*steel_prod_yr)/10**6)*self.lang_factor #Mil USD
+
+        self.eaf_operational_cost_yr = self.eaf_op_cost_tls*steel_prod_yr/10**6 #Mil USD per year
+
+        self.eaf_maintenance_cost_yr = self.maintenance_cost_percent*self.eaf_total_capital_cost #Mil USD per year
+
+        self.depreciation_cost = self.eaf_total_capital_cost/self.plant_life #Mil USD per year
+
+        self.coal_total_cost_yr = (self.carbon_cost_tls*self.mass_carbon_tls*steel_prod_yr/1000)/10**6 #(Mill USD per year)
+
+        self.lime_cost_total = (self.lime_cost*self.mass_lime_tls*steel_prod_yr/1000)/10**6
+
+        self.total_labor_cost_yr = self.labor_cost_tls*steel_prod_yr/10**6
+
+        direct_emissions_tls = (self.eaf_co2 + self.cao_emission + self.co2_eaf_electrode 
+                            + self.pellet_production) #tco2/tls
+
+        direct_emissions_yr = direct_emissions_tls * steel_prod_yr/10**6
+
+        self.total_emission_cost = direct_emissions_yr * self.emission_cost
+
+        save_outputs_dict = establish_save_output_dict()
+
+        save_outputs_dict['Shaft Total Capital Cost (Mil USD)'].append(self.eaf_total_capital_cost)
+        save_outputs_dict['Shaft Operational Cost (Mil USD per year)'].append(self.eaf_operational_cost_yr)
+        save_outputs_dict['Shaft Maintenance Cost (Mil USD per year)'].append(self.eaf_maintenance_cost_yr)
+        save_outputs_dict['Shaft Depreciation Cost (Mil USD per year)'].append(self.depreciation_cost)
+        save_outputs_dict['Total Carbon Cost (Mil USD per year)'].append(self.coal_total_cost_yr)
+        save_outputs_dict['Total Labor Cost (Mil USD per ton)'].append(self.total_labor_cost_yr)
+        save_outputs_dict['Total Lime Cost (Mil USD per year)'].append(self.lime_cost_total)
+        save_outputs_dict['Total Emission Cost (Mil USD per year)'].append(self.total_emission_cost)
+
+
+        return (save_outputs_dict, self.eaf_total_capital_cost, self.eaf_operational_cost_yr, self.eaf_maintenance_cost_yr,
+                self.depreciation_cost, self.coal_total_cost_yr, self.total_labor_cost_yr, self.lime_cost_total,
+                self.total_emission_cost)
+
+
+
+if __name__ == '__main__':
+    model_instance = eaf_model()
+
+    steel_output_desired = 1000 #(kg or kg/hr)
+
+    mass_outputs = model_instance.mass_model(steel_output_desired)
+    energy_outputs = model_instance.energy_model(steel_output_desired)
+    emission_outputs = model_instance.emission_model(steel_output_desired)
+
+    steel_output_desired_yr = 1000 #(ton/yr)
+
+    financial_outputs = model_instance.financial_model(steel_output_desired_yr)
+
+
+