Upload
others
View
8
Download
0
Embed Size (px)
Citation preview
Techno-Economic Evaluation of DeployingTechno-Economic Evaluation of Deploying CO2 Capture in an Integrated Steel Mill
Stanley Santos1*, Lawrence Hooey2, Jeremy Johns3, A d T bi 4Andrew Tobiesens4
Clean Coal Technology ConferenceClean Coal Technology ConferenceThessaloniki, Greece
May 2013May 20131IEA Greenhouse Gas R&D Programme
2Swerea MEFOS3Tata Steel Consulting
4Sintef Chemistry and Materials
Members of
St i C ittSteering Committee• Nils Edberg SSAB Chairperson• Nils Edberg, SSAB – Chairperson• Camilla Axelsson, Swedish Energy Agency
Helen Axelsson Jernkontoret• Helen Axelsson, Jernkontoret• Kim Kaersrud, SSAB
A it L S di h E A• Anita Larsson, Swedish Energy Agency• Stanley Santos, IEAGHG
P t Sik t LKAB• Peter Sikstrom, LKAB• Jan Olov Wikstrom, Swerea MEFOS
G Qi Z LKAB• Guang Qing Zuo, LKAB
Total value of the Project: 4 4 million SKrTotal value of the Project: 4.4 million SKrIEA GHG Contribution: 1.2 million SKr
Co-Authors of this Studyy• Swerea MEFOS Team
• Lawrence Hooey (Project Manager)• Mikael Larsson• Axel Boden
T t St l C lti• Tata Steel Consulting• Jeremy Johns• Vic Abraham• Vic Abraham• Mike Knight
• SINTEF Chemistry and MaterialsSINTEF Chemistry and Materials• Andrew Tobiesen• Karl Anders Hoff• Geir Haugen
• IEA Greenhouse Gas R&D Programme• Stanley Santos• Steve Goldthorpe
Objectives of the StudyObjectives of the Study• To specify a “REFERENCE” steel mill typical to Western• To specify a REFERENCE steel mill typical to Western
European configuration and evaluate the techno-economic performance of the integrated steel mill with and without CO2p gcapture.
• To determine the techno-economic performance, CO2 emissions and avoidance cost of the following cases:• An integrated steel mill typical to Western Europe as the base case.• An end of pipe CO2 capture using conventional MEA at two different levels
of CO2 capture rateof CO2 capture rate• An Oxygen Blast Furnace (OBF) and using MDEA for CO2 capture.
Terminologies / AbbreviationsTerminologies / Abbreviations
• OBF Oxy-Blast Furnace• OBF Oxy-Blast Furnace• OBF-PG Oxy-Blast Furnace Process Gas• OBF-TG Oxy-Blast Furnace Top Gas• TGR Top Gas Recycle• TGR Top Gas Recycle• BFG Blast Furnace Gas• BOFG Basic Oxygen Furnace Gas• COG Coke Oven Gas• COG Coke Oven Gas• SGP Steam Generation Plant
Integrated Steelmaking ProcessProcess• Raw Materials Preparation Plants
• Coke Production• Coke Production• Ore Agglomerating Plant (Sinter
Production)Li P d ti• Lime Production
• Ironmaking• Blast Furnace• Hot Metal Desulphurisation
• SteelmakingB i O St l ki (P i )• Basic Oxygen Steelmaking (Primary)
• Secondary Steelmaking (Ladle Metallurgy)
• Casting• Continuous Casting
• Finishing Mills• Finishing Mills• Hot Rolling Mills (Reheating & Rolling)
Extra-Ordinary Assumptions(For European Scenarios)(For European Scenarios)
• Only one type of steel product (standard grade HRC) produced and soldproduced and sold.
• Plant Ownership Structure not typical to European St l Mill S iSteel Mill Scenario• Captive Ownership: Power Plant, ASU and Lime Plant
• Captive Power Plant with Balanced Electricity Supply to the Steel Mill.
• Captive Coke Plant with Balanced Supply of Coke to the Steel Mill.
• Direct emissions related to the Pellets and Merchant Scrap not included in overall CO2 emissionScrap not included in overall CO2 emission accounting.
Direct CO2 Emissions from h REFERENCE S l Millthe REFERENCE Steel Mill
• Nearly 95% of the total CO2
Emissions from the Coke Plant9.31%
Power Plant46.99%
Integrated Mill that produces 4 million tonnes of Sinter Plant
13.85%
Hot Rolled Coil:• Power Plant (47.0%) Lime Plant
3.43%( )• Ironmaking (21.2%)• Sinter Production (14.0%)
Iron Making21.18%
Steelmaking
Slab Casting0.04%
Reheating & HRM2.76%
( )• Coke Production (9.3%)• Lime Production (3.4%)
REFERENCE Integrated Steel Mill(2090 kg per tonne of Hot Rolled Coil)
2.44%
( )
Key Messages from this StudyKey Messages from this Study
An Integrated Steel Mill is a complex industrialAn Integrated Steel Mill is a complex industrial process which consists of Multiple Point Sources of
CO2 EmissionsEmissions
Annual Emission
(kg/t HRC) (t/y)
100 Coke oven flue gas 191.37 765,495
UNIT Source of CO2 Emissions
CO2 Emissions
g ,
100 Coke oven gas flare 3.30 13,196
200 Sinter plant f lue gas (CO2 + CO) 289.46 1,157,825
300 Hot Stove f lue gas 415.19 1,660,769
400/1300 PCI Coal drying torpedo car and ladle heating (HM Desulphurisation) dif fue emissions 7 76 31 042
Coke Plant9.31%
Power Plant46.99%
400/1300 PCI Coal drying, torpedo car and ladle heating (HM Desulphurisation) dif fue emissions 7.76 31,042
300 Blast Furnace Gas flare 19.73 78,931
500/600 Basic Oxygen Furnace gas f lared and system losses, SM diffuse Emissions 51.02 204,089
700 Continuous Casting - dif fuse emissions (from slab cutting) 0.80 3,188
800 Reheating Furnace flue gas 57 71 230 833
Sinter Plant13.85%
800 Reheating Furnace f lue gas 57.71 230,833
900 Hot Rolling Mills - dif fuse emissions (from cutting and scarfing) 0.04 179
1000 Lime Plant f lue gas 71.62 286,493
1200 Pow er Plant f lue gas 982.13 3,928,513
Iron Making21.18%
Slab Casting
Reheating & HRM2.76%
Lime Plant3.43%
1300 Ancillaries transport fuel emissions (trucks and rails) 4.00 16,000
2094.14 8,376,554Total Emissions Steelmaking2.44%
0.04%
Key Messages from this StudyKey Messages from this Study
An Integrated Steel Mill is a complex industrialAn Integrated Steel Mill is a complex industrial process which consists of Multiple Point Sources of
CO2 Emissions
I ki P i ibl f l 80% f
CO2 Emissions
Ironmaking Process is responsible for nearly 80% of the Carbon Input that causes the majority of the Direct CO E i i (i 1640 t f 2090 k CO / t HRC) fCO2 Emissions (i.e. 1640 out of 2090 kg CO2 / t HRC) of
the Integrated Steel Mill
Nitrogen2 Nm3
R M t i l
BFG to Flare/Lost23 Nm3
Top Gas Cleaning
BFG Gas Holder
Raw MaterialsCoke 355 kgSinter 1120 kg (70%)Pellets 352 kg (22%)Lump 125 kg (8%)
BFG to Power Plant935 Nm3
BFG to Coke Plant185 Nm3
BF Dust15 kg
Limestone 13 kgQuartzite 11 kg
BF Screen Undersize BF Sludge
kFlue GasCOG
BFG to Hot Stoves479 Nm3
185 Nm3
23 kg 4 kg 780 Nm3COG7 Nm3Air358 Nm3DRR: 31%
FT: 2056oC
Recuperator
TGT: 140oCHM Si: 0.5%HM C:4.7%
Hot Blast
M i Ai
Cold Blast
Hot Stoves
PCI Coal152 kg
Nitrogen3 Nm3
48 Nm3Oxygen
Main Air Compressor
Air995 Nm3
BF Slag280 kg
Hot Metal1000 kg1470oC Steam
8 kgStea
All Values are reported as kg or Nm3 per tonne of hot metal (thm)
Carbon Balance of Ironmaking ProcessDirect CO2 Emissions of an Integrated Steel Mill (REFERENCE) Producing 4 MTPY Hot Rolled Coil2090 kg CO2/t HRC (2107 kg CO2/thm )
Carbon Input Carbon OutputCarbon Balance of Ironmaking Process
Carbon Input(kg C/thm)
Carbon Output(kg C/thm)
Coke 312.4 Hot Metal 47.0
Limestone 1.5 BF Screen Undersize 6.3
PCI Coal 132.2 Dust & Sludge 8.0
COG 1.3 BFG Export 266.4
BFG Flared 5.4
Hot Stove’s Flue For this case study, it was demonstrated that the ironmaking process is responsible for 78% of theHot Stove s Flue Gas 114.1
Total 447.5 Total 447.2
For this case study, it was demonstrated that the ironmaking process is responsible for 78% of thetotal carbon input of the steel mill. BUT only 21% of the carbon emitted as CO2 emissions isattributed to this process. The rest of the carbon emitted as CO2 are accounted to other processes(mostly end users of the by-product fuel gases) within the steel mill.
