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ULCORED
Direct Reduction Concept for ULCOS
a brief intoduction
Peter Sikström
LKAB
11th November 2013
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OUTLINE
• Introduction
• Todays dominating processes
• Potential for new DR-process
• Proposal for new processes
– Natural gas based
– Coal based
• Summary
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INTRODUCTION
Requirements for a new DR-Process proposed 2006:
1. Different from existing processes like Midrex or HYL.
2. The Plant should only have one source where CO2 leave the process.
3. The Energy consumption has to be less than 8,4 GJ / t DRI.
4. Equipment and operation has to be simple.
5. Potential for use of fuels other than natural gas.
6. Investment costs has to be comparable to existing plants / plant concepts.
7. There must be good reasons for tests – technically and economic.
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Midrex
TODAYS DOMINATING PROCESSES
HYL
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Midrex process configuration
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HYL PROCESS CONFIGURATION
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• Introduction
• Todays dominating processes
• Potential for new DR-process
• Proposal for new processes
– Natural gas based
– Coal based
• Summing-up
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• Use of oxygen instead of air in DR-plants results in
an off gas of 100 % CO2, which needs only to be
compressed.
• There should be possibilities to reduce the need of
natural gas in DR-processes by 15 – 20 %.
• Coal-, biomass-, bio waste gasification and
hydrogen can be an alternatives to natural gas.
Dominating CO2 emissions from DR – EAF route
arises from the DR-plant.
The main features for ULCORED :
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CO2 reforming
Steam Reforming
Thermal cracking
Partial oxidation
Water gas shift
Boudouards reaction
Complete combustion
CH4 + CO2 ↔ 2 CO + 2 H2
CH4 + H2O ↔ CO + 3 H2
CH4 ↔ C + 2 H2
CH4 + ½ O2 → CO + 2 H2
CO + H2O ↔ CO2 + H2
2 CO ↔ C + CO2
CH4 + 2 O2 → CO2 + 2 H2O
Ht = 247 kJ/mol Midrex
Ht = 206 kJ/mol HYL
Ht = 75 kJ/mol
Ht = -36 kJ/mol Ulcored
Ht = -41 kJ/mol
Ht = -173 kJ/mol
Ht = -803 kJ/mol
Source: TUDelft
Endothermic
Exothermic
REACTIONS STARTING FROM METHANE
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SMR ATR Pox
reactants CH4 + steam CH4 + O2 + steam CH4+O2 +steam
inlet T° 500-600 °C 750 °C NG 450°C O2 200°C
outlet T° 870 °C 900-1000 °C 1300-1400 °C
H/C in syngas 3 - 6 1,8 – 3,7 1,6 – 1,9
H2O content 5 % 18 % 10-13 %
estimated cost without piping, for ~ 40 000 Nm3/h
10 M€ 20 M€ ? 20 M€
(POx without shift)
Feed
(CnHm, …)
Steam Methane Reforming (SMR)
Endothermic: heating necessary
Auto-Thermal Reforming (ATR):
Combined oxidation and steam
reforming heat is balanced
Partial Oxidation (POx).
