ulcos: searc: searching for breakthroughhing for ......ulcos: searc: searc co 2-lean gcep carbon...

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ULCOS: Searc ULCOS: Searc CO 2 -lean GCEP Carbon Management in Manufa M Ultra Low CO 2 Stee hing for Breakthrough hing for Breakthrough Steelmaking Routes… acturing Industries, Stanford University, USA 16 April 2008 Mark Atkinson, on behalf of Jean-Pierre Birat European Program Coordinator elmaking [email protected] [email protected]

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Page 1: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 2: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 3: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 4: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 5: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 6: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

ersi

ty, U

SAEP

, Sta

nfor

d U

nive

08G

CE16

Apr

il 20

0

66

Page 7: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 8: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 9: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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.

Page 10: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

Top Gas RecyTop Gas Recyycling Blast Furnaceycling Blast FurnacePhase II of ULCOS-I

Page 11: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 12: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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.

Page 13: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 14: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

MeltingMelting Reduction: ISARNAReduction: ISARNAPhase II of ULCOS-I

Page 15: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 16: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 17: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

NeNeew Direct Reductionew Direct ReductionPhase II of ULCOS-I

Page 18: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 19: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 20: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

EleElectrolysis of iron orectrolysis of iron orePhase II of ULCOS-I

Page 21: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 22: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

Page 23: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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?)

Page 24: ULCOS: Searc: Searching for Breakthroughhing for ......ULCOS: Searc: Searc CO 2-lean GCEP Carbon Management in Manuf a M Ultra Low CO 2 Stee hing for Breakthroughhing for Breakthrough

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

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