Carbon Balance of Ironmaking ProcessDirect CO2 Emissions of an Integrated Steel Mill (REFERENCE) Producing 4 MTPY Hot Rolled Coil2090 kg CO2/t HRC (2107 kg CO2/thm )2090 kg CO2/t HRC (2107 kg CO2/thm )
Carbon from Coke & Limestone
314 kg Cg
Carbon from screen reject
Carbon Balance of Ironmaking Process
jto Sinter Plant
(Mostly as Reclaimed Coke)
6 kg C
Carbon Input(kg C/thm)
Carbon Output(kg C/thm)
Coke 312.4 Hot Metal 47.0
Limestone 1.5 BF Screen Undersize 6.3
PCI Coal 132.2 Dust & Sludge 8.0
COG 1.3 BFG Export 266.4
BFG Flared 5.4
For this case study, it was demonstrated that the ironmaking process is responsible for 78% of the total
Carbon from PCI Coal
132 kg C
Carbon in Hot Metal to BOS Plant
47 kg C
Hot Stove’s Flue Gas 114.1
Total 447.5 Total 447.2
o t s case study, t as de o st ated t at t e o a g p ocess s espo s b e o 8% o t e totacarbon input of the steel mill. BUT only 21% of the carbon emitted as CO2 emissions is attributed to thisprocess. The rest of the carbon emitted as CO2 are accounted to other processes (mostly end users ofthe by‐product fuel gases) within the steel mill.
STEEL MILL Battery Limit(REFERENCE Integrated Steel Mill)
UNIT 100: UNIT 200: UNIT 300:
COKE PRODUCTION SINTER PRODUCTIONHOT METAL PRODUCTION
UNIT 400: UNIT 500: UNIT 600:
HOT METAL DESULPHURISATION
BASIC OXYGEN STEELMAKING
SECONDARY STEELMAKING
UNIT 700: UNIT 800: UNIT 900:
CONTINUOUS SLAB CASTING
SLAB REHEATING HOT ROLLING MILL
UNIT 1000: UNIT 1100: UNIT 1200:
LIME PRODUCTION AIR SEPARATION UNIT (OXYGEN PRODUCTION)
POWER PLANT(OXYGEN PRODUCTION)
UNIT 1300:
ANCILLARY UNITSANCILLARY UNITS
STEEL MILL Battery Limit(Steel Mill with OBF & MDEA CO2 Capture)
UNIT 200 UNIT 300UNIT 100 UNIT 200:
SINTER PRODUCTION
UNIT 300:
HOT METAL PRODUCTION
UNIT 400:
UNIT 100:
COKE PRODUCTION
UNIT 500: UNIT 600:UNIT 400: UNIT 500:
BASIC OXYGEN STEELMAKING
UNIT 600:
SECONDARY STEELMAKING
HOT METAL DESULPHURISATION
UNIT 700: UNIT 800: UNIT 900:
UNIT 1000:
HOT ROLLING MILL
UNIT 1100: UNIT 1200:
CONTINUOUS SLAB CASTING
SLAB REHEATING
UNIT 2000:
LIME PRODUCTION AIR SEPARATION UNIT (HIGH PURITY O2 PROD.)
POWER PLANT
UNIT 3000: UNIT 4000:
STEAM GENERATION PLANT
AIR SEPARATION UNIT (LOW PURITY O2 PROD.)
