Supplemental Material: Mathematical model (SI system) Sinter plant Only the raw materials iron ore, coke and limestone are considered and the internal mass flow rate of coke to the blast furnace is the difference between the total amount of available coke (including external coke) and coke needed in sinter plant, ๐๐ = ๐๐ ๐๐ ๐๐๐ก๐๐ ๐ป๐๐ = ๐๐๐ ๐๐ ๐๐๐ก๐๐ ๐๐ ๐ต๐น ๐๐๐๐๐ = ๐๐๐๐๐ − ๐๐๐๐๐ ∀ ๐ ∈ {๐๐๐, ๐๐๐๐, ๐๐๐๐๐ ๐ก๐๐๐} (A-1) (A-2) (A-3) ๐ is the mass flow rate (t/h), ๐ represents iron ore, coke or limestone, ๐ is an empirical factor and ๐๐ denotes sinter plant. Table 1 Technical parameters for the sinter plant model k ore coke limestone SP X 0.96 0.046 0.0714 85.12 (MJ/t) Coke Plant Linear relations between mass flow rates of feed coal and the mass flow rate of coke and volume flow rate of coke oven gas used: ๐๐๐๐๐ = ๐๐ถ๐ ๐๐๐๐๐ ๐๐ถ๐๐บ = ๐๐ถ๐๐บ ๐๐๐๐๐ ๐ ๐ ๐๐ถ๐๐บ = ๐ฅ๐ถ๐๐บ ๐๐ถ๐๐บ ∀ ๐ ∈ {๐ถ๐, ๐ถ๐2 , ๐ป2 , ๐2 , ๐2 , ๐ถ๐ป4 } (A-4) (A-5) (A-6) where ๐ represents a mass flow rate (t/h), ๐ are empirical factors for estimating the amount of coke and coke oven gas, ๐ถ๐ is coke plant, ๐ถ๐๐บ is coke oven gas, ๐ is the volume flow rate (km3 n/h) and ๐ฅ stands for the molar composition of coke oven gas for the different components. Table 2 Technical parameters for the coke plant model k CO CO2 H2 O2 N2 CH4 x 0.0528 0.0177 0.5807 0.0014 0.0646 0.2828 COG CP 0.3197 0.6742 Hot Stoves The volume flow rate of blast and energy needed for the hot stoves is estimated by an efficiency factor of 0.6885. The heat is assumed to be generated by using internal fuel (off gases) and/or external oil supply. ๐ต๐น ๐ = ๐๐๐๐๐ ๐ก ๐๐ข๐ก ๐๐ โ๐ป๐ป๐ = ๐๐ป๐ (๐ป๐ป๐ − ๐ป๐ป๐ ) ๐ต๐น ๐๐2 = ๐๐๐๐๐ ๐ก ๐๐๐๐๐โ๐๐๐๐ก (A-7) (A-8) (A-9) where ๐ต๐น is the blast furnace, ๐ป๐ is hot stoves, โ๐ป is the difference between the enthalpies, ๐ป is the enthalpy (of input and output streams) and ๐ stands for the hot stove efficiency factor. Basic oxygen furnace The production of liquid steel is taken to be proportional to the amount of hot metal and scrap. We assumed 50% recovery of BOF off gases with fixed composition of CO and CO2 of 0.9 and 0.1, respectively. ๐ต๐น ๐๐๐ = (1.1453). ๐๐ป๐ ๐ต๐๐น ๐ต๐น ๐๐ต๐๐น๐บ = (0.0415). ๐๐ป๐ ๐ต๐น ๐๐๐ต๐๐น = (0.4562) . ๐๐ป๐ 2 ๐ต๐๐น ๐ต๐น ๐๐๐๐๐๐ = (0.25). ๐๐ป๐ ๐ต๐๐น ๐ต๐น ๐๐๐๐๐๐ ๐ก๐๐๐ = (0.06657). ๐๐ป๐ (A-10) (A-11) (A-12) (A-13) (A-14) where ๐ is mass flow rate (t/h), ๐๐ is liquid steel, ๐ป๐ is hot metal, ๐ต๐๐น is basic oxygen furnace, ๐ต๐๐น๐บ is basic oxygen furnace off gases. Power Plant The power plant is modeled in a way which produces utility