ulcos: searc: searching for breakthroughhing for ......ulcos: searc: searc co 2-lean gcep carbon...
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ULCOS: SearcULCOS: SearcCO2-lean
GCEP Carbon Management in Manufa
M
Ultra Low CO2 Stee
hing for Breakthroughhing for Breakthrough Steelmaking Routes…
acturing Industries, Stanford University, USA16 April 2008
Mark Atkinson, on behalf of Jean-Pierre BiratEuropean Program Coordinator
elmaking
[email protected]@arcelormittal.com
Ultra Low CO2 Steelma
ersi
ty, U
SA identify steel production routes wemissions by a factor 2 or more
EP, S
tanf
ord
Uni
ve worldwide targets in post-Kyoto negotia
select the most promising ones sustainability analysis
08G
CE develop the technology in order size at the end of the 5 year proprepare and launch the next ste
16 A
pril
200 prepare and launch the next ste
the program is supported financ(RFCS & 6th FP)(RFCS & 6th FP)
aking: program's targets
with the potential of mitigating CO2(European targets for 2020/2050, probably
tions)
by passing them all through a
r to be ready for a scale-up to commercial ogram (ULCOS-I)ep, ULCOS-IIep, ULCOS II
cially by the European Union
22
Program shedule
Technology deveTechnology deve
ersi
ty, U
SA
Technology deve
SP1 -New Blast Furnace
SP8-New Advanced C-lean &C-based
Phase 1Technology deve
SP1 -New Blast Furnace
SP8-New Advanced C-lean &C-based
SP1 -New Blast Furnace
SP8-New Advanced C-lean &C-based
Phase 1
EP, S
tanf
ord
Uni
ve
SP2-New Smelting Reduction
SP3-New NG Route to Steel
SP8-New Advanced C-lean &C-based Route to Steel
SP2-New Smelting Reduction
SP3-New NG Route to Steel
SP8-New Advanced C-lean &C-based Route to Steel
SP2-New Smelting Reduction
SP3-New NG Route to Steel
SP8-New Advanced C-lean &C-based Route to Steel
08G
CE
SP4-Hydrogen steel production
SP5-Electrolysis steel production
SP6-CO Capture & Storage for steelmaking
SP4-Hydrogen steel production
SP5-Electrolysis steel production
SP6-CO Capture & Storage for steelmaking
SP4-Hydrogen steel production
SP5-Electrolysis steel production
SP6-CO Capture & Storage for steelmaking
16 A
pril
200
SP9-Scenarios, sustainability, in
SP6-CO2 Capture & Storage for steelmaking
SP7-Biomass-based Steel production
SP9-Scenarios, sustainability, in
SP6-CO2 Capture & Storage for steelmaking
SP7-Biomass-based Steel production
SP6-CO2 Capture & Storage for steelmaking
SP7-Biomass-based Steel production
Project MProject M
elopment – 5 yearselopment – 5 years59 M€budget
TODAY
elopment 5 years
ULCOS – RFCSSP10-New C-based Steel production
SP11 Ne ad C based
elopment 5 years
ULCOS – RFCSULCOS – RFCSSP10-New C-based Steel productionSP10-New C-based Steel production
SP11 Ne ad C basedSP11 Ne ad C based
budget
SP11-New adv. C-based Steel production.
SP12-New Nat Gas-basedSteel Production
SP14-ULCOS-Process
for Steel Production
SP11-New adv. C-based Steel production.
SP11-New adv. C-based Steel production.