CO2 CAPTURE & COMPRESSION PLANT
UNIT 1300:
ANCILLARY UNITS
Integrated Steel Mill with OBFIntegrated Steel Mill with OBF and MDEA CO2 Captureand MDEA CO2 Capture Technology
Changes to the Steel Mill as compared to theChanges to the Steel Mill as compared to the REFERENCE Steel Mill (Base Case)
Materials Input & OutputM j R M t i l I t Prod cts and B Prod cts• Major Raw Materials Input:
• Iron Burden (Fines, Lumps, Pellets)• Energy and Reductant
C ki C l
• Products and By-Products:• Hot Rolled Coil (Standard Grade)• Coking Plant By-Products
C d T BTX d S l ho Coking Coal o PCI Coalo Natural Gas
• Fluxes (Limestone Quartzite Olivine
o Crude Tar, BTX and Sulphur• Steel Mill Slag
o Granulated BF Slag (Sale)o De S Slag (Landfill)• Fluxes (Limestone, Quartzite, Olivine,
CaC2, Burnt Dolomite) Merchant Scrap (External)
• Ferroalloys (FeMnC, FeSi-75,
o De-S Slag (Landfill)o BOF Slag (Sale & Landfill)o SM Slag (Landfill)
• BF Sludge and Dust (Landfill)y ( , ,De-Ox Aluminium)
• Major Intermediate Products• Coke (Lump & Breeze)
BF Sludge and Dust (Landfill)• MDEA Sludge (Landfill)• Liquid Argon
• Gas Network within Site( p )• Sinter• Hot Metal• Liquid Steel
• Gas Network within Site• Industrial Gases
o HP & LP Oxygen, Nitrogen and Argon• Off-GasesLiquid Steel
• Slab• Lime• HP & LP Oxygen
Off-Gaseso OBF Top Gaso OBF Process Gas (PG)o Coke Oven Gas (COG)HP & LP Oxygen
• Electricity• Steam
( )o Basic Oxygen Furnace Gas (BOFG)
• Steam (9 Bar, saturated)• Carbon Dioxide
Sinter Fines (Sweden) [ 61.6 ] [ 47.3 ]
BF/BOS Dust & Sludge [ 14.9 ]
Q t it [ 32.4 ]
Sinter Fines (Australia) [ 88.0 ] [ 5.1 ] Reclaimed Coke [ 5.1 ]
(ex BF Screen)
Sinter Fines (Brazil) [ 730.7 ] [ 15.2 ] BF Screen Undersize
(excl. coke)[ 15.2 ]
[ 239.8 ]Hard Coking Coal
Limestone [ 97.6 ]
[ 24.0 ]M ill Scales
[ 159.8 ]Soft Coking Coal
[ 8.7 ]
[ 7.8 ]
Olivine [ 22.6 ]
[ 34.1 ]BOS Slag
[ 34.1 ]
Quartzite[ 7.8 ]
HM Spillage / De-S Slag
Benzole (BTX)UNIT 1000 UNIT 200 UNIT 100 [ 3.8 ]
Sulphur
[ 146.0 ] LimePlant [ 10.9 ] Sinter Plant [ 54.4 ] Coke Plant
Crude Tar
Lime C o ke B reeze [ 12.8 ]
am
[ 5.8 ] Iron Making BF SludgeUNIT 300 & 400 [ 4.0 ]
Iron Ore Pellets [ 349.8 ] [ 150.8 ]
PCI CoalBF Granulated Slag
[ 3.3 ] [ 256.6 ] . [ 233.2 ]
LimeIron Ore Lumps
[ 124.3 ] S inter (58% F e) Lump C o ke [ 0.9 ]
[ 1,087.3 ]
Dia
gra
e)
[ 13.3 ]
M DEA Sludge[ 0.2 ]
CO2 Capture PlantUNIT 4000
Burnt Dolomite [ 11.8 ]
Calcium Carbide Purchased Scrap [ 126.4 ] H o t M eta l (95% F e)
[ 973.5 ]
FerroAlloy & A l [ 16.8 ]
UNIT 300 & 400 [ 4.0 ]
[ 3.2 ] de-S Slag
Flow
DO
2C
aptu
re
[ 31.7 ]
SM Slag
Liquid Steel (99% F e)
[ 8.6 ]
BOS Slag (Sale)
[ 1,086.3 ]
Burnt Dolomite
[ 56.0 ]
[ 75.5 ] Steel Making
BOS Slag
[ 5.2 ] UNIT 500 & 600
oces
s F/
MD
EA C
O
S lab [ 1,052.6 ]
[ 9.2 ]
Slab CasterUNIT 700 [ 27.2 ]
rial P
roll
with
OB
F
Legend M ill Scales
[ 1,000.0 ]
Reheating & HRM [ 42.1 ] Scrap
[xxx.x] - kg/t HRC (Dry Basis) UNIT 800 & 900 Hot Rolled Coil
[ 14.8 ]
Mat
er(S
teel
Mil
Material Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture)
Sinter Fines (Sweden) [ 61.6 ] [ 47.3 ]
BF/BOS Dust & Sludge [ 14.9 ]
Quartzite [ 32.4 ]
Sinter Fines (Australia) [ 88.0 ] [ 5.1 ] Reclaimed Coke [ 5.1 ]
(ex BF Screen)
Sinter Fines (Brazil) [ 730.7 ] [ 15.2 ] BF Screen Undersize
(excl. coke)[ 15.2 ]• Installation of Oxy-Blast Furnace
• Reduced coke consumptionR d d fl ti
[ 239.8 ]Hard Coking Coal
Limestone [ 97.6 ]
[ 24.0 ]M ill Scales
[ 159.8 ]Soft Coking Coal
[ 8.7 ]
[ 7.8 ]
Olivine [ 22.6 ]
[ 34.1 ]BOS Slag
[ 34.1 ]
[ 7.8 ]HM Spillage / De-S Slag• Reduced flux consumption
• Reduced GBF slag production• Reduce Coke Plant Capacity
[ 349.8 ] [ 150.8 ]
LimeIron Ore Lumps
[ 124.3 ] Sinter (58% F e) Lump C o ke [ 0.9 ]
[ 1,087.3 ]
Benzole (BTX)UNIT 1000 UNIT 200 UNIT 100 [ 3.8 ]
Sulphur
[ 146.0 ] LimePlant [ 10.9 ] Sinter Plant [ 54.4 ] Coke Plant
Crude Tar
Lime C o ke B reeze [ 12.8 ]• Reduced coking coal consumption• Reduced by-products production to sale
• Changes in Sinter Plant
[ 13.3 ]
M DEA Sl dCO2 Capture Plant
Calcium Carbide Purchased Scrap [ 126.4 ] H o t M etal (95% F e)
[ 973.5 ]
[ 5.8 ] Iron Making
[ 16 8 ]
BF SludgeUNIT 300 & 400 [ 4.0 ]
[ 3.2 ] de-S Slag
Iron Ore Pellets[ ] [ ]
PCI CoalBF Granulated Slag
[ 3.3 ] [ 256.6 ] . [ 233.2 ]• Reduced sinter ‘s CaO/SiO2 ratio from 1.80 to 1.65
• Reduced flux consumptionM DEA Sludge
[ 0.2 ]CO2 Capture Plant
UNIT 4000
[ 31.7 ]
SM Slag
Liquid Steel (99% F e)
BOS Slag (Sale)
[ 1,086.3 ]
Burnt Dolomite [ 11.8 ]
[ 56.0 ]
[ 75.5 ] Steel Making
BOS Slag
[ 5.2 ] UNIT 500 & 600
FerroAlloy & Al[ 16.8 ]
• Reduced in Flux Consumption• Limestone, Quartzite (OBF / Sinter)• Lime, Olivine (Sinter)
[ 8.6 ]
Slab [ 1,052.6 ]
[ 9.2 ]
Slab CasterUNIT 700 [ 27.2 ]
( )• Addition of CO2 capture plant
• handling of Make Up MDEA/Pz solvent and disposal of MDEA sludge
Legend M ill Scales
[ 1,000.0 ]
Reheating & HRM [ 42.1 ] Scrap
[xxx.x] - kg/t HRC (Dry Basis) UNIT 800 & 900 Hot Rolled Coil
[ 14.8 ]