requirements for the whole plant and external electricity and district heat based on demand or price as byproduct. The internal fuels (off gases) and oil is used as feedstock. The technical data is presented below: Table 3 Data for power plant model Efficiency Turbine [Steam, 75 bar ๏ 5 bar] Production of District Heat [Heat Exchanger, Tout=60 ’C] Production of electricity [Generator] η 0.79 0.9 0.95 Blast Furnace The general model for the blast furnace is described in the Appendix of ref. 8. For the sake of simplicity a surrogate model based on PLS and Kriging has been used in the present study BF ๐๐ = ๐ด1,๐ + ∑ ๐ด2,๐,๐ ๐๐BF 49 (A-15) ๐ BF 2 ) ๐ฬ๐ = ๐๐ + ∏ ๐พ๐ ๐ exp(−๐๐๐ ๐๐๐ (A-16) ๐ =1 2 ๐๐๐ = (๐๐BF − ๐ค๐ ๐ ) (A-17) where ๐ด1,๐ and ๐ด2,๐ are regression coefficients, ๐๐BF (n = 1,..,5) stands for the hot metal production (t/h), specific oil rate, pellet rate (kg/t hm ), blast oxygen content (%), or blast temperature (๏ฐC) that are the five inputs to the blast furnace model. The fifteen outputs BF ๐ฬ๐ (๐ = 1, … ,15) in the surrogate model are the specific coke rate (kg/t hm ), volume flow rate of top gases (km3 n/h), composition of top gases (H2 , N2 , CO2 , CO), top gas temperature (๏ฐC), sinter rate (kg/t hm ), blast volume flow rate (m3 n/h), (raceway) flame temperature (๏ฐC), burden residence time (h), bosh gas volume (km3 n/h), limestone rate (kg/t hm ), quartzite rate (kg/t hm ) and slag rate (kg/t hm ), ๐๐ is the generalized least 2 squares estimate for the polynomial term, ๐๐๐ is the correlation function parameters, ๐๐๐ = BF (๐๐ − ๐ค๐ ๐ ) are the differences between a point and the design sites ๐ค๐ ๐ , and ๐ is the number of random points that have been generated by the Latin hypercube method. The Kriging method has been used to estimate the last three terms based on s = 49 random input points. Table 4 Regression coefficients after scaling of the blast furnace-PLS model Coke rate Top Gas Volume CO Composition O2 Composition H2 Composition N2 Composition Top Gas Temp. Sinter Rate O2 Volume flow rate Blast Volume Rate Flame Temperature Residence time Basicity Slag flow Rate Bosh Gas Volume Hot Metal Oil Rate -0.005014 1.4760350 -1.025237 0.1237624 -0.0000019 Pellet Rate Blast Temperature -0.10781 -0.06647 A1 -0.009983 -0.004576 O2 Enrichment -0.278994 -5.187665 -0.000173 -0.00001 0.005796 -0.00000407 0.1058 0.0000009 -0.000182 0.000018 0.0054725 0.00003593 0.0578 0.0000033 0.0004412 -0.00000088 0.0013414 0.00001247 -0.0349 -0.0000023 -0.000085 -0.00000716 -0.0126100 -0.00004434 0.8712 0.0175255 1.095010 -0.02639143 -16.06648 -0.16139 657.704 0.0001598 76.819234 -0.000373 7.218492 -1.080164 -0.529055 0.002875 1267.9047 0.00001888 -4.832905 1572.14 30928.3 957.52657 54.53718 -5.095824 -5167.110 -56.48740 192363.2 -0.0193695 -3.326163 -0.016224 36.97700 0.624802 890.11 -0.0493425 0.012907 0.000237 0.004898 0.001405 11.162 0.0000080 -0.0224216 0.0006239 -0.021151 0.00004875 -0.117201 0.000327 -0.415930 -0.00001126 -0.0128152 0.9652 306.777 1354.9086 234.06044 -6.650835 -5182.449 -73.412888 191684.33 581.644 195.454 Membrane Process The operational pressure and molar flow rate (๐ค๐ฆ๐จ๐ฅ/๐ก) of the membrane process is estimated by ๐๐๐ค ๐๐๐ธ๐ โ๐๐โ ๐๐๐ธ๐ ๐น =( ๐ฆ๐ป2๐๐ธ๐ ๐ ๐ฆ๐ป2๐๐ธ๐ ๐ )( ๐น 1 − ๐๐ป๐๐ธ๐ 2 ๐น 1 − ๐ฆ๐ป2๐๐ธ๐ ๐๐ป๐๐ธ๐ 2 ) (A-18) ๐๐ป2๐๐ธ๐ = ๐๐ป๐๐ธ๐ ๐๐ป2๐๐ธ๐ 2 (A-19) ๐ ๐๐ ๐๐ธ๐ ๐น ๐น ๐ผ{๐⁄๐ป2 } ๐๐ป๐๐ธ๐ ๐ฆ๐ ๐๐ธ๐ ๐๐ป2๐๐ธ๐ 2 = ๐น ๐ฆ๐ป2๐๐ธ๐ ๐๐๐๐ธ๐ ๐๐ป2 [2 − ๐๐ป๐๐ธ๐ 2 (A-20) ๐ ๐๐๐ค ๐ฆ๐ป2๐๐ธ๐ ๐๐๐ธ๐ − ] − 2 [ ] (1 − ๐ผ{๐⁄๐ป2 } ) ๐น โ๐๐โ 1 − ๐ฆ๐ป2๐๐ธ๐ ๐๐ป๐๐ธ๐ ๐ ๐๐ธ๐ 2 ๐ผ(๐⁄๐ป2 ) ๐๐ป๐๐ธ๐ 2 ๐น = (1 − ๐๐ป๐๐ธ๐ )๐๐ป2๐๐ธ๐ 2 (A-21) ๐๐๐๐ธ๐ ๐๐ ๐น ๐ = ๐๐ ๐๐ธ๐ − ๐๐ ๐๐ธ๐ (A-22) โ๐๐โ ๐๐๐ธ๐ ๐น ๐ where and are the product and feed stream pressures, ๐ฆ๐ป2๐๐ธ๐ and ๐ฆ๐ป2๐๐ธ๐ are the mole fraction of hydrogen in feed and in the product streams and ๐๐ป๐๐ธ๐ is membrane 2 ๐๐๐ธ๐ hydrogen product recovery, ๐๐ป2 is the molar flow rate of hydrogen in the product stream, ๐๐๐ธ๐ ๐๐ ๐๐ is the molar flow rate of other components available in the product stream, ๐๐ป2 ๐๐ธ๐ is ๐๐ the molar flow rate of hydrogen in the byproduct, ๐๐ ๐๐ธ๐ is the molar flow rate of other ๐๐๐ค ๐๐๐ธ๐ components in the byproduct stream and ๐ผ{๐⁄๐ป2 } is the ratio of permeability coefficient of other components available in the stream to hydrogen. Table 5 Permeability coefficient for components in stream Component CO CH4 CO2 H2 O2 N2 Permeability 2.4 2.3 38 55 8.3 1.4 Pressure Swing Adsorption Process The operational pressure and molar flow rate (kmol/h) are expressed as ๐๐๐ค ๐๐๐๐ด โ๐๐โ ๐๐๐๐ด ๐น = ๐ฆ๐ป2๐๐๐ด (1 − ๐ ๐ ๐๐๐ด ) 1 − ๐ฝ๐๐๐ด (A-23) ๐น ๐๐ป2๐๐๐ด = ๐ ๐๐๐ด ๐๐ป2๐๐๐ด ๐๐๐๐๐ด ๐๐ป2 ๐๐๐๐๐ด ๐๐ ๐น (A-24) ๐ = ๐๐ป2๐๐๐ด − ๐๐ป2๐๐๐ด (A-25) ๐น = ๐๐ ๐๐๐ด (A-26) โ๐๐โ ๐๐๐ค where ๐๐๐๐ด and ๐๐๐๐ด are the low and high absolute pressure of the pressure swing cycle, ๐น๐๐๐ด ๐ฆ๐ป2 is the mole fraction of the hydrogen in the feed, ๐ ๐๐๐ด is the product recovery and βPSA ๐ ๐น is the adsorbent selectivity value, ๐๐ป2๐๐๐ด is the molar flow rate of the product stream, ๐๐ป2๐๐๐ด ๐๐๐๐๐ด is the molar flow rate of hydrogen in the feed stream, ๐๐ป2 ๐๐ ๐๐ ๐๐๐ด is the molar flow rate of hydrogen in