SP12-New Nat Gas-basedSteel Production
SP12-New Nat Gas-basedSteel Production
SP14-ULCOS-Process
for Steel Production
SP14-ULCOS-Process
for Steel Production
SP13-New Electricity-based Steel Production Phase 3SP13-New Electricity-based Steel Production
SP13-New Electricity-based Steel Production Phase 3
nnovation, training & dissemination
ULCOS – 6FPPhase 2
nnovation, training & dissemination
ULCOS – 6FPULCOS – 6FPPhase 2
33ULCOS
Management
ULCOSULCOS
Management
What is possible in t
CarboCoke
CO2capture & storage
ersi
ty, U
SA
Coke
CoalUse of C fromsustainable
biomass
EP, S
tanf
ord
Uni
ve
SyngasPlas
in Blast
biomass
08G
CE
Natural GasNatural gas prer
H2 prereduction
16 A
pril
200
H2 by electroHydrogenH2
H2 prereduction
Other reducing agents: Al d
Hydrogen
the long term?Existing
onBlast Decarbonatation
gtechnology
BlastFurnace
i
sma Furnace
Electric Arc Furnace
reduction
olysis of H2OElectricity
Electrons
Electrolysis
44dross, etc.
ElectronsNew
Technology
How to tackle the CO
C-based steel p
ersi
ty, U
SAEP
, Sta
nfor
d U
nive
Biomass-based steel production
08G
CE
p
16 A
pril
200
Electrolysis steel production
O2 issue…
production + CO2 Capture & Storage
Natural Gas-based steel production
55Hydrogen-based steel production
ersi
ty, U
SAEP
, Sta
nfor
d U
nive
08G
CE16
Apr
il 20
0
66
CO2emissions -
1 848
2 310
Scopekg CO2/t HRC
ersi
ty, U
SA
1 386
BF variants
BF benchmark
EP, S
tanf
ord
Uni
ve
924
BF variantsSmelting
08G
CE
0
462
16 A
pril
200
-462 ULC
OS
Ref
eren
ce
SP1
Ref
eren
ce
ULC
OS
Ref
eren
ce +
CC
S
BF-
Cha
rcoa
l Ref
eren
ce
BF1
Coa
l
BF
1 C
oal +
CC
S
BF
1 C
harc
oal +
CC
S
BF
2.1
Coa
l + C
CS
BF2
.2 C
oal +
CC
S
BF
2.2
Cha
rcoa
l + C
CS
BF
3.1
Coa
l + C
CS
BF
3.2
Coa
l + C
CS
BF
3.2
Cha
rcoa
l + C
CS
BF-
DR
I Ref
eren
ce
BF
3.2
DR
I + C
CS
2 D
RI +
CC
S +
CC
S SR
BF
4 C
oal +
CC
S
BF
4 C
harc
oal +
CC
S
BF2
with
out s
eque
stra
tion
Plas
ma
BF2
+ C
CS
NA
Hae
mat
ite b
asic
cas
e
RN
A H
aem
atite
HV
coa
l
aem
atite
MV
coa
l + C
CS
e 12
5kg
Cha
rcoa
l + C
CS
ISA
RN
A 1
00%
cha
rcoa
l
te 1
00%
Cha
rcoa
l + C
CS
-924
U
BF
3.2
Plas
ma
B
ISA
RN
ISA
R
ISA
RN
A H
a
ISA
RN
A H
aem
atite I
ISA
RN
A H
aem
atit
- 370g CO2/kWh
e 2 Hydrogen
F0F0
g Reduction F2
Direct Reduction
F4
Circ
ofer
EA
F H
aem
MV
r EA
F H
aem
MV
+ C
CS
ofer
EA
F H
aem
Cha
rcoa
er E
AF
Hae
m C
harc
CC
S
EAF
Hae
m L
V O
ptim
ised
em L
V O
ptim
ised
+ C
CS
Hae
m C
harc
oal O
ptim
ised
harc
oal O
ptim
ised
+ C
CS
DR
I+EA
F re
fere
nce
DR
I+EA
F
DR
I + E
AF
+ C
CS
New
DR
2%
C c
old
New
DR
0,2
% C
col
d
New
DR
0,2
% C
hot
LRI +
BF
LRI +
CC
S +
BF
LRI +
CC
S +
BF
+ C
CS
DR
I + A
