Vortrag STAHL Grüne und nachhaltige Roheisenerzeugung mit Gichtgasrückführung beim Hochofen und HIsarna Schmelzreduktion. ir.

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1 Grüne und nachhaltige Roheisenerzeugung mit Gichtgasrückführung beim Hochofen und HIsarna Schmelzreduktion The ULCOS-TGR BF and HIsarna developments ir. Jan van der Stel Der Beitrag von Stahl für ein kohlenstoffarmes Europa Düsseldorf - Germany 28 November 2013

2 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 2

3 1. Introducion 3

4 1.2. Main CO 2 emitters 65% Source: IEA CCS workshop November

5 2. ULCOS 5

6 2.1. ULCOS - Ultra Low CO 2 Steelmaking Reducing number of Blast Furnaces in Europe Increasing Productivity Increasing CO 2 concentration in the atmosphere BF is main producer of CO 2 within integrated steel works Close to theoretical minimum regarding reducing agents Small possibilities to reduce CO 2 emissions with existing blast furnace operation Breakthrough development is needed Approaching the limits reduction 475 kg/t HM 6

7 2.2 ULCOS - Ultra Low CO 2 Steelmaking subjects 1. Efficiency of carbon use New and Improved processes 2. Replacement of fossil carbon Biomass Hydrogen Electricity 3. Capture & Storage Natural gas prereduction Electrolysis CO2 capture & Storage New Blast Furnace Biomass Scenarios & Sustainability modelling New Smelting Reduction Hydrogen 7

8 2.3 ULCOS - Ultra Low CO 2 Steelmaking 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 8

9 2.4 ULCOS - Ultra Low CO 2 Steelmaking - Ironmaking process selection 2004 ULCOS - I Project 2010 ULCOS - II Project CO 2 and sustainability modelling Inventory process routes Selection progress Pilot plant Criteria CO 2 Economical Technical maturity Social Other environmental aspects Fit with existing configuration Industrial Demo

10 2.5 ULCOS - Ultra Low CO 2 Steelmaking - Ironmaking process selection 2004 CO 2 and sustainability modelling Inventory process routes ULCOS - I Project Selection 2010 ULCOS - II Project 4 processes selected ULCOS BF - Top Gas Recycling HISARNA - Smelting reducting Ulcored - Natural Gas Based Reduction ULCOWIN - Electrolysis of iron ore

11 2.6 ULCOS Process routes Coal and sustainable biomass Natural gas Electricity ULCOS BF HISARNA ULCORED ULCOWIN 11

12 3. ULCOS BF Top Gas Recycle BF 12

13 3.1 The ULCOS project objective Modification of the conventional blast furnace to reduce the CO2 emission by 50 % per ton of steel 13

14 3.2 How can CO 2 -emission from the blast furnace be reduced? 1 st Recycling of CO/H 2 from blast furnace top gas 2 nd Application of Capturing and Storage of CO 2 3 rd Use of biomass as a CO 2 neutral carbon source 4 th Substitution of CO by H 2 as reducing agent 5 th Use of C-lean DRI, HBI or LRI 6 th Use of C-lean electrical energy 14

15 3.3 History of alternative blast furnace processes 1920 Lance Hot reducing gas injection HRG-trials at BF2 with recycling CO2 free topgas Toulachermet (Russia) Mid of 80 s Development of a NFBF by NKK (Japan) 1984 NFBF-concept of Lu (Canada) Late 70 s Patent of Fink about a NFBF (Germany) Mid 60 s CRM at Cockerill-Seraing (Belgium)

16 3.4 The ULCOS Top Gas Recycle BF CO 2 removal from top gas Reheating of CO/H 2 gas Re-injection of CO/H 2 Use of pure Oxygen Storage of CO 2 possible Benefits 25 % less carbon usage 60 % CO2 reduction with CO2 storage 35 % coke rate reduction Productivity increase (to be determined) 16

17 4. ULCOS BF Developments 17

18 4.1. Tests prior to Experimental Blast Furnace campaigns 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 18

