• Introduction and Steel...3 History of ironmaking First iron produced in Asia Minor (Turkey) 3000...
Transcript of • Introduction and Steel...3 History of ironmaking First iron produced in Asia Minor (Turkey) 3000...
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Development of the Oxy-BF for CO2 Capture Application in Ironmaking Jan van der Stel Industry CCS workshop
Düsseldorf
8th – 9th November 2011
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Outline
• Introduction
• ULCOS BF process concept (TGRBF)
• ULCOS BF Developments
• Experimental Blast Furnace
• EBF results
• CO2 emission reduction
• Conclusion and Next Step
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History of ironmaking
First iron produced in Asia Minor (Turkey)
3000 B.C.
First blast furnaces Han dynasty (China)
206 B.C.
1709
Developing of the coking process and the use of coke in the blast furnace by Abraham Darby
Iron metallurgy brought to China via Scythes
800 B.C.
400 B.C. Iron produced by the Celts of Southern Britain
1800 B.C.
First iron weapons made by the Hittites (Turkey)
1950
Begin of the modern blast furnace technology
1311
First iron casting in Western Europe
Asoka column of pure iron (Delhi)
350
1480 Early blast furnace in Sussex Weald
Source: B. Korthas TKS
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Developments of the conventional blast furnace ironmaking
475 kg/t HM
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How can CO2-emission from the blast furnace be reduced?
4th Substitution of CO by H2 for reduction
1st Recycling of CO from blast furnace top gas
3rd Use of biomass
2nd Capturing and storage of CO2
5th Use of C-lean DRI, HBI or LRI
6th Use of C-lean electrical energy
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Conventional blast furnace Sinter, pellets lump ore, flux
& coke
Hot blast, moisture & oxygen
Coal or oil & oxygen
Scrap
Hot metal & slag
CO, CO2, N2, H2, H20
& dust
Partly reduced iron & biomass
Biomass &
hydrogen rich gas
Energetic use of the
top gas
CO2 capture & deposition
natural gas, tar or COG
Plasma torches
Waste plastic &
animal grease
Carbon input 407 kg/t HM
Injection of hot reduction gas
C-lean HBI, DRI
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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)
History of alternative blast furnace processes
2004
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The ULCOS project
• Ultra Low CO2 Steelmaking
• Consortium of European steel companies
• Aim : to decrease drastically (over 50 %) the CO2 emitted by the steel industry
• Budget : 60 M€
• Numerous ideas to reach objective
Modification of the conventional blast furnace to reduce the CO2 emission by 50 %
Core members
ArcelorMittal ILVA LKAB
Rautaruulli Oyj Saarstahl-DH
SSAB voestalpine Stahl
Tata Steel TKS
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ULCOS BF Concept
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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
The ULCOS Blast Furnace: Concept
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• Benefits
• 25 % less carbon usage
• 60 % CO2 reduction with CO2 storage application
• 35 % coke rate reduction
• Productivity increase (to be determined)
The ULCOS Blast Furnace
CO, CO2, ….
CO ….
CO2 ….
Transport
Storage
CO2 mitigation
~25 % at the BF
~55-60 % for the whole plant
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ULCOS BF Developments
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The Ulcos Blast Furnace Concepts
Gas cleaning
CO2 400 Nm3/tCO2
scrubber
Oxygen
PCI
Gas heater
Coke Top gas (CO, CO2, H2, N2)
Re-injection
Gas net(N2 purge)
CO, H2, N2
V4900 °C
1250 °C
V3
1250 °C
XV1900 °C
25 °C
Expected C-savings
25 % 24 % 21 %
Gas cleaning
CO2 400 Nm3/tCO2
scrubber
Oxygen
PCI
Gas heater
Coke Top gas (CO, CO2, H2, N2)
Re-injection
Gas net(N2 purge)
CO, H2, N2
V4900 °C
1250 °C
V4900 °C
1250 °C
V3
1250 °C
XV3
1250 °C
XV1900 °C
25 °C
V1900 °C
25 °C
Expected C-savings
25 % 24 % 21 %
Expected C-savings
25 % 24 % 21 %
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Developments
• Proces conditions TGR BF
• Behaviour of existing raw materials
• Ferrous (Sinter and Pellets)
• Injection coals
• Raceway conditions and tuyere design
• Shaftgas heating
• CO2-removal unit
• Design, engineering and modification of the EBF and its process
• Start up and shut down procedure
• Safety study
Effect of shaft injection level
Reduction tests under TGR BF conditions
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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
Design, Engineering and Modification of the Experimental BF
Gas heater
1200 C
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The ULCOS Blast Furnace concept at EBF in Luleå
Sinter, pellets & coke
Hot metal & slag
VPSA
O2 max. 500 m3/h
- 1250 C
- 1000 C
Pebble heater
Tail gas
Product gas
Gas cleaning system
Coal 170 kg/t HM
Product gas
BF gas
max. 2900 m3/h
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ULCOS Blast Furnace EBF campaigns
week 1 week 2 week 3 week 4 week 5 week 6 week 7Conventional start upReference PeriondStoppage: connecting the VPSAPeriod of TG recycling Version 3Stoppage: Open shft tuyeresPeriod of TG recycling Version 4Optimisation coal ratePellet OperationSinter and pellet OperationQuench
• 6 weeks test started Sept. 24, 2007
• 6 weeks test started Oct. 21, 2009
• 6 weeks test started oct. 18, 2010
• Production rate constant
• Maximise gas injection rate
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ULCOS BF EBF
Results
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Three concepts of operation tested
Export gas
Gas cleaning
CO2
CO2 scrubber
Gas heater
Oxygen
PCI
Export gas
Gas cleaning
CO2
CO2 scrubber
Gas heater
Oxygen
PCI
Export gas
Gas cleaning
CO2
CO2 scrubber
Oxygen
PCI
Gas heater
Basic operation data:
• Productivity = constant = 1.5 thm/h
• (the possible effect of recycling on productivity was not in the scope of the test campaigns)
• Furnace charge: 70% sinter + 30% pellets
• Reference coal injection levels: 130 and 170 kg/thm
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Blast Furnace and VPSA results
• No safety issue recorded.