MF
DR
I + A
MF
+ C
CS
SR H
2 D
RI +
EA
F
R H
2 D
RI +
EA
F +
CC
S
R H
2 D
RI +
EA
F +
CC
S
El. H
2 D
RI +
EA
F
Aqu
eous
Alk
alin
e
Met
alys
is
Sint
ef-N
TNU
Pyro
elec
tro
77
Circ
ofe
Circ
Circ
ofe
RH
F E
RH
F EA
F H
ae
RH
F EA
F H
RH
F EA
F H
aem
Ch SR
CM
R
Electrolysis
CO2emissions - 5g CO2
1 804
2 255
Scop
kg CO2/t HRC
ersi
ty, U
SA
1 353
BF variants
BF benchmark
EP, S
tanf
ord
Uni
ve
902
BF variantsSmelting
08G
CE
0
451
16 A
pril
200
-451 ULC
OS
Ref
eren
ce
SP1
Ref
eren
ce
ULC
OS
Ref
eren
ce +
CC
S
BF-
Cha
rcoa
l Ref
eren
ce
BF1
Coa
l
BF
1 C
oal +
CC
S
BF
1 C
harc
oal +
CC
S
BF
2.1
Coa
l + C
CS
BF2
.2 C
oal +
CC
S
BF
2.2
Cha
rcoa
l + C
CS
BF
3.1
Coa
l + C
CS
BF
3.2
Coa
l + C
CS
BF
3.2
Cha
rcoa
l + C
CS
BF-
DR
I Ref
eren
ce
BF
3.2
DR
I + C
CS
2 D
RI +
CC
S +
CC
S SR
BF
4 C
oal +
CC
S
BF
4 C
harc
oal +
CC
S
BF2
with
out s
eque
stra
tion
Plas
ma
BF2
+ C
CS
NA
Hae
mat
ite b
asic
cas
e
RN
A H
aem
atite
HV
coa
l
aem
atite
MV
coa
l + C
CS
e 12
5kg
Cha
rcoa
l + C
CS
ISA
RN
A 1
00%
cha
rcoa
l
t10
0%C
hl+
CC
S
-902
U
BF
3.2
Plas
ma
B
ISA
RN
ISA
R
ISA
RN
A H
a
ISA
RN
A H
aem
atite I
ISA
RN
AH
tit
2/kWh
pe 2
F0
Hydrogen
F0
g Reduction F2
Direct Reduction
F4
te 1
00%
Cha
rcoa
l + C
CS
Circ
ofer
EA
F H
aem
MV
r EA
F H
aem
MV
+ C
CS
ofer
EA
F H
aem
Cha
rcoa
er E
AF
Hae
m C
harc
CC
S
EAF
Hae
m L
V O
ptim
ised
em L
V O
ptim
ised
+ C
CS
Hae
m C
harc
oal O
ptim
ised
harc
oal O
ptim
ised
+ C
CS
DR
I+EA
F re
fere
nce
DR
I+EA
F
DR
I + E
AF
+ C
CS
New
DR
2%
C c
old
New
DR
0,2
% C
col
d
New
DR
0,2
% C
hot
LRI +
BF
LRI +
CC
S +
BF
LRI +
CC
S +
BF
+ C
CS
DR
I + A
MF
DR
I + A
MF
+ C
CS
SR H
2 D
RI +
EA
F
R H
2 D
RI +
EA
F +
CC
S
R H
2 D
RI +
EA
F +
CC
S
El. H
2 D
RI +
EA
F
Aqu
eous
Alk
alin
e
Met
alys
is
Sint
ef-N
TNU
Pyro
elec
tro
Electrolysis
88ISA
RN
A H
aem
atit
Circ
ofe
Circ
Circ
ofe
RH
F E
RH
F EA
F H
ae
RH
F EA
F H
RH
F EA
F H
aem
Ch SR
CM
R
Conclusions of phas
steel production routes can
ersi
ty, U
SA
by a factor 2 or more further intensive RTD workbecome available and use
EP, S
tanf
ord
Uni
ve become available and usebeside these breakthroughroutes, already developed,
08G
CE
, y p ,levels of cuts in CO2 emissULCOS has selected 4 bre
16 A
pril
200 in phase II, based
• either on using fossil reducingCCS and an original in-procesg p
• or on using carbon-lean electr
se I
n be designed to cut CO2 emissions
k is needed before they can actually d commerciallyd commercially
h routes, we have exhibited other , that can deliver intermediary , ysions eakthrough routes, for further work
g agents and fuels and pure O2 operation, on ss CO2 capture concept,
99
2 p pricity.
