Erasmus Mundus Conference Climate Change 26 27 Fev

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 n n 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 n Steel production (2007) 1. 3 billion tons worldwide. n Steel consumption (2015) 1. 8 billion tons. n n BRIC countries (Brazil, Russia, India, China) dynamically expanding their economies and infrastructures. Steel n Environment friendly material l n can be recycled indefinitely no loss of quality. 40% of steel produced is recycled from scrap Use in durable products/infrastructure l 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: CO 2/CO/H 2/N 2 Coke + Sinter 2 C + O 2 CO Fe 2 O 3 +3 CO 2 Fe + 3 CO 2 Molten ore+Coke 1500 o. C 1850 kg CO 2/t steel Pellet / Sinter Plant Raw ore → heat treatments/additives → Sinter/pellets (better properties) Pig iron

CO 2 Emissions x Climate Change n n n CO 2 Emissions Climate Change Natural disasters The best European steel plants are operating at the limits of what is presently technically possible. Breakthrough technologies for steelmaking industry

ULCOS (Ultra Low CO 2 Steelmaking) Project n Aim: design new steelmaking processes able to reduce by more than 50% the CO 2 emissions of the steel industry as compared to the current benchmark route (integrated plant, BF-CC) n Launched by the major European steel companies n Supported by European Commission n 48 partners, 59 M€ budget, 5 -year duration

Context: the European program ULCOS Sep 04 Fev 06 today Sep 09

SP 10 - Top Gas Recycling Blast Furnace with CCS (TGRBF CCS) Coke + Ore Top Gas CO 2/CO/H 2 n Concept: off gases separation (VPSA process) n n off gases separation (VPSA or PSA) CO recycled back into the furnace (reducing agent) n less amount of coke needed. n CO 2 CCS Molten Ore + Coke CO 2 Pure O 2 injection instead of preheated air n CO 2 to CCS No N 2 best for CCS Pig Iron Recycled CO to BF

SP 11 - HISARNA with CCS n CONCEPT: Melting cyclone + Ore Smelter in one vessel n n Coal preheating and partial pyrolysis in a reactor Melting cyclone (ore melting + prereduction) Ore fines Coal Smelter vessel (Ore → Iron final reduction) CO 2 Hot coupled process n n Off Gas (CO 2) Ore melted and reduced without any intermediate gas treatment, cooling or dedusting. Flexible process: n Melting cyclone (ore melting) Partial substitution of coal by biomass, NG or H 2 Twin Screw reactor (coal preheating) Converter (ore reduction)

SP 13 - Alkaline Electrolysis n n CONCEPT: transformation of iron ore into metallic Fe and O 2 using only electrical energy and low temperature. Current from A to C Fe 2 O 3 ore suspended in the alkaline solution No need of coke ovens, melting or reducing vessels (BF, converters, shaft furnace). Capture of O 2 CO 2 leanest process of steelmaking. No iron is presently produced industrially by electrolysis. n n Most innovative route currently being studied in ULCOS. Electrolysis of other metals (Al, Ni, Zn) already in industrial scale. Fe+3 → Fe reduction (Fe layer) 2 O-2 → O 2 oxidation (O 2 bubbles out) Aqueous solution of Na. OH (110°C) CO 2

H 2 for Iron and Steelmaking n Generation of hydrogen H 2 WP 4. 1 Iron ore SP 4 • H 2 O electrolysis • NG Reforming Main route defined Ore Pre-reduction with H 2 DRI Production of liquid metal in an EAF liquid steel Casting WP 4. 2 Nancy-Université Low CO 2 Emissions: from 200 to 400 kg CO 2/t steel Rolling HRC