the byproduct stream and is the molar flow rate of other components in the byproduct stream. In practice the value of the hydrogen recovery is less than 0.92 and for the adsorbent selectivity would be greater than 0.02. Reactors The molar flow rates for the gas reforming units are calculated by (linear) mass balances for fixed conversion reactor with NR parallel reactions for each component, ๐, and can be expressed as ๐๐ ๐๐๐ = ๐๐น๐ + ∑ ๐พ๐๐ ๐ฅ๐ ๐๐น๐(๐) (A-27) ๐=1 where ๐ is the number of reaction, ๐(๐) is the limiting component, ๐พ๐๐ is the stoichiometric coefficients which is positive, negative and zero for product, reactant and inert components and ๐ฅ๐ is the fraction converted per pass based on limiting reactant. Table 6 operation condition for different gasification process Reactor SMR CDR POR LPMEOH GPMEOH Operational condition CH4/H2O=3.681, P=20 bar, T=1153-1300 K ๐๐๐ ๐๐๐ ๐ฅ๐ถ๐ป = 81.46, ๐ฅ๐ถ๐ = 40.2 4 CH4/CO2=1, P=1 bar, T=1143-1313 K ๐๐ช๐ซ๐น ๐ช๐ฏ๐ = ๐. ๐๐ CH4/O2=2, P=1 bar, T=1073-1473 K ๐๐ท๐ถ๐น ๐ช๐ฏ๐ = ๐. ๐๐ H2/CO≥2, P=50 bar, T=523 K ๐๐ณ๐ท๐ด๐ฌ๐ถ๐ฏ = ๐. ๐, ๐๐ณ๐ท๐ด๐ฌ๐ถ๐ฏ = ๐๐. ๐ ๐ช๐ถ๐ ๐ช๐ถ H2/CO≥2, P=50 bar, T=533 K ๐๐ฎ๐ท๐ด๐ฌ๐ถ๐ฏ = ๐๐, ๐๐ฎ๐ท๐ด๐ฌ๐ถ๐ฏ = ๐๐ ๐ช๐ถ๐ ๐ช๐ถ Compressors The reference case of the compressor is assumed to operate isentropically, and the true operation is estimated with adiabatic, motor drive and mechanical efficiencies of ๐๐๐ = 0.9, ๐๐๐ = 0.9 and ๐๐๐๐โ = 0.85, respectively, ๐๐๐ข๐ก ๐๐๐ข๐ก (๐พฬ −1)⁄๐พฬ =( ) ๐๐๐ ๐๐๐ ∑๐ ๐๐ (๐ป๐๐ข๐ก,๐ − ๐ป๐๐,๐ ) ๐๐๐๐๐ = ๐๐๐ ๐๐๐ ๐๐๐๐โ ๐๐๐,๐๐๐๐ = ๐๐๐ข๐ก,๐๐๐๐ (A-28) (A-29) (A-30) where ๐out and ๐in are the outlet and inlet absolute temperatures, ๐out and ๐in are the outlet and inlet pressures, ๐พฬ is the average of specific heat ratio of the components in question and ๐๐๐๐๐ is the compressor work. Separation columns For distillation columns the composition of component in product is specified. The operational condition is presented in Table 7. The energy balance is expressed as ๐ฅ๐ป๐๐๐. = ๐ฅ๐ป๐๐๐๐. + ๐ฅ๐ป๐ ๐๐๐ ๐๐๐๐ (A-31) ๐ฅ๐ป๐๐๐๐. = ∑๐=๐๐๐๐๐๐๐๐๐ก๐ ๐๐(๐ ฬ + 1) ๐๐ ๐ป๐๐ (A-32) ๐๐๐ ๐ก๐๐๐๐๐ก๐ ๐ ๐ก๐๐๐๐ ๐ฅ๐ป๐ ๐๐๐ ๐๐๐๐ = ∑ ๐๐ ๐ถ๐๐ ๐ฅ๐๐ ๐๐๐ ๐๐๐๐ (A-33) ๐=๐๐๐๐๐๐๐๐๐ก๐ ๐๐ ๐๐๐ ๐ก๐๐๐๐๐ก๐ ๐ ๐ก๐๐๐๐ ๐ ๐ ๐๐๐๐๐๐ข๐๐ก = ๐ ๐ ๐๐๐๐๐ ๐ ๐ ๐๐๐๐ก๐ก๐๐ = (1 − ๐ ๐ )๐๐๐๐๐ (A-34) (A-35) where Δ๐ป๐๐๐๐. is the enthalpy change to condense the distillate product (kJ/mol), ๐ ฬ is the reflux ratio, ๐ป๐๐ is the heat of vaporization at given temperature (kJ/mol), ๐ถ๐ฬ ๐ is the specific heat capacity of the distillate component (kJ/(mol · K)), Δ๐๐ ๐๐๐ ๐๐๐๐ is difference of boiling point of