p g
(YEAR 06)
kg/t HRC
CO2 to Pipeline
859.8
UNIT 100
GJ/ t H R C
GJ/t HRC GJ/t HRC
Ancilliary Units Lime Plant Sinter Plant Coke Plant2.4247UNIT 1300 UNIT 1000 UNIT 200
GJ/t HRC GJ/t HRC GJ/t HRC GJ/t HRC
0.8289 0.0000
0.0000GJ/t HRC
0.0897 0.3022 0.0794 0.2280
Flare/Lost
COG
`
3.84
Nm3/t HRC5.02
kg/t HRC
728.50
7.79
ASU - LP O2 Prod.UNIT 3000
1 x 4200 TPD O2 Nm3/t HRC* 1580m3 working volume GJ/t HRC
UNIT 300
0.74472 x 8.5m diamet er heart h
46.64
251.04 1.6742kg/t HRC
N m 3 / t H R C Blast Furnace GJ/ t H R C
2 x PFR Kiln 1 x 410m2 st rand area m/ c 3 Bat t er ies / 120 Ovens
OBF PG
ptur
e)
kg/t HRC CO2 Capture PlantUNIT 4000
2x Absorbers & 1x St r ipper
2 x 220t Vessels GJ/ t H R C GJ/t HRC
55.73 UNIT 500
0.8817 0.2967Nm3/t HRC
Nm3/t HRC* UNIT 400
0.33 81.06Nm3/t HRC* BOS Plant kg/ t H R C
0.14Desulphurisation
Plant
Steam
BOFG
FD A C
O2
Cap
GJ/t HRCNm3/t HRC 2 x Laddle St at ions
0.11Nm3/t HRC Continuous Caster
0.0196UNIT 700
0.78Nm3/t HRC
Ladle Metallurgy0.2322
2.28UNIT 600
rk –
PFB
F/M
DEA
GJ/t HRC4 x Walking Beam Furnace
GJ/t HRCNm3/t HRC 2 x 2-St rands
Reheating1.4737UNIT 800
2.17Vent/Lost
WasteNitrogen
Net
wor
ill w
ith O
0.8453Nm3/t HRC1x 1250 TPDO2 8 x St eam Boilers(@50 t ph each) GJ/t HRC
Nm3/t HRC 2 x Reversing Mills
6 x Finishing Mills & 3 x Coilers
0.6597
6.28ASU - HP O2 Prod. Steam GenerationPower Plant
UNIT 1200
1x 215 MWe
GJ/t HRCUNIT 1100 UNIT 2000
2.63Hot Rolling Mill
UNIT 800
AO2
N2Gas
N(S
teel
M
kg/ t H R C702.06
GJ/t HRC
1 x 1250 TPD O2 8 x St eam Boilers (@ 50 t ph each) GJ/t C
Natural Gas
1 x 215 MWe
kg/t HRC
4.141.56 kg/t HRC
0.6535GJ/t HRC
3.6472Liquid Argon to Sale
Ar
(YEAR 06)
859.8
Gas Network - Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture)
kg/t HRC
CO2 to P ipeline
GJ/t HRC GJ/t HRC GJ/t HRC GJ/t HRC
0.0000GJ/t HRC
0.0897 0.3022 0.0794 0.2280
Flare/Lost
• Installation of Oxy-Blast Furnace• Added the Recycling of Top Gas with CO2 removal.• Delivery of Top Gas to the CO2 Capture and
3.84kg/t HRC ASU - LP O2 Prod.
UNIT 3000 UNIT 300
46.64
251.04 1.6742kg/t HRC
N m 3 / t H R C Blast Furnace GJ/ t H R C
UNIT 100
GJ/ t H R C2 x PFR Kiln 1 x 410m2 st rand area m/c 3 Bat t er ies / 120 Ovens
GJ/t HRC GJ/t HRC
Ancilliary Units Lime Plant Sinter Plant Coke Plant2.4247UNIT 1300 UNIT 1000 UNIT 200
GJ/t HRC GJ/t HRC GJ/t HRC GJ/t HRC
0.8289 0.0000
COG
OBF PG
• Delivery of Top Gas to the CO2 Capture and Compression Plant
• Introduction of OBF Process Gas (OBF PG -Recycled Top Gas after CO2 removal) to shaft and t
`
Nm3/t HRC5.02
728.50kg/t HRC
7.79UNIT 3000
1 x 4200 TPD O2
CO2 Capture PlantUNIT 4000
2x Absorbers & 1x St r ipper
Nm3/t HRC* UNIT 400
0 33 81 06
Nm3/t HRC* 1580m3 working volume GJ/t HRC
0.14Desulphurisation
Plant
UNIT 300
0.74472 x 8.5m diamet er heart h
Steam
tuyeres.• Reduced Off-Gas from BF as fuel for Plant Use.• Five folds increase to the consumption of Oxygen for
the blast furnace
GJ/t HRCNm3/t HRC 2 x Laddle St at ions
2 x 220t Vessels GJ/ t H R C GJ/t HRC
0.78Nm3/t HRC
Ladle Metallurgy0.2322
2.28UNIT 600
55.73 UNIT 500
0.8817 0.2967Nm3/t HRC
0.33 81.06Nm3/t HRC* BOS Plant kg/ t H R C
BOFG• Only requires 95% purity O2
• Oxygen is introduced to the OBF at the tuyeres level without pre-heating (cold).
• Replacement of Hot Stoves with Fired Heaters
GJ/t HRC
GJ/t HRCNm3/t HRC 2 x 2-St rands
Reheating1.4737UNIT 800
0.11Nm3/t HRC Continuous Caster
0.01962.17
UNIT 700
Vent/Lost
WasteNitrogen
ep ace e o o S o es ed ea e s• Purpose: to heat up the OBF-PG delivered to the shaft
level up to 900oC• Reduced COG consumption –
• NG is used as fuel for the Fired Heaters
Nm3/t HRC 2 x Reversing Mills
6 x Finishing Mills & 3 x Coilers
0.6597ASU - HP O2 Prod. Steam GenerationPower Plant GJ/t HRC
4 x Walking Beam Furnace
2.63Hot Rolling Mill
UNIT 800
N2
NG is used as fuel for the Fired Heaters.• Increased COG consumption by the PCI Coal
Drying Units.• No BFG Flaring (significantly minimise to nearly
)
kg/ t H R C702.06
GJ/t HRC
0.8453Nm3/t HRC1 x 1250 TPD O2 8 x St eam Boilers (@ 50 t ph each) GJ/t HRC
6.28
Natural Gas
UNIT 1200
1 x 215 MWe
kg/t HRC
4.141.56 kg/t HRC
0.6535GJ/t HRC
3.6472
UNIT 1100 UNIT 2000
Liquid Argon to Sale
ArO2
2zero)
(YEAR 06)
kg/t HRC859.8
Gas Network - Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture) Delivery of CO2 to
kg/t HRC
CO2 to P ipeline
GJ/t HRC GJ/t HRC GJ/t HRC GJ/t HRC
0.0000GJ/t HRC
0.0897 0.3022 0.0794 0.2280
Flare/Lost
• Installation of ASU with Low Purity O2
production to meet OBF demand.• Reduced the capacity of ASU – High Purity
yPipeline
3.84
5 02
kg/t HRC
7 79
ASU - LP O2 Prod.UNIT 3000 UNIT 300
0 74472 8 5 di t h t h
46.64
251.04 1.6742kg/t HRC
N m 3 / t H R C Blast Furnace GJ/ t H R C
UNIT 100
GJ/ t H R C2 x PFR Kiln 1 x 410m2 st rand area m/ c 3 Bat t er ies / 120 Ovens
GJ/t HRC GJ/t HRC
Ancilliary Units Lime Plant Sinter Plant Coke Plant2.4247UNIT 1300 UNIT 1000 UNIT 200
0.8289 0.0000
COG
OBF PG
• Reduced the capacity of ASU – High Purity O2 Production by ~43%.