Top Gas RecyTop Gas Recyycling Blast Furnaceycling Blast FurnacePhase II of ULCOS-I
Experimental campa
6 week test period from 24 Septe- Production rate constant
ersi
ty, U
SA
- PCI rate constant- Maximize gas injection rate
Tuyeres T
EP, S
tanf
ord
Uni
ve Tuyeres T
Export gas
Gas cleaning
08G
CE
CO2
CO2scrubber
16 A
pril
200 Gas
heater
Oxygen
PCI
aign, Fall 2007
ember 2007 on the LKAB EBF in Luleå:
Tuyeres + ShaftTuyeres + Shaft
Export gas
Gas cleaning
CO2
CO2scrubber
Gas heater
Oxygen
1111
PCI
Preliminary conclusio
1. no safety issue with the
ersi
ty, U
SA
2. smooth operation with t3. carbon savings up to 24
EP, S
tanf
ord
Uni
ve
4. stable gas efficiency in tstability of the EBF
08G
CE 5. start-up not especially d6. no carbon deposition
16 A
pril
200
7. smooth operation of the8. the first EBF campaign w8. the first EBF campaign w
has been a great succes
ons of the ULCOS EBF trial
new process.the new process4% at 156 kg/thm of coal.the shaft & control of thermal
difficult
e VPSA with the TGR-BF process
1212
with the TGR BF process ss.
Future plans
ersi
ty, U
SA need to start scaling up BF
EP, S
tanf
ord
Uni
ve
the TGR-BF concept is seemiddle term, as existing BF
08G
CE
, gtechnology and the BF culture iproduction.
16 A
pril
200
F and CCS operation
en as the most realistic one for the F can be retrofitted to the ULCOS s prevalent in the Steel Industry for mass
1313
MeltingMelting Reduction: ISARNAReduction: ISARNAPhase II of ULCOS-I
ISARNA's concept
offgas CC
ersi
ty, U
SA iron oreoxygen
EP, S
tanf
ord
Uni
ve
coaloxygen
08G
CE processgas
16 A
pril
200
hot metal and slagand slag
O ti
CS
pure O2 operation CO2 rich off-gas, CCS readyno raw material preparation p pnecessary (pulverized coal and pulverized ore)very compact cyclone to feedvery compact cyclone, to feed molten and slightly prereduced iron ore into the bath smelterproduces hot metalproduces hot metal rebirth of the Smelting Reduction concept in the new context of CO2lean ironmaking
1515
-lean ironmaking
Future plans
pure oxygen operation, CC
ersi
ty, U
SA
small experimental plant u
EP, S
tanf
ord
Uni
ve built at Saarstahl and expeyears of the 6FP ULCOS plater on (>2010): commerc
08G
CE later on (>2010): commercthen, commercial deploym
16 A
pril
200
CS
nder detailed design stage to be erimented with, during 5th and 6th
projectcial size pilot plantcial size pilot plantent…
1616
NeNeew Direct Reductionew Direct ReductionPhase II of ULCOS-I
New DR concep Bleed of N2 containing Hydrog
ersi
ty, U
SAEP
, Sta
nfor
d U
nive
100 % Oxygen
No reformer
08G
CE
20 % less energy consumption
Off gas = CO2
16 A
pril
200 g 2
Shifter gives high amount of H2 in treducing gas = high rate of reductio
+ opportunity to bleed out N2 and make a H2 stream which can be us
pten
the on
1818ed
Future plans
pure oxygen operation, CC
ersi
ty, U
SA
ygnatural gas and syngas ca
EP, S
tanf
ord
Uni
ve small LKAB DR pilot in Lulimplementation of the ULClater on, commercial scale
08G
CE
later on, commercial scale
16 A
pril
200
CSan feed the process
å OSeå at MEFOS (1 ton of DRI / h), withCOS-DR technology
pilot.pilot.
