2013 Grüne und nachhaltige Roheisenerzeugung mit ......Electrolysis CO2 capture Hydrogen & Storage...

Grüne und nachhaltige Roheisenerzeugung mit Gichtgasrückführung beim

Hochofen und HIsarna Schmelzreduktion The ULCOS-TGR BF and HIsarna developments

ir. Jan van der Stel STAHL 2013 – Stahl in Bewegung “Der Beitrag von Stahl für ein kohlenstoffarmes Europa“

Düsseldorf - Germany

28 November 2013

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STAHL 2013 – Stahl in Bewegung Der Beitrag von Stahl für ein kohlenstoffarmes Europa Düsseldorf - Germany - 28 November 2013

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Outline

• Introduction

• ULCOS

• ULCOS BF process concept (TGRBF)

• ULCOS BF Developments

• Demonstration of the ULCOS BF process concept at pilot scale

• HIsarna developments

• Next Steps

• Conclusions Vort

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1. Introducion

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1.2. Main CO2 emitters

Source: IEA CCS workshop November 2011

65%

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2. ULCOS

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• Reducing number of Blast Furnaces in Europe

• Increasing Productivity • Increasing CO2 concentration in the

atmosphere • BF is main producer of CO2 within

integrated steel works • Close to theoretical minimum regarding

reducing agents • Small possibilities to reduce CO2

emissions with existing blast furnace operation

• Breakthrough development is needed

2.1. ULCOS - Ultra Low CO2 Steelmaking

reduction

475 kg/t HM

Approaching the limits Vortrag

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2.2 ULCOS - Ultra Low CO2 Steelmaking subjects

1. Efficiency of carbon use New and Improved processes

2. Replacement of fossil carbon Biomass Hydrogen Electricity

3. Capture & Storage

Biomass

Natural gas pre-

reduction

Electrolysis

Hydrogen CO2 capture & Storage

New Smelting

Reduction

New Blast

Furnace

Scenarios & Sustainability

modelling

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• Program launched in 2004 • Core partners: ArcelorMittal, Tata Steel, ThyssenKruppStahl, Ilva,

Voestalpine, LKAB, Dillingen/Saarstahl, SSAB, Ruukki • Co-partners: over 40 Institutes, Universities, Engineering companies, etc • Objective: 50% reduction in CO2 emissions per ton of steel

from iron ore based steel production by 2050 • Breakthrough technologies

• ULCOS-BF • HISARNA • ULCORED • ULCOWIN/ULCOLYSIS

• Phase 1 ended in 2010 • Budget: 70 M€

2.3 ULCOS - Ultra Low CO2 Steelmaking

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2.4 ULCOS - Ultra Low CO2 Steelmaking - Ironmaking process selection

CO2 and sustainability modelling

Selection

Inventory process routes

Industrial Demo

2010

2018

2004 ULCOS - II Project

Criteria • CO2 • Economical • Technical maturity • Social • Other environmental aspects • Fit with existing configuration

Pilot plant

progress

ULCOS - I Project

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CO2 and sustainability modelling

Selection

Inventory process routes

ULCOS - I Project

2018

2004

ULCOS BF - Top Gas Recycling

Ulcored - Natural Gas Based Reduction

ULCOWIN - Electrolysis of iron ore

HISARNA - Smelting reducting

4 processes selected

2010 ULCOS - II Project

2.5 ULCOS - Ultra Low CO2 Steelmaking - Ironmaking process selection

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Coal and sustainable biomass Natural gas Electricity

2.6 ULCOS – Process routes

ULCOWIN ULCORED ULCOS BF HISARNA

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3. ULCOS BF

Top Gas

Recycle BF Vortrag

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Modification of the

conventional blast furnace

to reduce the CO2 emission

by 50 % per ton of steel

3.1 The ULCOS project objective

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3.2 How can CO2-emission from the blast furnace be reduced?

4th Substitution of CO by H2 as reducing agent

1st Recycling of CO/H2 from blast furnace top gas

3rd Use of biomass as a CO2 neutral carbon source

2nd Application of Capturing and Storage of CO2

5th Use of C-lean DRI, HBI or LRI

6th Use of C-lean electrical energy

1st Recycling of CO/H2 from blast furnace top gas

2nd Application of Capturing and Storage of CO2

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1985 – 1990 HRG-trials at BF2 with recycling CO2 free topgas Toulachermet (Russia)

1920 Lance Hot reducing gas injection

Late 70’s Patent of Fink about a NFBF (Germany)

1984 NFBF-concept of Lu (Canada)

Mid of 80’s Development of a NFBF by NKK (Japan)

Mid 60’s CRM at Cockerill-Seraing (Belgium)

