Transcript Hydrogen_Ironmaking_..

Erasmus Mundus Conference
“Climate Change”
26-27 Fev 2009 • Budapest
Hydrogen Ironmaking
A. Ranzani da Costa
F. Patisson
D. Wagner
Institut Jean Lamour, CNRS, Nancy-Université
Nancy - France
Importance of steel
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Steel  one of the most important
structural material in the world.
Automotive industry, construction,
mechanical engineering and
shipbuilding, computers, electronics.
Infrastructure projects  road, bridge,
rail
Essential for the high standard of
living in the developed world and for
the growth of emerging economies.
Steel Production
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Steel production (2007)   1.3 billion tons worldwide.
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Steel consumption (2015)   1.8 billion tons.
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BRIC countries (Brazil, Russia, India, China)  dynamically expanding their
economies and infrastructures.
Steel
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Environment friendly material
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can be recycled indefinitely
no loss of quality.
40% of steel produced is recycled from scrap
Use in durable products/infrastructure
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not enough scrap available.
Ironmaking today – Blast Furnace (BF)
Coke Plant:
Power Plant:
Coal → Coke
BF Off gases  Steam/Electricity
BF followed
by BOF and
CC
BF Off gases:
CO2/CO/H2/N2
Coke + Sinter
2 C + O2  CO
Fe2O3 +3 CO  2 Fe + 3 CO2
Molten
ore+Coke
1500oC
1850 kg
CO2/t steel
Pellet / Sinter Plant
Raw ore → heat treatments/additives
→ Sinter/pellets (better properties)
Pig iron
CO2 Emissions x Climate Change
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CO2 Emissions  Climate Change  Natural
disasters
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The best European steel plants are operating at the
limits of what is presently technically possible.
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Breakthrough technologies for steelmaking industry
ULCOS (Ultra Low CO2 Steelmaking) Project
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Aim: design new steelmaking processes able to reduce by
more than 50% the CO2 emissions of the steel industry as
compared to the current benchmark route (integrated plant,
BF-CC)
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Launched by the major European steel companies
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Supported by European Commission
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48 partners, 59 M€ budget, 5-year duration
Context: the European program ULCOS
Sep 04
Fev 06
today
Sep 09
Phase 1
SP1 – New
furnace
SP1blast
-New
Blast Furnace
SP8-New
Advanced C-lean
C-lean &&C-based
SP8
– New advanced
CRoute
based route to
steel to Steel
SP10SP10-New
– New C-based
C-based
steel
Steel
production
production
adv.C-based
C -basedsteel
SP11-New
SP11
– New adv.
.
production
Steel
production
SP2 – SP2-New
New smelting
reduction
Smelting
Reduction
SP3 – New
natural
route
steel
SP3-New
NGgas
Route
to to
Steel
SP12
– New natural
gas-based
SP12-New
Nat Gas-based
Steel Production
steel production
SP14
SP14-–
ULCOS
ULCOS-Process
Processfor
Steel Production
for Steel Production
steel
production
SP4 –SP4-Hydrogen
Hydrogen steel
production
production
SP5 SP5-Electrolysis
– Electricity steelsteel
production
SP13
– New electricity-based
steel
SP13-New
Electricity-based
Steel Production
production
SP6
– CO2 Capture & storage for
-CO
steelmaking
2
SP7
– Biomass-based steel
SP7-Biomass-based
Steelproduction
production
Phase 2
SP9 – Scenarios,
SP9-Scenarios,
sustainability,
sustainability,
innovation,
innovation,
training
training
& dissemination
& dissemination
Project Management
Phase 3
SP10 - Top Gas Recycling Blast Furnace with CCS
(TGRBF CCS)
Coke + Ore
Top Gas
CO2/CO/H2
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Concept: off gases separation
(VPSA process)
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off gases
separation
(VPSA or PSA)
CO  recycled back into the
furnace (reducing agent)
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less amount of coke needed.
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CO2  CCS
Molten
Ore + Coke
CO2
Pure O2 injection instead of
preheated air
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CO2 to CCS
No N2  best for CCS
Pig Iron
Recycled CO to BF
SP11 - HISARNA with CCS
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CONCEPT: Melting cyclone + Ore Smelter
in one vessel
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Coal preheating and partial pyrolysis in a
reactor
Melting cyclone (ore melting + prereduction)
Ore fines
Coal
Smelter vessel (Ore → Iron final
reduction)
CO2
Melting cyclone
(ore melting)
Hot coupled process
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Off Gas (CO2)
Ore melted and reduced without any
intermediate gas treatment, cooling or
dedusting.
Flexible process:
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Partial substitution of coal by biomass,
NG or H2
Twin Screw reactor
(coal preheating)
Converter
(ore reduction)
SP 13 - Alkaline Electrolysis
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CONCEPT: transformation of iron ore
into metallic Fe and O2 using only
electrical energy and low temperature.
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No need of coke ovens, melting or
reducing vessels (BF, converters, shaft
furnace).
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CO2 leanest process of steelmaking.
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No iron is presently produced
industrially by electrolysis.
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Most innovative route currently
being studied in ULCOS.
Electrolysis of other metals (Al, Ni,
Zn) already in industrial scale.
Current from A to C
Fe2O3 ore suspended in
the alkaline solution
Capture of
O2
Fe+3 → Fe reduction
(Fe layer)
2O-2 → O2 oxidation
(O2 bubbles out)
Aqueous solution of
NaOH (110°C)
CO2
H2 for Iron and Steelmaking
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Main route defined
Generation of
hydrogen
H2
WP4.1
Iron ore
Ore
Pre-reduction
with H2
DRI
Production of
liquid metal
in an EAF
liquid
steel
Casting
WP4.2
SP4
•H2O electrolysis
•NG Reforming
Nancy-Université
Low CO2 Emissions: from 200 to 400 kg CO2/t steel
Rolling
HRC