JP. Birat, 8 June 2012, Montreal
Low-CO2 steelmaking
Jean-Pierre BIRAT, ArcelorMittal
Industrial Technologies 2012
Integrating nano, materials and production
Cleaner Coal & Stronger Steel for a Sustainable Europe Workshop
Aarhus, 19-21 June 2012
1
Steel & Climate Change
JP. Birat, 8 June 2012, Montreal
 Steel & Carbon footprint: the dark side of the story (steel is a
problem)
• specific CO2 emissions: 0.6 (EAF), 2.3 (BF), 1.8 (world average)
tCO2/tsteel, globally about 5% of anthropogenic emissions. These are
actual (real) emissions, physics.
 Steel and avoided CO2: the bright side of the story (steel is
the solution)
• avoided emission are one order of magnitude larger than sectoral
emissions… but depend on authors to a very large extend. These are
not physical emissions, but "fiction"
 the world governance on Climate has decided that industrial
sectors are responsible for their real emissions but can get
credits for avoiding emissions (e.g. through CDMs).
2
JP. Birat, 8 June 2012, Montreal
Is this reasonable?
 follows the "polluter pays" principle, a "grave" approach
 another approach would attach the burden to the cradle… or
spread along the value chain (cf. law enforcement issues)
 a confusion between fossil fuels – which are burned, and
metals – which are reduced. Why should they be treated
similarly? What if politicians were physicists?
 the ETS system in Europe does NOT WORK (has not worked
yet!) and one reason is that metals are part of it! What a price
to pay!!!
3
JP. Birat, 8 June 2012, Montreal
Steel and what lies ahead of us…
 Major contradiction today between climate scientists'
proejctions and the willingness of society to act (e.g. carbon
price: 6.6 €/t)
 CO2 breakthrough program of worldsteel: many small
exploratory programs, a couple of larger ones, one (ULCOS)
really addressing the issue with the view to build
demonstrators
 some kind of final reckoning will come, but when?
RIO+20???
 there is room and a future for carbon-lean steel production,
not simply because of carbon, but also because these
solutions are attractive in a more general way…
4
Let's have a look at ULCOS' present status..
… as a demonstration of the previous statement…
JP. Birat, 8 June 2012, Montreal
Partners active in ULCOS II
6
ULCOS II develops all 4 ULCOS solutions
JP. Birat, 8 June 2012, Montreal
Coal & sustainable biomass
Natural gas
Electricity
Revamping BF
Greenfield
Revamping DR
Greenfield
ULCOS-BF
HIsarna
ULCORED
ULCOWIN
ULCOLYSIS
Pilot tests (1.5 t/h) Pilot plant (8 t/h) Pilot plant (1 t/h)
Demo phase
start-up 2010
to be erected in
under way
2013
7
Laboratory
pilots
ULCOS-BF project
JP. Birat, 8 June 2012, Montreal
CO2 storage
Florange
ULCOS I
4 projets RFCS + 1 FP
Eisenhüttenstadt-EHS
8
JP. Birat, 8 June 2012, Montreal
Cost, financing, schedule…
 cost not announced officially
 financing (obtained or expected):
•
•
•
•
•
•
German government (EHS)
NER-300 (Florange full CCS chain)
French government (Florange)
Lorraine regional bodies (Florange)
ULCOS consortium
ARCELORMITTAL
 EHS: start up scheduled 2014
 Florange: start up of relined P6 in 2014,TGR-BF in 2015 and
of ULCOS-BF (full CCS chain) in 2015 (31/12)
9
ULCOS-BF in Florange
New entrance for oversize parts
Level +20 m
JP. Birat, 8 June 2012, Montreal
Area for pre-assembly
Delivery area for oversize
parts and pre-assembly
Access road to slag deposit
Level +8 m
Level ±0 m
National Railways
TGR implantation (~20 000 m²)
BF P4
BF P6
Gas cleaning
Hot stoves
Iron Railways
10
JP. Birat, 8 June 2012, Montreal
ULCOS-BF in Florange
11
JP. Birat, 8 June 2012, Montreal
ULCOS-BF in Florange
12
CCS in a deep saline aquifer
JP. Birat, 8 June 2012, Montreal
Geological map of eastern Paris basin
(A-B: cross section position, from BRGM)
13
JP. Birat, 8 June 2012, Montreal
Storage concept
1000 m
CO2
14
JP. Birat, 8 June 2012, Montreal
NER-300 boundary conditions…
 ULCOS-BF demonstrator to be built and started up within 4
years
 the demonstrator has to operate for at least 10 years (NER300)
 industrial deployment, based on "technological realism"
(feasibility), might start in the 2020s
15
HIsarna
JP. Birat, 8 June 2012, Montreal
CO2
CCS
The plant was operated
from April 18 to June 11 2011
Iron ore
Oxygen
Oxygen
Coal
iron
New campaigns in 2012, 2013...