• Reduced Liquid Argon to Sale• Reduce Coke Plant Capacity
`
Nm3/t HRC5.02
728.50kg/t HRC
7.791 x 4200 TPD O2
CO2 Capture PlantUNIT 4000
2x Absorbers & 1x St r ipper
Nm3/t HRC* UNIT 400
0.33 81.063 BOS Pl t k / H R C
Nm3/t HRC* 1580m3 working volume GJ/t HRC
0.14Desulphurisation
Plant
0.74472 x 8.5m diamet er heart h
Steam
• Reduce Coke Plant Capacity• Reduced COG supply to the steel mill• Modification to coke oven’s underfire
heating fuel demand & composition
GJ/t HRCNm3/t HRC 2 x Laddle St at ions
2 x 220t Vessels GJ/ t H R C GJ/t HRC
0.78Nm3/t HRC
Ladle Metallurgy0.2322
2.28UNIT 600
55.73 UNIT 500
0.8817 0.2967Nm3/t HRC
Nm3/t HRC* BOS Plant kg/ t H R CBOFG
heating fuel demand & composition.• Reduced Fuel demand• Reduced COG consumption• Replacement of BFG by OBF-PG
GJ/t HRC4 x Walking Beam Furnace
GJ/t HRCNm3/t HRC 2 x 2-St rands
Reheating1.4737UNIT 800
0.11Nm3/t HRC Continuous Caster
0.01962.17
UNIT 700
Vent/Lost
WasteNitrogen
• Flaring should be nearly zero to meet COG demand
• Addition of CO2 capture plant
Nm3/t HRC 2 x Reversing Mills
6 x Finishing Mills & 3 x Coilers
0.6597
6.28ASU - HP O2 Prod. Steam GenerationPower Plant
UNIT 1200GJ/t HRC
UNIT 1100 UNIT 2000
2.63Hot Rolling Mill
UNIT 800
N2
• Requires processing of OBF Top Gas prior to CO2 capture.
• Delivery of the OBF Process Gas to OBF
kg/ t H R C702.06
GJ/t HRC
0.8453Nm3/t HRC1 x 1250 TPD O2 8 x St eam Boilers (@ 50 t ph each) GJ/t HRC
Natural Gas
1 x 215 MWe
kg/t HRC
4.141.56 kg/t HRC
0.6535GJ/t HRC
3.6472Liquid Argon to Sale
ArO2and other Plant Users
• Requires low pressure steam for solvent regeneration
(YEAR 06)
kg/t HRC859.8
Gas Network - Process Flow Diagram(Steel Mill with OBF/MDEA CO2 Capture)
kg/t HRC
CO2 to P ipeline
GJ/t HRC GJ/t HRC GJ/t HRC GJ/t HRC
0.0000GJ/t HRC
0.0897 0.3022 0.0794 0.2280
Flare/Lost
• Steam supplied by the Waste Heat Boilers of the Basic Oxygen Furnace
3.84
5 02
kg/t HRC
7 79
ASU - LP O2 Prod.UNIT 3000 UNIT 300
0 74472 8 5 di t h t h
46.64
251.04 1.6742kg/t HRC
N m 3 / t H R C Blast Furnace GJ/ t H R C
UNIT 100
GJ/ t H R C2 x PFR Kiln 1 x 410m2 st rand area m/c 3 Bat t er ies / 120 Ovens
GJ/t HRC GJ/t HRC
Ancilliary Units Lime Plant Sinter Plant Coke Plant2.4247UNIT 1300 UNIT 1000 UNIT 200
0.8289 0.0000
COG
OBF PG
• Supply steam to meet demand of:• Coke Plant• ASU – HP O2 Production
`
Nm3/t HRC5.02
728.50kg/t HRC
7.791 x 4200 TPD O2
CO2 Capture PlantUNIT 4000
2x Absorbers & 1x St r ipper
Nm3/t HRC* UNIT 400
0.33 81.063 BOS Pl t k / H R C
Nm3/t HRC* 1580m3 working volume GJ/t HRC
0.14Desulphurisation
Plant
0.74472 x 8.5m diamet er heart h
Steam
• ASU – LP O2 Production• No steam demand by the OBF
• Maximise the steam production from the
GJ/t HRCNm3/t HRC 2 x Laddle St at ions
2 x 220t Vessels GJ/ t H R C GJ/t HRC
0.78Nm3/t HRC
Ladle Metallurgy0.2322
2.28UNIT 600
55.73 UNIT 500
0.8817 0.2967Nm3/t HRC
Nm3/t HRC* BOS Plant kg/ t H R CBOFGWaste Heat Boilers installed at the Basic
Oxygen Furnace and deliver excess steam to CO2 capture plant.
GJ/t HRC4 x Walking Beam Furnace
GJ/t HRCNm3/t HRC 2 x 2-St rands
Reheating1.4737UNIT 800
0.11Nm3/t HRC Continuous Caster
0.01962.17
UNIT 700
Vent/Lost
WasteNitrogen
• Installation of Low Pressure Steam Generation Plant to meet CO2 Capture Pl t d d
Nm3/t HRC 2 x Reversing Mills
6 x Finishing Mills & 3 x Coilers
0.6597
6.28ASU - HP O2 Prod. Steam GenerationPower Plant
UNIT 1200GJ/t HRC
UNIT 1100 UNIT 2000
2.63Hot Rolling Mill
UNIT 800
N2
Plant demand.• Used OBF-PG and BOFG as the main fuel
and with NG as supplementary fuel to meet demand of the boilers
kg/ t H R C702.06
GJ/t HRC
0.8453Nm3/t HRC1 x 1250 TPD O2 8 x St eam Boilers (@ 50 t ph each) GJ/t HRC
Natural Gas
1 x 215 MWe
kg/t HRC
4.141.56 kg/t HRC
0.6535GJ/t HRC
3.6472Liquid Argon to Sale
ArO2meet demand of the boilers.
Electricity Network of the Integrated Steel Mill(Steel Mill with OBF/MDEA CO2 Capture)
kWh/ t H R C kWh/ t H R C kWh/ t H R C
Lime Plant Sinter Plant Coke PlantUNIT 1000 UNIT 200 UNIT 100
2.6 34.8 10.9Captive Power Plant
REF. Steel Mill OBF Steel Mill w/ CO2
Capture
38.0ASU - HP O2 Prod.
UNIT 1100
kWh/ t H R C1 x 1200 TPD O2
Blast FurnaceUNIT 300
2 x 8.5m diamet er heart h
1580m3 working volume
2 x PFR Kiln 1 x 410m2 st rand area m/ c 3 Bat t er ies / 120 Ovens
215 MWe (Net) 292 MWe (Net)
32.1% 56.9%
BFG BOFG NG NG
UNIT 3000
kWh/ t H R C120.3
ASU - LP O2 Prod.
1 x 4100 TPD O2
DesulphurisationPlantUNIT 400
29.8kWh/ t H R C
BFG, BOFG, NG NG
400 kWh/t HRC 573 kWh/t HRC
85% Load Factor 89% Load Factor
2x Absorbers & 1x St r ipper
Steam Generation
143.2CO2 Capture Plant
kWh/ t H R CUNIT 4000
2 x 220t Vessels
48.8kWh/ t H R C
Ladle Metallurgy
UNIT 500BOS PlantGas Fired Boiler NGCC Single Shaft
4.8Ancilliary Units
UNIT 1300
8 x St eam Boilers (@ 50 t ph each)
11.0Steam Generation
kWh/ t H R CUNIT 2000
Continuous Caster10.9UNIT 700
Ladle MetallurgyUNIT 600
2 x Laddle St at ions• Scope for Improvements:
• Deployment of CHP or COGEN Plant instead of Steam Boilers to generate steam for CO2capture plant
kWh/ t H R C
4 x Walking Beam Furnace
ReheatingUNIT 800
kWh/ t H R C2 x 2-St rands
capture plant• To evaluate other possible waste heat
recovery within the steel mill for steam generation.