1919
EleElectrolysis of iron orectrolysis of iron orePhase II of ULCOS-I
Electricity-based Steelm
Direct decomposition of iron oxide:
ersi
ty, U
SA
2000 Pyroelectrolysis:1600°C
EP, S
tanf
ord
Uni
ve
1500
08G
CE
500
1000
Alkaline electrowinning: 110°C
iron ore
16 A
pril
200
individual particle
0
500 Alkaline electrowinning: 110 Cpurification
iron ore iron oxid
making
Fe2O3 Fe(metal) + O2(gas)
anodesself crucib le
m olten iron
m olten s lag
oxygen evo lution
current
rectifie r
anodesself crucib le
m olten iron
m olten s lag
oxygen evo lution
current
rectifie r
→conceptcathode barscathode bars
→DC EAF analogy
C
liquid steel
→Aluminum analogyC
electrowinning melting
2121
de iron metal liquid steel
Future plans - electr
the most original route exp
ersi
ty, U
SA
g ppotential for "zero emissionappropriate electricity prod
EP, S
tanf
ord
Uni
ve
project still running at a ratthe lack of prior experience
08G
CE takes place rather quickly!application is both long-termore laboratory work need
16 A
pril
200 more laboratory work need
olysis
plored within ULCOS, with a p ,n" in conjunction with the duction (not necessarily nuclear!)
ther fundamental level, because of e in the area, although scaling-up
rm and a "long shot"ded for several more yearsded for several more years.
2222
ConclusionsConclusions
ULCOS-I has exhibited a
ersi
ty, U
SA
technologies with the poa factor 2 to 4
EP, S
tanf
ord
Uni
ve
full scale implementationcarbon-lean technologie
08G
CE shelf in the steel sector, emissions by 50/60% in
16 A
pril
200
all breakthrough routes nbe cleverly adapted to th
t ( )sector (shorter-term solution?)electricity is considered
a series of process potential of cutting emissions by
n still requires much RTD, as es are not available off-the-
which has already cut the last 40 yearsneed CCS; the concept has to he original features of the
t h C l2323
, except when C-lean (longer-term solution?)
Conclusions
implementation and de
ersi
ty, U
SA
p2015 to 2050, provided same everywhere in the wi 2050 th t l i d
EP, S
tanf
ord
Uni
ve in 2050, the steel indusshort of its targets of reproduction is likely to b
08G
CE
production is likely to bspecific CO2 emissionswhat might be needed,
16 A
pril
200 g ,
processes, which can apanel of technologies w
eployment can take place from p y pthe constraints on CO2 are the
world.t ld id i ht till bstry worldwide might still be
eduction, as the increase in balance out the reduction inbalance out the reduction in s. , then, are zero-emissions , ,also be found in the ULCOS with some more adaptations.
2424
ULCOS I
U
ULCOS-I
TGR BF
TGR-BF enand constru
ersi
ty, U
SA
TGR-BF
Storagestep 1
Steps 2:Site sel. Injec
EP, S
tanf
ord
Uni
ve
2008 2009 2010 2011 2012
08G
CE
ISARNA(early pilot tests)
Additionalpilot tests
16 A
pril
200
New DR Small pilot(1t/h)
Eng. aCons
Electrolysis Laboratory wo
ULCOS II ( )
ULCOS-II umbrella
ULCOS-II (a)ng.uct.
Demo.tests
Step 3:tion start-up
Step 4:Industrial storage
2 2013 2014 2015 ULCOS-II (b)Commercial-scale
testsEngineering
and construct.
ULCOS-II (b)
Commercial-scaletests
andstr.
2525
ork Single cellEng.
ULCOS is part of a w
ersi
ty, U
SAEP
, Sta
nfor
d U
nive
CO2
08G
CE
COO
16 A
pril
200
9-Mar-08
worldwide initiative…
2 breakthrough program
7TH intermediaryORDINATION COMMITTEE MEETING
Brussels, Belgium
2626