16
ULCORED
Concept details
JP. Birat, 8 June 2012, Montreal
Good fuel for complete plant
H2 rich
Full CO2 capture in the process
CO2 removal
CO2 storage potential
Gas cleaning
CO2 storage
Shifter
O2 instead of air (no N2 in system)
Reforming by a POX reactor
DRI reactor
High H2 content in reduction
shaft by water-gas shifter
Oxygen
DRI cooler
Natural gas
POX
GREEN FIELD
DRI
(CO + H2O = H2 + CO2)
Bleed of H2 containing N2
Melting in an EAF (Comeltfurnace)
17
JP. Birat, 8 June 2012, Montreal
ULCOWIN
anode
Cell#1
Cell#2
thermodynamic voltage
V
1,24
1,24
ohmic drop
V
0,17
0,13
kinetic drop
V
0,39
0,24
Total voltage
V
1,8
1,6
0,7
0,9
Mwh/t
3,7
2,56
%
50
72
Faradic yield
energy need
energy efficiency
18
Electrolysis and renewable energies…
JP. Birat, 8 June 2012, Montreal
PV cell
Electrolysis cell
19
-1,5
-2,0
40,0
30,0
0,0
20
ULCOLYSIS
> 50% reduction vs. benchmark BF
ULCOWIN
0,0
ULCORED
0,5
MIDREX+CCS
1,0
MIDREX
1,5
HIS+CCS+EAF
2,0
HISARNA+EAF
CO2 captured
ULCOLYSIS
ULCOWIN
MIDREX + CCS
MIDREX
ULCORED
HISARNA+CCS+EAF
HISARNA+CCS
HISARNA+EAF
HISARNA
40
TGRBF V4
120
HISARNA+CCS
IS
W
IN
LY
S
O
ED
10-20% reduction vs. benchmark BF
BBF
O
LC
R
S
C
15,0
BBF+CCS(PP)
U
LC
O
LC
EX
R
ID
EX
+C
U
U
R
140
HISARNA
Scope 2
M
20,0
TGR-BF V4
-1,0
Natural gas and biomass gas
BBF+CCS(PP)
Scope 1
ID
5,0
M
BB
BB
F+
F
C
C
S(
PP
TG
)
R
-B
F
V4
H
IS
A
H
R
IS
N
AR
A
N
A+
H
C
IS
C
S
AR
H
IS
N
AR
A+
N
E
AF
A+
C
C
S+
EA
F
GJ/t HRC
Coals, oil and other C-rich sources
BBF
-0,5
BB
BB
F+
F
C
C
S(
PP
TG
)
R
-B
F
V4
H
IS
AR
H
IS
N
AR
A
N
A+
H
C
IS
C
S
AR
H
IS
N
AR
A+
E
N
AF
A+
C
C
S
+E
A
F
M
ID
R
M
E
ID
X
R
E
X+
C
C
S
U
LC
O
R
ED
U
LC
O
W
IN
U
LC
O
LY
S
IS
t CO2/t HRC
JP. Birat, 8 June 2012, Montreal
ULCOS solutions' results
25,0
Electricity and energy vectors (steam, H2)
CO2 release
Raw material and energy
Fix
100
10,0
80
60
0,0
20
still a "regret" solution vs. benchmark BF
0
2010
100,0
x
inde
90,0
80,0
70,0
60,0
50,0
Cost of avoided CO2 = 1/2 end-of-pipe CCS
20,0
10,0
100%
80%
BBF
60%
ULCOS-BF
MIDREX
JP. Birat, 8 June 2012, Montreal
40%
ULCORED
20%
0%
Acidification
Eutrophication
Photochemical
ozone creation
100%
resource depletion
80%
2050 footprints
BBF
60%
HISARNA(+CCS)
ULCOWIN
40%
ULCOLYSIS
20%
0%
Acidification
Eutrophication
21
Photochemical
ozone creation
resource depletion
JP. Birat, 8 June 2012, Montreal
Conclusions
 the future of carbon lean policies is still uncertain
 .. and so is the future of carbon-lean technologies in the steel
sector
 but solutions like ULCOS's have the potential to change the
sector technology way beyond carbon dioxide emissions and
to constitute a major technology shift, part of the new
Kondratief linked to the green economy?
22
FP6 and RFCS grants from the Commission and from French
and Dutch agencies are gratefully acknowledged.
Thank you!