Steam used for enhancing CH4
conversion and avoid soots
SYNGAS PRODUCTION TECHNIQUES
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T= 1085°C
Iron Ore
DRI
T= 420°C
T= 780°C
T= 1085°CT= 1085°C
Iron OreIron Ore
DRIDRI
T= 420°CT= 420°C
T= 780°CT= 780°C
CH4 + CO2 + Heat ↔ 2 CO + 2 H2
CO2 + N2 in off gas
CH4 + H2O + Heat ↔ CO + 3 H2
CO2 + (N2) in off gas
MIDREX HYL ZR
POX
pilot
CH4 + ½ O2 ↔ CO + 2 H2 + Heat
CO2 in off gas
Steam reforming CO2 reforming
Partial oxidation
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POX PILOT AT LINDE
Piping and Instrument Diagram
ERPOX _ H2 rich feed gas
Y : / EFV / !Projekte/ 2471_XL-ATR / Umbau / Zeichnungen /Fließschema14.vsd
DN 800
DN 1400
E 01
R 01
DN 25
zum Siphon
LI
B 02
V503
501
PI TIRSH
401 401
DN 800
H
HH
AusgabeDatum PFP01ERPOX
Proj.- Nr.: 2471 2972
FI502
SG607
V602
FI602
FI608
SG608
V611
FI609
701/2701/1
702/1
703/1
704/2704/1
D
DN25
TIR
502
23.9.08
V5
09
V5
10
DN
10
DN
10
TI503
TIRS
TIRSTIRS
TIRS
TIRSTIRS
HH_P
H
HH_P
H
HH_P
H
HH_P
H
HH_P
H
HH_P
H
TIR
802
AD (barü)AT (°C)
Tautz
DN 80
TIRS
803a
803b
TIRS
HH
HH
V512
Cooling water, T=15 °C,
ca. 3 m³/h
flare
FIR TIR
101 101
PIR
101
FIR TIR
201 201
PIR
201
N2
N2, T ca. 25 °C, ca. 3
Nm³/h
O2
CH4,LNG,C3H8,H2
QE 2, Combustion
chamber
QE 1, Feed
QE 3, Product gas
ERPOX, Linde LE
Probe distance to burner:
90/150/210/270 cm
H2-
Trailer
TI
901
Data registration
Local measurement
TI
902
TI901
PI902
FIR
901
LNG
TI504
• Tested in two campaigns
• New designed burner for H2 rich feed gas
• Tube reactor with preheated gas
- 60% H2
- 40% CH4
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CONCLUSIONS BY LINDE
• The burner and reactor could be operated without problems.
• A stable flame without significant noise production could be
demonstrated.
• The soot production is expected lower than 300-460 mg/Nm³
wet gas volume.
• Due to the atm pressure, the CO2 and CH4 content will be
higher than the pre-calculations on the basis of assumed
equilibrium.
• A higher operation pressure up to 7 bar(a) will reduce this
contents
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• Introduction
• Todays dominating processes
• Potential new DR-process
• Proposal for new processes
– Natural gas based
– Coal based
• Summary
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ULCORED
• No reformer
• No heater
• High pressure
Less gas velocity in the shaft, gives less fluidisation, less
fines leaving the shaft
CO2-removal and POx units are smaller than Midrex/HYL
shifter/reformer
Less electric power need for recycle compressor
PSA instead of VPSA can be used
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ULCORED
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In depth studies of ULCORED
Fundamental modeling
– Pellet scale models
• LSG2M and NTNU
– Reduction models – reduction kinetics
– Shaft models
• LSG2M, NTNU and SSSA
– Process models by flow sheet simulations • MEFOS developed an HSC-model in SP 12
• IRMA developed in SP 2 by Corus
• ASPEN developed by LSG2M in SP 9
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Achievements from modeling
Fundamental reduction modelling
– Fundamental understanding of the DR process including
dissemination of knowledge to the Universities
Flow sheet modelling
– Optimisation of the process layout to fit the ULCORED
process in steel plant environment
– Process understanding including dynamics
Different approaches - similar results
– Create credible basis for evaluation of the concept in
different scenarios
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Natural gas ULCORED
Concept details
Full CO2 capture in the process
CO2 storage potential
O2 instead of air (low N2 in system)
Reforming by a POX reactor
High H2 content in reduction
shaft by water-gas shifter (CO + H2O = H2 + CO2)
Bleed of H2 containing N2
Useful fuel for complete plant
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Natural gas ULCORED
CO2 removal
CO2 storage
GREEN FIELD DRI
