EU Industry Day 22 nd February 2018, Brussel Smart Carbon Usage, Process Integration and Carbon Capture and Usage Michael Hensmann, VDEh-Betriebsforschungsinstitut GmbH (BFI) Dr. Koen Meijer, Tata Steel (TATA) Dr. Markus Oles, thyssenkrupp AG (tk)
Technological pathways to reduce CO 2 emissions in the EU 28 steel sector 2
Smart Carbon Usage Intelligent use of steelmaking routes with fossile fuels (coal, natural gas, etc.) while at the same time cutting the CO 2 quantities they produce Process Integration Reduced use of carbon and equivalent CO 2 emissions by modifications of existing and alternative ironmaking/steelmaking processes with or without CCS Carbon Capture and Usage Usage of CO, CO 2 with or without Hydrogen as feedstock for valuable products like fuels or basic chemicals 3
Process Integration IGAR (Injection de Gaz Réformé) PEM (Primary Energy Melter) Source: ArcelorMittal Source: SMS-Group Reforming of steel plant gases and injection in Blast Furnace to reduce coal/coke consumption New metallurgical process based on low quality scrap melting with metallurgical/natural gas Technology: Plasma torch and reactor to heat and reform gases Potential CO 2 savings: 0,1-0,3 tonne CO 2 per tonne of crude steel For one typical plant 500 ktco 2 eq/a Total EU scope estimated is 10 MtCO 2 eq/a Timeline: Validation in 2020 Technology: Pre-melting of scrap in shaft vessel with gas burners and subsequent superheating process Potential CO 2 savings: 1 ton CO 2 per tonne melted scrap For one typical plant 200 ktco 2 eq/a Total EU scope estimated is 2500 ktco 2 eq/a Timeline: Go to live PEM installation 2019; Integration in 2021 4
Carbon Capture and Usage Steelanol Source: ArcelorMittal Construction of commercial scale facility to create bio-ethanol from steel waste gases Technology: Production of bio-ethanol via gas-fermentation Potential CO 2 savings: If all steel mill gasses of EU 28 conventional steel plants (BF-BOF route) are converted into ethanol the yearly production potential of app. 14,5 million t/y of EtOH will reduce CO 2 emissions by 33,3 million t/y. Timeline: Go to live 2019 5
LowCarbonFuture Exploitation of projects for low carbon future steel industry RFCS accompanying measure project Start of the project: 01.04.2018 Duration of project: 24 months 6
Main Objectives: Evaluation and promotion of projects and dissemination of knowledge dealing with CO 2 mitigation in iron and steelmaking Finding solutions for future collaboration and enabling technology transfer between all actors like steel producers, plant manufacturers, associated industrial sectors (energy, hydrogen, chemistry ), institutes for applied research and universities Generation of a roadmap stating research needs for breakthrough technologies to guide EU steel industry towards the EU climate goals Implementing key findings in the strategic research agenda of the European Steel Technology Platform (ESTEP) Support the update of the Steel Roadmap, EU Masterplan and EUROFER s BIG-Scale initiative 7
HIsarna
HIsarna process The HIsarna development originates from the ULCOS project It is presently developed by: Tata Steel Europe thyssenkrupp Steel Europe ArcelorMittal voestalpine Paul Wurth HIsarna is a game changing technology for the steel industry 9
HIsarna One step from raw material to hot metal Iron ore Coal Hot metal Iron ore Coal Coking/Agglomeration Ironmaking Hot metal 10
Total investment of 70 M 11
Time schedule and costs of HIsarna Demo Pilot plant experiments 2018 2019 2020 2021 2022 2023 2024 2025 I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV Demo plant engineering Go / No Go decision Demo plant construction Commisioning and ramp up Go/No Go decision First hot metal A Demo plant capacity of 1.2 M thm/year is foreseen The development costs of the program above will be 500 M 12
The benefits of HIsarna The HIsarna process fits in an integrated steel site and offers both environmental and economic benefits compared with present technology Economic benefits Lower operating and investment costs No dependency on coking coals Excellent recycling potential and flexibility, recycling of waste oxides, Zn containing dusts, LD slag and scrap Low capture costs for CO 2 (N 2 -free topgas with already concentrated CO 2 at single process stack) Environmental benefits CO 2 emission reduction up to 80 % with CCS Lower emissions SO X, NO X, dioxines and fine dust 13
Carbon as raw material for methanol and urea production 14
The right mixture of CO 2 and other gases are necessary for Carbon Capture and Use (CCU) 2 Mio. Nm 3 waste gas per hour H 2 Hüttengas Steel Energy Digital Data Chemical 15
Carbon as raw material for methanol and urea production 16
Carbon2Chem as raw material : Beyond for sectoral methanol mitigation and urea production Until 2030 Energy Steel Chemical CO 2 Limits of sectoral mitigation reached Open cross-sectoral synergetic potentials Major Challenges Cross-sectoral network (contracts, accounting, cooperation, etc.) Energiewende (transition towards renewables) Regulatory framework (energy & climate policies post 2020, EEG, etc.) Industrial application (further development of existing technologies) Investments / Market needs Permits / Construction 17
Carbon2Chem as raw : material From idea for methanol to commercial and urea implementation production Research in Carbon2Chem Carbon2Chem Pilot plant Commercial implementation Basics IP is created (closed level) Transfer Ideas to the pilot plant Operating experience Phase I: Proof of Concept Start: 2015 End: ~ 2020 Contribution to the commercial implementation Phase II: Scale-up on industrial scale Start: 2020 financing required 18
Carbon2Chem as raw : material From idea for methanol to commercial and urea implementation production Research in Carbon2Chem Carbon2Chem Pilot plant Commercial implementation Total funding (BMBF) for all 17 partners: 60 million project spending's tk: 60 million Total project spending's: 120 million Estimated cost for demonstration phase: 500 million 50 % invest in small plant 20 % utilities 20 % Staff 10 % R&D support Contribution to the commercial implementation Start: 2023 Required financing up to 1 billion per plant 19
Water electrolysis / network stability Sustainable methanol production Gas cleaning / catalysis Higher alcohols / polyalcohols Polymers OME Carbon2Chem as raw : material Project for partners methanol and and urea production Sub-projects L0 System Integration Carbon2Chem Lab Technical plant L1 L2 L3 L4 L5 L6 MPI-CEC Umsicht Siemens ZBT ISE MPI-CEC RUB Umsicht Clariant tk RUB MPI-CEC Umsicht Clariant tk RUB RWTH- ITMC Umsicht tk MPI-KOFO RWTH-ITMC RWTH-LTT RWTH-AVT RWTH-CAT Umsicht KIT-IKFT TU KL VW Linde tk 20
Carbon2Chem as raw : Targets material for methanol and urea production We use the carbon from metallurgic gases as a starting material for chemical products We reduce the CO 2 emissions in the cross-industry network We use surplus electricity from renewable energies as a source of energy We provide an essential contribution to climate protection and the Energiewende 21
Smart Carbon Usage Cutting CO 2 emissions in fossile fuel based steelmaking Michael Hensmann michael.hensmann@bfi.de Dr. Koen Meijer koen.meijer@tatasteel.com Dr. Markus Oles markus.oles@thyssenkrupp.com