Air Separation and CO2 Capture Units for Blast Furnace

Jean-Pierre TRANIER IEA GHG Iron & Steel CCS Workshop, Dusseldorf, 8th November 2011

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Overview Technology options for CO2 capture Top Gas Recycle Blast Furnace Air Separation Unit Conclusions

Agenda

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Air Liquide : a wide portfolio of technologies to reduce CO2 emissions

H2 energy

Biofuels

Photovoltaic

IGCC

Oxy-combustion

Steel plants H2 plants

Cement plants

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Partner in key pilot and large scale projects

30 MWth oxy-combustion boiler with CO2 capture & storage AL’ scope: burner, O2 , CO2 dryer

TOTAL Lacq - FRANCE (2010) CO2 Free Steam Generation

Experimental blast furnace with CO2 capture European program, 48 partners AL’ scope: CO2 removal unit (PSA)

ULCOS MEFOS - SWEDEN (2006) Low CO2 Steelmaking

20 MWth PC & 30 MWth

CFB oxy-combustion boilers

AL’ scope: CPU

CIUDEN – Spain (2011+) Carbon Capture test facility

200 MWe Oxy-coal Power plant

with CO2 capture for CCS

AL’ scope: ASU, CPU & mixer

FUTUREGEN 2.0 – USA (2010+) Clean coal power plant

Industrial blast furnace with CO2 capture & storage AL’ scope: ASU & CPU FEED study

ULCOS Florange - FRANCE (2010) Low CO2 Steelmaking

30 MWe coal oxy-combustion boiler with CO2 partial capture and storage AL’ scope: ASU, CPU

CS Energy – AUSTRALIA (2011+) Clean power pilot plant

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Overview Technology options for CO2 capture Top Gas Recycle Blast Furnace Air Separation Unit Conclusions

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Routes for CCS

Partial Oxidation Gasification Reforming

Post combustion capture

Example: Amines N2/CO2 separation

Transport

Shift CO+H2O<>CO2+H2

+ Rectisol/amines

H2 based process

Pre-combustion

Oxy-combustion

Post-combustion

Storage

CO2 capture units

1

2

3

Air based process

Gasification C+1/2O2<>CO

Oxygen based

process

CO/CO2 separation

Compression or liquefaction

Fossil fuels

Fossil fuels

(e.g. Coal)

1

2

3 O2

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Feed CO2 content

CO

2 P

uri

ty

20% 1% 80% 60% 40% 100%

Cryogenics

Membranes

Air Liquide CO2 separation technologies

MEDAL TM

Absorption

Adsorption

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Overview Technology options for CO2 capture Top Gas Recycle Blast Furnace Air Separation Unit Conclusions

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CO CO2 H2 (N2)

Rich CO2

CO, H2 (N2)

O2

General principle : 1. Nitrogen Free / Full Oxygen Blast Furnace 2. CO2 separation from CO and H2 which are recycled to BF

ULCOS concept : Top Gas Recycle Blast Furnace

ASU

CO/CO2 separation

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CO2 Capture from Blast Furnace

Amine scrubbing (aMDEA)

PSA + cryogenics

CAPEX

Price of electricity/CAPEX

Typical sensitivity study

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Mefos pilot plant

Since beginning of 2007, 9 test campaigns have performed (6-8 weeks duration each)

CO/CO2 separation tested using either VPSA or PSA cycles Several adsorbents tested (V)PSA concept for CO/CO2 separation on BFG validated TGR-BF and conventional BF modes tested

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Mefos pilot plant

Stable operation Simulation tool validated for Blast Furnace Gas Ageing of adsorbents assessed Successful trials of (V)PSA during challenging operating conditions

0

200

400

600

800

1000

1200

1400

1600

1800

07:12:00 07:40:48 08:09:36 08:38:24 09:07:12 09:36:00

Time (26/10/07)

Inje

ctio

n g

as f

low

rate

(N

m3/

h)

Stable flowrate ~5% fluctuations

CO recovery as predicted

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2 periods of tests :

Oct-Dec 2010

Feb-Jul 2011

Florange : filtration pilot

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Del

ta P

(m

bar)

Examples of pressure drop evolution

Period 1 Period 2

T3

temps (jour - h : m) ; du 18 au 21 Mars 2011

Del

ta P

(m

bar)

Temps (min:sec) Temps (min:sec)

T1 T2

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CO CO2 H2 (N2)

Rich CO2

CO, H2 (N2)

O2

Export CO2

Florange demonstration unit

CO , H2 ( N2)

ASU

PSA

CPU

Pre-FEED (Pre-Front End Engineering Design) completed mid-2011

FEED Study launched in September 2011 PSA chosen versus VPSA Size: 200 000 Nm3/h of Blast Furnace Gas

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Overview Technology options for CO2 capture Top Gas Recycle Blast Furnace Air Separation Unit Conclusions

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OXIAL–Air Liquide Solution for Air Enrichment

Existing Blast Furnace Blower(s)

OXIAL

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Overview Technology options for CO2 capture Top Gas Recycle Blast Furnace Air Separation Unit Conclusions

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Conclusions

Air Liquide has been deeply involved in the ULCOS program and has demonstrated in Mefos pilot plant the feasibility and the performances of a (Vacuum) Pressure Swing Adsorption system associated with Top Gas Recycle Blast Furnace

Filtration pilot plant at Florange has been successfully operated

Next step is to demonstrate Top Gas Recycle Blast Furnace at commercial scale

A new offer of Air Separation Unit dedicated to Blast Furnace application could almost reduce power consumption by a factor of 2 compared to high pressure, high purity oxygen for basic oxygen furnace

THANK YOU FOR YOUR ATTENTION

Contact jean-pierre.tranier@airliquide.com