3.3 History of alternative blast furnace processes

2004

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• CO2 removal from top gas

• Reheating of CO/H2 gas

• Re-injection of CO/H2

• Use of pure Oxygen

• Storage of CO2 possible

3.4 The ULCOS Top Gas Recycle BF

Benefits • 25 % less carbon usage • 60 % CO2 reduction with CO2 storage • 35 % coke rate reduction • Productivity increase (to be determined)

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4. ULCOS BF Developments

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• Different ULCOS-BF concepts developed

• Recirculation of blast furnace top gas • VPSA/PSA operation + CCS • Injection of decarbonated top gas

‒ Shaft ‒ Tuyeres ‒ Temperature

• Mathematical modelling to find process with highest carbon saving potential

• Process modelling according to data from a commercial European BF

• Laboratory testing

Version 1

Version 3

Version 4

4.1. Tests prior to Experimental Blast Furnace campaigns

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Version 1 Version 3 Version 4

Gas temperature

Shaft tuyeres

Hearth tuyeres

900°C

25°C

1200°C

900°C

1200°C Gas distribution

Shaft tuyeres

Hearth tuyeres

80%

20%

100%

Optimized according to process

Concerns Small raceways

Tuyere design

PCI combustion at

low RAFT Effect and position of

shaft injection

Calculated c-savings (%) 21 25 26

4.2 Tests prior to Experimental Blast Furnace campaigns

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• Extensive HAZOP studies • Erection of an PSA/VPSA plant • Modification of existing EBF

equipment

4.3 Preparations prior to the ULCOS trials

Sinter/Pellets/Lump ore

Coke

Coal & Cold O2

Slag & Hot Metal

Top gas

to export

CO2 Removal

CO2 to storage

900 °C

3

2

1

Gas heater

1200 °C

• Installation of new EBF equipment • Simulated ULCOS-BF operation

using cold nitrogen • Training of personnel

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5. ULCOS BF

EBF Campaigns

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• ULCOS BF campaigns operated in 2007, 2009 and 2010 • Varied BF operation tested:

‒ Amount of recirculated gas; ‒ Coal injection (130 and 170 kg/tHM); ‒ Temperature;

• Quenching and excavation of the blast furnace shaft after each campaign;

• Process evaluation of blast furnace and VPSA/PSA unit • Metallurgical and mechanical testing of burden material

5.1 THREE successful Campaigns

K-20 B&Q

K-23 Q

K-25 B&Q

Baskets & Quench Quench alone

08/11/07

18/10

REFERENCE VERSION 3 VERSION 4 (1100 °C)

REFERENCE VERSION 3 VERSION 1

12/11 24/11/09

03/12/10

B&Q Q

02/10 17/10

28/10

27/10

REFERENCE VERSION 4 (900 °C)

25/09

16/10

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5.2. Blast Furnace and VPSA results

• THREE ULCOS BF campaigns • No safety issue recorded; • The EBF operation under ULCOS

BF mode was very smooth; • VPSA operated without any failure

and with the required gas quality; • Good connection between EBF

and VPSA; • Carbon savings up to 24%.

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5.3 BF Results: Carbon input and gas injection

K 23: V3

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5.4 CO2 emission reduction

• Reduced emissions by 24% in version 4 for EBF case • Evaluation of VPSA/PSA + CCS indicates possible reduction of CO2

emissions by up to 50%

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Coal and sustainable biomass Natural gas Electricity

ULCOS – Process routes

ULCOWIN ULCORED ULCOS BF HISARNA

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6. HIsarna Vort

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6.1 HIsarna technology

Comparison with the BF route

Iron ore

coal

coke

sinter

Liquid iron

Blast furnace

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6.1 HIsarna technology

Comparison with the BF route

Iron ore

coal

coke

sinter

Liquid iron

Blast furnace

Direct use of coal and ore No coking and agglomeration

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6.2. Combined technology

• The HIsarna technology combines CCF pre-reduction and melting technology with HIsmelt final reduction technology

HIsmelt

iron ore oxygen

iron ore oxygen

CCF

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The HIsarna ironmaking process for continuous production of liquid hot metal has a unique combination of environmental and economical benefits:

Economic benefits:

• Reduced OPEX and CAPEX compared to Greenfield blast furnace route

• Wider range of raw material qualities (Ore: P, Zn, S, Ti or alkali)

• Use of plant waste oxides (BOF, BF dust or mining reverts)

Environmental benefits:

• 20 % lower energy usage and CO2 emissions per ton

• 80 % lower CO2 emission with CO2 capture & storage (CCS)

• Reduction of other emissions (e.g., NOx, SOx, dust and CO)

6.3 The benefits of HIsarna

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6.4 The HIsarna pilot plant

Iron ore injection

Hot metal Slag

Dust collection

Gas cooler Bag

houseIncinerator

Coal injection

Iron ore injection

Hot metal Slag

Dust collection

Gas cooler Bag

houseIncinerator

Coal injection

Design capacity: 8 thm/h

Coal injection: 6 t/h

Ore injection: 20 t/h Vort

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6.4 The HIsarna pilot plant

Gas Cooler Coal / lime silos

Incinerator Reactor building

Hot Metal / Slag pot

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6.5 Pilot plant developments The HIsarna process has developed from conceptual design to the first experiments in the pilot plant. In May 2011 the first metal was tapped.