• The EBF operation was very smooth : • constant productivity (production was not an aim)
• smooth burden descent
• good hot metal quality
• high thermal stability
• nearly no equipment failure
• BF recovery after shut-downs was easy
• VPSA operated without any failure and with the required gas quality:
• Recycling ratios up to 90% were possible;
• It always provided the required gas amount and the required gas quality (CO2 < 3%);
• The CO recovery was 88 %.
• Good connection between EBF and VPSA
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Reductant Saving K-20
0
200
400
600
800
1000
1200
27/09/2007 07/10/2007 17/10/2007 27/10/2007 06/11/2007
Operating time [day]
Red
ucta
nt ra
te [k
g/tH
M],
Rec
ycle
gas
[N
M3/
tHM
]
-30
-20
-10
0
10
20
30
Car
bon
savi
ng [%
]
Coal and coke
Recycle gas
Carbon saving
reference Version 3 Version 4
K-20 results: reductant rate, recycled gas injection and carbon saving
Version 3
Version 4
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reference Version 3 Version 1
Reductant Saving K-23
0
200
400
600
800
1000
1200
20/10/2009 27/10/2009 03/11/2009 10/11/2009 17/11/2009 24/11/2009
Operating time [day]
Red
ucta
nt ra
te [k
g/TH
M]
- Rec
ycle
gas
[N
M3/
THM
]
-30
-20
-10
0
10
20
30
Car
bon
Savi
ng [%
]
Coal and Coke
Recycle gas
Carbon saving
K-23 results: reductant rate, recycled gas injection and carbon saving
Version 3
Version 1
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BF Results: Carbon input and gas injection
K 23: V3
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BF results: Carbon savings
The carbon savings are:
• In terms of (coke + coal): up to 140 kg/thm
• In terms of carbon: up to 129 kg/thm
• Results are in agreement with model calculations
80879072Top gas recycle ratio [%]
18232415Carbon saving [%]
Version 1Version 3Version 4Version 3
K-23K-20
80879072Top gas recycle ratio [%]
18232415Carbon saving [%]
Version 1Version 3Version 4Version 3
K-23K-20
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BF quench results: Burden Material
Reduction profile:
• centre working furnace
Similar behavior as in conventional BF:
• Strength index shows linear trend with reduction degree;
• sinter disintegration
PL1
PL4
PL7
PL10
PL13
PL16
PL19
PL22
PL25
PL28
PL31ncnmnw
sample point
Pellet samples
PL1
PL4
PL7
PL10
PL13
PL16
PL19
PL22
PL25ncnmnw
sample point
Sinter samples
90-10080-9070-8060-7050-6040-5030-4020-3010-200-10
T3
T1
T2
Northnw
nm
nc
Reduction degree of sinter and pellet samples north-axis
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CO2 Emission Reduction
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Oxy Blast Furnace Carbon saving and CO2 reduction
-20 -10 0 10 20 30
Version 1
Version 3
Version 4
CO2 reduction [%/tHRC] Carbon Saving at BF [%/tHM]
• A 24% C-saving/tHM at the BF should be feasible
• A 15% reduction of CO2/tHRC emission should be feasible
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CO2 emission reduction
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Next Step and
Conclusion
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Scale up to industrial
The campaigns showed the possibilities of the ULCOS Blast Furnace for: • Industrial operating point
• Safe closed loop operation
• Gas preheating
• Topgas de-CO2
• Thermal control
• Reduction of ores in the shaft
• Low coke rates
Special attention for: • Tuyere technology
(product gas + Oxygen + Coal)
• Shaft gas injection, distribution of gas over radius
• Product gas heating
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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
Outlook – ULCOS II
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• It has been possible to Oxy BF process concept at the EBF;
• No safety issue has been recorded with the new process;
• The EBF and VPSA operations were smooth with good results;
• Three different blast furnace concepts has been developed;
• The Carbon savings were up to 24 %;
• The VPSA plant was able to remove CO2 efficiently from BF topgas;
• Campaigns showed that conventional burden material can be used.
• For the steelmaking site, with the application of CO2 capture and storage saving of 60% is possible;
Conclusions ULCOS BF
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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)
History of alternative blast furnace processes
2004
2007 – 2010 BF Campaigns with the CCS concept at the EBF (Zweden)
II 2015 – …. Demonstration of TGR BF
In Florange (NER300) (France)
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Thank you for your attention Thanks to the
European Commission for its financial support.
For more info on Ulcos: WWW.ulcos.org