• BUT – this may not be possible for
573.4 UNIT 1200
1 x GT-HRSG-ST (Single Shaf t )
2 x Reversing Mills
105.3kWh/ t H R C
6 x Finishing Mills & 3 x Coilers
Hot Rolling MillPower Plant
kWh/ t H R CUNIT 900
a g ea u ace
several European Steel Mills as they provide district heating.
Nitrogen2 Nm3
BFG to Flare/Lost23 Nm3
Top Gas Cleaning
BFG Gas Holder
Raw MaterialsCoke 355 kgSinter 1120 kg (70%)Pellets 352 kg (22%)
BFG to Power Plant935 Nm3
BFG to Coke PlantCleaning Gas Holder
BF Dust15 kg
Lump 125 kg (8%)Limestone 13 kgQuartzite 11 kg
BF Screen U d i BF Sl d
BFG to Hot Stoves479 Nm3
BFG to Coke Plant185 Nm3
Undersize23 kg
BF Sludge4 kg
Flue Gas780 Nm3
COG7 Nm3Air358 Nm3DRR: 31%
FT 2056 C
Recuperator
FT: 2056oCTGT: 140oCHM Si: 0.5%HM C:4.7%
Hot Blast Cold Blast
Hot Stoves
PCI Coal152 kg
Nitrogen3 Nm3
48 Nm3Oxygen
Main Air Compressor
Air995 Nm3
BF Slag280 kg
Hot Metal1000 kg152 kg1470oC
8 kgSteam
Oxy-Blast Furnace Operation(Picture of OBF courtesy of Tata Steel)
Raw Materials OBF Top Carbon Dioxide867 kg
Coke 253 kg
Nitrogen5 Nm3
CO2 Capture & Compression Plant
pGas
Top Gas Cleaning1385 Nm3
Coke 253 kgSinter 1096 kg (70%)Pellets 353 kg (22%)Lump 125 kg (8%)Limestone 6 kgQ i 3 k
OBF Process GasBF Dust
BF Sludge15 kg 938 Nm3
Quartzite 3 kg
Steam2.0 GJ
OBF Screen Undersize21 kg
Natural Gas Flue Gas352 Nm3
BF Sludge
Air
4 kg
332 Nm3 18 Nm3DRR: 11%FT: 2140oCTGT: 170oCHM Si 0 5%
563 Nm3900oC
OBF Process Gas Fired Heaters
HM Si: 0.5%HM C:4.7%
BF Slag
OBF‐PG to Steel Works
Oxygen
235 k
253 Nm3
205 Nm341oC
171 Nm3Nitrogen
Hot MetalPCI Coal1000 kg1470oC
152 kg
235 kg 171 Nm3Nitrogen5 Nm3
Carbon Balance of Ironmaking Process(Equipped with OBF and MDEA/Pz CO2 Capture)
Direct CO2 Emissions of an Integrated Steel Mill (with OBF & MDEA CO2Capture) Producing 4 MTPY Hot Rolled Coil1115 kg CO2/t HRC (1124 kg CO2/thm ) Nitrogen
(Equipped with OBF and MDEA/Pz CO2 Capture)
1115 kg CO2/t HRC (1124 kg CO2/thm )
Lime Plant
Power Plant18.94%
Steam Generation Plant
25.13%
Raw Materials
CO2 Capture & Compression Plant
OBF Top Gas
Carbon Dioxide
Top Gas Cleaning1385 Nm3
867 kgCoke 253 kgSinter 1096 kg (70%)Pellets 353 kg (22%)Lump 125 kg (8%)Limestone 6 kg
g5 Nm3
Coke Plant11.22%
Sinter Plant23.83%Iron Making
4.65%
Steelmaking4.58%
Slab Casting0.07%
Reheating & HRM5.18%
Lime Plant6.41%
Compression Plant
OBF Process GasBF Dust
BF Sludge15 kg
4 kg
938 Nm3
Limestone 6 kgQuartzite 3 kg
Steam2.0 GJ
OBF Screen Undersize21 kg
C b I t C b O t t
Carbon Balance of Ironmaking Process563 Nm3
OBF Process Gas Fi d H t
Natural Gas Flue Gas352 Nm3
Air332 Nm3 18 Nm3
DRR: 11%FT: 2140oCTGT: 170oCHM Si: 0.5%HM C:4.7%
Carbon Input(kg C/thm)
Carbon Output(kg C/thm)
Coke 227.7 Hot Metal 47.0
Limestone 0.7 BF Screen Undersize 4.6
900oC
BF Slag
Fired Heaters
OBF‐PG to Steel Works
Oxygen
235 kg
253 Nm3
205 Nm341oC
171 Nm3Nitrogen
PCI Coal 132.2 Dust & Sludge 8.0
Natural Gas 12.0 OBF PG Export 64.5
PG Heater Flue Gas 12.0 For this case study, the Oxy-Blast Furnace has the potential to reduce carbon input to theiron making process by 17% as compared to the REFERENCE case (@447 5 kg C/thm)
Hot MetalPCI Coal1000 kg1470oC
152 kg
235 kgg5 Nm3
CO2 Captured 236.3
Total 372.7 Total 372.4
iron making process by 17% as compared to the REFERENCE case (@447.5 kg C/thm).This is due to the reduced consumption of the coke. ULCOS has reported a higher carboninput reduction potential of up to ~28%. Further reduction of CO2 emissions could only beachieved by CCS.