Shifter
Gas cleaning
DRI reactor
DRI cooler
H2 rich
Natural gas
Oxygen
POX
CO2 removal
CO2 storage
GREEN FIELD DRI
Shifter
Gas cleaning
DRI reactor
DRI cooler
H2 rich
Natural gas
Oxygen
POX
H2 rich gas
Bleeding N2 and for
use in the steel plant
Feed to the cooling
zone to re-heat the
gas to the POX
CO+H2O=CO2+H2
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Excess gas for
external users
Coal gasification
Dust and sulphur removal
Hot or cold
Coal
Oxygen
CO2 removal
CO2 storage
BROWN FIELDGREEN FIELD DRI
Shifter
Gas cleaning
DRI reactor
DRI cooler
Excess gas for
external users
Coal gasification
Dust and sulphur removal
Hot or cold
Coal
Oxygen
CO2 removal
CO2 storage
BROWN FIELDGREEN FIELD DRI
Shifter
Gas cleaning
DRI reactor
DRI cooler
Dust and sulphur removal
Hot or cold
Coal
Oxygen
CO2 removal
CO2 storage
BROWN FIELDGREEN FIELD DRI
Shifter
Gas cleaning
DRI reactor
DRI cooler
Concept details
Reducing gas from coal in a
gasifier, e.g. Shell gasifier
CO2 storage
O2 instead of air
High H2 content in reduction
shaft by WGS water-gas shifter
H2 excess gas for external
users
Coal based ULCORED
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Dust and sulphur
removal Hot or cold
Coal
Oxygen
CO2 removal
CO2 storage
Excess gas for
external users
BROWN FIELDGREEN FIELD DRI
Shifter
Gas cleaning
DRI reactor
DRI cooler
Coal gasification
Dust and sulphur
removal Hot or cold
Coal
Oxygen
CO2 removal
CO2 storage
Excess gas for
external users
BROWN FIELDGREEN FIELD DRI
Shifter
Gas cleaning
DRI reactor
DRI cooler
Coal gasification
Coal based ULCORED
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The purpose of an integration of ULCORED into the existing steelmaking system is to
utilise the possibility to have one CO2 emission point from the system, instead of having
one per heating gas consumer
Natural gas / Coal
Oxygen ULCORED
Power
station
Electric
arc
furnace
Ladle
furnace Casting
Hot
rolling
mill HRC
CO2
Electric power
H2 rich gas, in plant usage
DRI
92% Met.
Gas holder
Integration into a steel plant
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Material-Balance related to 1 t DRI (cold) (Metallization 92%, Carbon 2,76 %)
0 0
*Remark
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Mass-Balance for new DR-Concept (cold DRI)
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Energy-Balance for new DR-Concept (cold DRI)
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Energy consumption and CO2 emissions
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Capex & Opex
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• Can be ”quick-fix” for a brown field improvement of CO2
emissions, especially where natural gas is relatively cheap.
• By integration in a steel plant, LRI can be a choice considering
the successful tests made in the LKAB Experimental BF.
– The LRI-tests with a DR-product reduced to only 65% metallization
degree respond very positive in the BF with stable operation and coke
consumption at 200 kg/tHM.
• Tests has to be done to prove the concept.
SUMMARY
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EXPERIMENTAL DR PLANT
• Production: 1 ton Fe/h
• Recirculation of top gas
• Working pressure (shaft) 0-8 bar (g)
• Gas flow: ~1700-3100 Nm3/h
• Temp to shaft: 900-1050 ºC
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EXPERIMENTAL DR PLANT
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WE STRIVING FOR A SUSTAINABLE FUTURE
32
THANK YOU
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CHARGING A PRE-REDUCED BURDEN INTO EBF
Trials during 2 campaigns in the Experimental BF
DRI at 15, 30 and 60 % of the burden
Reductant rate decrease up to 26 %
Emission of CO2 decreased up to 24%
LRI at 50 and 100 % of the burden
Reductant rate decrease up to 33 %
Emission of CO2 decreased up to 37%
Significant productivity increase with increasing amount of pre-reduced iron ore
DRI metallisation degree over 90 %. LRI metallization degree about 65%