Climate Change, the Steel Industry and the Race to the

MoonMoon

Lawrence Kavanagh

January 8, 2008

Goal is relatively clear…but not how to get there

•Reduce CO2 emissions by 50% by 20502050

•Believed to result in temperature increase of < 2 degrees

Energy use

R & D into new processes

R & D into new processes opens up large energy savings and CO 2

mitigation opportunities

1990 2006

Lowest energy/CO 2possible today’s processes

2020

Lowest energy/CO 2possible tomorrow’s processes

Energy consumption per ton shipped in U.S. steel industry

60

M B

TU

/Ton

29% reduction29% reduction29% reduction29% reduction

Energy consumption per ton shipped inU.S. steel industry [MBTU]

0

10

20

30

40

50

60

1950

1955

1960

1965

1970

1975

1980

1985

1990

1995

2000

2001

2002

2003

2004

2005

2006

M B

TU

/Ton

29% reduction29% reduction29% reduction29% reduction

Energy use

R & D into new processes

R & D into new processes opens up large energy savings and CO 2

mitigation opportunities

1990 2006

Lowest energy/CO 2possible today’s processes

2020

Lowest energy/CO 2possible tomorrow’s processes

CO2 Breakthrough Program

• Two projects ready for Phase 2:– Molten Oxide Electrolysis—MIT

– Hydrogen Flash Smelting—Univ. of Utah

• Two still under study– Sequestration using Steelmaking Slags—UMR

– Steel Works as Sequestration Works—Columbia University

Hydrogen Flash Smelting

• Develop an ironmaking process based on:

– Hydrogen

– Without coke– Without coke

– Without pelletization/sintering

• Main goal:

Significant reduction in energy consumption

and CO2 generation in the steel industry

CO2 Emissions

BF[kg/tonHM]

Prop'd (Using

H2)[kg/ton

Prop'd (Using CH4)

[kg/ton

Prop'd (Using Coal)

[kg/ton

Calculated CO2 Emissions

HM] [kg/tonHM]

[kg/tonHM]

[kg/tonHM]

CO2Emission 1671* 71 650 1145

Bench-Scale Flash Furnace

Hydrogen Flash SmeltingPhase Two

• Comprehensive tests of various gaseous reducing agents & fuels

• Pilot Scale Research

� Complete material and energy balances; economics; scale-up factors

• Design & cost estimation of the industrial test facility

Molten Oxide Electrolysis-Objectives

� Assess the technical viability of the

production of iron by molten oxide

electrolysiselectrolysis

� Identify inert anode and its ability to sustain oxygen evolution

� Develop a fully functional laboratory-scale electrolysis cell that produces metallic iron along with by-product oxygen

Environmental Impact & Energy Savings

� COCOCOCO2222 emissions reduced from 1750 emissions reduced from 1750 emissions reduced from 1750 emissions reduced from 1750

kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast kg/tonne liquid steel for benchmark blast

furnace technology to 345 kg/tonne liquid furnace technology to 345 kg/tonne liquid furnace technology to 345 kg/tonne liquid furnace technology to 345 kg/tonne liquid

steel: a fivesteel: a fivesteel: a fivesteel: a five----fold reductionfold reductionfold reductionfold reduction

Electrolytic production of molten iron

iron

Steelmaking by Molten Oxide ElectrolysisBuild Pilot Cell

10,000 Amp

2.3 Volts

~ 180 kg/day Fe

~ 77 kg/day O2

Anode Area 2 m2

(FeOx) Fe+2(llll) + ½ O2

Current density 5A/cm2

1800oK

Variables to Measure:

Efficiency

Vary Temperature

Vary Voltages

Process Operating Costs

Process Parameters

Fe+2+2e Feo

100

120

140

160

180

Mic

rogr

ams

per

Cub

ic M

eter

Top 20 Particulate Matter Cities per World BankPlus Top U.S. City (Los Angeles #66)

Red = ChinaOrange = IndiaPink = EgyptYellow = IndonesiaPurple = ThailandGreen = USA

0

20

40

60

80

Del

hi

Cai

ro

Cal

cutta

Tia

njin

Cho

ngqu

ing

Luck

now

Kan

pur

Jaka

rta

She

nyan

g

Zhe

ngzh

ou

Jina

n

Lanz

hou

Bei

jing

Tai

yuan

Ahm

edab

ad

Che

ngdu

Ans

han

Wuh

an

Nan

chan

g

Har

bin

Ban

gkok

Cha

ngch

un

Zib

o

Sha

ngha

i

Gui

yang

Kun

min

g

Los

Ang

eles

Mic

rogr

ams

per

Cub

ic M

eter

The Race to the Moon

Call to action: May 25, 1961

Apollo 11 launch: July 16, 1969

Eight Years to Success•Eight years

•$23 billion

•National Goal

•Coordinated approach

Man lands on Moon: July 20, 1969

•Coordinated approach

The Solution to Global Climate Change….

• is based on technology, e.g., new process development [energy supply, cars, ind.]• should be a national program based on a • should be a national program based on a national goal [50% by 2050?]• linked to a global program

Follow the Space Program model…