Note:Note:• Current study only illustrates one of• Current study only illustrates one of
the many options available for oxy-y p yblast furnaces
This do not represents the choice• This do not represents the choice made by the ULCOS Programme.made by the ULCOS Programme.• Florange Project
Ei hütt t dt P j t• Eisenhüttenstadt Project
The Ulcos Blast Furnace Concepts
Coke Top gas Coke Top gas
Gas cleaning
Coke p g(CO, CO2, H2, N2)
Gas net(N2 purge)
Gas cleaning
Coke p g(CO, CO2, H2, N2)
Gas net(N2 purge)
CO2 400 Nm3/tCO2
scrubber CO2 400 Nm3/tCO2
scrubber
Gas heater
CO, H2, N2V4900 °C
V3X
V1900 °C
Gas heater
CO, H2, N2V4900 °CV4900 °C
V3X
V3X
V1900 °CV1900 °C
Oxygen
PCI Re-injection
1250 °C 1250 °C 25 °COxygen
PCI Re-injection
1250 °C1250 °C 1250 °C1250 °C 25 °C25 °C
Re injection Expected C-savings
25 % 24 % 21 %
Re injection Expected C-savings
25 % 24 % 21 %
Expected C-savings
25 % 24 % 21 %
29
CO2 Capture & Compression Plant PFD(Steel Mill – OBF and MDEA CO2 Capture)(Steel Mill – OBF and MDEA CO2 Capture)
CO2 Capture & Compression Plant PFD(Steel Mill – OBF and MDEA CO2 Capture)(Steel Mill OBF and MDEA CO2 Capture)
• Equipment Configuration:• 2x Process Gas Compressors (2 to 4 Bara)2x Process Gas Compressors (2 to 4 Bara)• 2x Absorbers (1 per OBF)• 1x Stripper Column• 2x CO2 Compression Train with Glycol (TEG) Dehydration Unit
• Solvent• MDEA 40%• Piperazine 10%
E D d• Energy Demand• Steam 2.02 GJ/t HRC• Electricity 143 2 kWh/t HRC• Electricity 143.2 kWh/t HRC
• Capture Performance• ~860 kg/t HRC (867 kg/thm)860 kg/t HRC (867 kg/thm)• ~47% CO2 Avoided• 94% capture rate
Separation and Capture of CO2 from OBF also has several other optionsalso has several other options(Data from ULCOS Programme)
PSA VPSA• PSA, VPSA• VPSA +VPSA
Cryogenics Separation ofSeparation of non-CO2
tcomponents• Chemical
Absorption
Techno-Economic Model(REFRENCE Steel Mill)( C Stee )
MAIN INTERMEDIATE PRODUCTS
WASTE PRODUCTSRAW MATERIALS MAJOR PROCESSES EXPORTED PRODUCTS
N atural Gas
ENERGY BY-PRODUCTS & OTHER IND. GASES
PLANT BY-PRODUCTS
Power PlantUNIT 1200
Electricity
Air Separation UnitUNIT 1100
P C I C o al
UNIT 1200
Oxygen Waste N itro genLiquid A rgo n
H ard C o king C o al
Semi-So ft C o king C o alN itro gen
A rgo n
Olivine
Coke PlantQuartzite
C o ke Oven Gas C rude T ar, B enzo le, Sulphur
Lime
C o ke B reeze
Lump C o ke
Lime PlantUNIT 1000
Limesto ne
UNIT 100
Iron Making
Sinter
B F R eturns & R eclaimed
UNIT 200Sinter F ines R eturnsSinter Plant
Iro n Ore - Lumps
Iro n Ore - F ines
Iro n Ore - P e llets
B OS Slag, D ust & SludgeSteel Making
ScrapUNIT 500 & 600
UNIT 300 & 400
B OS Gas
Steam
M erchant Scrap
B F Gas Iron Making Granulated B F Slag de-S Slag & B F SludgeC o ke, B F D ust , de-S Slag/ H M Spillage
H o t M etal
B OS Slag & SM SlagB OS SlagLiquid Steel
F erro A llo ys / D eo x A l
UNIT 700
UNIT 800 & 900
M ill ScaleReheating & Rolling
ScrapSlab
Hot Rolled CoilC o nsummables and Other Wo rks & Operat io n Scrap
Continuous Caster
C aC 2 P o wder
B urnt D o lo mite M ill Scale
Plant By-Products Sold to Users at Fixed Price & Credit to Producers
Energy & Fuel Gases So ld at Fixed Price to Users & Credit to Producers
Exported By-Products Sold at Fixed Price
Expenses
Waste Products Charged at Cost to Producers
Waste Nitrogen Vented at Zero Value
Raw M aterials & Consummables Bought at Fixed Price and Sold Directly to the Users
INTERNAL CUSTOM ERS (USERS) Products Sold to Users at Producer's Direct Cost
Hot Rolled Co il So ld at Variable / M arket PriceBy-Product Gases Sold to Users at Zero Value
Techno-Economic Model(Steel Mill with OBF & MDEA CO2 Capture)(Stee t O & CO Captu e)
H ard C o king C o al
EXPORTED PRODUCTS WASTE PRODUCTS
N atural Gas Power Plant Electric ityUNIT 1200
RAW MATERIALS ENERGY BY-PRODUCTS & OTHER IND. GASES MAJOR PROCESSES MAIN INTERMEDIATE
PRODUCTS PLANT BY-PRODUCTS Captured CO2 Emission
H ard C o king C o al
Semi-So f t C o king C o al
Steam Boiler SteamUNIT 2000
Limesto neLime Plant Lime
UNIT 1000
P C I C o al
Olivine
C rude T ar, B enzo le , Sulphur
QuartziteUNIT 100
Lump C o ke
C o ke B reezeC o ke Oven Gas Coke Plant
Iro n Ore - F ines
Sinter F ines R eturnsSinter Plant SinterUNIT 200
Iro n Ore - Lumps
B F R eturns & R eclaimed C o ke, B F D ust, de-S
Slag/ H M SpillageC O2 C aptured fro m OB FIro n Ore - P ellets B F Gas Iron Making H o t M etal Granulated B F Slag de-S Slag & B F Sludge
UNIT 300 & 400
M erchant Scrap
B OS Gas B OS Slag, D ust & SludgeSteel Making Liquid Stee l B OS Slag B OS Slag & SM Slag
SteamUNIT 500 & 600
ScrapF erro A llo ys / D eo x A l
B urnt D o lo mite M ill ScaleContinuous Caster Slab
UNIT 700Scrap
C alcium C arbide
M ill ScaleC o nsummables and
Other Wo rks & Operat io n Expenses
Reheating & Rolling Hot Rolled CoilUNIT 800 & 900Scrap
N itro genAir Separation Unit H igh P urity Oxygen Liquid A rgo n Waste N itro gen
A rgo nUNIT 1100
Air Separation Unit Lo w P urity Oxygen Waste N itro gen/ A rgo nUNIT 3000
M D EA / P z CO2 Capture Plant C O2 (110 bar & 99%) M D EA SludgeUNIT 4000
C t M d l A t i d B i f C l l t i
Exported By-Products So ld at Fixed Price Waste Products Charged at Cost to Producers
By-Product Gases Sold to Users at Zero Value Sinter Fines Return Sold at Zero ValueHot Ro lled Coil Sold at Variable / M arket Price Waste Nitrogen Vented at Zero Value
Raw M aterials & Consummables Bought at Fixed Price and So ld Directly to the Users INTERNAL CUSTOM ERS (USERS)
Products So ld to Users at Producer's Direct Cost
Energy & Fuel Gases Sold at Fixed Price to Users & Credit to Producers
Plant By-Products Sold to Users at Fixed Price & Credit to Producers
Total Investment Cost(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)
Total Investment Cost - Cont’d(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)
Annual O&M Cost(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)
Revenues from By-Products(REFERENCE vs OBF/MDEA Case)(REFERENCE vs. OBF/MDEA Case)
Cost of Steel Production – BreakdownB k P i f $ 23Breakeven Price of $575.23
$575.23
$135Capital Cost
Break Even Price
55% of the Cost is related to
$120
$118
Iron Ore (Fines, Lumps & Pellets)
Fuel & Reductantto
Raw Materials, Energy and Reductant
$11
$53
Fluxes
Purchased Scrap & FerroAlloys
$70
$12
M i &O h O&M
Labour
Other Raw Mat'l & Consummables
$55
$0.0 $100.0 $200.0 $300.0 $400.0 $500.0 $600.0
Maintenance & Other O&M
B k P i f HRC &B kd ($/ )Breakeven Price of HRC & Breakdown ($/t)
Cost of Steel Production – BreakdownB k P i f $630 22Breakeven Price of $630.22
Increase in CAPEX and Fuel Cost due to the addition of the CO2 capture facilities represents a $47of the CO2 capture facilities represents a $47