19 4.2 Tests prior to Experimental Blast Furnace campaigns Gas temperature Shaft tuyeres Hearth tuyeres Gas distribution Shaft tuyeres Hearth tuyeres Concerns Version 1 Version 3 Version C 25 C 1200 C 80% 20% 100% Small raceways Tuyere design PCI combustion at low RAFT 900 C 1200 C Optimized according to process Effect and position of shaft injection Calculated c-savings (%)

20 4.3 Preparations prior to the ULCOS trials Extensive HAZOP studies Erection of an PSA/VPSA plant Modification of existing EBF equipment Coal & Cold O 2 Sinter/Pellets/Lump ore Coke C 1200 C Installation of new EBF equipment Simulated ULCOS-BF operation using cold nitrogen Training of personnel CO 2 Removal Gas heater Top gas to export CO 2 to storage 3 Slag & Hot Metal 1 20

21 5. ULCOS BF EBF Campaigns 21

22 5.1 THREE successful Campaigns 25/09 K-20 REFERENCE VERSION 3 VERSION 4 (1100 C) B&Q 16/10 K-23 REFERENCE VERSION 3 VERSION 1 Q 18/10 K-25 REFERENCE VERSION 4 (900 C) B&Q B&Q 02/10 17/10 27/10 Baskets & Quench 28/10 Q Quench alone 12/11 24/11/09 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 08/11/07 03/12/10 22

23 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%. 23

24 5.3 BF Results: Carbon input and gas injection K 23: V3 24

25 5.4 CO 2 emission reduction Reduced emissions by 24% in version 4 for EBF case Evaluation of VPSA/PSA + CCS indicates possible reduction of CO 2 emissions by up to 50% 25

26 ULCOS Process routes Coal and sustainable biomass Natural gas Electricity ULCOS BF HISARNA ULCORED ULCOWIN 26

27 6. HIsarna 27

28 6.1 HIsarna technology Comparison with the BF route Blast furnace sinter Iron ore coke coal Liquid iron 28

29 6.1 HIsarna technology Comparison with the BF route Blast furnace sinter Iron ore coke coal Direct use of coal and ore No coking and agglomeration Liquid iron 29

30 6.2. Combined technology The HIsarna technology combines CCF pre-reduction and melting technology with HIsmelt final reduction technology iron ore oxygen CCF HIsmelt iron ore oxygen 30

31 6.3 The benefits of HIsarna 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 CO 2 emissions per ton 80 % lower CO 2 emission with CO 2 capture & storage (CCS) Reduction of other emissions (e.g., NOx, SOx, dust and CO) 31

32 6.4 The HIsarna pilot plant Iron ore injection Coal injection Hot metal Incinerator Slag Gas cooler Bag house Dust collection Design capacity: 8 thm/h Coal injection: 6 t/h Ore injection: 20 t/h 32

33 6.4 The HIsarna pilot plant Reactor building Incinerator Gas Cooler Coal / lime silos Hot Metal / Slag pot 33

34 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. Negotiations with ULCOS Concept development Engineering Construction 2010 Campaign A Campaign B Campaign B Preparations Industrial Demo 2015 Campaign C

35 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 35

36 6.6 Milestones of 3 campaigns 2010 Completion of pilot plant 2011 Campaign A: - Feasibility of new process - First tap May 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 36

37 7. Next steps 37

38 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-co 2 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 38

39 Demonstration of TGR BF 1920 Lance Hot reducing gas injection HRG-trials at BF2 with recycling CO2 free topgas Toulachermet (Russia) Mid of 80 s Development of a NFBF by NKK (Japan) 1984 NFBF-concept of Lu (Canada) BF Campaigns with the CC(S) concept Late 70 s Patent of Fink about a NFBF (Germany) Mid 60 s CRM at Cockerill-Seraing (Belgium)

40 7.2 Outlook ULCOS II CO 2 emissions of the steel plant: - 60% O 2 CO -100 kg coke/t steel CO 2 Underground storage of CO 2 Full CCS demonstrator in Florange, NER-300 proposal 40

41 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 41

42 8. Conclusions 42

43 Conclusions ULCOS BF AND HIsarna Developments 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 CO 2 efficiently from BF topgas; Reduction of CO 2 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 43

44 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: 44