distillate product and feed temperature (K) and ๐ is the split fraction of component in each stream. Table 7 Operational condition for each separation column Separation Column MEOH DME GSP WSP TSA COPure Operational condition P=3.4 bar, T=318 K ๐ ๐๐๐กโ๐๐๐๐ = 99.9, R=1.5 P=11.2 bar, T=318 K ๐ ๐๐๐กโ๐๐๐๐ = 1, R=20 P=11.2 bar, T=318 K ๐๐๐๐ ๐๐ = 1 P=20 bar, T=383 K ๐ป๐๐๐๐๐ = ๐ P=1 bar,T=273-573K ๐ ๐ถ๐ = 0.99 Low P,T ๐ ๐ถ๐ = 0.98 Mixer and Splitter units For mixers and splitter units, linear mass balance is considered for input(s) and output(s) ๐ ๐ ๐๐๐๐ฅ๐๐ = ∑ ๐๐๐,๐ ๐ (A-36) ๐ ๐๐ ๐๐๐๐ก๐ก๐๐,๐ = ๐๐ ๐๐๐๐ (A-37) where ๐ is the number of streams, k is the components and ๐ is the specified fraction for each output stream. Enthalpy analysis For all considered units in polygeneration system and carbon capturing and sequestration, the difference between input and output enthalpies is calculated by ๐2 ๐3 ๐4 ๐ต5๐ (A-38) ๐ป๐ − ๐ป๐,298 = ๐ต1๐ ๐ + ๐ต2๐ ( ) + ๐ต3๐ ( ) + ๐ต4๐ ( ) − ( ) 2 3 4 ๐ + ๐ต6๐ − ๐ต7๐ where ๐ is temperature in 10−3 K, ๐ป๐ is the standard enthalpy in kJ/mol, and ๐ต๐ are the parameters obtained from NIST Chemistry Web book. The energy efficiency of heat exchangers is assumed to be 0.7. Table 8 Coefficients in enthalpy estimation k CO CO2 H2 O2 O2 N2 N2 CH4 H2O B1 25.56 24.99 33.066 31.32 30.032 28.98 19.505 -0.703 30.092 B2 6.096 55.19 -11.363 -20.23 8.77 1.854 19.887 108.477 6.8323 B3 4.05 -33.69 11.43 57.86 -3.988 -9.647 -8.598 -42.521 6.7934 B4 -2.67 7.95 -2.77 -36.50 0.788 16.635 1.369 5.862 -2.5344 B5 0.131 -0.14 -0.158 -0.0073 -0.741 0.00012 0.527 0.678 0.0843 B6 -118.00 -403.61 -9.98 -8.903 -11.324 -8.672 -4.935 -76.843 -250.88 B7 -110.52 -393.52 0 0 0 0 0 -74.873 -241.82 T 298-1200 298-1200 298-1000 100-700 700-2000 100-500 500-2000 298-1300 500-1700 Objective Function The net present value (NPV) of the project is estimated by ๐๐๐ = − (1 − ๐ถ๐ผ = ๐ถ๐ผ ๐๐๐ ๐๐ ( ๐ 1 1 1 1 โ โ (1 − )) ๐ถ๐ผ + โ (1 − ) ๐๐ ๐ ๐๐ ๐๐๐ ๐ฟ ๐ฟ (1 + ๐ฟ) (1 + ๐ฟ)๐๐๐ ๐ ๐ ๐๐๐ ๐๐ ) ๐๐ = ๐ถ๐๐ ๐ก๐๐๐๐๐ ๐ก๐๐๐ − ๐๐๐๐๐๐๐๐๐๐ข๐๐ก๐ + ๐ถ๐๐ ๐ก๐๐๐๐ ๐ ๐๐๐ ๐๐๐ ๐ ๐๐๐ข๐๐ ๐ก๐๐๐ก๐๐๐ (A-39) (A-40) (A-41) where ๐ถ๐ผ is the total Capital Investment cost of equipment for gasification, carbon capturing and sequestration and methanol units, which are expressed by a linear approximation with fixed cost charge of the Guthrie’s Modular Method with cost update factor for 2010, and NP is the annual Net Profit of the integrated system, ๐ = 40% is tax rate, ๐๐๐ = 30 and ๐๐๐ = 10 years life and depreciation time of project and ๐ฟ = 12% is the annual discount rate.