increase in the breakeven price of HRC
Impact of the OBF/MDEA CO2 Capture Plant to the Breakeven Cost of HRC Production(Very Specific to this Study)
• Capital Cost increased by 18.8%• Fuel and Reductant Cost increased by 17.3%
• Coking Coal Cost – decreased by ~24%N t l G C t i d b 495%• Natural Gas Cost – increased by ~495%
• Iron Burden Cost increased by 1.0%• Iron Ore (Fines Lumps and Pellets) Purchased Scrap & Ferroalloys• Iron Ore (Fines, Lumps and Pellets), Purchased Scrap & Ferroalloys
• Fluxes Cost decreased by 9.4%• Significant reduction of limestone and quartzite consumptiong q p
• Other Consumable Cost increased by 15.7%• Increased in cost of raw water consumption• Additional cost due to Chemicals & Consumables used by SGP.• Additional cost due to MDEA/Pz Solvent Make Up
• Labour Cost increased by 1 4%• Labour Cost increased by 1.4%• Maintenance and Other OPEX increased by 10.4%
Key Messages from this StudyKey Messages from this Study
To incorporate OBF and CO2 Capture in an IntegratedTo incorporate OBF and CO2 Capture in an Integrated Steel Mill prodcuing 4 million tonnes of HRC per year would require an additional $ 753 million in CAPEXwould require an additional $ 753 million in CAPEX
based on New Build Steel Mill Analysis
In terms of OPEX – the steel mill with OBF and MDEA CO2 Capture would require an additional p q
US$ 120 Million per year
This estimates is based on pre feasibility level havingThis estimates is based on pre-feasibility level – having a defined +/-30% accuracy -
and are based on conservative assumptionsand are based on conservative assumptions
Evolution of Coking Coal Price(Data provided by P. Baruya – IEA CCC)
Summary of Results$80.00
y(Sensitivity to Coke Price)
$60 00
$70.00
) OBF/MDEA Case+ $92/t Coke
$50.00
$60.00
ost (US$/t) /
EOP‐L1 Case
$
$30.00
$40.00
voidance Co
OBF Base CaseCO2 Avoidance Cost = ~$56.4/t
$20.00
$
CO2Av
$
It should be noted that Steel Mill used a significant variety of coking coal depending on market price (low to high quality coking coal)
$‐
$10.00 p g p ( g q y g )
COKE is a tradable commodity
0.5P 1P 1.5P 2P 2.5P
Price of Coking Coal
Important Notep• The OBF and MDEA CO2 Capture CAN NOT be p
classified as Post- or Oxy- or Pre- Combustion CO2
Capture TechnologiesCapture Technologies.• Blast furnace is a reduction process (not combustion!)• Separation of the CO2 from the top gas is more
analogous to the removal of CO2 during the processing of natural gas.
• Raw Top Gas from OBF is mainly CO (46%) and CO2
(34%)
Composition of OBF T G P G BOFG d COGOBF Top Gas, Process Gas, BOFG and COG.
OBF Process GasWet Basis (%vol.)
Coke Oven GasCOG
Wet Basis (%vol.)
Basic Oxygen Furnace Gas
(BOFG)
OBF Top Gas(OBF‐TG)
to CO2 Capture Plant
OBF Process Gas (OBF‐PG)
from CO2 Capture Plant Recycled to BF
CH4 23.04H2 59.53CO 3.84
H2 2.64 8.56 12.64
CO 56.92 45.69 67.46
CO2 0.96N2 5.76O 0 19
CO2 14.44 33.89 3.00
N2 13.83 10.07 14.86
12 16 1 79 2 04 O2 0.19H2O 3.98Other HC 2.69
H2O 12.16 1.79 2.04
LHV (MJ/Nm3) ‐wet 17.33
LHV (MJ/Nm3) ‐ wet
7.47 6.69 9.87
Concluding Remarksg• Steel Mill with OBF/MDEA CO2 Capture producing 4
MTPY standard Hot Rolled Coil was defined in detailMTPY standard Hot Rolled Coil was defined in detail in the study.
M B l• Mass Balance• Gas Network• Electricity Network• CO2 emissions of each unit
• Study was able to established a baseline cost for an yIntegrated Steel Mill equipped with OBF, Top Gas Recycle and MDEA/Pz CO2 capture technology.y p gy
Concluding RemarksCo c ud g e a s• Techno-Economics of Iron and Steel Production is very site
ifispecific. • Strategy for CCS Implementation to an integrated steel mill is also very site
specific.p
• IMPORTANT to have a like for like assessment between steel mills without and with CO2 capture.
• Re-emphasized that this study is not meant to develop and evaluate the best available technology for the steel mill and CO2
capture.• One of the main objectives of this study is to establish a Techno-
E i E l ti M th d l (T t) th t ld bEconomic Evaluation Methodology (Transparent) that could be used to estimate cost of CO2 capture in an integrated steel mill on a like for like basisa like for like basis.
Concluding Remarksg• This study only touches the surface...
REFERENCE Steel Mill is based on T pical• REFERENCE Steel Mill is based on Typical Average European Configuration.• It should be expected that there will be inefficiency
in some aspects of the steel mill.p• To maintain a like for like analysis – the CO2
capture configuration can’t include all the Bestcapture configuration can t include all the Best Available Technology as expected for Greenfield Steel Works. (For Example – Steam GenerationSteel Works. (For Example Steam Generation Plant)
Key Message from this Studyy g y• Key to the deployment of CO2 capture technologies using top
l t bl t f h ld l i i thgas recycle to a blast furnace should also maximise the reduction in the coke consumption to make it cost competitive.
• Post-Combustion CO2 Capture – i.e. capture of CO2 from the flue gas of different stacks within the integrated steel mill isflue gas of different stacks within the integrated steel mill - is not a cost competitive option!• This is not the options considered by the global steel community.p y g y
• REPORTING CO2 Avoidance Cost for a complex industrial REPORTING CO2 Avoidance Cost for a complex industrial processes is meaningless – without establishing the assumptions used for the REFERENCE Plant without CO2 Capture.• This is not a good indicator for these cases yet we are trapped in it...
Thank YouStanley SantosIEA Greenhouse Gas R&D ProgrammeIEA Greenhouse Gas R&D [email protected] @ g g g
Back Up Slidep
Key Price Inputsy p• Price inputs for externally and internally
d t i l b d t lsourced raw materials are based on actual operating price data adjusted to long term trends.
• Major intermediate products are priced basedMajor intermediate products are priced based on the gate of the specific operating unit (“Factory”)( Factory ).
• Revenues from sale of by-products is credited to the source of this materials.
• Details of these inputs are presented in the• Details of these inputs are presented in the excert of the Volume 1 Report
Notes on Investment CostNotes on Investment Cost• The integrated steel mill is assumed to have an g
economic life of 25 years as the basis for appraisalappraisal.
• The cost evaluation was developed in US$ (2010) Wh th i(2010). Where necessary, the conversion was based on the following exchange rates:• € 1.00 = US$ 1.34• £ 1 00 = US$ 1 55£ 1.00 = US$ 1.55
• The estimate accuracy is within the range +/-30%30%.