2004

2009 2010 2011 2012

2007

Campaign A

Campaign B

Engineering

Concept development

Negotiations with ULCOS

Construction

Campaign B

2015

Preparations

Industrial Demo

Campaign C

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6.5 Pilot plant developments

• Suitable location (former de-S plant) at Tata Steel IJmuiden

• Project execution:

• Tata Steel Engineering • Tata Steel Research • European steelmakers • EU equipment suppliers • Rio Tinto

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6.6 Milestones of 3 campaigns

2010 Completion of pilot plant

2011 Campaign A: - Feasibility of new process

- First tap May 2011

2012 Campaign B: - First long operating period

- Standard raw materials

- 65 % of design capacity reached

2013 Campaign C: - First use of steam coal

- First use of low grade ore

- First metal delivered to BOF

- Good plant availability

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7. Next steps

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7.1. ULCOS BF: Scale up to industrial

The Experimental BF campaigns showed the possibilities of the Top Gas Recycling Blast Furnace concept for: • Industrial operating point • Safe closed loop operation with VPSA • Gas preheating • Top gas de-CO2

• Thermal control • Low coke rates

Special attention is required for: • Tuyere technology

(product gas + Oxygen + Coal) • Shaft gas injection, distribution of gas over radius • Product gas heating

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1985 – 1990 HRG-trials at BF2 with recycling CO2 free topgas Toulachermet (Russia)

1920 Lance Hot reducing gas injection

Late 70’s Patent of Fink about a NFBF (Germany)

1984 NFBF-concept of Lu (Canada)

Mid of 80’s Development of a NFBF by NKK (Japan)

Mid 60’s CRM at Cockerill-Seraing (Belgium)

2004

Demonstration of TGR BF

2007 – 2010 BF Campaigns with the CC(S) concept Vort

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CO2

CO O2

Underground storage of CO2

-100 kg coke/tsteel

CO2 emissions of the steel plant: - 60%

Full CCS demonstrator in Florange,

NER-300 proposal

7.2 Outlook – ULCOS II

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7.2 HIsarna Forward plan No quick fix possible: Earliest industrialization 2020

New project is planned to start in 2014

Partners: Tata Steel, TKS, ArcelorMittal, voestalpine, Paul Wurth

Two additional HIsarna pilot plant campaigns are foreseen:

2014: Campaign D of 6 weeks » Testing wider range of raw materials

» Increasing productivity (finding upper limit)

2015: Campaign E of 6 months » Demonstrating refractory life under stable operating

conditions

» Final check for design flaws before scale up

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8. Conclusions

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• It has been possible to apply the Top Gas Recycling Blast Furnace process concept at the EBF;

• No safety issue has been recorded with the new process; • EBF and VPSA operations were smooth with good results; • The Carbon savings were up to 24 %; • The VPSA plant removed CO2 efficiently from BF topgas; • Reduction of CO2 over 50%/tHRC could be achievable

for industrial application;

• Next step should be a demonstrator plant on industrial scale.

• HIsarna process has been demonstated on pilot scale; • HIsarna is a high risk/high reward innovation that can potentially

have a strong environmental and economical impact on the steel industry;

• Environmental impact: without CCS 20 % CO2 reduction with CCS 80 % CO2 reduction

• With the ULCOS and HIsarna project the European steel industry is proactively approaching the Climate Change issue

Conclusions ULCOS BF AND HIsarna Developments


• No safety issue has been recorded with the new process; • EBF and VPSA operations were smooth with good results; • The Carbon savings were up to 24 %; • The VPSA plant removed CO2 efficiently from BF topgas; • Reduction of CO2 over 50%/tHRC could be achievable






• With the ULCOS and HIsarna project the European steel industry is proactively approaching the Climate Change issue


• No safety issue has been recorded with the new process; • EBF and VPSA operations were smooth with good results • The Carbon savings were up to 24 %; • The VPSA plant removed CO2 efficiently from BF topgas; • Reduction of CO2 over 50%/tHRC could be achievable






• With the ULCOS and HIsarna project the European steel industry is proactively approaching the Climate Change. issue

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Thank you for your attention Thanks to:

The European Commission for its financial support. EU FP6, RFCS

Rio Tinto/HIsmelt Dutch Ministry of Economic Affairs

More info: WWW.ulcos.org

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http://www.ulcos.org/

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2013 Grüne und nachhaltige Roheisenerzeugung mit ......Electrolysis CO2 capture Hydrogen & Storage...

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